description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND OF THE INVENTION
[0001] The invention relates to a device for fastening a rain sensor to a support.
[0002] One such device is known from EP 1 040 962 A2. In that device, a base part is configured in a ring shape and surrounds the rain sensor. A cover part in the form of the stem of a rear view mirror can be clipped onto the base part.
[0003] Known from DE 100 60 447 A1 is an interior mirror system with a built-in sensor system and the various fastening means used to interconnect the parts of the interior mirror system and the sensor system.
[0004] In addition, devices for fastening a rain sensor to a support are known in practice, and usually comprise a cage part that surrounds a disk-shaped head portion of a rain sensor, is glued to a pane of glass serving as a support, and carries a spring that acts on the head portion to press it against the pane of glass.
SUMMARY OF THE INVENTION
[0005] The present invention provides a device for fastening a rain sensor to a support that is distinguished by a particularly small and therefore esthetically pleasing design and a comparatively high pressing force.
[0006] By virtue of the fact that in the inventive device, the rain sensor comprising a neck portion and a roundish head portion is interposed between a base part and a cover part and its head portion is held in place by the obliquely set edge tongues and the neck portion by neck webs, the head portion being pressed against the support by the pressure-exerting resilient tongue and the force so applied being conducted into the adhesive coating via the edge webs of the cover part and the side webs of the base part, the result is a comparatively slender design accompanied by relatively high pressing forces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 is a perspective view of an exemplary embodiment of an inventive device with a rain sensor interposed between a base part and a cover part;
[0009] FIG. 2 is a perspective view of the base part according to FIG. 1 , seen from below;
[0010] FIG. 3 is a perspective view of the cover part according to FIG. 1 ;
[0011] FIG. 4 is a cross section of the exemplary embodiment according to FIGS. 1 to 3 ; and
[0012] FIG. 5 is a longitudinal section of the exemplary embodiment according to FIGS. 1 to 4 .
[0013] Corresponding reference characters indicate corresponding parts throughout the several views. Although the exemplifications set out herein illustrate embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
DETAILED DESCRIPTION
[0014] FIG. 1 is a perspective view of an exemplary embodiment of an inventive device, comprising a base part 1 and a cover part 2 which are detachably connected to each other. In the representation of FIG. 1 , a rain sensor 3 having a roundish head portion 4 and a neck portion 5 appended to said head portion 4 is interposed between base part 1 and cover part 2 .
[0015] In the exemplary embodiment according to FIG. 1 , base part 1 comprises two side webs 6 , 7 disposed parallel to each other and oriented at right angles to a base plate 8 . Appended to the side webs 6 , 7 at one end are edge tongues 9 , 10 oriented at angles to said side webs 6 , 7 and splayed outwardly at a shallow angle. When the inventive device is used according to the invention, the edge tongues 9 , 10 , each of which has an edge region that is bent outwardly in the insertion direction of the rain sensor 3 , rest against the outer peripheral surface of the head portion 4 belonging to the rain sensor 3 and disposed adjacent the inventive device, and thereby secure it particularly against lateral movement.
[0016] The cover part 2 is configured with a cover plate 11 at the end of which is formed a pressure-exerting resilient tongue 12 , which in the intended arrangement of the rain sensor 3 rests on head portion 4 and presses it against a pane of glass (not shown in FIG. 1 ) serving as a support. Cover part 2 is further provided with longitudinal portions 13 , 14 , oriented substantially at right angles to cover plate 11 and pointing away from pressure-exerting resilient tongue 12 , which are configured with edge regions bent in the direction of base part 1 , and at the free ends of which are formed respective clasping tongues 15 , 16 , which are set at right angles to cover plate 11 and which in the assembled arrangement of the exemplary embodiment clasp the side webs 6 , 7 of base part 1 .
[0017] FIG. 2 is a perspective view of the base part 1 according to FIG. 1 , looking from below at two L-shaped adhesive regions 17 , 18 of an adhesive coating, which lie with their short, broader legs in the longitudinal direction of a transverse portion 19 of base plate 8 that is oriented at right angles to side webs 6 , 7 , and with their long, narrower legs in the longitudinal direction of longitudinal portions 20 , 21 of base plate 8 , which are also oriented at right angles to side webs 6 , 7 . A central web 22 is formed between longitudinal portions 20 , 21 , in the region of the ends of the long legs of adhesive regions 17 , 18 . Comparatively narrow, elongated adhesive regions 23 , 24 of the adhesive coating are present on end regions belonging to longitudinal portions 20 , 21 and extending away from transverse portion 19 beyond central web 22 .
[0018] The adhesive coating is implemented in the form of a so-called hot-melt adhesive, which is applied at a relatively low temperature at which it incipiently melts onto and adheres to base part 1 , and, after being heated to a relatively high temperature at which it melts completely, to liquefaction, bonds the base part 1 to a support such as for example a pane of glass. To ensure a constant distance between base part 1 and the support, spacers 25 are provided in transverse portion 19 , longitudinal portions 20 , 21 and central web 22 of base plate 8 . In the exemplary embodiment shown, the terminating edges of transverse portion 19 and longitudinal portions 20 , 21 are for the most part configured with rounded bends around adhesive regions 17 , 18 , 23 , 24 , to obtain controlled flow properties, among other purposes.
[0019] The neck webs 26 , 27 , between which the neck portion 5 of the rain sensor 3 is to be arranged are added in the end regions of longitudinal portions 20 , 21 , substantially perpendicular thereto and consequently parallel to side webs 6 , 7 . Neck webs 26 , 27 , which are bent at their ends, comprise, as latching means, detent recesses 28 , 29 arranged mutually offset in the longitudinal direction of base part 1 .
[0020] It can further be seen from FIG. 2 that formed in side webs 6 , 7 of base part 1 are retaining openings 30 , 31 , which serve to engage a retaining device on the incipient melting of the hot-melt adhesive in adhesive regions 17 , 18 , 23 , 24 . Also formed at the ends of side webs 6 , 7 are detent tongues 32 , 33 , 34 , 35 of a latching arrangement, which protrude laterally outwardly beyond side webs 6 , 7 . Finally, configured on the side webs 6 , 7 are tongue recesses 36 , 37 and laterally protruding stop tongues 38 , 39 that regionally cover tongue recesses 36 , 37 .
[0021] FIG. 3 is a perspective view of the cover part 2 of the exemplary embodiment according to FIG. 1 . As is particularly clear in FIG. 3 , pressure-exerting resilient tongue 12 comprises, joined to cover plate 11 , a resilient portion 40 that is bent inwardly away from cover plate 11 , and a bearing portion 41 , which is bent oppositely to the inflection of resilient portion 40 and which comes to rest, by its side facing away from cover plate 11 , on the head portion 4 of the rain sensor 3 .
[0022] Cover part 2 is further provided with edge webs 42 , 43 running substantially parallel to each other and oriented at right angles to cover plate 11 , and extending between pressure-exerting resilient tongue 12 and clasping tongues 15 , 16 . Edge webs 42 , 43 are each provided with a splayed tongue 44 , 45 that juts laterally outwardly from the respective edge web 42 , 43 . Said splayed tongues 44 , 45 are dimensioned and positioned such that in the assembled arrangement of base part 1 and cover part 2 , they each engage in a respective tongue recess 36 , 37 provided in a side web 6 , 7 of base part 1 and bear against the appurtenant stop tongue 38 , 39 . By this means, in combination with the lapping-over of clasping tongues 15 , 16 , cover part 2 can be detachably secured in base part 1 with virtually no play.
[0023] Finally, it can be appreciated from FIG. 3 that formed in cover plate 11 is a counter-resilient tongue 46 that protrudes from cover plate 11 in a direction away from base part 1 .
[0024] FIG. 4 is a cross section of the exemplary embodiment of an inventive device with interposed rain sensor 3 according to FIGS. 1 to 3 , mounted on a glass pane 47 serving as a support, for example in the form of a windshield or rear window of a motor vehicle. It can be appreciated from FIG. 4 , for one thing, that stop lugs 48 , 49 , which are appended to the neck portion 5 of rain sensor 3 and which are mutually offset in the longitudinal direction of said neck portion 5 , engage in the stop recesses 28 , 29 and secure the rain sensor 3 . It can further be seen from FIG. 4 that the side webs 6 , 7 of base part 1 and the edge webs 42 , 43 of cover part 2 bear against each other as splayed tongues 44 , 45 engage in tongue recesses 36 , 37 , causing splayed tongues 44 , 45 to be braced outwardly against stop tongues 38 , 39 , as can be appreciated from FIG. 1 , and that as a result, the force exerted by pressure-exerting resilient tongue 12 on head portion 4 of rain sensor 3 is conducted into base part 1 via the entire edge face. Adhesive regions 17 , 18 , 23 , 24 thus are substantially evenly loaded over their entire area of connection to glass pane 47 , thus preventing linear separation beginning at the edge face.
[0025] From an overall standpoint, it can be clearly seen from FIG. 4 that the width of the inventive device is substantially the same as the diameter of head portion 4 of rain sensor 3 , and is therefore comparatively narrow.
[0026] FIG. 5 is a longitudinal section of the exemplary embodiment of an inventive device with interposed rain sensor 3 according to FIGS. 1 to 4 , onto which a covering cap 50 has been snapped, engaging with the stop tongues 32 , 33 , 34 , 35 . It can be seen especially clearly from FIG. 5 that counter-resilient tongue 46 is biased against covering cap 50 and that the latter is therefore fastened without play. It can further be appreciated from FIG. 5 that the resilient portion 40 of pressure-exerting resilient tongue 12 , which is bent inwardly in the direction of edge webs 42 , 43 , is distinctly flattened, while pressure-exerting resilient tongue 12 exerts a comparatively high pressing force on head portion 4 that is sufficient to enable the rain sensor 3 to perform its measurement task while at the same time preventing artifacts at the interface with glass pane 47 .
[0027] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | The invention relates to a device for fastening a rain sensor ( 3 ) to a support. Said device comprises a base ( 1 ) that is provided with an adhesive on the side facing the support for fastening it on the support, two lateral webs ( 6, 7 ) aligned in a substantially perpendicular manner in relation to abase plate ( 8 ) of a base ( 1 ), two opposite neck webs for fixing a neck section ( 5 ) of the main sensor ( 3 ) and two tilted lateral tongues ( 9, 10 ) for fixing a spheroid top section ( 4 ) of the rain sensor ( 3 ). The device is provided with a cover part ( 2 ) which comprises edge webs that can be engaged with the lateral webs ( 6, 7 ) of the base ( 1 ) and a resilient spring tongue ( 12 ) that is biased and rests against the top section ( 4 ) of an interposed rain sensor ( 3 ). The inventive device has an especially compact and esthetically appealing design and allows for a comparatively high contact pressure. | 1 |
[0001] This Application claims benefit of priority from U.S. patent application Ser. No. 11/797,168 filed May 1, 2007 which is a continuation-in-part of PCT Patent Application No. PCT/IB2006/051874 filed May 24, 2006, which in turn claims the benefit of U.S. Provisional Patent Applications Nos. 60/683,788 filed May 24, 2005; 60/716,100 filed Sep. 12, 2005; and 60/742,460 filed Dec. 5, 2005.
[0002] This application is also a continuation-in-part of pending U.S. patent application Ser. No. 11/582,354 filed Oct. 18, 2006.
[0003] In addition, this application claims priority from U.S. Provisional Patent Applications Nos. 60/852,392 filed Oct. 18, 2006, 60/860,485 filed Nov. 22, 2006, 60/860,486 filed Nov. 22, 2006 and 60/877,162 filed Dec. 27, 2006.
[0004] The contents of all of the above documents are incorporated by reference as if fully set forth herein.
FIELD AND BACKGROUND OF THE INVENTION
[0005] The present invention, in some embodiments thereof, relates to stent assemblies that are deployed in bifurcated vessels and, more particularly, but not exclusively, to bifurcating stent assemblies having low bulk at vessel bifurcations between branch vessels and parent vessels.
[0006] While mono-tubular stents have resulted in improved long-term blood flow, stents are associated with severe problems when deployed in a bifurcated lumen, meaning a parent lumen from which a branch vessel splits. It is estimated that 15% to 20% of all stents are deployed at bifurcations.
[0007] Treatment of stenotic lesions at bifurcations is associated with increased early complications including compromise of either the branch vessel or the parent vessel and increased potential for restenosis.
[0008] One method for stenting a bifurcating vessel includes placing a first stent having a substantially circular side opening in a parent vessel and a second stent having a flared end for stenting the branch vessel.
[0009] The first stent is positioned in the lumen of the parent vessel and expanded, after which the second, flared stent is pressed through the side opening of the first stent and expanded in the branch vessel.
[0010] One drawback of this method is the difficulty of properly aligning the side opening of the first stent with the branch vessel bifurcation so that the branch vessel stent passes into the branch vessel. Another drawback of this system is that the second, flared, stent is difficult to position properly, and may protrude into the blood stream causing thrombosis.
[0011] Another method of treating bifurcations is called the crush method, an example of which is seen in U.S. Patent application 20050049680 (Fischell et al), the entirety of which is hereby incorporated by reference as if fully disclosed herein.
[0012] In this method, a first stent is placed into the branch vessel and expanded so that a portion of the stent protrudes into the parent vessel. A second stent is expanded in the parent vessel, crushing the protruding portion of the first stent against the parent vessel wall around the branch vessel opening.
[0013] If the first stent is not properly crushed, however, the end of the stent will protrude into the bloodstream, often resulting in thrombosis. Additionally, during crushing, the first stent may pull away from the branch vessel so that there is no support of the branch vessel where support is needed most. Finally, the crush method deposits a large amount of metal at the entrance to the branch vessel lumen, where the tissue is thin and often incapable of supporting the metallic bulk, resulting in restenosis.
SUMMARY OF THE INVENTION
[0014] According to some embodiments of the invention there is provided a stent assembly comprising two radially expandable mesh stents separated by a distance with a common stent jacket spanning the distance therebetween.
[0015] In embodiments, the assembly is configured to be positioned so the two mesh stents are located in a parent vessel on either side of a branch vessel bifurcation and the jacket spans the lumen associated with a bifurcation.
[0016] A mesh stent in a contracted state is delivered the site and passed through an aperture in the jacket into the branch vessel and expanded. The aperture expands so that the third stent remains at least partially covered by the stent jacket and the stent jacket spanning between the first, second and third stents supports the stenotic tissue of the bifurcation therebetween.
[0017] The stents are optionally deployed using any one of several techniques, including inter alia pre dilatation angioplasty, post angioplasty, and the above noted “kissing technique” and direct dilation stenting techniques.
[0018] In other embodiments an end of the third stent, in an unexpanded state, is pressed into the jacket and the third stent is expanded, thereby stretching a portion of the stent jacket. Thereafter, the expanded jacket portion is punctured by a puncturing instrument, and an expanding balloon is expanded within the punctured portion. Thereafter, the third stent is passed into the branch vessel and expanded.
[0019] In still further embodiments, a stent assembly comprises two radially expandable mesh parent vessel stents separated by a distance with a common stent jacket spanning the distance therebetween. Third and fourth stents are transported within the lumen formed by the first and second stents and the jacket therebetween. Upon reaching an in situ location, the first and second stents are expanded and the third and fourth stents are pressed through the jacket therebetween to expand in branch vessels.
[0020] According to one aspect of the present invention, there is provided a stent assembly for expanding in vivo vessels, the assembly comprising: two stents, a first stent and a second stent, the two stents positioned so that a forward end of the first stent is separated by a predetermined distance from a rearward end of the second stent, and a stent jacket spanning the predetermined distance such that a first end of the jacket is operatively associated with the first stent and a second end of the jacket is operatively associated with the second stent.
[0021] In embodiments, upon radial expansion of the first stent and the second stent, the first end of the jacket expands radially encircles at least a portion of the first stent and the second end of the jacket expands radially and encircles at least a portion of the second stent.
[0022] In embodiments, the stent jacket spanning the predetermined distance comprises a length sufficient to longitudinally encircle an axially disposed third stent in a contracted state and axially disposed and movably set on a guide wire.
[0023] In embodiments, the stent jacket spanning the predetermined distance comprises an internal surface configured to have a cross sectional diameter sufficient to encircle the third stent while the assembly is being delivered to an in situ location.
[0024] In embodiments, the guide wire is configured with an angulated distal portion that allows manipulation proximate to a portion of the stent jacket following expansion of the first stent and the second stent at the in situ location.
[0025] In embodiments, the angulated distal portion comprises an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0026] In embodiments, the angulated distal portion of the guide wire has a constant cross-sectional diameter and the stent jacket spanning the predetermined distance comprises at least one aperture of sufficient diameter to allow passage of the cross-sectional diameter.
[0027] In embodiments, the portion of the guide wire is configured with sufficient strength to be manipulated through the aperture.
[0028] In embodiments, the at least one aperture is expandable and configured to expand to a diameter sufficient to encircle an outer surface of the third stent while the third stent in the contracted state.
[0029] In embodiments, the mean diameter of the at least one aperture is configured to further expand when the contracted third stent is expanded while encircled by the aperture.
[0030] In embodiments, at least a portion of the stent jacket spanning the predetermined distance is configured to encircle at least a portion of an outer surface of the third stent when the third stent is in an expanded state.
[0031] In embodiments, a first end of the third stent comprises a friction surface configured to catch a portion of the stent jacket when the friction surface stent is pressed against the portion while the third stent is expanding.
[0032] In embodiments, the stent jacket comprises a stretchable material configured to stretch across the first end of the stent while the third stent is expanding during the pressing.
[0033] In embodiments, following expansion of the third stent, a stretched portion of the stent jacket is configured to be punctured by a puncturing tool.
[0034] In embodiments, the stent jacket includes an intact portion spanning the predetermined distance, the intact portion configured to remain intact following the puncturing.
[0035] In embodiments, at least a portion of the intact portion includes at least one fold, the at least one fold being adhered by a pressure-sensitive self-adhering adhesive.
[0036] In embodiments, the punctured portion of the stent jacket is expandable and configured to form a mean diameter that is sufficient to allow the third stent to pass through the puncture.
[0037] In embodiments, the puncturing tool includes an expandable balloon.
[0038] In embodiments, the stent jacket spanning the predetermined distance comprises at least one aperture configured to encircle the expandable balloon in a contracted state.
[0039] In embodiments, the at least one aperture is configured to rip as the expandable balloon is inflated.
[0040] In embodiments, a portion of an outer surface of the third stent is configured to slidingly pass through the aperture following the rip and the aperture is configured to remain encircled around at least a portion of an outer surface of the third stent.
[0041] In embodiments, while the assembly is being delivered to an in situ location: a first portion of the stent jacket spanning the predetermined distance is configured to encircle the axially disposed third stent in a contracted state, and a second portion of the stent jacket spanning the predetermined distance is configured to encircle an axially disposed fourth stent in a contracted state.
[0042] In embodiments, the guide wire upon which the third stent is set comprises a first guide wire and the fourth stent is axially set on a second guide wire having an angulated distal portion comprising an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0043] The assembly according to any one of the previous claims, wherein following expansion the vessels are supported with one layer of stent metal.
[0044] In embodiments, for example for use in a coronary vessel, the first stent is positioned between at least one millimeter and not more than about 20 millimeters from the second stent.
[0045] In other embodiments, the first stent is positioned about three millimeters from the second stent. Optionally, the first stent and second stent are placed in positions that stretch the jacket therebetween.
[0046] In embodiments, upon radial expansion of the first and second stents, the first jacket end expands radially and encircles at least a portion of the first stent and the second end of the jacket expands radially and encircles at least a portion of the second stent.
[0047] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0048] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of about 15 atmospheres.
[0049] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0050] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0051] In embodiments, during expansion, the first stent and the third stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0052] In embodiments, during expansion, the first stent and the third stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of about 15 atmospheres.
[0053] In embodiments, during expansion, the second stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0054] In embodiments, during expansion, the second stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0055] In embodiments, at least a portion of the intact portion includes a pressure-sensitive self-adhering adhesive.
[0056] In embodiments, the adhesive is an adhesive from the group of adhesives comprising: fibrin, biological glue, collagen, hydrogel, hydrocolloid, collagen alginate, and methylcellulose.
[0057] In embodiments, at least a portion of the at least one fold is configured to adhere in response to pressure of at least about one atmosphere and no more than about 20 atmospheres.
[0058] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0059] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of about 15 atmospheres.
[0060] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0061] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0062] In embodiments, during expansion, the first stent and the third stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0063] In embodiments, during expansion, the first stent and the third stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of about 15 atmospheres.
[0064] In embodiments, during expansion, the second stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0065] In embodiments, during expansion, the second stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0066] In embodiments, the third stent is set at an angle to an axis passing through the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0067] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0068] In embodiments, during expansion, the third stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0069] In embodiments, the third stent is positioned to expand substantially outward and substantially radially opposite to the expansion of the fourth stent.
[0070] In embodiments, during expansion, the fourth stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0071] In embodiments, during expansion, the fourth stent is of a sufficient diameter to press at least a portion of the inner walls of a branch vessel with a pressure of about 15 atmospheres.
[0072] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of at least one atmosphere and no more than about 50 atmospheres.
[0073] In embodiments, during expansion, the first stent and the second stent are of a sufficient diameter to press at least a portion of the inner walls of a parent vessel with a pressure of about 15 atmospheres.
[0074] In embodiments, the stents comprise a metallic base from the group consisting of: stainless steel, nitinol, tantalum, MP35N alloy, a cobalt-based alloy, a cobalt-chromium alloy, platinum, titanium, or other biocompatible metal alloys.
[0075] In embodiments, the stents are selected from the group consisting of: a cardiovascular stent, a coronary stent, a peripheral stent, an abdominal aortic aneurysm stent, a cerebral stent, a carotid stent, an endovascular stent, an aortic valve stent, and a pulmonary valve stent.
[0076] In embodiments, the stent jacket comprises a material manufactured by a process from the group consisting of: interlacing knitting, interlocked knitting, braiding, interlacing, and/or dipping a porous mold into one or more reagents.
[0077] In embodiments, during expansion the stents are configured to expand in a manner that dilates the adjacent lumens.
[0078] In embodiments, following expansion the lumens are supported by one layer of stent metal.
[0079] According to one aspect of the invention, there is provided a method for manufacturing a stent assembly for expanding in vivo vessel lumens, the method comprising: providing two axially aligned radially expandable mesh stents, comprising a first stent having a forward end at a predetermined distance from a rearward end of a second stent, attaching a first end of a stent jacket to the first stent, attaching a second end of the stent jacket to the second stent, such that an intermediate portion of the jacket spans the predetermined distance, and encircling a third stent in a contracted state coaxially aligned within the jacket.
[0080] In embodiments the method includes: expanding the two axially radially expandable mesh stent, and angling the third stent at an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0081] In embodiments the method includes: angling a fourth stent at an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0082] In embodiments, the radially expandable stent comprises a metallic base from the group consisting of: stainless steel, nitinol, tantalum, MP35N alloy, a cobalt-based alloy, a cobalt-chromium alloy, platinum, titanium, or other biocompatible metal alloys.
[0083] In embodiments, the radially expandable stent comprises a bio degradable/bio-absorbable base from the group consisting of: PGLA, PLLA, PLA, bio-resorbable magnesium, or other bio resorbable compounds.
[0084] In embodiments, the jacket and the stents comprise a material selected from the group consisting of: polyethylene, polyvinyl chloride, polyurethane, nylon and a biocompatible polymer fiber.
[0085] In embodiments, the jacket and the stents comprise a material selected from the group consisting of: nitinol, stainless steel shape memory materials, metals, synthetic biostable polymer, a natural polymer, and an inorganic material. In embodiments, the biostable polymer comprises a material from the group consisting of: a polyolefin, a polyurethane, a fluorinated polyolefin, a chlorinated polyolefin, a polyamide, an acrylate polymer, an acrylamide polymer, a vinyl polymer, a polyacetal, a polycarbonate, a polyether, a polyester, an aromatic polyester, a polysulfone, and a silicone rubber.
[0086] In embodiments, the natural polymer comprises a material from the group consisting of: a polyolefin, a polyurethane, a Mylar, a silicone, and a fluorinated polyolefin.
[0087] In embodiments, the jacket and the stents comprise a material having a property selected from the group consisting of: compliant, flexible, plastic, and rigid.
[0088] In embodiments, the assembly includes an active pharmaceutical ingredient.
[0089] In embodiments, the API comprises a chemotherapeutic selected from the group consisting of peptides, proteins, nucleic acids, monoclonal antibodies, L-cell agonists, super oxide dismutase Interleukin-10, glucorticoids, sulphazalazine, calcitonin, insulin, 5-fluoracil, leucovorin, fluoropyrimidine S-1,2-deoxycytidine, analgesics, antibacterials, antibiotics, antidepressants, antihistamines, antihelminths, anti-inflammatory agents, antiirritants, antilipemics, antimicrobials, antimycotics, antioxidants, antipruritics, antiseptic, antiswelling agents, antiviral agents, antiyeast agents, astringents, topical cardiovascular agents, chemotherapeutic agents, corticosteroids, fungicides, hormones, hydroxyacids, lactams, non-steroidal anti-inflammatory agents, progestins, statines, sanatives and vasodilators and mixtures thereof.
[0090] In embodiments, the API comprises an analgesic selected from the group consisting of benzocaine, butamben picrate, dibucaine, dimethisoquin, dyclonine, lidocaine, pramoxine, tetracaine, salicylates and derivatives, esters, salts and mixtures thereof.
[0091] In embodiments, the API comprises an antibiotic selected from the group consisting of amanfadine hydrochloride, amanfadine sulfate, amikacin, amikacin sulfate, aminoglycosides, amoxicillin, ampicillin, ansamycins, bacitracin, beta-lactams, candicidin, capreomycin, carbenicillin, cephalexin, cephaloridine, cephalothin, cefazolin, cephapirin, cephradine, cephaloglycin, chloramphenicols, chlorhexidine, chlorhexidine gluconate, chlorhexidine hydrochloride, chloroxine, chlorquinaldol, chlortetracycline, chlortetracycline hydrochloride, ciprofloxacin, circulin, clindamycin, clindamycin hydrochloride, clotrimazole, cloxacillin, demeclocycline, diclosxacillin, diiodohydroxyquin, doxycycline, ethambutol, ethambutol hydrochloride, erythromycin, erythromycin estolate, erythromycin stearate, farnesol, floxacillin, gentamicin, gentamicin sulfate, gramicidin, griseofulvin, haloprogin, haloquinol, hexachlorophene, iminocylcline, iodochlorhydroxyquin, kanamycin, kanamycin sulfate, lincomycin, lineomycin, lineomycin hydrochloride, macrolides, meclocycline, methacycline, methacycline hydrochloride, methenamine, methenamine hippurate, methenamine mandelate, methicillin, metronidazole, miconazole, miconazole hydrochloride, minocycline, minocycline hydrochloride, mupirocin, nafcillin, neomycin, neomycin sulfate, netilmicin, netilmicin sulfate, nitrofurazone, norfloxacin, nystatin, octopirox, oleandomycin, orcephalosporins, oxacillin, oxytetracycline, oxytetracycline hydrochloride, parachlorometa xylenol, paromomycin, paromomycin sulfate, penicillins, penicillin G, penicillin V, pentamidine, pentamidine hydrochloride, phenethicillin, polymyxins, quinolones, streptomycin sulfate, tetracycline, tobramycin, tolnaftate, triclosan, trifampin, rifamycin, rolitetracycline, spectinomycin, spiramycin, streptomycin, sulfonamide, tetracyclines, tetracycline, tobramycin, tobramycin sulfate, triclocarbon, triclosan, trimethoprim-sulfamethoxazole, tylosin, vancomycin, yrothricin and derivatives, esters, salts and mixtures thereof.
[0092] In embodiments, the API comprises an antihistamine selected from the group consisting of chlorcyclizine, diphenhydramine, mepyramine, methapyrilene, tripelennamine and derivatives, esters, salts and mixtures thereof.
[0093] In embodiments, the API comprises a corticosteroid selected from the group consisting of alclometasone dipropionate, amcinafel, amcinafide, amcinonide, beclomethasone, beclomethasone dipropionate, betamethsone, betamethasone benzoate, betamethasone dexamethasone-phosphate, dipropionate, betamethasone valerate, budesonide, chloroprednisone, chlorprednisone acetate, clescinolone, clobetasol, clobetasol propionate, clobetasol valerate, clobetasone, clobetasone butyrate, clocortelone, cortisone, cortodoxone, craposone butyrate, desonide, desoxymethasone, dexamethasone, desoxycorticosterone acetate, dichlorisone, diflorasone diacetate, diflucortolone valerate, difluorosone diacetate, diflurprednate, fluadrenolone, flucetonide, flucloronide, fluclorolone acetonide, flucortine butylesters, fludroxycortide, fludrocortisone, flumethasone, flumethasone pivalate, flumethasone pivalate, flunisolide, fluocinolone, fluocinolone acetonide, fluocinonide, fluocortin butyl, fluocortolone, fluorometholone, fluosinolone acetonide, fluperolone, fluprednidene acetate, fluprednisolone hydrocortamate, fluradrenolone, fluradrenolone acetonide, flurandrenolone, fluticasone, halcinonide, halobetasol, hydrocortisone, hydrocortisone acetate, hydrocortisone butyrate, hydrocortisone cyclopentylpropionate, hydrocortisone valerate, hydroxyltriamcinolone, medrysone, meprednisone, α-methyl dexamethasone, methylprednisolone, methylprednisolone acetate, mometasone furoate, paramethasone, prednisolone, prednisone, pregnenolone, progesterone, spironolactone, triamcinolone, triamcinolone acetonide and derivatives, esters, salts and mixtures thereof.
[0094] In embodiments, the API comprises a hormone selected from the group consisting of methyltestosterone, androsterone, androsterone acetate, androsterone propionate, androsterone benzoate, androsteronediol, androsteronediol-3-acetate, androsteronediol-17-acetate, androsteronediol 3-17-diacetate, androsteronediol-17-benzoate, androsteronedione, androstenedione, androstenediol, dehydroepiandrosterone, sodium dehydroepiandrosterone sulfate, dromostanolone, dromostanolone propionate, ethylestrenol, fluoxymesterone, nandrolone phenpropionate, nandrolone decanoate, nandrolone furylpropionate, nandrolone cyclohexane-propionate, nandrolone benzoate, nandrolone cyclohexanecarboxylate, androsteronediol-3-acetate-1-7-benzoate, oxandrolone, oxymetholone, stanozolol, testosterone, testosterone decanoate, 4-dihydrotestosterone, 5a-dihydrotestosterone, testolactone, 17a-methyl-19-nortestosterone, desogestrel, dydrogesterone, ethynodiol diacetate, medroxyprogesterone, levonorgestrel, medroxyprogesterone acetate, hydroxyprogesterone caproate, norethindrone, norethindrone acetate, norethynodrel, allylestrenol, 19-nortestosterone, lynoestrenol, quingestanol acetate, medrogestone, norgestrienone, dimethisterone, ethisterone, cyproterone acetate, chlormadinone acetate, megestrol acetate, norgestimate, norgestrel, desogrestrel, trimegestone, gestodene, nomegestrol acetate, progesterone, 5a-pregnan-3b,20a-diol sulfate, 5a-pregnan-3b,20b-diol sulfate, 5a-pregnan-3b.-ol-20-one, 16,5a-pregnen-3b-ol-20-one, 4-pregnen-20b-ol-3-one-20-sulfate, acetoxypregnenolone, anagestone acetate, cyproterone, dihydrogesterone, fluorogestone acetate, gestadene, hydroxyprogesterone acetate, hydroxymethylprogesterone, hydroxymethyl progesterone acetate, 3-ketodesogestrel, megestrol, melengestrol acetate, norethisterone and derivatives, esters, salts and mixtures thereof.
[0095] In embodiments, the API comprises a non-steroidal anti-inflammatory agent selected from the group consisting of azelaic acid, oxicams, piroxicam, isoxicam, tenoxicam, sudoxicam, CP-14,304, salicylates, aspirin, disalcid, benorylate, trilisate, safapryn, solprin, diflunisal, fendosal, acetic acid derivatives, diclofenac, fenclofenac, indomethacin, sulindac, tolmetin, isoxepac, furofenac, tiopinac, zidometacin, acematacin, fentiazac, zomepirac, clindanac, oxepinac, felbinac, ketorolac, fenamates, mefenamic, meclofenamic, flufenamic, niflumic, tolfenamic acids, propionic acid derivatives, ibuprofen, naproxen, benoxaprofen, flurbiprofen, ketoprofen, fenoprofen, fenbufen, indopropfen, pirprofen, carprofen, oxaprozin, pranoprofen, miroprofen, tioxaprofen, suprofen, alminoprofen, tiaprofen, pyrazoles, phenylbutazone, oxyphenbutazone, feprazone, azapropazone, trimethazone and derivatives, esters, salts and mixtures thereof.
[0096] In embodiments, the API comprises a vasodilator selected from the group consisting of ethyl nicotinate, capsicum extract and derivatives, esters, salts and mixtures thereof. In embodiments, the stent assembly includes a low-bulk mesh jacket designed to promote a stable layer of endothelial cells.
[0097] In embodiments, the mesh comprises fiber having a low diameter that allows each endothelial cell to fully cover and overlap each fiber, thereby forming a layer of endothelial cells that adhere to tissue on either side of the fiber. The thus formed endothelial layer is substantially stable with a substantially reduced tendency to break away and form emboli.
[0098] In embodiments, the mesh fiber comprises material that encourages adherence of endothelial cells, thereby encouraging endothelial layer stability.
[0099] In embodiments, each mesh fiber is spaced a distance from a neighboring fiber thereby preventing a single endothelial cell from adhering to more than one fiber, thereby reducing the chance that endothelial cells will break free of the stent, for example as a result of natural stent pulsation during blood flow.
[0100] In embodiments, the stent jacket optionally comprises a mesh that is knitted. In accordance with some embodiments of the present invention, the stent jacket mesh is optionally formed from a single fiber or a single group of fibers.
[0101] In embodiments, the stent assembly includes a stent jacket comprising an expansible mesh structure, formed of fibers of a diameter between about 7 micrometers and about 18 micrometers, the diameter having a property of forming a substantially stable layer of endothelial cells, covering the fibers, thus reducing to platelet aggregation, and an expansible stent, operatively associated with the stent jacket.
[0102] In embodiments, the fiber diameter is between about 10 micrometers and about 15 micrometers.
[0103] In embodiments, the fiber diameter is between about 11 micrometers and about 14 micrometers.
[0104] In embodiments, the fiber diameter is between about 12 micrometers and about 13 micrometers.
[0105] In embodiments, the fiber diameter is between about 12.5 micrometers. In embodiments, the mesh is formed as a single knit. In embodiments, the fiber is formed from multiple filaments.
[0106] In embodiments, the mesh jacket structure comprises a retracted state and a deployed state, and further in the deployed state, the mesh structure defines apertures having a minimum center dimension, which is greater than about 180 micrometers, thus minimizing occurrences of a single endothelial cell adhering to more than one fiber, across one of the apertures, and reducing a chance of endothelial cells breaking free as a result of natural stent pulsation with blood flow.
[0107] In embodiments, the minimum center dimension is greater than about 200 micrometers.
[0108] According to another aspect of the invention, there is provided a method for manufacturing a stent assembly for expanding in vivo vessel lumens, the method comprising: providing two axially aligned radially expandable mesh stents, comprising a first stent and a second stent, at a predetermined distance from each other, attaching a first end of a stent jacket to the first stent, attaching a second end of the stent jacket to the second stent, such that an intermediate portion of the jacket spans the predetermined distance, and encircling a third stent in a contracted state coaxially aligned within the jacket.
[0109] In embodiments the method includes: expanding the two axially radially expandable mesh stent, and angling the third stent at an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0110] In embodiments the method includes: angling a fourth stent at an angle to an axis running between the first stent and the second stent of at least about 15 degrees and no more than about 165 degrees.
[0111] Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0112] Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.
[0113] In the drawings:
[0114] FIGS. 1 a - 1 d show deployment of prior art stents in bifurcating vessels;
[0115] FIGS. 2 a - 2 e show stents and stent jackets being deployed in cross sections of bifurcating vessels, according to embodiments of the invention; and
[0116] FIGS. 3 a - 8 d show alternative embodiments of the stents and stent jackets of FIG. 2 e being deployed in cross sections of bifurcating vessels, according to embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0117] The present invention, which relates to stent assemblies configured for assembling in bifurcating vessels, is herein described, by way of example only, with reference to the accompanying drawings. The principles and operation of the present invention may be better understood with reference to the drawings and accompanying descriptions.
[0118] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
[0119] Referring now to the drawings:
[0120] In FIG. 1 a , arteries 127 form an upper branch vessel lumen 151 , a proximal parent vessel lumen 129 and a distal parent vessel lumen 125 .
[0121] FIGS. 1 b - 1 d show the crush method, noted above, for treating a bifurcation. As seen in FIG. 1 b , a crush stent assembly 100 comprises a branch stent 206 configured for expansion in upper branch lumen 151 . Branch stent 206 , shown herein without a jacket, comprises a metal or polymer tubular structure having mesh-like, apertures 270 . Branch stent 206 is shown encircling a balloon 260 and, upon expansion of balloon 260 , branch stent 206 expands radially outward.
[0122] As seen in FIG. 1 c , branch stent 206 has expanded radially in upper branch lumen 151 so that branch stent 206 presses against a stenotic area of tissue 240 , thereby compressing and cracking stenotic area 240 radially outward within upper branch lumen 151 . To further ensure flow of blood, a second balloon (not shown) is expanded against a flange 102 to crush flange 102 into proximal lumen 129 and into distal lumen 125 .
[0123] Deployed stent assembly 100 crushes stenotic tissue 240 in lumens 151 , 129 and 125 , thereby allowing better circulation through arteries 127 . However, as noted above and seen in FIG. 1 d , branch stent 206 creates a significant amount of metal related to flange 102 that may subject artery walls 127 to restenosis, in addition to causing turbulence and thrombosis formation.
[0124] Referring to FIG. 2 a , in an embodiment of the present invention, a stent system 200 , comprises a proximal parent vessel stent 202 and a distal parent vessel stent 208 that are covered by an external jacket 204 . Assembly 200 is positioned in artery 127 so that proximal stent 202 is positioned in proximal lumen 129 and distal stent 208 is positioned in distal lumen 125 . In embodiments, for example for use in a coronary vessel, proximal stent 202 is positioned between at least one millimeter and not more than about 20 millimeters from distal stent 208 . In other embodiments, proximal stent 202 is positioned about three millimeters from distal stent 208 . Optionally, proximal stent 202 and distal stent 208 are placed in positions that stretches external jacket 204 therebetween.
[0125] In alternative embodiments proximal stent 202 and distal stent 208 are configured and appropriately sized as cardiovascular stents, peripheral stents, abdominal aortic aneurysm stents, cerebral stents, carotid stents, endovascular stents, aortic valve stents, and pulmonary valve stents.
[0126] As seen in FIG. 2 b , balloon 260 has been inflated, thereby expanding stents 202 and 208 so that stent jacket 204 spans upper branch lumen 151 .
[0127] Optionally, balloon 260 is inflated in a manner that crushes stent jacket 204 to aid in opening in lumens 151 , 129 and 125 and to avoid jailing of upper branch lumen 151 by stent jacket 204 .
[0128] As seen in FIG. 2 c , balloon 260 has been removed and the structure of stent jacket 204 can be appreciated. Stent jacket 204 typically comprises a knitted material having large apertures 103 .
[0129] As seen in FIG. 2 d , branch stent 206 positioned on balloon 260 has been pressed into stent jacket 204 , through one of apertures 103 . As seen in FIG. 2 e , branch stent 206 has been expanded, thereby expanding aperture 103 and causing an encircling portion of jacket 231 to encircle branch stent 206 .
[0130] In addition to the support provided by stents 202 , 206 and 208 , stent jacket 204 spanning therebetween, supports stenotic tissue 240 at the bifurcation of upper branch lumen 151 . Using stent jacket 204 as a support along the bifurcation of upper branch lumen 151 results in low bifurcation-related bulk that could cause restenosis and/or thrombosis noted above.
[0131] In alternative embodiments, balloon 260 ( FIG. 2 d ) is first used alone to predilate one of apertures 103 , after which unexpanded branch stent 206 is pressed through predilated aperture 103 and expanded in upper branch lumen 151 .
[0132] In embodiments, stents 202 , 206 and 208 comprise any metallic base including, inter alia: stainless steel, nitinol, tantalum, MP35N alloy, a cobalt-based alloy, a cobalt-chromium alloy, platinum, titanium, or other biocompatible metal alloys.
[0133] In further embodiments, stents 202 , 206 and 208 are deployed in any vessel comprising, inter alia: cardiovascular tissue, peripheral tissue, an abdominal aortic aneurysm, cerebral tissue, carotid tissue, endovascular tissue, aortic valves, and/or pulmonary tissue.
[0134] In still further embodiments, stent jacket 204 comprises any material manufactured by a process including, inter alia: interlacing knitting, interlocked knitting, braiding, interlacing, and/or dipping a porous mold into one or more reagents.
[0135] As used herein, any reference to a “knitted material” includes any material that is manufactured by a knitting process, including, inter alia: a material knitted from a single fiber, similar to the process used in pantyhose nylon; a double fiber knit, referred to as a “double knit material”; and includes fibers, either mono filament or multi filament fiber of, inter alia: polyethylene, polyvinyl chloride, polyurethane, nylon, a biocompatible polymer fiber, and stainless steal nitinol, or any other metal.
[0136] In embodiments, proximal stent 202 , distal stent 208 and branch stent 206 comprise a metallic base from the group consisting of: stainless steel, nitinol, tantalum, MP35N alloy, a cobalt-based alloy, a cobalt-chromium alloy, platinum, titanium, or other biocompatible metal alloys.
[0137] In embodiments, proximal stent 202 , distal stent 208 and branch stent 206 are manufactured with sufficient diameters to press at least a portion of the inner walls of artery 127 with a pressure of at least one atmosphere and no more than about 50 atmospheres. In embodiments, proximal stent 202 , distal stent 208 and branch stent 206 are manufactured with sufficient diameters to press at least a portion of the inner walls of artery 127 with a pressure of about 15 atmospheres.
[0138] FIG. 3 a shows a stent system 300 in which proximal stent 202 has been deployed in proximal lumen 129 , and branch stent 206 has been deployed in upper branch lumen 151 , while stent jacket 204 spans across distal lumen 125 . Typically, upper branch lumen 151 has a smaller diameter than proximal lumen 129 and first balloon (not shown) having a smaller expanded diameter is used to expand branch stent 206 .
[0139] As seen in FIG. 3 b , following expansion of stent 206 , a second balloon 260 having a large expanded diameter is used to expand proximal lumen stent 202 .
[0140] As seen in FIG. 3 b , distal parent vessel stent 208 is pushed through apertures 103 . As seen in FIG. 3 c and distal parent vessel stent 208 has been expanded in distal lumen 125 .
[0141] Referring to FIG. 4 a , arteries 127 include a lower side branch lumen 152 . As seen in FIG. 4 b , a dual branch stent assembly 400 comprises stent jacket 204 having an upper sleeve 406 that is partially inside-out and surrounding upper branch stent 206 . Stent jacket 204 further comprises a lower sleeve 412 that is inside out and surrounding a lower branch stent 212 .
[0142] Dual branch stent assembly 400 has been positioned so that distal stent 208 , upon expansion with a balloon (not shown), opens distal lumen 125 . Proximal stent 202 is then expanded with balloon 260 to open proximal lumen 129 .
[0143] As seen in FIG. 4 c , balloon 260 has been positioned inside lower branch stent 212 and during expansion, balloon 260 is used to push lower branch stent 212 into lower branch lumen 152 , thereby straightening lower jacket 204 so that sleeve 412 is no longer inside-out. Balloon 260 then expands lower branch stent 212 to open lower branch lumen 152 .
[0144] As seen in FIG. 4 d , balloon 260 has been positioned inside upper branch stent 206 and, during expansion, balloon 260 is used to push upper branch stent 206 into upper branch lumen 151 , thereby straightening upper branch sleeve 406 . Balloon 260 then expands upper branch stent 206 to open upper branch lumen 151 .
[0145] As seen in FIG. 4 e , an encircling portion 271 of lower branch sleeve 412 , partially covers lower branch stent 212 while an encircling portion 281 of upper branch sleeve 406 partially covers upper branch stent 206 , thereby providing support of stenotic tissue 240 therebetween.
[0146] Referring to FIG. 5 a , a stent assembly 500 has been positioned and expanded so that proximal stent 202 is positioned in proximal lumen 129 and distal stent 208 is positioned in distal lumen 125 . Stent jacket 204 , positioned between stents 202 and 208 , includes a stretchable material 510 . As seen in FIG. 5 b , balloon 260 , surrounded by unexpanded upper branch stent 206 has been pressed into stretchable material 510 , causing stent jacket 204 to bulge into upper branch lumen 151 .
[0147] In FIG. 5 c , balloon 260 has been expanded, thereby causing a partial expansion of upper branch stent 206 . Partially expanded upper branch stent 206 stretches stretchable material 510 , creating considerable tension on the portion of stent jacket 204 that spans upper branch lumen 151 .
[0148] In FIG. 5 d , balloon 260 has been partially deflated and pressed in an upward direction 512 , thereby puncturing material 510 and creating an opening 518 . Partially deflated balloon 260 is then moved in a downward direction 514 and partially inflated to expand and be secured within upper branch stent 206 . Balloon 260 and upper branch stent 206 are then moved in upward direction 514 causing upper branch stent 206 to pass through opening 518 and into upper branch lumen 151 .
[0149] Balloon 260 is then fully expanded to cause upper branch stent 206 to fully expand. As seen in FIG. 5 e , upper branch stent 206 is partially covered by stretchable material 510 , fully expanded in upper branch lumen 151 while balloon 260 has been deflated and is being moved in direction 514 to be removed percutaneously from artery 127 .
[0150] Referring to FIG. 6 a , a stretch stent assembly 600 has been positioned and expanded so that proximal stent 202 is positioned in proximal lumen 129 and distal stent 208 is positioned in distal lumen 125 . As seen in FIG. 6 b , balloon 260 , has been pressed into stretchable material 510 , causing stent jacket 204 to bulge into upper branch lumen 151 .
[0151] In FIG. 6 c , balloon 260 has been fully expanded, thereby puncturing material 510 and creating opening 518 . In FIG. 6 d , balloon 260 has been partially deflated and pulled downward in direction 514 . Following loading of upper branch stent 206 , as seen in FIG. 6 e , balloon 260 is partially inflated to move upper branch stent 206 through opening 518 . With upper branch stent 206 properly positioned in upper lumen 151 , balloon 260 is then fully expanded so that upper branch stent 206 expands to fully open upper branch lumen 151 .
[0152] Balloon 260 is then deflated and pulled percutaneously in proximal direction 514 and removed from arteries 127 . FIG. 6 f shows branch stent 206 fully expanded in branch lumen 151 and balloon 260 being removed in direction 514 .
[0153] Referring to FIG. 7 a , assembly 700 has been positioned and expanded so that proximal stent 202 is positioned in proximal lumen 129 and distal stent 208 is positioned in distal lumen 125 . A catheter 262 spans from distal lumen 125 through proximal lumen 129 and is positioned adjacent to upper branch lumen 151 with upper branch stent 206 surrounding balloon 260 .
[0154] In embodiments, as seen in FIG. 7 b , catheter 262 is pulled in a proximal direction 710 until the distal portion of catheter 262 is fully contained within balloon 260 . Catheter 262 is then moved in a distal direction 712 to cause stretchable material 510 to bulge into upper branch lumen 151 .
[0155] As seen in FIG. 7 c , balloon 260 has been expanded, thereby expanding upper branch stent 206 , piercing material 510 and creating opening 518 . As seen in FIG. 7 d , balloon 260 has been deflated, leaving upper branch stent 206 partially covered by stent jacket 204 .
[0156] Referring to FIG. 8 a , stent system 800 comprises a jacket having billowing walls 812 that include an upper billowing wall potion 810 . In embodiments, billing walls include a biocompatible adhesive so that upon inflation, balloon 260 presses billowing wall 812 against artery 127 , thereby creating folds in billowing walls 812 .
[0157] As balloon 260 continues to expand, folds in billowing wall 812 are compressing to adhere to each other and compressed against artery 127 . In distinct contrast, as seen in FIG. 8 c , upper billowing wall portion 810 is adjacent to upper branch lumen 151 , is pressed into branch lumen 151 and does not form adherent folds.
[0158] As seen in FIG. 8 d further expansion of upper branch stent 206 punctures stent jacket 204 , creating a punctured opening 840 and upper branch stent 206 has opened upper branch lumen 151 .
[0159] As used herein, the terms proximal and proximally refer to a position and a movement in an upstream direction from lumen 129 toward vessel lumen 151 . As used herein, the terms distal and distally refer to a position and a movement, respectively, in a downstream direction from lumen 151 toward lumen 129 . In embodiments, stent jacket 204 has a thickness of at least about 20 microns and no more than about 200 microns.
[0160] It is expected that during the life of a patent maturing from this application many relevant bifurcating stent materials and manufacturing techniques will be developed and the scope of the term bifurcating stent is intended to include all such new technologies a priori.
[0161] As used herein the term “about” refers to ±10%
[0162] The terms “comprises”, “comprising”, “includes”, “including”, “having” and their conjugates mean “including but not limited to”. This term encompasses the terms “consisting of” and “consisting essentially of”.
[0163] The phrase “consisting essentially of” means that the composition or method may include additional ingredients and/or steps, but only if the additional ingredients and/or steps do not materially alter the basic and novel characteristics of the claimed composition or method.
[0164] As used herein, the singular form “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a compound” or “at least one compound” may include a plurality of compounds, including mixtures thereof.
[0165] Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
[0166] Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.
[0167] As used herein the term “method” refers to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the chemical, pharmacological, biological, biochemical and medical arts.
[0168] As used herein, the term “treating” includes abrogating, substantially inhibiting, slowing or reversing the progression of a condition, substantially ameliorating clinical or aesthetical symptoms of a condition or substantially preventing the appearance of clinical or aesthetical symptoms of a condition.
[0169] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.
[0170] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
[0171] All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. | Disclosed is a stent assembly for expanding in vivo vessels, the assembly comprises: two stents, a first stent and a second stent, the two stents positioned so that a forward end of the first stent is separated by a predetermined distance from a rearward end of the second stent, and a stent jacket spanning the predetermined distance such that a first end of the jacket is operatively associated with the first stent and a second end of the jacket is operatively associated with the second stent. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to data security and cryptography and to improving the security of computer enabled cryptographic processes.
BACKGROUND
[0002] In the field of data Security, there is a need for fast and secure encryption. This is why the AES (Advanced Encryption Standard) cipher has been designed and standardized to replace the DES (Data Encryption Standard) cipher. Cryptographic algorithms are widely used for encryption and decryption of messages, authentication, digital signatures and identification. AES is a well known symmetric block cipher. Block ciphers operate on blocks of plaintext and ciphertext, usually of 64 or 128 bits length but sometimes longer. Stream ciphers are the other main type of cipher and operate on streams of plain text and cipher text 1 bit or byte (sometimes one word) at a time. There are modes of operation (notably the ECB, electronic code block) where a given block is encrypted to always the same ciphertext block. This is an issue which is solved by a more evolved mode of operations, e.g. CBC (cipher block chaining) where a chaining value is used to solve the 1-to-1 map.
[0003] AES is approved as an encryption standard by the U.S. Government. Unlike its predecessor DES (Data Encryption Standard), it is a substitution permutation network (SPN). AES is fast to execute in both computer software and hardware implementation, relatively easy to implement, and requires little memory. AES has a fixed block size of 128 bits and a key size of 128, 192 or 256 bits. Due to the fixed block size of 128 bits, AES operates on a 4×4 array of bytes. It uses key expansion and like most block ciphers a set of encryption and decryption rounds (iterations). Each round involves the same processes. Use of multiple rounds enhances security. Block ciphers of this type use in each round a substitution box (s-box). This operation provides non-linearity in the cipher and significantly enhances security.
[0004] Note that these block ciphers are symmetric ciphers, meaning the same key is used for encryption and decryption. As is typical in most modern ciphers, security rests with the (secret) key rather than the algorithm. The s-boxes or substitution boxes accept an n bit input and provide an m bit output. The values of m and n vary with the cipher and the s-box itself. The input bits specify an entry in the s-box in a particular manner well known in the field.
[0005] Many encryption algorithms are primarily concerned with producing encrypted data that is resistant to decrypting by an attacker who can interact with the encryption algorithm only as a “Black Box” (input-output) model, and cannot observe internal workings of the algorithm or memory contents, etc due to lack of system access. The Black Box model is appropriate for applications where trusted parties control the computing systems for both encoding and decoding ciphered materials.
[0006] However, many applications of encryption do not allow for the assumption that an attacker cannot access internal workings of the algorithm. For example, encrypted digital media often needs to be decrypted on computing systems that are completely controlled by an adversary (attacker). There are many degrees to which the Black Box model can be relaxed. An extreme relaxation is called the “White Box” model. In a White Box model, it is presumed that an attacker has total access to the system performing an encryption, including being able to observe directly a state of memory, program execution, modifying an execution, etc. In such a model, an encryption key can be observed in or extracted from memory, and so ways to conceal operations indicative of a secret key are important.
[0007] Classically, software implementations of cryptographic building blocks are insecure in the White Box threat model where the attacker controls the execution process. The attacker can easily lift the secret key from memory by just observing the operations acting on the secret key. For example, the attacker can learn the secret key of an AES software implementation by observing the execution of the key schedule algorithm.
[0008] Hence there are two basic principles in the implementation of secure computer applications (software). The Black Box model implicitly supposes that the user does not have access to the computer code nor any cryptographic keys themselves. The computer code security is based on the tampering resistance over which the application is running, as this is typically the case with SmartCards. For the White Box model, it is assumed the (hostile) user has partially or fully access to the implemented code algorithms; including the cryptographic keys themselves. It is assumed the user can also become an attacker and can try to modify or duplicate the code since he has full access to it in a binary (object code) form. The White Box implementations are widely used (in particular) in content protection applications to protect e.g. audio and video content.
[0009] Software implementations of cryptographic building blocks are insecure in the White Box threat model where the attacker controls the computer execution process. The attacker can easily extract the (secret) key from the memory by just observing the operations acting on the secret key. For instance, the attacker can learn the secret key of an AES cipher software implementation by passively monitoring the execution of the key schedule algorithm. Also, the attacker could be able to retrieve partial cryptographic result and use it in another context (using in a standalone code, or injecting it in another program, as an example).
[0010] Content protection applications such as for audio and video data are one instance where it is desired to keep the attacker from finding the secret key even though the attacker has complete control of the execution process. The publication “White-Box Cryptography in an AES implementation” Lecture Notes in Computer Science Vol. 2595, Revised Papers from the 9th Annual International Workshop on Selected Areas in Cryptography pp. 250-270 (2002) by Chow et al. discloses implementations of AES that obscure the operations performed during AES by using table lookups (also referred to as TLUs) to obscure the secret key within the table lookups, and obscure intermediate state information that would otherwise be available in arithmetic implementations of AES. In the computer field, a table lookup table is an operation consisting of looking in a table (also called an array) at a given index position in the table.
[0011] Chow et al. (for his White Box implementation where the key is known at the computer code compilation time) uses 160 separate tables to implement the 11 AddRoundKey operations and 10 SubByte Operations (10 rounds, with 16 tables per round, where each table is for 1 byte of the 16 byte long—128 bit—AES block). These 160 tables embed a particular AES key, such that output from lookups involving these tables embeds data that would normally result from the AddRoundKey and SubByte operations of the AES algorithm, except that this data includes input/output permutations that make it more difficult to determine what parts of these tables represent round key information derived from the AES key. Chow et al. provide a construction of the AES algorithm for such White Box model. The security of this construction resides in the use of table lookups and masked data. The input and output mask applied to this data is never removed along the process. In this solution, there is a need for knowing the key value at the compilation time, or at least to be able to derive the tables from the original key in a secure environment.
[0012] The conventional implementation of a block cipher in the White Box model is carried out by creating a set of table lookups. Given a dedicated cipher key, the goal is to store in a table the results for all the possible input messages. This principle is applied for each basic operation of the block cipher. In the case of the AES cipher, these are the shiftRow, the add RoundKey, the subByte and the mixColumns operations.
[0013] However, Chow et al. do not solve all the security needs for block cipher encryption in a White Box environment. Indeed, the case where the cipher key is derived through a given process and so is unknown at the code compilation time is not addressed by Chow et al. Further, the publication “Cryptanalysis of a White Box AES Implementation” by Olivier Billet et al., in “Selected Areas in Cryptography 2004” (SAC 2004), pages 227-240 is a successful attack on a White Box cipher of the type described by Chow et al., indicating weaknesses in Chow et al.'s approach.
SUMMARY
[0014] This disclosure is of a powerful, efficient and new solution to harden the extraction of data from an AES (or other) cipher in a White Box environment by means of a protection process. Further, the present method may be used in a more general case of other cryptographic processes, e.g., encryption or decryption of respectively a plaintext or ciphertext message. The present disclosure therefore is directed to hiding the states of the process in a better way. This disclosure further is of efficient solutions to protect AES (or other cipher) states in a White Box implementation using group field automorphisms and multiplicative masks.
[0015] The present protection method masks the state (value) of the cryptographic process at the level of each cipher operation, in terms of the input and output state of each operation or selected operations. In this sense masking means obscuring the “clear” (conventional) value of the state by applying to the state a masking or mask value via a logical or mathematical operation.
[0016] While generally such masking is well known, the present method allows application of dynamic (changing) masks values even though the actual cipher operations are kept static (not changing.) The mask values here are applied by an arithmetic multiplication process. The multiplication is performed using conventional mathematical logarithms, so the actual mask function calculations are performed as an addition of two logarithms modulus some integer value.
[0017] The present system and method address those cases where there is a need to harden “dynamically” the process against an attacker. This aspect of the present disclosure can be combined with other protection solutions.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 shows, in the prior art, AES encryption.
[0019] FIG. 2 shows a computing system in accordance with the invention.
[0020] FIG. 3 shows a computing system as known in the art and used in accordance with the invention.
DETAILED DESCRIPTION
AES Description
[0021] See the NIST AES standard for a more detailed description of the AES cipher (Specification for the ADVANCED ENCRYPTION STANDARD (AES), NIST, http://csrc.nist.gov/publications/fips/fips197/fips-197.pdf). The following is a summary of the well known AES cipher. The AES cipher uses a 16 byte cipher key, and has 10 rounds (final plus 9 others). The AES encryption algorithm has the following operations as depicted graphically in prior art FIG. 1 and showing round zero of the 9 rounds:
11 AddRoundKey Operations 10 SubByte Operations 10 ShiftRow Operations 9 MixColumn Operations
[0026] AES is computed using a 16-byte buffer (computer memory) referred to as the AES “state” in this disclosure and shown in FIG. 1 .
[0027] To summarize,
(i) AddRoundKeys (ARK) logically XOR (the Boolean exclusive OR operation) some subkey bytes with the state bytes. (ii) ShiftRows (SR) are a move from one byte location to another. (iii) MixColums (MC) are a linear table-look up (TLU), applied to 4 bytes. (iv) SubBytes (SB) are a non-linear TLU, applied to 1 byte.
[0032] Preliminarily to the encryption itself, in the initial round in FIG. 1 , the original 16-byte cipher key is expanded to 11 subkeys designated K0, . . . , K10, so there is a subkey for each round during what is called the key-schedule. Each subkey, like the original key, is 16-bytes long.
[0033] The following explains AES decryption round by round. For the corresponding encryption (see FIG. 1 ), one generally performs the inverse of each operation, in the inverse order. (The same is true for the cryptographic processes in accordance with the invention as set forth below.) The inverse operation of ARK is ARK itself, the inverse operation of SB is the inverse subbyte (ISB) which is basically another TLU, the inverse operation of MC is the inverse mix column (IMC) which is basically another TLU, and the inverse operation of SR is the inverse shift row (ISR) which is another move from one byte location to another.
[0034] Expressed schematically, AES decryption is as follows:
ARK (K10) ISR ISB ARK (K9) IMC ISR ISB ARK (K8) IMC ISR ISB ARK (K7) IMC ISR ISB ARK (K6) IMC ISR ISB ARK (K5) IMC ISR ISB ARK (K4) IMC ISR ISB ARK (K3) IMC ISR ISB ARK (K2) IMC ISR ISB ARK (K1) IMC ISR ISB ARK (K0)
[0075] Without lack of generality, the exemplary description here of the present method is for decryption, but it is evident that the method in accordance with the invention can be used also for encryption (see FIG. 1 showing conventional AES encryption) or other cryptographic processes. The method in accordance with the invention also can easily be applied to other variants of AES with more rounds (the 192 and 256-bit key length versions) as well as to other block ciphers and more generally to non-block ciphers and other key based cryptographic processes.
[0076] AES is considered very efficient in terms of execution on many different computer architectures since it can be executed only with table lookups (TLU) and the exclusive-or (XOR) operation. It is known that the AES state can be handled as a 4×4 square of bytes. As a square, it can be seen as 4 columns of 4 bytes each.
[0077] As described above, AES decryption is a succession of basic operations: ISB for the inverse of SubByte, IMC (for the inverse of MixColumn) and ISR (for the inverse of ShiftRow). The ISR operation modifies the state by shifting each row of the square. This operation does not modify the bytes themselves but only their respective positions. The ISB operation is a permutation from [0, 255] to [0, 255], which can be implemented by a table look-up.
[0078] The IMC operation is a bijective linear function from a column (4B) to a column. As a linear function, it accepts a matrix as a representation expressed as:
[e, 9, d, b] [b, e, 9, d] [d, b, e, 9] [ 9 , d, b, e]
where each coefficient in this matrix represents a linear function applied to a byte. For a vector [w, x, y, z] of four bytes, the output of operation IMC is expressed as:
[[e.w XOR 9.x XOR d.y XOR b.z], [b.w XOR e.x XOR 9.y XOR d.z], [d.w XOR b.x XOR e.y XOR 9.z], [9.w XOR d.x XOR b.y XOR e.z]]
[0087] In order to be implemented efficiently, one needs to modify the order of the operations executed in AES decryption. Since IMC is a linear operation and since the ARK operation consists of logically XORing a constant to the AES state, these operations can be permuted. This idea is known and is used often in optimized AES decryption implementations.
[0088] However, this implies a modification of the keys used in the ARK operation. Let Ki be the 16-Byte subkey used in the round designated by index value i and let Ki1, Ki2, Ki3 and Ki4 be the four sets of four bytes of the keys related to the columns of the AES state. By definition,
[0000] Ki=[Ki 1 ,Ki 2 ,Ki 3 ,Ki 4].
[0089] The normal flow of operations for an AES decryption is expressed as:
ARK ([Ki1, Ki2, Ki3, Ki4]) IMC
[0092] But this is equivalent to:
IMC ARK ([IMC(Ki1), IMC(Ki2), IMC(Ki3), IMC(Ki4)])
because operation IMC is linear.
[0095] For this reason, the AES decryption is expressed schematically as:
ARK (K10) ISR ISB IMC ARK (Kx9) ISR ISB IMC ARK (Kx8) ISR ISB IMC ARK (Kx7) ISR ISB IMC ARK (Kx6) ISR ISB IMC ARK (Kx5) ISR ISB IMC ARK (Kx4) ISR ISB IMC ARK (Kx3) ISR ISB IMC ARK (Kx2) ISR ISB IMC ARK (Kx1) ISR ISB ARK (K0)
where Kxi is the subround key designated above Ki and modified as explained above (with the application of the IMC operation to it). So in this new flow of operations, each ISB operation is followed by an IMC operation except for the ISB operation between keys Kx1 and K0. This property improves efficiency between K10 and K1. Note that the computation of keys Kxi can be done in the key initialization phase.
[0136] Let IS be the function applying operation ISB on a byte and let “->” define the function “x->f(x)” meaning “x becomes f(x)” so:
IS1 is the function on x: x->09.IS(x) IS2 is the function on x: x->0b.IS(x) IS3 is the function on x: x->0d.IS(x) IS4 is the function on x: x->0e.IS(x)
[0141] These functions are permutations from [0, 255] to [0, 255] and are implemented by a table look-up.
[0142] Applying operations ISB and IMC to a vector designated [w, x, y, z] as in the previous example is done by computing:
[[IS4(w) XOR IS1(x) XOR IS3(y) XOR IS2(z)], [IS2(w) XOR IS4(x) XOR IS1(y) XOR IS3(z)], [IS3(w) XOR IS2(x) XOR IS4(y) XOR IS1(z)], [IS1(w) XOR IS3(x) XOR IS2(y) XOR IS4(z)]]
[0147] So to apply the operations ISB and IMC during the rounds 10 to 1, it is sufficient to apply the functions IS1 to IS4 to each byte. The output bytes remain to be logically XORed together to obtain the output of the function, as shown in the example.
[0148] Note that the final decryption round is different since no IMC operation is used. This implies that instead of using the operations ISi, it suffices to replace them by the operation IS.
[0149] To sum up, the AES decryption is understood as a sequence of ARK and (ISB-IMC) operations. The (ISB-IMC) operation is done by table look-up and XOR operations. This last operation is implemented with 64 table look ups for each round (4 for each byte) and 48 XOR operations.
AES Properties
[0150] The following describes known properties of components of the AES cipher that are used in the present method to improve security of the AES (or any similar) cipher. The SubByte (SB) operation was intentionally chosen by the designers of the AES cipher. As well known, in the SB operation, each data byte in the array (state) is updated using an 8-bit substitution box called the S-box. The S-box is a result of a multiplication inverse in the Galois Field of 256, referred to as GF (2 8 ), to provide nonlinearity to the cipher. The S-box combines the inverse function extended to 0 with an invertible affine function. SubByte thus is a function GF(2 8 ). A Galois field in mathematics is a field (e.g., a set) that contains only a finite number of elements, called the “order”. So for the operation in GF(2 8 ):
[0000] SB( x )= A ( x 254 )
[0000] where A is the given affine function (see the AES cipher specification) and x is the cipher state value. This is on a byte considered as an element of GF(2 8 ). An affine function performs an affine transformation on its argument (e.g., a vector) to linearly transform (rotate or scale) and translate X (shift) the argument to another vector. The notation A(X) means the affine function applied to value X.
[0151] One can then write in terms of the cipher operations SB, ISB:
[0000] SB= A oINV,
[0000] and
[0000] ISB=INVo A −1
[0000] where INV is the multiplicative inversion in GF(2 8 ), A −1 is the inverse of the affine function A, and symbol “o” designates a composition of functions. (Multiplicative inversion here means conventionally that the inversion of x is 1/x, unless x=0 when 1/x=x 254 .) Due to this equality, there are some useful properties of input and output masks that may be applied to SB and ISB and the other cipher operations.
[0152] Let M λ designate the linear matrix that computes in GF(2 8 ) the multiplication by element λ, where λ is a non-zero element (member) of GF(2 8 ). Since this is a multiplication and since λ≠0, it has the following property:
[0000] INVo M λ =K 1/λ oINV
[0000] where 1/λ is 1 divided by the value of λ in GF(2 8 ).
[0153] From this equality, one derives:
[0000]
SB
·
M
λ
=
A
·
M
1
/
λ
·
A
-
1
·
SB
=
N
1
/
λ
·
SB
[0000] where N 1/λ also designates a linear permutation expressed as a matrix. This means that certain linear permutations applied on the state input of operation SB, for instance to mask the state, imply a linear output mask on the output state of operation SB, that also masks the state. So here the masking involves multiplying the state value to be masked by λ. Unmasking (recovery of the original state value) involves multiplying by the inverse of λ, expressed as 1/λ or λ −1 .
[0154] The equivalent relation for the ISB operation is:
[0000] ISBo N 1/λ =M λ oISB
[0155] A similar property allowing use of multiplicative masks in GF(2 8 ) exists for the functions designated fi:
[0000] fi:x→x 2i , for i in the set [1, 7].
[0156] These seven functions in GF(2 8 ) in mathematics are called field automorphisms and it is known that they correspond to linear permutations. They can be represented by matrices designated Fi. There is a similar relation between these correspondences and the AES SB cipher operation:
[0000]
SB
·
Fi
=
A
·
F
i
·
A
-
1
·
SB
=
G
i
·
SB
[0000] where G i is a linear permutation as well.
[0157] If MF λ,i denotes the matrix:
[0000]
MF
λ,i
=M
λ
oF
i
[0000] then:
[0000]
SB
·
MF
λ
,
i
=
A
·
MF
1
/
λ
,
i
·
A
-
1
·
SB
=
:
NG
1
/
λ
,
i
·
SB
,
where
“
=
:
”
means
the
definition
of
NG
1
/
λ
,
i
Present Method—Example of AES Decryption
[0158] Since it is convenient in accordance with the invention to manipulate the input mask of the ISB operation (but this is not limiting), here the conventional AES decryption operations (described above) are re-ordered or grouped as follows:
ARK (K10) ISB IMC ARK (Kx9) ISB IMC ARK (Kx8) . . . ISB IMC ARK (Kx1) ISR ISB ARK (K0)
[0173] The operations are grouped this way here because even if one does not know how the sequence of operations:
ISB IMC ARK
is implemented, the present masking methods can still be used. Due to the above described mathematical properties of AES or similar ciphers, the link between the input mask value and output mask value for any operations is independent of the operations' sequence.
[0177] The following is an example (for the first AES decryption round) of application of the input and output mask values for each cipher operation in accordance with the invention:
[0000]
Operation
State Input Mask Value
State Output Mask Value
ARK (NG 1/λ,i (K10))
NG 1/λ,i
NG 1/λ,i
ISB
NG 1/λ,i
MF λ,i
IMC
MF λ,i
MF λ,i
ARK (MF λ,i (Kx9))
MF λ,i
MF λ,i
[0178] The ISB and IMC operations are each conventional, while the round keys K10 and Kx9 (respectively used for the ARK operations for input and output states to ISB) are themselves multiplicably masked respectively with mask permutations NG 1/λ,i and MF λ,i . So here non-static (dynamic) mask values are multiplicably applied to each state, but the cipher operations ISB, IMC and ARK themselves are static (do not change.) It does not matter how the round is executed. Note for the first AES round this is done differently since the round key K10 is expressed as ARK (NG 1/λ,i (K10)). This ensures that the input state to the following ISB operation has the correct mask value.
[0179] It is also possible to provide dynamic (changing over time) masking. Assume that the input mask value of a cipher round is NG 1/λ,i then:
[0000]
Operation
State Input Mask
State Output Mask
ISB
NG 1/λ,i
MF λ,i
IMC
MF λ,i
MF λ,i
ARK (Kx8)
MF λ,i
MF λ,i XOR Kx8 XOR MF λ,i (Kx8)
[0180] This is not only valid for Kx8 but for any Kxj with j≠10. So after the round, it is necessary to compute XOR Kx8 XOR (Kx8) of the state to obtain a state with the mask MF 1/λ,i applied.
[0181] Then to obtain an input mask NG 1/λ′,j for the next cipher round, it is necessary to apply the next operation:
[0000] ( MF λ,i ) −1 oNG 1/λ′,j =( MF λ,i ) −1 oAoMF 1/λ′,i oA −1
[0182] One can then apply the same process to all cipher rounds, so:
[0000] ( MF λ,i ) −1 =( M λ oF i ) −1 =F 8-i oM 1/λ =Mi/λ 2̂(8-i) oF 8-i
[0000] where F 8 is equal to F 0 (since the subtraction is performed modulo 8 for GF(2 8 )).
[0183] Let Cst a,b be defined as:
[0000] Cst a,b :=( MF λa,ia ) −1 oNG 1/λb′,ib ( Kxb XOR MF λa,ia ( Kx b ))
[0184] To illustrate execution of this process in the form of pseudo-code (a non-executable portrayal of actual computer code), assume that mask values λ 10 and λ 9 are precomputed:
for a block of input data, compute λ 8 and precompute:
[0000] Cst 9,8 =( MF λ9,i9 ) −1 oNG 1/λ8′,i8 ( Kx 9XOR MF λ9,i9 ( Kx 8)) Execute the round key K10-K9 cipher round Apply (MF λ9,i9 ) −1 o NG 1/λ8′,i8 to the state Apply XOR Cst 9,8 to the state Execute the K8 round key cipher round For all cipher rounds where the round index is r (where the size of the r loop depends on the version of AES):
From the output data of ARK(Kxr):
compute k r-2 compute Cst apply MF 1/λr,ir o NG 1/λr-1,ir-1 XOR Cst r,r-i
Execute the cipher round r by conventional application of the inverseSubByte (ISB), and inverseMixColumn (IMC) operations.
[0197] This approach can be also used in combination with the “P world” approach to cryptographic obfuscation (see commonly owned U.S. patent application Ser. No. 12/972,145, filed Dec. 17, 2010, entitled “Securing Keys of a Cipher using Properties of the Cipher Process” incorporated herein by reference in its entirety) and with conventional XOR applied masks as well.
[0198] There are no other intermediate states that are a direct function of the clear state (which is the state of a non-White Box implementation of the AES cipher having the same execution applied on the same key and message.) Indeed, here each byte depends at all times on the previous state, due to the chained values λ i and i. In particular, this violates the assumption made in the above mentioned Billet et al. attack that the White Box state is necessarily a static function (a function that is independent of the input message) of the clear state, so the Billet et al. attack is thereby defeated.
[0199] Note that performing the computation in the above pseudo-code in the order:
apply MF 1/λr,ir o NG 1/λr-1,ir-1 then XOR Cst r,r-i
is important. If instead the XOR step is applied before the linear permutation, and if the linear permutation is performed in two steps (first N and then M), the values' correlations with the clear state are available to a White Box environment attacker, thereby compromising security because the Billet et al. attack can be mounted successfully.
[0202] With this approach, the Billet et al. attack is rendered much more complex. Indeed, an attacker must first find value λ in order to mount his attack, so he needs to test (for GF(2 8 )) 255 different values of λ and the 8 values of i to succeed. This leads to a final complexity of about 2 35 =255*8*2 24 computations, with 2 24 being the relative complexity of the Billet et al. attack. The complexity can be made even greater, since it is possible to generalize to four different couples (λ,i) for each round, one couple per column of the AES cipher state. This leads to an attack of relative complexity 2 68 . It is possible to use other Galois fields such as GF(2 16 ) or GF(2 32 ) or GF(2 64 ), although much more computational power would be needed.
[0000] Efficient Application of MF λ,i o NG λ′,i′
[0203] It is desirable to compute efficiently MF 1/λr,ir o NG 1/λr-1,ir-1 . Efficient means a method that does not require computing all the tables MF 1/λr,ir o NG 1/λr-1,ir-1 (here there are about 8×255=2,040 such functions), in order to modify these masks as quickly as possible.
[0204] The field GF(2 8 ) by definition has a multiplicative group structure. This multiplicative group is also cyclic, meaning there exist generators g (integers which are elements of GF(2 8 )) such that all non-zero elements X of the field can be computed as:
[0000]
X=g
x
[0000] with x being a member of the set [0, 254].
[0205] Due to this property, the λ multiplication operation in GF(2 8 ) to do the masking can be efficiently implemented as follows:
[0000] Let L and E be the conventional mathematical functions such that:
[0000] L ( X )= x
[0000] E ( x )= g X , so L is the conventional mathematical logarithm operation, and E is the conventional mathematical exponentiation (power of) operation in base g.
[0207] The following describes in more detail the operations in the above pseudo-code. Using functions L and E, for X≠0≠Y:
[0000] X*Y=E ( L ( X )+ L ( Y ) modulo 255),
[0000] since as well known adding logarithms is a way of performing multiplication. As also well known, addition performed in computer hardware or software is much faster than multiplication (which is done by repeated additions). So these functions allow efficient implementation of the multiplication masking operation in GF(2 8 ) by performing only: 3 table lookups (E once and L twice), 1 addition, and 1 modulo operation. The special case of 0 is treated separately since 0*X=0 (since there is no logarithm of zero).
[0208] Applied to the execution of M 2 , on X from L(λ), this is expressed as:
[0000] M λ ( X )= E ( L ( X )+ L (λ) modulo 255), if X≠ 0
[0000] M λ (0)=0, if X= 0
[0209] This can be done for all values of X in the set [0, 255].
[0210] Applied to the execution of F i (see above where F designates the GF(2 8 ) automorphisms), this is:
[0000] F i ( X )= E (2 i *L ( X ) modulo 255), if X≠ 0
[0000] F i (0)=0, if X= 0
[0211] To implement the computation of MF λ,i o NG λ′,i′ , (as explained above) compute:
[0000]
M
λ
oF
i
oAoM
λ′
oF
i′
oA
−1
[0212] This implies knowing the tables representing A and A −1 and applying successively:
A −1 the multiplication by λ′, as explained above for M λ (X) the application of F i′ , as explained above for F i (X) A the multiplication by λ, as explained above for M λ (X) the application of F i , as explained above for F i (X)
[0219] So implementing this requires only 3 table lookups and several arithmetical operations modulo 255.
[0220] Note that there exist multiple examples of the tables expressing L and E, such that a multiplication by λ can use different tables. This is a consequence of there being different generators for GF(2 8 )*, where here “*” denotes the invertible elements of GF(2 8 ). Certain elements of GF(2 8 ) can be a generator, except 0 and 1. (Only 128 elements can be generators.) This is a way to implement dynamic masks.
Additional Elements: Using L and E for the Entire AES Process
[0221] To use the lookup tables for all inputs, one first defines these functions for the special value 0. Let:
[0000] L (0)=255
[0000] E (255)=0
[0222] This way it is established that even 0 has an image through function L and can be returned to the non-logarithmic world by applying function E. In mathematics, if x is a member of set X, then for a function f, f(x) is the “image” of x. So the image of f is the set included in set X of all the f(x), for all the members x in X. Define here the “L world” as the realm of the image of L (the logarithm operation).
Applying Permutations to the L (Logarithm) World
[0223] Let L be expressed as a permutation, then a permutation designated P in the “real” world is designated P L in the L world and defined as:
[0000] P L ( x )= L ( P ( E ( x )))
[0000] where as before the logarithm operation is L(X)=x.
[0224] This gives the function equality:
[0000]
P
L
=LoPoE
[0225] So any function or permutation performed in the “real” (unmasked) world can be translated into the L world.
Multiplication in the L World
[0226] As explained above, a multiplication is performed as a modular addition e.g. modulus 255, in the L (logarithm) world. This makes this operation efficient in terms of computer software and/or hardware. Note the need to take care of the special value 0 case, since as explained before, for value 0, the above addition method does not work. One manages this 0 value case separately as explained above.
[0000] XOR in the L world
[0227] To compute the value of X XOR Y (the Boolean exclusive OR operation performed on two arguments designated X and Y) in the L world (designated here XOR L ), an additional table is needed.
[0228] Let 1 L be the function:
[0000] 1 L ( x )= L (1XOR E ( x ))
[0229] Use the array associated with this function to perform the computation of XOR L . Assume that X≠0≠Y, then:
[0000] X XOR Y=X *(1XOR X −1 *Y )
[0230] So for x, y≠255 (in GF(2 8 )):
[0000] x XOR L y=x +(1 L (( y−x ) modulo 255)) modulo 255
[0231] For x=255:
[0000] x XOR L y=y
[0232] The XOR L operation (that is, XOR in the L world) requires only these operations: 1 addition, 1 subtraction, 2 modulo operations and 1 table lookup.
[0233] Note that the XOR L operation may be computed from Z L arrays (where Z L is a generalization of 1 L for values other than 1) as well, using the equations for any invertible element Z in (GF(2 8 ):
[0000] X XOR Y=X*Z −1 *( Z XOR( X −1 *y*Z ))
[0000] x XOR y=x−z +( Z L (( y+z−x )modulo 255)) modulo 255
[0234] With these three methods, one implements the AES cipher in the L world. In particular, in this L world, all logical XOR operations can be eliminated, which enhances security since the associated software code thereby is quite different from that for a conventional AES cipher implementation. Another point is that the L world can be applied directly to any implementation of the AES cipher, masked statically and/or dynamically, with XOR masks or linear permutations applied.
[0235] The XOR computation also can be “randomized” during execution of the code, since one can switch at any time to the 1 L or to the Z L table lookups. So at any time in the code execution, one can randomly change over to the L world, making understanding by an attacker more complicated.
[0236] This causes a small performance degradation of the code execution, since the XOR operations in this L world are more complicated than a straightforward computation. However, this degradation is acceptable in practice in view of the security added by this implementation.
[0237] FIG. 2 shows in a block diagram relevant portions of a computing device (system) 160 in accordance with the invention which carries out the cryptographic processes as described above. This is, e.g., a server platform, computer, mobile telephone, Smart Phone, personal digital assistant or similar device, or part of such a device and includes conventional hardware components executing in one embodiment software (computer code) which carries out the above examples. This code may be, e.g., in the C or C++ computer language or its functionality may be expressed in the form of firmware or hardware logic; writing such code or designing such logic would be routine in light of the above examples and logical expressions. Of course, the above examples are not limiting. Only relevant portions of this apparatus are shown for simplicity. Essentially a similar apparatus encrypts the message, and may indeed be part of the same platform.
[0238] The computer code is conventionally stored in code memory (computer readable storage medium) 140 (as object code or source code) associated with conventional processor 138 for execution by processor 138 . The incoming ciphertext (or plaintext) message (in digital form) is received at port 132 and stored in computer readable storage (memory 136 where it is coupled to processor 138 . Processor 138 conventionally then partitions the message into suitable sized blocks at partitioning module 142 . Another software (code) module in processor 138 is the decryption (or encryption) module 146 which carries out the masking and decryption or encryption functions set forth above, with its associated computer readable storage (memory) 152 .
[0239] Also coupled to processor 138 is a computer readable storage (memory) 158 for the resulting decrypted plaintext (or encrypted ciphertext) message. Storage locations 136 , 140 , 152 , 158 may be in one or several conventional physical memory devices (such as semiconductor RAM or its variants or a hard disk drive). Electric signals conventionally are carried between the various elements of FIG. 6 . Not shown in FIG. 2 is any subsequent conventional use of the resulting plaintext or ciphertext stored in storage 145 .
[0240] FIG. 3 illustrates detail of a typical and conventional embodiment of computing system 160 that may be employed to implement processing functionality in embodiments of the invention as indicated in FIG. 2 and includes corresponding elements. Computing systems of this type may be used in a computer server or user (client) computer or other computing device, for example. Those skilled in the relevant art will also recognize how to implement embodiments of the invention using other computer systems or architectures. Computing system 160 may represent, for example, a desktop, laptop or notebook computer, hand-held computing device (personal digital assistant (PDA), cell phone, palmtop, etc.), mainframe, server, client, or any other type of special or general purpose computing device as may be desirable or appropriate for a given application or environment. Computing system 160 can include one or more processors, such as a processor 164 (equivalent to processor 138 in FIG. 2 ). Processor 164 can be implemented using a general or special purpose processing engine such as, for example, a microprocessor, microcontroller or other control logic. In this example, processor 164 is connected to a bus 162 or other communications medium.
[0241] Computing system 160 can also include a main memory 168 (equivalent of memories 136 , 140 , 152 , and 158 ), such as random access memory (RAM) or other dynamic memory, for storing information and instructions to be executed by processor 164 . Main memory 168 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor 164 . Computing system 160 may likewise include a read only memory (ROM) or other static storage device coupled to bus 162 for storing static information and instructions for processor 164 .
[0242] Computing system 160 may also include information storage system 170 , which may include, for example, a media drive 162 and a removable storage interface 180 . The media drive 172 may include a drive or other mechanism to support fixed or removable storage media, such as flash memory, a hard disk drive, a floppy disk drive, a magnetic tape drive, an optical disk drive, a compact disk (CD) or digital versatile disk (DVD) drive (R or RW), or other removable or fixed media drive. Storage media 178 may include, for example, a hard disk, floppy disk, magnetic tape, optical disk, CD or DVD, or other fixed or removable medium that is read by and written to by media drive 72 . As these examples illustrate, the storage media 178 may include a computer-readable storage medium having stored therein particular computer software or data.
[0243] In alternative embodiments, information storage system 170 may include other similar components for allowing computer programs or other instructions or data to be loaded into computing system 160 . Such components may include, for example, a removable storage unit 182 and an interface 180 , such as a program cartridge and cartridge interface, a removable memory (for example, a flash memory or other removable memory module) and memory slot, and other removable storage units 182 and interfaces 180 that allow software and data to be transferred from the removable storage unit 178 to computing system 160 .
[0244] Computing system 160 can also include a communications interface 184 (equivalent to part 132 in FIG. 2 ). Communications interface 184 can be used to allow software and data to be transferred between computing system 160 and external devices. Examples of communications interface 184 can include a modem, a network interface (such as an Ethernet or other network interface card (NIC)), a communications port (such as for example, a USB port), a PCMCIA slot and card, etc. Software and data transferred via communications interface 184 are in the form of signals which can be electronic, electromagnetic, optical or other signals capable of being received by communications interface 184 . These signals are provided to communications interface 184 via a channel 188 . This channel 188 may carry signals and may be implemented using a wireless medium, wire or cable, fiber optics, or other communications medium. Some examples of a channel include a phone line, a cellular phone link, an RF link, a network interface, a local or wide area network, and other communications channels.
[0245] In this disclosure, the terms “computer program product,” “computer-readable medium” and the like may be used generally to refer to media such as, for example, memory 168 , storage device 178 , or storage unit 182 . These and other forms of computer-readable media may store one or more instructions for use by processor 164 , to cause the processor to perform specified operations. Such instructions, generally referred to as “computer program code” (which may be grouped in the form of computer programs or other groupings), when executed, enable the computing system 160 to perform functions of embodiments of the invention. Note that the code may directly cause the processor to perform specified operations, be compiled to do so, and/or be combined with other software, hardware, and/or firmware elements (e.g., libraries for performing standard functions) to do so.
[0246] In an embodiment where the elements are implemented using software, the software may be stored in a computer-readable medium and loaded into computing system 160 using, for example, removable storage drive 174 , drive 172 or communications interface 184 . The control logic (in this example, software instructions or computer program code), when executed by the processor 164 , causes the processor 164 to perform the functions of embodiments of the invention as described herein.
[0247] This disclosure is illustrative and not limiting. Further modifications will be apparent to these skilled in the art in light of this disclosure and are intended to fall within the scope of the appended claims. | In the field of computer enabled cryptography, such as a keyed block cipher having a plurality of rounds, the cipher is hardened against an attack by a protection process which obscures the cipher states and/or the round keys using the properties of group field automorphisms and applying multiplicative masks (instead of conventional XOR masks) to the states of the cipher, for encryption or decryption. This is especially advantageous in a “White Box” environment where an attacker has full access to the cipher algorithm, including the algorithm's internal state during its execution. This method and the associated computing apparatus are useful for protection against known attacks on “White Box” ciphers, by eliminating XOR operations with improved masking techniques and increasing complexity of reverse engineering and of attacks. | 6 |
FIELD OF THE INVENTION
[0001] The present invention generally regards the holding of stents during manufacture to enable the application of therapeutic and/or protective coatings. More specifically, the present invention pertains to a method for high-throughput, efficient and uniform coating of stents, wherein the stents placed on rotating fixtures on a conveyer, and the conveyer passes the rotating stents through a coating spray or immersion bath to apply a coating to the stents.
BACKGROUND
[0002] Medical implants are used for innumerable medical purposes, including the reinforcement of recently re-enlarged lumens, the replacement of ruptured vessels, and the treatment of disease such as vascular disease by local pharmacotherapy, i.e., delivering therapeutic drug doses to target tissues while minimizing systemic side effects. Such localized delivery of therapeutic agents has been proposed or achieved using medical implants which both support a lumen within a patient's body and place appropriate coatings containing absorbable therapeutic agents at the implant location.
[0003] The delivery of expandable stents is a specific example of a medical procedure that involves the deployment of coated implants. Expandable stents are tube-like medical devices, typically made from stainless steel, Tantalum, Platinum or Nitinol alloys, designed to be placed within the inner walls of a lumen within the body of a patient. These stents are typically maneuvered to a desired location within a lumen of the patient's body and then expanded to provide internal support for the lumen. The stents may be self-expanding or, alternatively, may require external forces to expand them, such as by inflating a balloon attached to the distal end of the stent delivery catheter.
[0004] Because of the direct contact of the stent with the inner walls of the lumen, stents have been coated with various compounds and therapeutic agents to enhance their effectiveness. These coatings may, among other things, be designed to facilitate the acceptance of the stent into its applied surroundings. Such coatings may also be designed to facilitate the delivery of one of the foregoing therapeutic agents to the target site for treating, preventing, or otherwise affecting the course of a disease or tissue or organ dysfunction.
[0005] Where the stent has been coated, care must be taken during its manufacture and delivery within the patient to ensure the coating is evenly applied and firmly adherent to the stent, and further that the coating is not damaged or completely removed from the implant during the deployment process. When the amount of coating is depleted the implant's effectiveness may be compromised and additional risks may be inured into the procedure. For example, when the coating of the implant includes a therapeutic, if some of the coating were removed during deployment, the therapeutic may no longer be able to be administered to the target site in a uniform and homogenous manner. Thus, some areas of the target site may receive high quantities of therapeutic while others may receive low quantities of therapeutic. Similarly, if the therapeutic is ripped from the implant it can reduce or slow down the blood flowing past it, thereby, increasing the threat of thrombosis or, if it becomes dislodged, the risk of embolisms. In certain circumstances, the removal and reinsertion of the stent through a second medical procedure may be required where the coatings have been damaged or are defective.
[0006] The mechanical process of applying a coating onto a stent may be accomplished in a variety of ways, including, for example, the spraying of the coating substance onto the stent and so-called spin-dipping, i.e., dipping a spinning stent into a coating solution to achieve the desired coating. Common to these processes is the need to apply the coating in a uniform manner to ensure an intact, robust coating of the desired thickness is formed on the stent. In order to achieve the desired uniform and complete coating, it has been common for the stents to be handled individually, with each stent separately loaded onto a stent holder and the coating applied to the stent before the next stent is coated. This individual handling typically has resulted in low production rates of coated stents. A further disadvantage of these prior stent coating processes is that, because the stents are wire mesh structures with substantial void area between the mesh wires, the utilization of the stent coating material sprayed toward the stents is very low. For example, in some cases the amount of stent coating sprayed toward the stent which actually adheres to the stent mesh is less than five percent.
[0007] Thus, there is a need for a method for coating stents which efficiently applies the stent coating material in a manner that results in a high quality, uniform coating on the stents at high coated stent production rates.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a method for overcoming the foregoing disadvantages. Specifically, in a first step of a first embodiment of the method, stents are loaded with high speed stent handling equipment onto rotating pins that are mounted to an endless conveyer belt. In a second step, while the stents are rolling about their longitudinal axes atop the rotating pins, stent coating material is applied as the endless belt advances the stents through a stent coater containing a coating sprayer. As the stents are returned toward the stent loading area by the endless belt, they receive additional coating material from the coating sprayer as they pass a second time through the coating spray downstream of the initial coating location. The coated stents are then removed from their holders before the endless belt returns the stent holders to the stent loading area to receive new uncoated stents.
[0009] A number of alternative embodiments for performance of the method of the present invention are envisioned. For example, there may be a number of alternative embodiments for performing the stent placement step, such as providing stents pre-mounted on stent holders with rotating pins equipping with corresponding stent holder receivers to facilitate stent handling by automated stent placement equipment. Similarly, in the step of applying the coating material, rather than spraying the coating material perpendicularly across the endless belt, the coating may be applied from a sprayer aligned with the major axis of the endless belt such that the rolling stents have a longer exposure to the coating spray. The sprayer may also apply the coating while the spray head is rotating about the line of rolling stents. In a further embodiment, the coating application step may be performed by drawing the rolling stents through a coating bath. Other embodiments extend the stent coating step to include the endless belt reversing direction several times to cause the rolling stents to pass several times through the downstream portions of the coating spray to improve coating material utilization, and the inclusion of additional stent processing steps between the coating application step and the coated stent unloading step, such as accelerating the drying of the stent coating by advancing the coated stents through an infrared coating dryer.
[0010] The result of the various foregoing embodiments of the method of the present invention is high volume, efficient and lower-cost production of stents with a highly uniform coating on their exterior and, in desired, interior surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic overhead view of a stent coating process in accordance with an embodiment of the method the present invention.
[0012] FIG. 2 is a side view showing a stent and the upper portion of a rotating pin on which the stent is placed in accordance with the method of the present invention.
[0013] FIG. 3 is a side illustration of stent-bearing rotating pins mounted on a conveyer belt in accordance with the method of the present invention.
[0014] FIG. 4 is an overhead view of the stent-bearing rotating pins and conveyer belt shown in FIG. 3 in accordance with the method of the present invention.
[0015] FIG. 5 is a schematic overhead view of the stent-bearing rotating pins and conveyer belt shown in FIG. 3 illustrating an alternative approach for the step of applying the stent coating in accordance with the method of the present invention.
[0016] FIG. 6 are schematic side views of alternative stent holders and rotating pin mounts for engaging and holding stent holders for performing the step of placing the stents on the conveyer in accordance with the method of the present invention.
[0017] FIG. 7 is a schematic side view of the stent-bearing rotating pins and conveyer belt shown in FIG. 3 showing an alternative approach to the step of applying the stent coating by immersing the stents into a coating bath in accordance with the method of the present invention.
DETAILED DESCRIPTION
[0018] The present invention is directed to a method for overcoming the foregoing disadvantages by applying a stent coating to stents that are being rolled about their longitudinal axis, where the stents are loaded onto rotating holders affixed to a conveyer, and the conveyer carries the rotating stents and holders through a coating applicator one or more times.
[0019] The method of the present invention in a first embodiment is as follows. In this first embodiment, a conveyer in the form of an endless belt 1 is arranged around a first pulley 2 at a first end 3 of the belt and a second pulley 4 at a second, opposite end 5 of the belt. Endless belt 1 may be advanced by rotating either pulley 2 or pulley 4 . Backing plates 6 are provided in the region between pulleys 2 and 4 . The backing plates, which can be located adjacent to either the inner or outer face of the belt, are arranged to contact outer peripheral edges of rotating pins 7 mounted on endless belt 1 (details of rotating pins 7 and their mounting are discussed further, below). When endless belt 1 is advanced, the friction between the outer peripheral portions of rotating pins 7 and backing plates 6 causes the pins to rotate.
[0020] As a first step of the method in this embodiment, stents 8 are placed with automated stent placement equipment (not illustrated) onto rotating pins 7 as endless belt 1 is advanced. In this embodiment, the stents are loaded onto the rotating pins near the first end 3 of the endless belt, and advance toward second end 5 as endless belt 1 advances. In FIG. 1 , the freshly loaded, uncoated stents are on endless belt 1 on the lower side of the illustration, moving from first end 3 toward second end 5 . At a location along endless belt 1 separate from the stent loading location, a stent coater 9 is positioned such that it dispenses a stent coating spray toward endless belt 1 when activated. In this embodiment, stent coater 9 includes a stent coating sprayer 10 located near second end 5 which sprays the coating material generally perpendicularly across endless belt 1 . The stent coater may further include a housing (not illustrated) to contain and potentially reclaim coating overspray.
[0021] In the second step of the method in this first embodiment, endless belt 1 is advanced to cause stents 8 to roll about their longitudinal axes as their respective pins 7 rotate (due to the pins' frictional engagement with backing plate 6 ). As endless belt 1 advances, the rolling stents 8 are simultaneously carried along the path of endless belt 1 into and out of the stent coater. The step of applying the stent coating to the stents is performed by causing coating sprayer 10 to dispense the stent coating onto stents 8 as they pass through the stent coater. Further, because endless belt 1 reverses direction at pulley 4 , stent coating spray that passes by or through the stents moving toward second end 5 can be utilized to apply additional coating material to the stents as they pass from second end 5 back toward first end 3 , thereby substantially improving the efficiency of the coating process. Finally, as the coated stents 8 approach first end 3 , they are removed from their respective rotating pins 7 by automated stent removal equipment (not illustrated), prior to the rotating pins' return to the stent loading area for loading of new uncoated stents.
[0022] The rotating pins 7 in this embodiment, and their relationship to endless belt 1 , backing plates 6 and stents 8 , are now further described. FIG. 2 illustrates a schematic view of the upper portion of a rotating pin 7 and its relationship to stent 8 . When placed onto rotating pin 7 , stent 8 is oriented with its longitudinal axis generally in line with the longitudinal axis of a rotating pin 7 . Rotating pin 7 is sized such that when stent 8 is placed over the top of pin 7 , the stent is supported by pin 7 in a manner which ensures that stent 8 rotates with pin 7 when the pin is rotated around its longitudinal axis. In this embodiment, rotating pin 7 has a radial extension or shelf 11 upon which stent 8 rests when placed over the top of pin 7 . Alternatively, rotating pin 7 may have a tapered shape, such that the inner diameter of stent 8 rests directly upon the tapered sides of pin 7 . Rotating pin 7 is preferably configured such that its protrusion into the interior annular region of stent 8 , while sufficient to ensure stent 8 is retained on the pin during its transit through stent coating applicator 9 , is minimized in order to minimize the extent to which pin 7 interferes with the application of the coating spray to the inner surface of stent 8 .
[0023] FIG. 3 shows the general arrangement of rotating pins 7 and stents 8 on endless belt 1 in the first embodiment. In both FIG. 3 a and FIG. 3 b , stents 8 rest on the tops of rotating pins 7 , which are in turn rotably held on belt 1 . Any of a variety of conveyer arrangements well known in the art may be used to rotably hold pins 7 . In this embodiment, the pins are held by belt links 12 of endless belt 1 . The belt links 12 may be arranged any suitable manner that permits the pins 7 to rotate about their longitudinal axes as the belt advances, such as with interlocking fingers or hooks 13 on the ends of the links which cooperate with the pins 7 and an adjacent link to effectively use rotating pins 7 as hinge pins in the endless belt, as illustrated in FIG. 3 a . Alternatively, endless belt 1 may be an endless rubber belt to which are mounted U-shaped brackets which loosely capture rotating pins 7 between the belt and the brackets, as illustrated in FIG. 3 b.
[0024] In order to provide for the rotation of rotating pins 7 as endless belt 1 advances, a flange 14 is provided in this embodiment on each rotating pin 7 . As shown in the overhead view in FIG. 4 , flange 14 is of sufficient radius that its outer periphery is in rolling contact with backing plates 6 as endless belt 1 advances, thereby causing pins 7 and their respective stents 8 to roll about their longitudinal axes as belt 1 advances. Flange 14 may be provided above, below, or in a gap through, endless belt 1 , as desired to provide positive engagement of flanges 14 against backing plates 6 . As those of skill in the art will readily recognize, a variety of alternative means other than backing plates 6 may be provided to cause rotating pins 7 to roll stents 8 , such as gear-drive of the rotating pins, so as long as the desired rotation of stents 8 is obtained. Alternatively, rotating pins 7 may be rotated by means that are independent of the means that advance endless belt, for example, by a separate electric motor.
[0025] The diameter of flange 14 and the speed of advance of endless belt 1 are adjusted as necessary to ensure an optimal stent coating is obtained. This requires stents 8 to be rotated at a rate that is slow enough to ensure effective coverage of outer and inner portions of stent 8 by sprayer 10 as the stents traverse through the coating spray, but fast enough to ensure that the stents make at least one complete revolution while stent 8 is within the spray pattern from sprayer 10 . An endless belt advance speed of 0.1-10 cm per second and a stent rotation rate of 10-100 degrees per second may be used to obtain satisfactory coating of stents with the foregoing roll coating method.
[0026] In addition to executing the step of applying the coating to the stents 8 using a spray applicator aligned perpendicular to the direction of advance of endless belt 1 , a number of alternative spray configurations can be envisioned. For example, in order to minimize the interference of rotating pins 7 with the application of the coating to the inner surface of stents 8 , coating sprayer 10 may be elevated above endless belt 1 and aligned to dispense the coating spray downward at an angle toward the rolling stents 8 . As shown in FIG. 5 , coating sprayer 10 could also be located above endless belt 1 and aligned with the belt such that it sprays in the direction of stent travel and thus has an extended opportunity to apply the coating to the stents. In a further alternative sprayer embodiment, the coating sprayer may be provided on means such as a rotating arm that permits the sprayer to rotate around the rolling stents as they are advanced on the conveyer. Performing the coating application step in this embodiment provides further assurance a uniform coating will be obtained at high coated stent production levels.
[0027] An additional embodiment of the present method includes multiple direction reversals of endless belt 1 downstream of coating sprayer 10 such that stents 8 re-enter the spray dispensed from sprayer 10 several times before belt 1 returns to a stent removal station. By expanding the coating application step in this manner, this embodiment provides for enhanced coating efficiency as each pass of stents 8 through the downstream portions of the coating spray further improves the utilization of the sprayed coating and thereby improves coating efficiency.
[0028] A further advantage of the foregoing method is that after the step of applying the coating to the rolling stents, there may be provided additional steps which enhance high volume coated stent production. An exemplary further embodiment of the present method thus may include the step of passing the stents through a coating dryer (such as an infrared heater) following the application of the coating, wherein the rolling stents present all their coated surfaces to the dryer for even, accelerated drying prior to removal from their respective rotating pins 7 . Alternatively, the conveyer and/or the stent holder may be heated to accelerate coating drying rates before the stents are removed from the conveyer.
[0029] In the foregoing first embodiment, the stents are placed on rotating pins with upper portions that are shaped to directly receive the stents. Alternatively, in the first step of the present high-volume coating method process, the stents may be supplied for loading onto endless belt 1 already mounted on individual stent holders, where the upper portion of rotating pins 7 is adapted to grasp one end of the holder. FIG. 6 shows three example stent holder and cooperating rotating pin arrangements which are amenable to high-volume automated stent placement and removal operations. In FIG. 6 a , stent 8 is mounted on stent holder 15 . Stent holder 15 in turn is locked within a bayonet-type receiving portion 16 on top of rotating pin 7 , where an extension 17 of stent holder 15 has been inserted into receiving portion 16 and rotated to lock the stent holder in place. Similarly, FIG. 6 b illustrates another stent holder 15 formed from a nitinol wire that holds stent 8 by spring force at contact points on the stent's inner surface, where receiving portion 16 is a spring-loaded clamp that grasps one end of stent holder 15 . FIG. 6 c shows a further exemplary embodiment, wherein stent holder 15 is a wire frame with triangular ends 18 , stent 8 is held under a light compressive force between the ends 18 , and extension 17 from stent holder 15 is a wire that is placed into the receiving portion 16 of rotating pin 7 (in this case, a hole drilled into the top of pin 7 ). FIG. 6 d shows another exemplary embodiment, wherein stent holder 15 is an inflatable balloon that lightly presses against the inner surface of stent 8 and is held, in this embodiment, in a receiving portion 16 that grasps one end of the stent holder balloon 5 .
[0030] It should be understood that the foregoing description of various exemplary embodiments of possible stent holders and mating receiving mounts is not intended to be limiting, and a number of modifications and alternatives may be employed that would facilitate the performance of the present stent coating method at high production levels. Further, alternative coating and drying step arrangements may be employed, such as feeding the stents through multiple coating and drying cycles to apply a plurality of coats of coating material before the completed coated stent is removed from its stent holder, or conveying the stents through a plurality of coating sprayers spraying a plurality of different coatings, with or without drying periods between the coating layer applications.
[0031] The foregoing alternative approaches to the stent placement step, which positively constrain stents 8 to remain mounted on rotating pins 7 , facilitate a further embodiment of the present method. In this embodiment, rather than performing the step of applying the stent coating by using a stent coating sprayer, the coating may be applied by advancing endless belt 1 through a stent coating bath 19 , as schematically illustrated in FIG. 7 . It should be apparent to those of skill in the art that while positive control of rolling stents 8 on the top of rotating pins 7 is not a necessary prerequisite to use of a coating bath, use of the foregoing alternative stent holders coupled to the rotating pins enhances the control of the stents as they pass through coating bath 19 . It should be further noted that while endless belt 1 is shown in FIG. 7 as being turned to a horizontal position to pass through coating bath 19 , no orientation limitations are intended to be implied by the foregoing description, as a number of modifications and equivalent alternative arrangements are possible. For example, endless belt 1 may be arranged above the coating bath and located such that stents 8 are held and rotated about their longitudinal axes below belt 1 , such that only the stents and their holders pass through the coating bath during the coating application step.
[0032] The term “therapeutic agent” as used herein includes one or more “therapeutic agents” or “drugs.” The terms “therapeutic agents” and “drugs” are used interchangeably herein and include pharmaceutically active compounds, nucleic acids with and without carrier vectors such as lipids, compacting agents (such as histones), virus (such as adenovirus, andenoassociated virus, retrovirus, lentivirus and α-virus), polymers, hyaluronic acid, proteins, cells and the like, with or without targeting sequences.
[0033] Specific examples of therapeutic agents used in conjunction with the present invention include, for example, pharmaceutically active compounds, proteins, cells, oligonucleotides, ribozyrnes, anti-sense oligonucleotides, DNA compacting agents, gene/vector systems (i.e., any vehicle that allows for the uptake and expression of nucleic acids), nucleic acids (including, for example, recombinant nucleic acids; naked DNA, cDNA, RNA; genomic DNA, cDNA or RNA in a non-infectious vector or in a viral vector and which further may have attached peptide targeting sequences; antisense nucleic acid (RNA or DNA); and DNA chimeras which include gene sequences and encoding for ferry proteins such as membrane translocating sequences (“MTS”) and herpes simplex virus-1 (“VP22”)), and viral, liposomes and cationic and anionic polymers and neutral polymers that are selected from a number of types depending on the desired application. Non-limiting examples of virus vectors or vectors derived from viral sources include adenoviral vectors, herpes simplex vectors, papilloma vectors, adeno-associated vectors, retroviral vectors, and the like. Non-limiting examples of biologically active solutes include anti-thrombogenic agents such as heparin, heparin derivatives, urokinase, and PPACK (dextrophenylalanine proline arginine chloromethylketone); antioxidants such as probucol and retinoic acid; angiogenic and anti-angiogenic agents and factors; agents blocking smooth muscle cell proliferation such as rapamycin, angiopeptin, and monoclonal antibodies capable of blocking smooth muscle cell proliferation; anti-inflammatory agents such as dexamethasone, prednisolone, corticosterone, budesonide, estrogen, sulfasalazine, acetyl salicylic acid, and mesalamine; calcium entry blockers such as verapamil, diltiazem and nifedipine; antineoplastic/antiproliferative/anti-mitotic agents such as paclitaxel, 5-fluorouracil, methotrexate, doxorubicin, daunorubicin, cyclosporine, cisplatin, vinblastine, vincristine, epothilones, endostatin, angiostatin and thymidine kinase inhibitors; antimicrobials such as triclosan, cephalosporins, aminoglycosides, and nitorfurantoin; anesthetic agents such as lidocaine, bupivacaine, and ropivacaine; nitric oxide (NO) donors such as lisidomine, molsidomine, L-arginine, NO-protein adducts, NO-carbohydrate adducts, polymeric or oligomeric NO adducts; anti-coagulants such as D-Phe-Pro-Arg chloromethyl ketone, an RGD peptide-containing compound, heparin, antithrombin compounds, platelet receptor antagonists, anti-thrombin antibodies, anti-platelet receptor antibodies, enoxaparin, hirudin, Warafin sodium, Dicumarol, aspirin, prostaglandin inhibitors, platelet inhibitors and tick antiplatelet factors; vascular cell growth promotors such as growth factors, growth factor receptor antagonists, transcriptional activators, and translational promotors; vascular cell growth inhibitors such as growth factor inhibitors, growth factor receptor antagonists, transcriptional repressors, translational repressors, replication inhibitors, inhibitory antibodies, antibodies directed against growth factors, bifunctional molecules consisting of a growth factor and a cytotoxin, bifunctional molecules consisting of an antibody and a cytotoxin; cholesterol-lowering agents; vasodilating agents; agents which interfere with endogeneus vascoactive mechanisms; survival genes which protect against cell death, such as anti-apoptotic Bcl-2 family factors and Akt kinase; and combinations thereof. Cells can be of human origin (autologous or allogenic) or from an animal source (xenogeneic), genetically engineered if desired to deliver proteins of interest at the insertion site. Any modifications are routinely made by one skilled in the art.
[0034] Polynucleotide sequences useful in practice of the invention include DNA or RNA sequences having a therapeutic effect after being taken up by a cell. Examples of therapeutic polynucleotides include anti-sense DNA and RNA; DNA coding for an anti-sense RNA; or DNA coding for tRNA or rRNA to replace defective or deficient endogenous molecules or interfering RNA sequences. The polynucleotides can also code for therapeutic proteins or polypeptides. A polypeptide is understood to be any translation product of a polynucleotide regardless of size, and whether glycosylated or not. Therapeutic proteins and polypeptides include as a primary example, those proteins or polypeptides that can compensate for defective or deficient species in an animal, or those that act through toxic effects to limit or remove harmfull cells from the body. In addition, the polypeptides or proteins that can be injected, or whose DNA can be incorporated, include without limitation, angiogenic factors and other molecules competent to induce angiogenesis, including acidic and basic fibroblast growth factors, vascular endothelial growth factor, hif-1, epidermal growth factor, transforming growth factor αand β, platelet-derived endothelial growth factor, platelet-derived growth factor, tumor necrosis factor α, hepatocyte growth factor and insulin like growth factor; growth factors; cell cycle inhibitors including CDK inhibitors; anti-restenosis agents, including p15, p16, p18, p19, p21, p27, p53, p57, Rb, nFkB and E2F decoys, thymidine kinase (“TK”) and combinations thereof and other agents useful for interfering with cell proliferation, including agents for treating malignancies; and combinations thereof. Still other useful factors, which can be provided as polypeptides or as DNA encoding these polypeptides, include monocyte chemoattractant protein (“MCP-1”), and the family of bone morphogenic proteins (“BMP's”). The known proteins include BMP-2 , BMP-3, BMP-4, BMP-5, BMP-6 (Vgr-1), BMP-7 (OP-1), BMP8, BMP-9, BMP-10, BMP-11, BMP-12, BMP-13, BMP-14, BMP-15, and BMP-16. Currently preferred BMP's are any of BMP-2, BMP-3, BMP-4, BMP-5, BMP-6and BMP-7. These dimeric proteins can be provided as homodimers, heterodimers, or combinations thereof, alone or together with other molecules. Alternatively or, in addition, molecules capable of inducing an upstream or downstream effect of a BMP can be provided. Such molecules include any of the “hedgehog” proteins, or the DNA's encoding them.
[0035] While the present invention has been described with reference to what are presently considered to be preferred embodiments thereof, it is to be understood that the present invention is not limited to the disclosed embodiments or constructions. On the contrary, the present invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the disclosed invention are described and/or shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single embodiment, are also within the spirit and scope of the present invention. | An improved method for high-volume production of coated stents with highly uniform stent coatings using a roll coating technique is provided. In a first embodiment, uncoated stents are placed onto rotating stent holders with automated stent handling equipment. The holders are mounted on an endless conveyer belt which advances the stents toward a stent coater. As the stents advance through the coater, the holders rotate, thereby rolling the stents about their longitudinal axes as coating material is sprayed toward them, ensuring the stents are uniformly coated on their exterior and interior surfaces. After the conveyer turns to carry the coated stents back toward the loading area, the rotating stents pass again through the coating spray, downstream of the initial coating location, thereby increasing the efficient utilization of the coating material. The conveyer then advances the coated stents to an unloading area for removal before the holders return to the stent loading area to receive new stents. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a process for treating wool materials, and to a composition for use in such treatment. It is particularly applicable to the treatment of aged or harshly treated wool textiles to restore at least in part their original properties.
It has long been known that wool consists largely of protein (`keratin`). The physical form of most proteins is strongly affected by the arrangement of disulphide linkages between cysteine residues.
SUMMARY OF THE INVENTION
The present invention arises from the realisation that an aged or ill-treated material comprising wool is likely to have undergone denaturing of the constituent protein, with disruption of the original pattern of disulphide linkages. If this original pattern can be at least partly restored, the material may be `rejuvenated`.
In one aspect the invention provides a process for treating a material comprising wool in which the material is contacted with a composition which comprises an aqueous medium containing a protein disulphide isomerase, under conditions such that the enzyme can catalyse rearrangement of disulphide linkages in the material. Generally the composition will contain a cofactor for the enzyme.
An isomerase is preferable to (for example) a reductase since the latter requires the presence of a hydrogen donor such as NADPH. However for some purposes other types of enzyme may be useful.
The material comprising wool will generally be a fabric which comprises sufficient wool to affect its properties so that it is amenable to enzymic rejuvenation. The wool may be sheep wool or other animal hair with analogous properties.
Preferably the composition contains substantial amounts of only one enzyme.
In a second aspect the invention provides an enzyme-containing composition for use in such a process. The composition may be usable directly or, more usually, after one or more preliminary steps such as dilution, solution or admixture. A composition may comprise a stable enzyme preparation comprising an enzyme and a carrier (which may be water, generally including a buffer; and/or may be a (preferably soluble) solid).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A suitable type of enzyme is the protein disulphide isomerase E.C.5.3.4.1, hereafter referred to as PDI. This enzyme is well-characterised and is commercially available from GENZYME (Genzyme Biochemicals Lts., Maidstone, England; Genzyme Corp., Boston, Mass., U.S.A.). It has been described by N.Lambert and R.B.Freedman (1983 Biochem.J. 213 225-234). This type of enzyme seems to occur in every eukaryotic tissue which synthesises a secreted protein. The most easily obtainable tissue type is bovine liver PDI. This may be isolated as follows.
500g of diced bovine liver is washed with physiological saline and extracted at neutral pH with phosphate buffer which contains 1% Triton. This gives an enzyme extract which is then concentrated and purified by procedures involving heat treatment, ammonium sulphate precipitation, ion exchange chromatography, dialysis and finally lyophilization. (See the paper by Lambert and Freedman for fuller details.)
A purer enzyme may be prepared by genetic engineering, i.e. using cloned DNA in a suitable culture.
For use, it is generally necessary to add a very small amount of a low molecular weight thiol as a cofactor. (The concentration need only be of the order of micromolar.)
An example of a suitable thiol which is readily available and is acceptable for treatment of fabrics is dithiothreitol or, more preferably, reduced glutathione.
A suitable composition for use contains 0.01 to 1.0g, preferably 0.03 to 0.3g, of PDI and 1 to 1000, preferably 10 to 1000, micromoles of a cofactor per litre, buffered to a pH in the range of 7 to 8, preferably pH 7.5. A phosphate buffer is preferred. It may also contain other components, e.g. selected from perfumes, and carriers. A wetting agent (to aid penetration of the hydrophobic sheath of a wool fibre) such as a cationic surfactant, is not generally required. Since the thiol is susceptible to aerial oxidation, the storage form of the composition should provide protection from air. The enzyme and cofactor are preferably stored separately as freeze dried powders. The cofactor component thereof, may include the phosphate buffer and any other components, and be stored in an air-free vessel, e.g, a foil sachet, possibly under nitrogen, and/or in an encapsulated form. The enzyme should be protected from harmful materials, e.g. by being packaged analogously to the cofactor. For use, a sachet of cofactor and phosphate buffer is opened and the contents are dissolved in water, preferably at 28° C. Then the enzyme is added.
Fabric is treated at a temperature slightly above room temperature, e.g. 25° to 40° C., preferably 25° to 32° C., most preferably 28° C., for a period of up to 24 hours. The relaxed, now renovated, textile will then be rinsed free of the PDI suspension and the residual enzyme can be removed if necessary - by a `biological`- washing powder type treatment followed by a final rinse.
The PDI may be modified to improve its stability or effectiveness. Thus it may be dissociated into its subunits, which can show greater activity (presumably since the active sites are then more accessible, particularly to bulky substrates such as keratin, than in the whole enzyme). The enzyme (which term includes a dissociated subunit of natural PDI) may be immobilised on a carrier. A suitable carrier has a large surface area, since an insoluble substrate such as keratin cannot penetrate into the interior. Thus we may use polystyrene beads or other carriers of synthetic polymers (such as polyvinyl resins, nylon, and isocyanate-capped polyurethane foam). This can improve stability and aid storage and use. An enzyme immobilised on a suitable carrier may be recoverable for re-use. An immobilised cofactor is also a possible option. An immobilised component may be recovered by flotation or by adsorption on a suitable material. A support such as polyurethane foam may be constituted as a sponge which can be physically applied to a fabric and easily removed afterwards. The enzyme may be chemically modified to alter its binding properties and Km value.
An example of an embodiment of the invention will now be described.
EXAMPLE
A child's jumper (made of 100% lambswool) was washed harshly at excessive temperature (45°) using a liquid detergent. It was then cut in half. A "control" half was soaked in phosphate buffer at 28° for 4 hours. The "test" half was soaked at 28° for 4 hours in a composition embodying the invention and containing:
PDI (Genzyme) 1g/1
Reduced glutathione (Sigma) 1mM
Phosphate buffer 50mM (to pH 7.5)
Distilled water.
The two halves were dried and compared. The control half was found to be mis-shapen and stretched, whereas the test half had regained its original shape, size and elasticity. | A process and composition for treating a material comprising wool to ameliorate ageing, mis-shaping and shrinkage employ an enzyme (protein disulphide isomerase) and a cofactor therefor. | 3 |
This application is a Continuation of PCT/AU2006/001122, filed 8 Aug. 2006, which claims benefit of Serial No. 2006903269, filed 16 Jun. 2006 in Australia and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications.
FIELD OF THE INVENTION
This invention relates to underground boring and more particularly to an improved microtunnelling system and apparatus.
In this document “microtunnelling” is considered to comprise trenchless horizontal boring of a bore of the order of 600 millimetres and less.
BACKGROUND OF THE INVENTION
Modern installation techniques provide for underground installation of services required for community infrastructure. Sewage, water, electricity, gas and telecommunication services are increasingly being placed underground for improved safety and to create more visually pleasing surroundings that are not cluttered with open services.
Currently, the most utilised method for underground works is to excavate an open cut trench. This is where a trench is cut from the top surface and after insertion of piping or optical cable is then back-filled. This method is reasonably practical in areas of new construction where the lack of buildings, roads and infrastructure does not provide an obstacle to this method. However, in areas supporting existing construction, an open cut trench provides obvious disadvantages, major disruptions to roadways and high possibility of destruction of existing infrastructure (i.e. previously buried utilities). Also, when an open cut trench is completed and backfilled the resultant shift in the ground structure rarely results in a satisfactory end result as the trench site often sinks. Open trenches are also unsafe to pedestrians and workers.
Another concept employed for underground works is that of boring a horizontal underground hole. Several methods employ this philosophy as it generally overcomes the issues of disruption to roads and infrastructure as described for open cut trenches however even these methods have their inherent problems.
One method is horizontal directional drilling (HDD). In this method a boring device is situated on the ground surface and drills a hole into the ground at an oblique angle with respect to the ground surface. A drilling fluid is typically flowed through the drill string, over the boring tool, and back up the borehole in order to remove cuttings and dirt. After the boring tool reaches a desired depth, the tool is then directed along a substantially horizontal path to create a horizontal borehole. After the desired length of borehole has been obtained, the tool is then directed upwards to break through to the surface. A reamer is then attached to the drill string, which is pulled back through the borehole, thus reaming out the borehole to a larger diameter. It is common to attach a utility line or other conduit to the reaming tool so that it is dragged through the borehole along with the reamer. A major problem with this method is that the steering mechanism is extremely inaccurate and unsuitable for applications on grade. The stop and start action utilised by the operator results in a bore that is not completely straight. The operator has no way of knowing exactly where the hole goes which can result in damage to existing utilities. This could pose a safety threat particularly if the services in the area are of a volatile nature.
Another method is the pilot displacement method. This method uses a drill string pushed into the ground and rotated by a jacking frame. A theodolite is focused along the drill string as a point of reference to keep the line on grade. This system is not accurately steered. The slant on the nose is pointed in the direction of intended steering. The position of the head is monitored through a total station with a grade and line set and measuring this point against a target mounted in the head of the pilot string. If the ground conditions are homogenous and the conditions absolutely perfect, it will produce a satisfactory bore. Unfortunately this is rarely the case. Ground conditions are generally variable the pilot tube will tend to steer towards whichever ground offers the least resistance irrespective of the direction in which you are the steering. As the drill strings are generally short, the time to drill is often slow with repeated connections making the process tedious. Once the bore reaches the reception shaft augers are attached and pulled back along the bore to displace the spoil into the reception shaft. This then has to be manually removed which is time consuming.
Slurry style microtunnelling utilises slurry reticulation to transport spoil removal throughout the installation process. Two lines are fed via a starting shaft along the bore. The pipes are jacked via a hydraulic jacking frame into the hole. Water is forced along the feed pipe to the cutting face where the spoil slurry of rock and mud is forced back along the return pipe. Whilst enjoying a good degree of accuracy, this system requires a structural shaft that needs a massive amount of force to push the pipes. This results in a large, expensive jacking shaft pit that is time consuming to build. The sheer weight and size of the components make them slow to connect and cumbersome to use. If the unit becomes damaged or stuck in the bore, the only method available to retrieve the unit would be to dig down onto the drill head location.
In one form of boring machine shown by US Patent Application No. US2004/0108139 to Davies and corresponding to Australian Patent 2003262292 there is disclosed a micro tunnelling machine having a tunnelling head with a boring bit which is forced in a horizontal direction by an hydraulic thruster. The direction of the head is laser guided. The beam strikes a target in the head and a camera relays an image of the target to an operator located at the tunnel entrance. The operator adjusts the direction by admitting water and draining water from a pair of rams inside the head, which move the boring bit up and down or left and right. A semi automatic version is disclosed in which a microprocessor adjusts the direction until the operator assumes control. In particular the invention is claimed to be a guidance system for the boring head of a micro-tunnelling machine of the type which bores in a selected direction and inclination using laser beam guidance having the endmost part of the drive to the boring bit adjustable in two directions at 90°, wherein, the endmost part of the drive has a target for the laser beam, means to convey an image of the target and the laser strike position thereon to an operator situated remotely from the boring head and input means for the operator to adjust the direction of the endmost part of the drive.
The major approach of the directional control of the disclosed apparatus of US Patent Application No. US2004/0108139 to Davies is to have the drive shaft connected at its end distal to the cutting edge in a manner that allows the drive shaft to move as required and to allow the cutting element to be redirected to correct position as determined by the laser controlled directional system. However this form of apparatus places all the strain on an elongated movable drive shaft retained by cylinders and therefore readily increases the risk of breakage. There is clearly a need to provide an improved system to decrease chance of breakage of the drill head components.
It can be appreciated that present methods of underground tunnelling are cumbersome, inaccurate; and require repeated halting of boring operations due to waste removal and heating effects. Moreover, there is an inherent delay resulting from replacement of parts of conventional boring systems since it usually requires the boring tool to be recovered from the site and returned to the assembly factory. Recovery in itself can be cumbersome and expensive particularly if a new vertical access hole is required to recover the tool. This could damage the road or services under which the bored tunnel is extending. Further present systems are unable to accurately remain on fixed boring direction, which are often needed when a buried obstruction is detected or changing soil conditions are encountered.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided an apparatus and method for underground boring on grade more particularly to an improved microtunnelling system and apparatus.
In this document “microtunnelling” is considered to comprise trenchless horizontal boring of a bore of the order of 600 millimetres and less. This is particularly relevant to the insurgence of pipes of the order of around 300 millimetres.
The drawbacks of current microtunnelling technology are significant and have been overcome or are at least ameliorated by the current invention including one or more of the following improvements and other improvements as will be understood from the description.
A first fundamental improvement is the use of an external casing with flow channels therein and the drive rod mounted therein and allows for all cabling and hosing to be mounted in an external cavity, which thereby allows for continuous cabling over a plurality of encased intermediate drill rods.
A second fundamental improvement is the incorporation of the driveline within the vacuum chamber. Incorporating the rotation within the vacuum achieves multiple goals. Firstly, the vacuum area can be dramatically increased and so maximize the machines ability to remove spoil and in such increased productivity. Secondly, the rotation component of the drill rod generates heat. The removal of this heat from the laser area is critical to laser accuracy. By combining the rotation into the vacuum area, any heat generated is immediately removed and the laser therefore is unaffected.
A third fundamental improvement is the steering mechanism of the encased drill rod using radially protrusions engaging steering shell to direct the drill head and prevent any undue force on the drill head centrally mounted within the casing.
A fourth fundamental improvement is the modular structure of the drill head by a plurality of disc like modules that can be created by direct external etching, drilling or casting or the like and be combined in cylindrical shells to form a readily assembled drill head.
A fifth fundamental improvement is the modular components of the drive means that allows for differing rotational units to be used with a thrust unit that provides linear pull as well as push capabilities. This allows matching of rotational units to material being bored and size of pipe being inserted and further allows for reverse reaming to a larger diameter after initial bore has been accurately drilled.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention is more readily understood an embodiment will be described by way of illustration only with reference to the drawings wherein:
FIG. 1 is a perspective view of a drive means of a microtunnelling system and apparatus in accordance with the invention including a thrust module and rotation module mounted on a rack system and further including a vacuum for assisting return slurry;
FIG. 2 is a perspective exploded view of a drill head able to be driven by the drive means of FIG. 1 for use in the microtunnelling system and apparatus in accordance with the invention;
FIG. 3 is a front view of an enclosed drill head with front cutting means able to be driven by the drive means of FIG. 1 for use in the microtunnelling system and apparatus in accordance with the invention;
FIG. 4 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section A-A;
FIG. 5 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section B-B;
FIG. 6 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section C-C;
FIG. 7 show front and rear perspective views of the steering module of the drill head of FIG. 2 ;
FIG. 8 is a side view of the of the steering module of FIG. 7 and a cross sectional view through section B-B;
FIG. 9 show front and rear perspective views of the bearing module of the drill head of FIG. 2 ;
FIG. 10 is a side view and a cross sectional view of a drill shaft;
FIG. 11 show front and rear perspective views of the front bearing bush of the drill head of FIG. 2 ;
FIG. 12 is a side view of the of the front bearing bush of FIG. 11 and a cross sectional view through section A-A;
FIG. 13 is a cross sectional view of the enclosed drill head showing the pressure fluid path through the modules to the bearing module and the front bearing bush supporting the front cutting arm;
FIG. 14 is a perspective view of a drive rod for extending between the drive means of FIG. 1 and the drill head of FIG. 2
FIG. 15 is a perspective reverse view of the drive rod of FIG. 6 ;
FIG. 16 is are end views of the drive rod of FIGS. 14 and 15 showing mating male and female ends; and
FIG. 17 is a perspective detailed view of the drill rod of FIGS. 14 and 15 showing the toggle locking mechanism.
FIG. 18 is a rear perspective view of a vacuum assisted precision reamer showing the connection means to the drill rod and rearward facing cutting face.
FIG. 19 is a front perspective view of a vacuum assisted precision reamer of FIG. 18 showing the connection means to the product pipe to be installed.
FIG. 20 is a rear perspective view of a vacuum assisted precision reamer of FIG. 18 .
FIG. 21 is a cross-sectional view through section A-A of FIG. 20 of a vacuum assisted precision reamer of FIG. 18 showing the internal pressure fluid passages, vacuum cavity, air channel, input drive shaft, planetary gear set, cutter hub and bearing.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings there is shown a microtunnelling apparatus and system that comprises a drive system ( 11 ), a drill head section ( 20 ) and intermediate drill rods ( 41 ) allowing extension of the boring hole created by the drill head section driven by the drive system.
The drive system ( 11 ) as shown in FIG. 1 includes a power source and a track system for allowing limited linear drive of the power source. The track system includes a rack and pinion gearing system ( 12 ) to allow maintained linear thrust pressure along the length of the track. The power source includes a hydraulic thrust module ( 13 ), which reciprocates a rotation module ( 14 ) housed in the thrust box in the launch shaft. The product pipe can be either pushed or pulled into place for pipeline completion.
To the front of the rotation module ( 14 ) is attached encased intermediate drill rods ( 41 ) such as shown in FIGS. 14 and 15 .
Attached to the distal end of the last intermediate drill rod ( 41 ) is attached a drill head ( 20 ) shown in exploded view in FIG. 2 and in cross sectional views in FIGS. 4 , 5 , and 6 . As such a drill rotor assembly ( 21 ) connected to the end of the drill shaft or drill rod ( 22 ) and connecting to intermediate drill rods ( 23 ) form a continuous drill string that is driven by the external drive means ( 11 ) comprising the hydraulic thrust module ( 13 ), reciprocating a rotation module ( 14 ) and linearly movable on the rack and pinion gearing system ( 12 ).
The casing ( 42 ) of the intermediate drill rods ( 41 ) and the casing of the drill head ( 20 ) formed by the steering shell (M 6 ) and the rear shell (M 5 ) form a continuous covering of the continuous drill string with internal defined continuous bores or channels. In particular a vacuum channel ( 51 ), as shown particularly in FIG. 16 , can be formed by a number of continuous cavities extending along the length of the intermediate drill rods ( 41 ) to the drill head ( 20 ). This vacuum channel ( 51 ) has vacuum seals at connecting female end ( 46 ) to maintain vacuum between longitudinally engaged and aligned intermediate drill rods. Within this vacuum channel 51 is located the connecting intermediate drill rods ( 41 ). A separate air channel ( 52 ) is formed by a separate number of continuous cavities extending along the length of the intermediate drill rods ( 41 ) to the drill head ( 20 ). This forms a linear channel within which the controlling laser can penetrate to the drill head ( 20 ). By the separation of the heat generating drill rod ( 22 ) to the linear laser channel and the cooling effect of the return slurry along the vacuum channel ( 51 ) creates a highly effective and accurate steering mechanism.
The microtunnelling system and apparatus further includes:
a) drill head with fluid bearing bush and modular construction b) enclosed drill rods with internal cooling system c) pullback extraction reamer d) rack and pinion thrust module with rotation unit e) rod loading system f) microprocessor control system.
In use upon excavation of a launching shaft, the base of the shaft would be prepared for the installation of the drilling machine. The shaft would typically have a pipe invert start point already marked and a line surveyed. A laser would be set up in the shaft at the extreme rear on line and grade. Thick boards are typically placed along the base of the shaft horizontally on grade. The microtunnelling drive means ( 11 ) including thrust module ( 13 ) and rotation unit ( 14 ) is lowered into the shaft and set up on line and grade.
The drill head ( 20 ) is lowered into the shaft and data, hydraulic and pressure fluid lines ( 44 ) are attached to the drill head ( 20 ). The drill head size and ground conditions are entered into the control panel which selects appropriate parameters for drill thrust speed and force, drill rotation speed and torque, vacuum flow and pressure, and pressure fluid flow. The drill head is attached to the vacuum thrust adaptor mounted on the rotation unit. Once set in launch mode, the vacuum unit is started and the pressurised drill fluid is actuated to eject at the drill face. The drill head is launched into the earth face.
The hole is cut via a combination of rotating cutting tooling and assisted by ejecting pressurised fluid. This pressurised fluid flow, which also acts as a fluid bearing, is shown in bold in FIG. 13 . Whilst drilling, the drill head ( 20 ) is thrust into the ground with the slurry/spoil being vacuumed up back into vacuum pipe ( 15 ) into a waste tank for removal. Once the drill head is completely in the ground the thrust, rotation, vacuum and pressure fluid is stopped. The drill head is detached from the vacuum thrust adaptor, and the thrust trolley with rotation unit return to the starting position.
Once in the start position an intermediate drill rod ( 41 ) is loaded either manually with a crane or via the use of the automated rod loader. Once the drill rod is sitting in the bed of the thrust module the thrust trolley and rotation unit are started at low speed, low thrust and low torque respectively to engage the drill rod. The rod engagement is automatic in that the drill rod has self-aligning pins ( 48 ) that accurately aligns the rod to both the drill head and the drill machine. Upon full alignment and further forward travel, the self-locking toggles (shown in detail in FIG. 17 ) engage behind the locking pins to affect a solid connection. Control hoses and cables ( 44 ) are inserted into the concave cavity ( 43 ) of the outer cover or casing ( 42 ) encasing the drill rod ( 23 ). Vacuum and pressure fluid resume with the drilling process reverting to preset drilling speed, thrust and torque. This process is continued until the final bore end point is reached.
Operation of the microtunnelling machine is performed remotely via a control box, which displays all the current pressure and speed settings. The control box is computerised and integrates the control of the steering, thrust module, rotation unit, vacuum unit and the pressure fluid. The operator can adjust any of the parametric settings to perfectly suit the current ground conditions. Both the drilling process and the steering process can be automated via the use of integrated computer software and can also be manually controlled. Throughout the drilling process the drill position is monitored via the laser hitting a target positioned in the drill head ( 20 ) and viewed through the use of closed circuit television (CCTV) so that the operator or software package constantly steers the drill head to keep the laser in the centre of the target.
Once the bore is complete there are three options; progress the drill rods into the reception shaft whilst inserting jacking pipes, pull back to the launching shaft whilst trailing a pipe directly behind it, or remove the drill rods prior to pipe insertion.
Currently, the microtunnelling industry only allows for forward excavation. The current invention is the only system of microtunnelling that incorporates precision back reaming. As shown in FIGS. 18 to 21 there is provision for the drill head ( 20 ) to be replaced by a back reamer ( 60 ) that is similarly connected to the intermediate drill rod ( 41 ) and driven by the drill string and external drive means. However instead of forward facing drill rotor assembly ( 21 ) of similar diameter to the drill head ( 20 ), instead there is a rearward facing reaming assembly ( 61 ) of larger diameter to the intermediate casing ( 42 ). The pipe can be installed by back reaming and attaching pipe to open cylindrical end housing ( 65 ) mounted at the very end of the back reamer ( 60 ). Thereby as the back reamer ( 60 ) is drawn back by the drive means ( 11 ) while undertaking rotational drilling with rearward facing reaming assembly ( 61 ) of larger diameter, a pipe of same or smaller diameter is drawn along and laid in the enlarged bore.
Back reaming allows use of low cost reamers to open the hole for different pipe size installations. Back reaming also utilises one size drill head and drill rod for each thrust module which in turn simplifies the rod loading process and reduces overall equipment cost.
Looking at the apparatus in further detail the system includes:
Guidance system with a laser striking a target, which is monitored to constantly maintain an accurate position. Vacuum: Use of vacuum allows for clean operation, fast extraction minimising regrind and Vacuum also reduces volume area occupied by extraction unit Pressure Fluid: Allows for enhanced cutter life whilst creating greater option via the use of drill fluid when dealing with different drill conditions. Drill rods: providing the ability to push or pull means that we can cut in both directions. This allows the machine to essentially drill a pilot hole accurately on the thrusting forward of the line and then cut back or open the hole as you pull back. As the line and grade of the hole is already determined the tooling required is simplistic and inexpensive which allows the machine to be more versatile through a large range of hole sizes at minimal cost. Pulling back in microtunnelling is unique. By only using one sized drill rod for each unit the jacking frame can be customised to automate the loading and unloading of the drill rods. With automated loading and unloading of drill rods the system reduced the need for man entry whilst operating. This enhances safety on the worksite.
The thrust module, which is installed in the launching shaft, can provide 300 kN force for thrust and pullback of 2.5 metre stroke within a longitudinal space of 3.0 metres. The thrust module uses rack and pinion gearing for increased stroke to retracted length ratio. It provides a high load capability with positive force. Pressure, force and speed are fully adjustable for both thrust and pull back and have a programmable stroke with adjustable limit stops for the trolley assembly. Overall the thrust module allows fast drop in boxes for the rotation unit.
A variety of rotation modules can be selectively utilised with the one thrust module according to the requirements. Rotation modules ideally cater for one drill diameter, by maximising available hydraulic power, rotating at ideal speeds (rpm) by maintaining optimum cutting face surface speeds (m/min) to best utilise working range of tungsten and carbide cutting inserts, and by maintaining the most desirable cut face/vacuum area ratio. Other sizes of rotation modules can also be used but with less efficiency.
Each rotation module comprises its own hydraulic motor (low speed/high torque, high speed/low torque, two-speed automatic selective unit, or other) coupled through a drive train assembly (chain and sprockets, simple gear box, planetary gearbox, or other) to rotate a drive shaft with a hexagonal end, which is to be coupled to the drill string inside the drill rods.
Each rotation module also includes a Vacuum thrust adaptor for connection with drill rods. This vacuum thrust adaptor incorporates the features suited to each drill rod, being vacuum sealing method, drill rod alignment, drill string torque transmission connection, thrust face and pullback connection. The Vacuum thrust adaptor also houses any hydraulic clamping and disconnection mechanisms for drill rods.
The microtunnelling machine targets extremely precise small diameter trenchless pipe installations particularly <600 mm and more particularly <300 mm. This is achieved by tracking a laser striking a target in the drill head, which is monitored via CCTV in the drill head and then steered accordingly to maintain line and grade. A unique fluid bush assembly transmits water and thrust to the rotating cutting face, where the pressure water and subsequent cutting spoil are mixed to a slurry for removal by vacuum extraction.
The drill head utilises a unique radial steering system capable of directly variable directional changes to continually and precisely cut the bore hole. The drill head is progressed through the ground by connecting subsequent drill rods between the drill head and thrust module until final bore length is achieved. These drill rods are either encased or open and combine rotation shaft/drill string, vacuum, air and control channels providing mechanical and control workings. Hydraulics, water and data is remotely controlled and utilised by the operator at the remote control panel and conveyed by cables and pressure hoses.
The front cutting rotor assembly consists of tungsten, carbide or other sintered hard metal inserts housed both axially and radially on a variety of face styles. The shape of the front cutting face varies remarkably with ground conditions, and can be flat, piloted or conical in shape and is built to suit.
All front cutting rotors are designed so that cuttings large enough to potentially block drill head vacuum cavity are kept ahead of cutters for further processing (mixing, cutting, grinding or shattering). Once cuttings are small enough, they are permitted past the cutter face for vacuum extraction.
A clay cutting face will have a multitude of spokes (range from 3 to 6) possibly connected together again to an outer rim. The main consideration is the clay consistency, as the openings through the cutting face are calculated to restrict cut spoil ahead of the cutter until small enough to be able to fit through the vacuum chamber of the drill head. When clay is soft it is easy to drill, but builds on itself and can cause blockages if the correct cutter is not chosen.
A shale cutting face will be similar to the clay version, but face openings are modified to allow for front regrind of large chipped material prior to vacuum extraction.
A rock cutting face generally comprises a cutter face with three, six or nine conical roller assemblies with peripheral openings (usually three) for cutting spoil extraction. Utilising multiple small diameter conical rollers, each set of three are staggered in distance and angle from the front face. The inner set of three cones being most forward, the intermediate set radially skewed from the inner at 60 degrees and setback by 25-100% of the cut diameter, and the final set again radially skewed from the intermediate at 60 degrees to bring the inner conical portion back in line with the radial centre-lines of the inner set of cones, and setback from the intermediate face by another 25-100% of the cut diameter. Roller cutter face then has the benefit of continual steering capability, increased stability in non-homogenous ground conditions, and increased chip rate resulting in less regrind time prior to vacuum extraction of spoil.
Downhole drilling technology has been using “tri-cone” rollers to cut rock for decades. They are available in a variety of grades—soft, medium and hard formation. A tri-cone roller utilises three conical rollers, equispaced at 120 degrees, fitted with hard metal inserts each rotating about their own bearing shaft. The conical shape of each roller, tapered into the centre of the cutting face, rotating about an axis skewed 60 degrees forward in towards the centre of the cutter results in a full flat face cut diameter. The resultant large flat cutting face is very difficult to maintain stability in non-homogenous ground, and due to the size of three rollers required to obtain the full cut diameter, the axial distance travelled prior to any steering response is often half the cut diameter.
All front cutting rotors have pressure fluid ports. Holes are drilled radially to the centre of the cutter to coincide with the porting on the drill shaft. Additional holes are drilled axially from both the front and rear faces of the cutter. These holes are sized approx 2 mm diameter to allow extreme pressure at face for best cutting and mixing qualities with minimal pressure fluid usage. An internal chamfer on front ports to increase surface area at opening only to allow for blockage ejection. Rear ports are directed back towards drill head to aid in clearing any residues from air channel and vacuum cavity.
All front cutting rotors have a central cavity for connection with the drill shaft in the drill head. This cavity is either threaded with a trapezoidal or acme thread taking up onto a shoulder on the shaft, or a hollow hexagon for the quick connection arrangement used in conjunction with a front threaded cone and lock bolt. Both styles accommodate for through shaft and cutter pressure fluid transmission.
The drill head drives the front cutting rotor by way of the drill shaft. The front of the shaft is a male hexagonal drive, with 75-100% of across flats dimension of the hexagon in length, with a front threaded extension generally 50-75% of the across flats dimension of the hexagon in diameter, and 75-100% of the thread diameter in length.
The drill rod is radially drilled (eg 3×5 mm diameter holes at 120 degrees) through the faces of the hexagonal final drive through to a central larger axial port (eg 8 mm-12 mm diameter). This axial port is drilled as a blind hole into the drill shaft, to the length corresponding to the position of the front fluid bush. Here, another series of smaller radial holes are drilled through to meet with the axial port (eg 3×5 mm diameter holes at 120 degrees). These holes are peened (eg 8-10 mm concave diameter) to eliminate any seal degradation from the rotating shaft.
The front fluid bearing bush encapsulates this mid-front section of the drill rod and provides a centralised bearing location capable of high radial and thrust forces combined. The peened radial holes of the drill rod are longitudinally aligned with the internal radial pressure fluid distribution groove of the fluid bearing bush.
This groove is in turn fed pressure fluid from radial drill holes (eg 6×5 mm diameter holes equispaced at 60 degrees). Fluid cannot escape to the rear of the fluid bush due to an energising U-cup seal placed at the rear of M 1 bearing module. Pressure fluid is proportionally distributed—to the drill shaft axial port through to the front cutting rotor, creating back pressure to distribute to the annulus area between the outside diameter of the drill rod and the inside diameter of the fluid bush. This is achieved by high helix angle, low depth multi-start grooves machined on the inside of the fluid bush from the front edge of the distribution groove to the front face of the fluid bush (eg triple-start, 20 mm pitch 0.5 mm deep grooves with 1.5 mm concave radius). This pressure fluid is then channelled to a helical spiral groove on the front face of the bush (eg single 10 mm pitch continuously decreasing right-hand 0.5 mm deep face groove with 1.5 mm concave radius). This channelling effect essentially hydrostatically separates the shaft from the bush both radially and axially, to counteract steering and thrust face forces. The relationship is linearly proportional in that the higher the load, the harder the faces act against one another, providing a greater hydrostatic seal, which in turn acts to repel the two components. Hence we have a bearing, which mechanically transfers load, provides a pressure fluid swivel, and continually lubricates and cools itself. This method allows a very strong shaft construction with minimal stress riser points, and excellent pressure fluid conveyance.
The drill head functions to drive the front cutting rotor by means of a drill rod. The bore hole position is monitored within the drill head by means of a laser set at the launch shaft indicating a position on a target mounted in the drill head. A camera within the drill head is directed at the target, and relays a video image to a video screen viewed by the machine operator. The operator controls any required steering direction changes. Steering is achieved by altering the position of the cutting face relative to the bore hole.
The prior art was to manufacture a cylindrical drill head, and moving the cutting face. One steering method is to pivot the front portion of the drill head vertically and horizontally. Although effective in steering, this required the laser target to be situated a considerable distance from the cutting face. The further rearward the laser target position, the further the distance is required to be drilled prior to an update of current bore face location.
Another steering method is to move the drill shaft within the drill head. This has the advantage of being able to mount the laser target further forward in the drill head, and therefore, providing a more accurate target to bore face position. However, the pivotal mounting of these steering mechanisms provides a weak steering with high failure rates and increased maintenance.
These past methods of steering are physically large and cumbersome, and due to plumbing required to each hydraulic cylinder, makes this method unsuitable to small diameter drill head design. The invention entails construction of a modular drill head for increased strength and reduced size.
The drill head is of a segmental modular design to minimise overall size while achieving maximum strength and durability. Each module is centralised and retained by the next module by male and female stepped spigots. Clamping of each module achieves angular alignment and axial clamping. Each module is designed for its particular purpose in the drill head, and all hydraulic, fluid, air and vacuum channels are interconnected by way of stepped face seals. It is this method of construction that allows the use of integrated pressure porting, reliable bearing design, maximum vacuum area, good air channel ducting, maximum forward position of laser target area and plumb indicator for visual head tilt indication.
The drill head and steering module for use in the microtunnelling system has a steering shell M 2 mounted axially on the drive rod ( 22 ) in a manner to allow radial movement and having a plurality of radially mounted pistons able to engage the inner surface of the steering shell M 6 such that the control of the protrusion of the plurality of radially mounted pistons controls the direction of the steering shell.
As shown particularly in FIG. 8 , the plurality of radially mounted pistons is included in a circular steering module fitting around the drill rod and having radial bores from which the radially mounted pistons protrude. The circular steering module includes a spoked wheel effect with the radial bores extending at least partially along the radial extending spokes. Preferably cavities are between the spokes to allow axial pathways. The circular steering module includes ports near the radial centre and able to receive water or hydraulic fluid for driving the pistons to protrude from the radial bores and engage the inner surface of the steering shell.
As shown in FIG. 2 , the drill head includes a modular construction having a plurality of circular disc like elements for axial alignment and abutment and mounting within a cylindrical shell, wherein each of the circular disc like elements is created by direct bore construction and the axial alignment and abutment creates continuous axial and radial channels allowing fluid flow, vacuum waste return channel, and control flows.
One of the circular disc like elements forms a bearing module M 1 at the front of the drill head with flow paths for providing axially extending fluid jets to assist cutting and radially extending flow paths to assist aquaplaning bearings of the rotating cutting means.
One of the circular disc like elements forms a steering module M 2 at the front of the drill head with flow paths for providing axially extending fluid jets to control protrusion of pistons to engage the outer cylinder and alter direction of the drill head.
One of the circular disc-like elements forms a spacer module M 3 within the drill head with flow paths for providing axially extending flow paths to adjacent modules.
One of the circular disc like elements forms a mounting module M 4 at the rear of the drill head with flow paths for providing axially extending flow paths and able to form non rigid mounting of base of outer cylinder.
The drill rod ( 22 ) and connected intermediate drill rods ( 23 ) are a steel rod drive shaft, with male and female hexagonal ends to effect connection and resist torsional forces. The drill rod and connected intermediate drill rods are retained within either end of the drill rod end plates by front and rear rod bush bearings. The drill rod and connected intermediate drill rods are housed in an axially extending tubular section ( 51 ) to separate the bearings from the spoil through the vacuum section. The axially extending tubular section drill string housing is located fully within the vacuum chamber, surrounded by the vacuum channel and vacuum cavities. It is this full surround by vacuum that functions to absorb heat created by the rotating drill string, transferring it directly to the slurry and spoil cuttings and fluid returning from the drill head, and in turn to the vacuum waste tank.
The laser beam used for drill head guidance travels through the protected top air channel ( 52 ). It is the effective removal of heat and creation of a stable laser environment that minimises otherwise unavoidable hot-cold transitions at every drill rod connection. In past drill rods, these hot-cold transitions cause consecutive and culminating laser refraction, leading to an inaccurate borehole.
During connection the drill rods ( 23 , 23 ) are pushed together. The vacuum thrust adaptor has two conical combination pins ( 48 ) in the male drill rod end plate ( 47 ) about the rod's longitudinal axis and centred vertically about the drive, and offset equidistant about the horizontal plane. These combination pins have a conical taper at the front and align with two bores ( 49 ) in the female drill rod end plate ( 46 ) about the rod's longitudinal axis. As the pins are further inserted, the drill rod is aligned to a horizontal plane; the drill rod and connected hexagonal intermediate drill rods are aligned and further inserted until the two end plate faces are mating.
Consecutively during this alignment process, the toggles mounted to the female end plate are caused to pivot about the pivot bush axis, moving radially outwards from the end plate diameter, allowing the major diameter of the combination pins past the toggles. Once the Combination Pins pass the major diameter, the toggles are allowed to spring back to their original position, moving in between the combination pins and the female end plate, thus locking the connection, and allowing either thrust or pullback under load. Once the drill rod end plates are mated face to face, the vacuum and laser space are sealed due to the elastomeric seals inserted in the milled grooves of the female plate.
Referring to FIGS. 2 , 4 , and 5 the M 1 bearing module comprises of a circular disc with a central stepped bore for the location of the front fluid bearing bush. The housing is cross-drilled to divert an axial pressure fluid port originating to the side of the drill rod, connected to a radially drilled port which in turn connects to a radial groove on the inside of the central bore. Two additional smaller radial grooves—one to the rear and one to the front of the channel groove provide housing for o-ring seals which completes this cavity and directs all pressure fluid through to the radial holes drilled through the fluid bush. The radial pressure cavity also connects to a vertical radial port fitted with a jetted plug, which directs some fluid to the Annulus between the steering ring and steering shell M 6 . At the rear of the M 1 bearing module is a self-energising u-cup seal retained by a soft metal bush to complete the front seal cavity.
As shown in FIGS. 2 , 6 , 7 and 8 the M 2 steering module comprises a circular disc with a central bore through which the drill rod passes. At the top and to the sides are air channels. At the bottom is the vacuum cavity. There are four radial drillings, bores and counter bores equispaced around the circumference of the disc. Four independent oil ports drilled axially from the rear of the housing and countersunk with face sealing enter the lower portion of the radial drilling in each of the four bores. These bores house the steering pistons with high pressure seals. With pressurised hydraulic oil entering any of these cavities, the associated piston is forced radially outward providing force to move the steering shell M 6 . The piston is retained from ejection from the housing by a stepped gland ring incorporating a piston rod wiper and auxiliary seal which in turn is retained by an internal circlip within the stepped bore.
The M 6 steering shell comprises a hollow tubular section with a front end stepped return section reducing in inside diameter then tapered both internally and externally towards the front. This front stepped return is faced up against the front of M 1 bearing module, and the main inner bore has full annular clearance around the circumference of the steering ring assembly allowing the shell to move about radially in any direction. As one piston in the M 2 steering module is actuated, the M 6 steering shell is forced radially and moves with the extending piston. As the opposing side of the M 6 steering shell moves in towards the steering ring assembly, the piston radially opposed to that actuated is in turn retracted, allowing for the next steering manoeuvre. The same applies to the other set of pistons acting about an axis at 90 degrees to the first set of pistons. This actuation on 2-cylinder movement axes, either independently or together allows the drill head to alter its shaft and cutter position relative to the bored hole thus providing steering control.
The hydraulically steered drill head has a fast system for changing cutting tooling. Rock capabilities have been enhanced with the design of a rock roller system for the microtunnelling unit.
The drill head has been modified to accommodate the covered drill rod system and designed to allow for the introduction of automated steering. Drill head segmental design allows for strength and durability whilst enhancing the ability to maintain drill head positioning via hydraulic rams holding a position of one circular piece within a second circular ring providing for maximum strength in minimal space.
The drill shaft must rotate freely under high loads, and pressure fluid must be transferred to the drill face. The use of high-pressure fluids out of the drill face allows for enhanced tooling life whilst also giving the ability to flush tacky ground.
The prior art was to retain the shaft within steel bearings, either tapered roller, or ball bearings with needle thrust bearing. This solved the mechanical rotation issue, but brought with it a whole plethora of associated problems to do with sealing bearings from ingress of cutting spoil and water, both ingredients deadly to bearings. Maintenance is increased as seals and bearings have to be replaced regularly. If a bearing was to seize, it would halt the complete drilling process, drill head would have to be removed for overhaul, causing unplanned down-time and site delays.
The prior art for pressure fluid transmission is with a pressure swivel assembly, which rotates about the shaft axis. The swivel construction would be tubular in design with two pressure seals axially opposed to retain a central pressure chamber within the swivel. A threaded inlet port enters this central pressure chamber radially, flows around the axis of the cavity, through a radial hole drilled in the drill shaft, then through an axial hole in the drill shaft to the front face. This design required external retention of the swivel housing to stop it rotating with the drill shaft, causing radial side-loads on one inside face, in turn, causing seal failure and therefore leakage. The seals had to have a high preload to accommodate high pressure, and would wear grooves in the drill shaft, causing leakage. The swivel would be located behind the target position, so any water spray from leaks would upset visual sight of target. Using pipe fittings from the swivel housing with elbows to bring hose in axially beside drill shaft meant size was too large to be used in small diameter drill heads, assembly and maintenance of hose and fittings would be awkward at best.
The invention entails construction of a modular designed drill head, with integrated pressure fluid conveyance cavities. Further, the invention includes the use of a fluid bearing bush to act as a front drill rod bearing and pressure swivel in one assembly. The fluid bearing bush is retained in the M 1 bearing module by three grub screws (equispaced at 120 degrees). Pressure fluid directed to the distribution groove in the M 1 bearing module is sealed form escaping past the inside of the stepped bush bore and the outside diameter of the fluid bearing bush by means of two O-ring seals on each side of the distribution groove. This M 1 bearing module distribution groove is longitudinally aligned with radial drill holes (eg 6×5 mm diameter holes equispaced at 60 degrees) around the perimeter of the fluid bearing bush. These drill holes enter the inside diameter of the bush and are interconnected with an internal radial distribution groove within the fluid bearing bush. Fluid cannot escape to the rear of the fluid bush due to an energising U-cup seal placed at the rear of M 1 bearing module.
The fluid bearing bush encapsulates a mid-front section of the drill rod and provides a centralised bearing location capable of high radial and thrust forces combined. The peened radial holes of the drill rod are longitudinally aligned with the internal radial pressure fluid distribution groove of the fluid bearing bush.
Pressure fluid is proportionally distributed—through radial holes in the drill shaft, connecting to an axial port through to the front cutting rotor, creating back pressure to distribute to the annulus area between the outside diameter of the drill rod and the inside diameter of the fluid bush. This is achieved by high helix angle, low depth multi-start grooves machined on the inside of the fluid bush from the front edge of the distribution groove to the front face of the fluid bush (eg triple-start, 20 mm pitch 0.5 mm deep grooves with 1.5 mm concave radius).
This pressure fluid is then channelled to a helical spiral groove on the front face of the bush (eg single 10 mm pitch continuously decreasing right-hand 0.5 mm deep face groove with 1.5 mm concave radius). This channelling effect essentially hydrostatically separates the shaft from the bush both radially and axially, to counteract steering and thrust face forces. The relationship is linearly proportional in that the higher the load, the harder the faces act against one another, providing a greater hydrostatic seal, which in turn acts to repel the two components.
Hence we have a bearing, which mechanically transfers loads, provides a pressure fluid swivel, and continually lubricates and cools itself. This method allows a very strong shaft construction with minimal stress riser points, excellent radial and axial bearing loads, excellent impact resistance, excellent pressure fluid conveyance, minimal assembly and maintenance costs, and is field replaceable.
The position of the target at the extreme front of the drill head ultimately enhances the drills ability to be extremely accurate and responsive to positional changes. The use of high-pressure fluids out of the drill face allows for enhanced tooling life whilst also giving the ability to flush tacky ground. The ability to run drill fluids at the cutting face creates greater efficiencies within cutting and assists our abilities through varied ground conditions. Front bearing combination of high load axial and thrust bearing with a high-pressure fluid and integrated lubrication system.
The drill rods are inserted and connected consecutively with the thrust module to allow bore hole progression while maintaining drill string, vacuum, air channel, hydraulic, pressure and data line connection. The drill rod transmits torque from the rotation unit mounted on the thrust module to the drill head at the bore face via a drill rod and connected intermediate drill rods. The drill rod also transmits thrust from the rotation unit mounted on the thrust module to the drill head at the bore face via a vacuum tube.
The prior art was to have the vacuum tube section aligned longitudinally with the drill string, situated below it, generally to rest on the invert of the borehole. This allows cutting spoil extraction by vacuum.
The vacuum tube has bearing bushes mounted at each end along the drill rod and connected intermediate drill rods axis to retain the drill rod and connected intermediate drill rods, and male and female cleats at each end for connection by means of a manual pin inserted to two holes either vertically or horizontally aligned. The drill string is exposed, causing possible operator injury from the rotating shaft. The connection method with manual pin insertion is tedious, and pin extraction after bore completion is difficult.
The manual connection method required clearance to allow manual connection. This clearance between subsequent drill rods allows each rod to rotate slightly about its axis as a result of drill string rotational torque. This rotation, possibly only 1 degree per rod, extrapolates the error the further the borehole. Final error over a 100 m bore could be a 50-degree rotation, causing an inaccurate target position relative to the start point. This target position is then potentially out by up to 100 mm.
The borehole is not peripherally supported, causing ground collapse in certain ground conditions, thereby blocking laser and target view, and halting drilling operation. The bearings are directly under the laser position, causing hot sections at each end of the drill rod and a cooler section between the bearings. These hot-cold transitions cause consecutive and culminating laser refraction, leading to an inaccurate borehole.
The microtunnelling system uses a casing mounted on the drill rod that includes at least two axially extending cavities or bores wherein liquid is axially transported along one of said axially extending cavities or bores under pressure to the drill head to assist drilling and resulting slurry is vacuum returned along the other of said axially extending cavities or bores. However as drill rods are fully enclosed, and slightly smaller than the drill head diameter allowing the microtunnelling machine to be effective in collapsing ground conditions, under water table, soft or hard ground. The vacuum or slurry spoil extraction volume within the drill rod provides minimum restriction to increase productivity and length of lines achievable. With all moving components enclosed, the drill rod is safer to use.
Rotation within vacuum or slurry spoil eliminates heat from bearings, minimising laser distortion and wear and tear to the equipment. Enclosed laser space for stability of beam. Provides airflow to equalise temperature and humidity, more accurate operation. Automatic alignment system speeds and simplifies operation. Automatic clamping system, for positive joining, withstands full load in both forward and reverse directions. Clamping system maintains strong sealing of vacuum. Fully encapsulated hose and dataline pocket, protecting sensitive data and pressure lines.
The pullback extraction reamer is used to increase the size of a microtunnelled bore hole. This is advantageous for operators as one size microtunnelling drill head and drill rods can be used in conjunction with a pullback extraction reamer in various bore sizes, while maintaining good productivity. Once the drill head reaches the reception shaft, the drill head is removed from the end of the drill rod and replaced by the pullback extraction reamer. The product pipe to be installed can be coupled to the pipe pullback adaptor mounted on the rear. Drilling is now commenced in reverse, or pullback mode. The drill string is coupled to a drive spur gear that rotates three planetary gears fixedly mounted to the vacuum thrust plate. The spur gears are meshed inside an internal ring gear that is fixed to the cutter hub, allowing the cutter hub to rotate at a lower speed but higher torque than its input drive. The cutter hub is mounted to the pipe pullback adaptor by way of thrust and radial bearings. This embodiment allows the drill rod and pullback pipe to remain rotatably fixed and the reamer cutter hub can rotate about the longitudinal axis at a greater torque. The cutter hub is typically concave within its cutting face, so that as it is pulled back through the ground, slurry and spoil are offered to the vacuum or slurry channel entrance for evacuation.
It should be understood that the above description is of a preferred embodiment and included as illustration only. It is not limiting of the invention. Clearly a person skilled in the art without any inventiveness would understand variations of the microtunnelling system and apparatus and such variations are included within the scope of this invention as defined in the following claims. | The present disclosure relates to a drill head having a drill head main body including a front end portion and a back end portion. The back end portion is configured to be connected to a drill rod. A steering shell is mounted over the front end portion. A drive shaft extends through the back end portion and the front end portion of the drill head main body. The drive shaft has a front end adapted for connection to a cutting unit and the drive shaft is rotatably supported within a bearing at the front end portion of the drill head main body. A steering shell driving arrangement is incorporated into the front end portion of the drill head main body for generating relative radial movement between the steering shell and the drill head main body. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit, under 35 U.S.C. Section 119(e), to U.S. Provisional Application Ser. No. 60/775,172, filed Feb. 21, 2006, the entirety of which is expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is directed to an apparatus for improving the visibility of a camouflage ground hunting blind. More particularly, the present invention relates to a high visibility cover that provides a hunter using a camouflage hunting blind with a high degree of safety and convenience without interfering in any undesirable manner with hunting technique or the hunter's ability to engage in hunting activities.
[0004] 2. Related Art
[0005] The success of most hunters in many types of hunting largely depends upon the ability of the hunter to blend with the environment. In addition to using a variety of natural objects, hunters have often turned to a variety of camouflage articles to assist them in blending with their surroundings. Recently, there has been a trend towards the use of portable camouflage ground hunting blinds in a variety of hunting activities. These blinds are generally portable and can be assembled and disassembled relatively easily and quickly. These hunting blinds generally protect hunters from the environment while concealing them from game animals. Such blinds typically contain a variety of openings and/or windows positioned on the sides of the blinds for the hunter's ease in monitoring and shooting at game outside of the blind. Ground hunting blinds typically do not have any loose articles or fabric hanging from outside of the blind as such loose items can be moved by the wind, and frighten various game animals away.
[0006] For various safety reasons, most local hunting laws require hunters to wear apparel that is highly visible to other hunters. This is especially true during firearm hunting seasons. The use of high visibility colors such as Hunter Orange has been shown to significantly reduce the number of hunting related accidents. “Hunter Orange” refers herein to colors such as blaze orange, hunter orange, fluorescent orange, daylight fluorescent orange, Ten Mile, camouflage orange, Hunter Safety Green, fluorescent chartreuse, fluorescent yellow, any other highly visible color that is approved or will be approved for hunting under local or national laws, any combination thereof, and the like. The highly visible apparel can take the form of a jacket, a vest, a hat, pants, or the like. As disclosed in U.S. Pat. No. 5,159,718, the entirety of which is expressly incorporated herein by reference, some garments incorporate patches of fluorescent orange in the garments themselves. Other garments incorporate Hunter Orange in a camouflage pattern.
[0007] Under most local laws, the area of Hunter Orange must meet certain size limitations. For example, in Wisconsin, during any gun or muzzleloader season, no person may hunt any game, except water fowl, unless at least 50% of the person's outer clothing above the waist is colored Blaze Orange. Further, a hat, if worn, must be at least 50 % Blaze Orange. In other states, for example, apparel must contain at least a certain number of square inches of visible Hunter Orange.
[0008] The trend towards the use of portable camouflage ground blinds has been noticed even in those types of hunting activities that require garments colored Hunter Orange. Despite the blaze orange clothing requirement, hunters using such ground blinds are nearly or totally concealed from other hunters in the field. As a result, there is a concern that the use of such blinds will eventually lead to an increase in hunting related accidents.
[0009] Some camouflage blind manufacturers have attempted to address this concern by incorporating small patches of high visibility material into their camouflage hunting blinds. For example, some hunting blinds contain a swatch or patch of blaze Hunter Orange material that may be exposed during certain hunting seasons but covered with a camouflage patch during other seasons. These patches, however, are often small and difficult for other hunters in the area to see. As such, these measures are believed to be fairly ineffective in limiting the risk of hunting accidents. Further, because many hunters already own a portable camouflage ground blind, many are hesitant to purchase another hunting blind incorporating such patches of visible material.
[0010] It is also well-known to attach a protective, water-repellant or water-resistant covering to a tent or other portable structure to offer additional protection from the elements and additional ventilation to occupants. Such coverings are often referred to as “tent flies.” Tent flies have distinct drawbacks, however, with respect to improving the visibility of ground camouflage blinds to other hunters. Tent flies are generally designed to protect tents from rain and moisture. As such, tent flies primarily cover the roofs of tents and therefore may be difficult to see from a side view or the ground level. Further, tent flies are typically not composed of a high visibility color. In addition, such tent flies typically extend like canopies beyond the perimeter of the underlying tent. Indeed, most tent flies are designed to be staked separately from the underlying tent. As such, tent flies require much more ground space than the underlying tent and therefore are difficult to utilize in most hunting conditions. Further, because tent flies are typically staked separately from the tent, tent flies often require significant time and assembly. In addition, the canopy-like features of a tent fly tend to be moved by wind and that movement can frighten game animals.
[0011] Tent flies are also generally designed to improve air flow and ventilation around a tent. The additional ventilation afforded by such tent flies is disadvantageous when hunting from a ground blind. Additional air flow often results in additional movement that can spook game. Further, human scent spooks many game animals. Good hunters are careful about masking their scent and hunting blinds are often designed to help hide a hunter's scent. Improved air flow around a ground blind may defeat many of the scent masking capabilities of a ground blind. Finally, many hunting activities occur during the fall and winter seasons when temperatures are lower. Ground blinds are generally designed to cut the wind and trap warm air to help keep the occupant warm. Improved air flow and ventilation around a ground blind can diminish this desired insulating effect.
SUMMARY OF DISCLOSED EMBODIMENTS
[0012] A simple covering is needed to minimize hunting accidents that may be caused by the use of camouflage hunting blinds.
[0013] This invention provides a simple apparatus for improving the visibility to other hunters of a camouflage hunting ground blind to reduce the risk of hunting-related accidents. This invention separately provides a covering that is designed to fit over most sizes and shapes of camouflage blinds. This invention separately provides a covering that may be drawn close to the underlying hunting blind to minimize the overall size of the system, potentially improve the scent-mask and insulting effects of the underlying blind, and eliminate any loose or daggling fabric or items that might be prone to move with the wind and thereby frighten game animals. In addition, this invention separately provides a covering that is very portable and easy to assemble and use in connection with most camouflage blinds.
[0014] These and other features and advantages of various exemplary embodiment of systems according to this invention are described in or are apparent from, the following detailed descriptions of various exemplary embodiments of various devices and/or structures according to this invention.
BRIEF DESCRIPTION OF DRAWINGS
[0015] Various exemplary embodiments of the systems and methods according to this invention will be described in detail, with reference to the following figures, wherein:
[0016] FIG. 1 is a perspective view of the cover according to an exemplary embodiment of the present invention suspended over a camouflage blind.
[0017] FIG. 2 is a perspective use showing an exemplary embodiment of the present invention operatively in use over a camouflage blind.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0018] With reference to FIG. 1 , a first exemplary embodiment of the present invention is shown in the form of a cover assembly 10 that comprises a cover top 12 , a plurality of stirrups 14 , a plurality of lower panels 16 , and a flexible cord 24 . The cover top 12 may take a variety of forms including, octagonal, round or square shape. In one exemplary embodiment, the cover top 12 may be as shown in FIG. 1 .
[0019] In one embodiment, the cover top 12 comprises a plurality of interconnected triangular sections 18 . In one exemplary embodiment, the sides of each triangular section 18 are substantially straight while the base of each triangular section 18 arches toward the vertex in a parabolic or catenary fashion. As shown in FIG. 1 , the cover top 12 in one embodiment is formed by attaching a first side of a first triangular section 18 to a first side of a second triangular section 18 , attaching a second side of the second triangular section 18 to a first side of a third triangular section 18 , attaching a second side of the third triangular section 18 to a first side of a fourth triangular section 18 and attaching a second side of the fourth triangular section 18 to a second side of the first triangular section 18 such that the vertex of each triangular section 18 meets at or about the same point. The triangular sections 18 may be interconnected by any variety of methods and arrangements. In one exemplary embodiment, the sides of the triangular sections 18 are sewn or stitched. In one embodiment, the stitching is hidden on the interior of the cover top 12 so the stitching is not visible from the exterior of the cover top 12 . The sides of the triangular sections 18 may also be attached using an adhesive or fasteners such as hook and loop fasteners such as Velcro(& fasteners. Alternatively, the cover top 12 may be integrally formed.
[0020] In one exemplary embodiment, a plurality of stirrups 14 are attached to the cover top 12 . In one embodiment, each stirrup 14 is a single length of material that is attached at one end to a corner of the cover top 12 . The stirrups 14 may be attached to the cover top 12 by any variety of methods and arrangements. In one exemplary embodiment, the stirrups 14 are sewn or stitched to the cover top 12 . The stirrups 14 may also be attached to the cover top 12 using an adhesive or fasteners such as hook and loop fasteners such as Velcro® fasteners. Alternatively, the stirrups 14 and the cover top 12 may be integrally formed.
[0021] The stirrups 14 may be manufactured in a variety of shapes depending upon the shape and structure of the ground blind 11 to be covered. As can be appreciated by one skilled in the art, the stirrups 14 may take a variety of shapes provided the shape does not interfere with ingress or egress from the underlying ground blind 11 or otherwise obstruct any doors 13 , windows 15 or other openings of the blind 11 . In one exemplary embodiment, the stirrups 14 will be elongated and are long enough to allow the distal end to extend to or nearly to the bottom of the blind 11 when in use to cover a blind 11 . In one embodiment, the width of the stirrup 14 may be generally consistent throughout the length of the stirrup 14 . In one embodiment, the width of the stirrup 14 at the end of the stirrup 14 connected to the cover top 12 may be greater than the width of the stirrup 14 at the opposite end. In one embodiment, the stirrup 14 may have parabolic longitudinal edges. In one embodiment, the longitudinal edges of a stirrup 14 may follow a parabolic contour such that the width of the stirrup 14 between opposed edges is less at the waist or central portion of the stirrup 14 than the aft or fore portions.
[0022] In one embodiment, at least a portion of the perimeter of the cover top 12 comprises at least one plurality of sleeve structures 22 formed therein. In one embodiment, the longitudinal edge of each stirrup 14 and the edge of the base of each triangular section 18 comprising the cover top 12 are folded and an attachment seam 20 is sewn there along to form a plurality of sleeve structures 22 along substantially all of the perimeter of the cover assembly 10 . In one embodiment, a single flexible cord 24 passes through each of the sleeve structures 22 leaving a loop of flexible cord 24 at the distal end of each stirrup 14 . Accordingly, in one embodiment, the stitching between the cover top 12 and each stirrup 14 does not extend into the sleeve structure 22 to in any way engage the flexible cord 24 .
[0023] In one embodiment, the flexible cord 24 may not be a closed loop. In one embodiment, a plurality of flexible cords 24 operatively associated to the distal ends of a plurality of stirrups 14 may be used. In one embodiment, the flexible cord 24 may be operatively associated with the cover assembly 10 .
[0024] In one embodiment, the flexible cord 24 is made of rubber or some other type of elastic material such as that known as a “bungee cord.” Other types of flexible cords 24 such as ropes, belts and the like may be used but some degree of elasticity is desirable. In one embodiment, a rip cord in combination with a tensioner is used. In one embodiment, the flexible cord 24 is sized in a manner so that the flexible cord 24 may be pulled in a stretched condition once the covering assembly 10 is placed over the camouflage ground blind 11 .
[0025] In one embodiment, each set of adjacent stirrups 14 are interconnected to lower panels 16 . In one embodiment, the lower panels 16 are generally stitched or sewn to the stirrups 14 . In one embodiment, the stitching between the lower panels 16 and the stirrups 14 does not extend into the sleeve structure 22 . In one embodiment, the lower panels 16 are attached to the stirrups 14 at approximately the attachment seam 20 . The lower panels 16 and stirrups 14 may also be attached using an adhesive or fasteners such as hook and loop fasteners such as Velcro® fasteners. Alternatively, the stirrups 14 and lower panels 16 may be integrally formed. In one exemplary embodiment, at least a first side of at least one lower panel 16 is coupled to a stirrup 14 by at least one detachable fastener such as a button, snap, Velcro® attachment or the like to permit the first side of the lower panel 16 to be detached from the stirrup 14 when desired.
[0026] The lower panels 16 may be manufactured in a variety of shapes depending upon the type of ground blind 11 to be covered. As can be appreciated by one skilled in the art, the lower panels 16 may take a variety of shapes provided the shape does not obstruct any openings or windows 15 of the blind 11 . In one embodiment, the lower panels 16 are in a substantially catenary or parabolic form. Such a form offers a number of advantages. For example, the catenary form is more stable and less likely to flap or move in a breeze. In addition, the catenary form can cover additional surface area of the underlying ground blind 11 without interfering with or obstructs any portion of the windows 15 and other openings in the blind 11 , while improving the visibility of the cover assembly 10 and underlying ground blind 1 1 to other hunters.
[0027] According to alternative embodiments, the cover top 12 , stirrups 14 , and lower panels 16 may be made from any number of a variety of materials and have any number of different arrangements and configurations to provide the user with an article configured to suit multiple types and shapes of ground blinds 11 . In one embodiment, cover top 12 , stirrups 14 and lower panels 16 are formed from any material typically used in the tent construction industry. Such material typically has the characteristics of being water-resistant and/or fire-resistant. Examples of this material include polyester, nylon, canvas, vinyl reinforced polyester, mesh or the like which could be sewn and yet withstand the elements that could be encountered during a hunting outing.
[0028] In one embodiment, the cover top 12 , stirrups 14 and lower panels 16 are made from material that is highly visible to other hunters. In one embodiment, at least one of the cover top 12 , stirrups 14 and lower panels 16 are made from material that is Hunter Orange in color. In one exemplary embodiment, the cover top 12 , stirrups 14 and lower panels 16 are made from 300 denier textured polyester Safety Orange material.
[0029] As shown in FIG. 2 , in one embodiment, the cover assembly 10 is configured to substantially cover a variety of camouflage blinds 11 without obstructing the views from or ability to open windows 15 , doors 13 , and other apertures of the underlying camouflage blind 11 . In one embodiment, the cover assembly 10 is adapted to be coupled to and/or positioned over a camouflage blind 11 such that the stirrups 14 extend down the outside corners of the camouflage blind 11 as shown in FIG. 2 . In one embodiment, the cover assembly 10 is adapted to be positioned over a camouflage blind 11 such that the stirrups 14 extend down the sides of the camouflage blind 11 between the door 13 , windows 15 and other openings of the blind. The flexible cord 24 may then be operatively connected to exterior stakes such as any stakes holding the blind 11 . The user may tighten the flexible cord 24 across all of the margins of the stirrups 14 and cover top 12 which have a sleeve structure 22 , to hold down all such margins and prevent any portion of the cover assembly 10 from moving in a breeze. In this stretched condition, the flexible cord 24 produces tensioning forces which are applied to the cover top 12 and stirrups 14 which, in turn apply these tensioning forces to the camouflage blind 11 . It is these tensioning forces that maintain the covering assembly 10 in a taut position when the covering assembly 10 is in a secured state over the camouflage blind 11 .
[0030] While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents. | A high visibility cover adapted for use with a camouflage hunting blind that permits the blind to be easily visible to other hunters while at the same time not interfering with the use of the blind or the hunting technique of the occupant. More specifically, the high visibility cover is designed to universally and securely fit most sizes and shapes of hunting blinds. | 4 |
BACKGROUND OF THE INVENTION
This application has relation with U.S. patent applications Ser. Nos. 07/795,989 (filed Nov. 22, 1991) now U.S. Pat. No. 5,191,815, 07/850,283 (filed Mar. 12, 1992) now U.S. Pat. No. 5,203,235, 07/878,469 (filed May 5, 1992) now U.S. Pat. No. 5,233,889, 07/939,600 (filed Sep. 2, 1992) now U.S. Pat. No. 5,305,665 and 07/969,072 (filed Oct. 30, 1992) now U.S. Pat. No. 5,249,483.
1. Field of the Invention
The present invention relates in general to automotive automatic transmissions, and more particularly to a control system for the automotive automatic transmissions.
2. Description of the Prior art
In automotive automatic transmissions, there has been proposed a control system, in which a so-called "inertial phase keeping time" for which the transmission gear ratio is being varied is measured, and the line pressure applied to a friction element, such as, clutch or the like, is controlled to a lower level during the gear change operation so that the inertial phase keeping time can take a desired value. However, in case wherein the line pressure is quite low, the gear change can not be completed within the time for which the line pressure is controlled low. When, under this condition, the line pressure is raised thereafter, the friction element is engaged suddenly, which causes a marked shift shock.
In order to solve such drawback, a measure has been proposed, which is shown in Japanese Patent First Provisional Publication 2-21059. That is, in the measure, a so-called "inertial phase starting time" elapsed from issuance of a gear change instruction to the time when the inertial phase actually starts is measured, and when the measured time exceeds a predetermined time (that is, when, due to lowering in the line pressure, the starting of the inertial phase is delayed), the line pressure is raised irrespective of the inertial phase keeping time.
When, for example, a select position switch is out of order, and thus when, irrespective of D-range signal being fed to a control unit, the transmission is kept in N-range, operation of a shift solenoid effected by the gear change instruction does not induce the change of the gear ratio.
However, due to its inherent construction, the above-mentioned measure has the following drawback.
That is, even under the above-mentioned condition, the line pressure is raised by judging that the inertial phase starting time is too long. Accordingly, when thereafter the gear change operation actually starts, the gear change is carried out with the higher line pressure, which causes a marked shift shock.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a control system for an automotive automatic transmission, which is free of the above-mentioned drawback.
According to the present invention, there is provided a control system which controls an automotive automatic transmission having a friction element powered by a line pressure. The control system comprises first means for detecting a gear ratio provided by the transmission; second means for measuring an inertial phase keeping time elapsed from the time when a change of the gear ratio starts to the time when the change ends; third means for adjusting the line pressure in a manner to harmonize the inertial phase keeping time with a first predetermined time; fourth means for measuring an inertial phase starting time elapsed from issuance of a gear change instruction to the time when the change of the gear ratio starts; fifth means for increasing the line pressure irrespective of condition of the third means when the inertial phase starting time exceeds a second predetermined time; and sixth means for suppressing the operation of the fifth means in case wherein even when the inertial phase starting time exceeds a third predetermined time longer than the second predetermined time, the change of the gear ratio fails to occur.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic illustration of an automotive automatic transmission to which a control system of the present invention is applied;
FIG. 2 is a TABLE showing ON/OFF (viz., engaged/disengaged) conditions of various friction elements of the automatic transmission with respect to various gear positions selected by the transmission;
FIG. 3 is a schematic illustration of a hydraulic circuit of the automatic transmission;
FIG. 4 is a schematic illustration of a control unit which constitutes an essential part of the control system of the present invention;
FIG. 5 is a flowchart showing programmed operation steps which are carried out periodically in an interruption subroutine for controlling the line pressure:
FIG. 6 is a flowchart showing programmed operation steps which are carried out periodically in another interruption subroutine for controlling the gear change;
FIG. 7 is a flowchart showing programmed operation steps which are carried out for correcting and renewing a correction value;
FIG. 8 is a graph showing a data map of line pressure used in a condition wherein the transmission is not under gear changing;
FIG. 9 is a graph showing a correction data map of line pressure used in a condition wherein the transmission is under upshifting;
FIG. 10 is a graph showing the characteristic curves of an inertia phase starting time "T1" and an inertial phase keeping time "T2"; and
FIG. 11 is a graph showing changes of gear ratio, output torque and line pressure with respect to time elapsed.
DETAILED DESCRIPTION OF INVENTION
In the following, the present invention will be described in detail with reference to the accompanying drawings.
In FIG. 1, there is schematically shown an automotive automatic transmission of a type which has four forward speeds (one being overdrive) and one reverse.
The transmission comprises an input shaft 13 to which a torque of an engine output shaft 12 is transmitted through a torque converter 10. Designated by numeral 14 is an output shaft of the transmission through which a driving force is fed to a final drive device (not shown).
Between the input and output shafts 13 and 14, there are disposed, in the illustrated manner, a first planetary gear unit 15, a second planetary gear unit 16, a reverse clutch 18, a high clutch 20, a forward clutch 22, an overrunning clutch 24, a low-and-reverse brake 26, a band brake 28, a low-oneway clutch 29 and a forward-oneway clutch 30.
The torque converter 10 has a lock-up clutch 11 installed therein.
The first planetary gear unit 15 comprises a sun gear S1, an internal gear R1, pinion gears P1 each meshing with both the sun gear S1 and the internal gear R1, and a pinion gear carrier PC1 carrying the pinion gears P1.
The pinion gear carrier PC1 is connectable to the input shaft 13 through the high clutch 20, and the sun gear S1 is connectable to the input shaft 13 through the reverse clutch 18.
The second planetary gear unit 16 comprises a sun gear S2, an internal gear R2, pinion gears P2 each meshing with both the sun gear S2 and the internal gear R2, and a pinion gear carrier PC2 carrying the pinion gears P2.
The pinion gear carrier PC1 of the first planetary gear unit 15 is connectable to the internal gear R2 of the second planetary gear unit 16 through the forward clutch 22 and the forward-oneway clutch 30 which are connected in tandem or through the overrunning clutch 24 which is arranged in parallel with the tandem connected clutches 22 and 30.
The sun gear R2 of the second planetary gear unit 16 is constantly connected with the input shaft 13, and the internal gear R1 of the first planetary gear unit 15 and the pinion gear carrier PC2 of the second planetary gear unit 16 are constantly connected with the output shaft 14.
The low-and-reverse brake 26 can fix the pinion gear carrier PC1 of the first planetary gear unit 15 and the band brake 28 can fix the sun gear S1 of the first planetary gear unit 15.
The low-oneway clutch 29 is so arranged as to permit only a normal rotation (viz., the rotation in the same direction as the engine output shaft 12) of the pinion gear carrier PC1 of the first planetary gear unit 15. That is, a reversed rotation of the pinion gear carrier PC1 is suppressed by the clutch 29.
By selectively engaging and disengaging the clutches 18, 20, 22, 24, 29 and 30 and the brakes 26 and 28 in various combinations, the elements (viz., S1, S2, R1, R2, PC1 and PC2) of the first and second planetary gear units 15 and 16 are forced to change their operating conditions. With this changing, the ratio of rotation speed of the output shaft 14 relative to that of the input shaft 13 can be variously changed.
FIG. 2 is a table showing the various gear positions (viz., first, second, third and fourth forward speeds and a reverse) which are given by the ON/OFF (viz., engaged/disengaged) conditions of the clutches 18, 20, 22, 24, 29 and 30 and the brakes 26 and 28.
In the table, the mark "0" means "ON" or engaged condition of the associated clutch or brake and "blank" means "OFF" or disengaged condition of the same. The mark "(0)" means that the engaged condition does not participate in power transmission in the established gear speed. It is to be noted "α1" or "α2" is a ratio of the number of teeth of the sun gear S1 or S2 relative to that of the internal gear R1 or R2, and the "GEAR RATIO" is the ratio of the rotation speed of the input shaft 13 relative to that of the output shaft 14.
FIG. 3 shows a hydraulic control circuit for controlling operation of the above-mentioned automatic transmission. The control circuit comprises a line pressure control valve 40, a pressure modifier valve 42, a line pressure control solenoid 44, a modified pressure accumulator 46, a pilot valve 48, a torque converter relief valve 50, a lock-up control valve 52, a first shuttle valve 54, a lock-up control solenoid 56, a manual valve 58, a first shift valve 60, a second shift valve 62, a first shift solenoid 64, a second shift solenoid 66, a servo-charger valve 68, a 3-2 timing valve 70, a 4-2 relay valve 72, a 4-2 sequence valve 74, a first reducing valve 76, a second shuttle valve 78, an overrunning clutch control valve 80, an overrunning clutch solenoid (viz., engine brake controlling solenoid) 82, an overrunning clutch reducing valve 84, a 1-2 accumulator 86, a 2-3 accumulator 88, a 3-4 accumulator 90, a N-D accumulator 92, an accumulator control valve 94 and a filter 96. These elements are connected in such a manner as is shown in the drawing.
The torque converter 10 has therein pressure apply and release chambers 11a and 11b for the lock-up clutch 11. This torque converter 10, the forward clutch 22, the high clutch 20, the band brake 28, the reverse clutch 18, the low-and-reverse brake 26 and the overrunning clutch 24 are connected to the hydraulic control circuit in the illustrated manner. The band brake 28 has a pressure apply chamber 28a for the second speed, a pressure release chamber 28b for the third speed and a pressure apply chamber 28c for the fourth speed incorporated therewith.
An oil pump 34 of capacity variable vane type, an oil cooler 36, a front lubrication circuit 37 and a rear lubrication circuit 38 are connected in the illustrated manner. The oil pump 34 is equipped with a feedback accumulator 32.
The hydraulic control circuit of this type is described in detail in Japanese Patent First Provisional Publication No. 63-251652.
FIG. 4 shows schematically a control unit 300 which controls the operation of the solenoids 44, 56, 64, 66 and 82. As shown, the control unit 300 comprises an input interface 311, a reference pulse generator 312, a central processing unit (CPU) 313, a read only memory (ROM) 314, a random access memory (RAM) 315 and an output interface 316, an address bus 319 and a data bus 320.
Information signals from an engine speed sensor 301, a vehicle speed sensor 302 (output shaft revolution speed sensor), a throttle valve opening degree sensor 303, a select position switch 304, a kick down switch 305, an idle switch 306, a full throttle switch 307, an oil temperature switch 308, an input shaft speed sensor 309 and an over-drive switch 310 are fed to the control unit 300 through the input interface 311. Instruction signals from the control unit 300 are fed through the output interface 316 to the shift solenoids 64 and 66, the overrunning clutch solenoid 82, the lock-up control solenoid 56 and the line pressure control solenoid 44.
The control unit 300 controls the automatic transmission in such a manner as is depicted in the flowcharts of FIG. 5, 6 and 7. The control is applied to a transmission gear change, for example to 1-2 gear change and the like, controlling the line pressure and the gear change.
FIG. 5 shows a flowchart of programmed operation steps which are carried out periodically in an interruption subroutine for controlling the line pressure.
At step 100, a judgment is carried out as to whether a flag "FX" is 1 or not, that is, whether the transmission is under gear changing or not. If NO, that is, when the transmission is not under gear changing, the operation flow goes to step 102. At this step, as is shown in the graph of FIG. 8, from a data map of line pressure for the "not under gear changing B0 condition", which is indicated by the solid line of FIG. 8, a duty ratio "D" corresponding to the current throttle valve opening degree "TH" is searched, and at step 104, the duty ratio thus searched is outputted to the line pressure control solenoid 44.
While, if YES at step 100, that is, when the transmission is under gear changing, the operation flow goes to step 106. At this step, from a data map of line pressure for the "under gear change condition", which is indicated by the broken line of FIG. 8, a duty ratio "D" corresponding to the current valve opening degree "TH" is searched. The data map varies in accordance with the gear position selected and the mode of gear shifting (viz., upshift or downshift). At step 108, a judgement is carried out as to whether the gear change is an upshift or not. If NO, that is, when the gear change is a downshift, the operation flow goes to step 104 wherein the duty ratio "D" thus searched is outputted to the line pressure control solenoid 44. While, if YES at step 108, that is, when the gear changing is an upshift, the operation flow goes to step 110 wherein from a correction data map (as shown in FIG. 9) prepared by an after-described learning control, a correction value "ΔD" corresponding to the current throttle valve opening degree "TH" is searched, and at step 112, the sum of the duty ratio "D" and the correction value "ΔD" is outputted to the line pressure control solenoid 44.
FIG. 6 shows a flowchart of programmed operation steps which are also carried out periodically in another interruption subroutine for controlling the gear change.
At step 120, a judgement is carried out as to whether the flag "FX" is 1 or not, that is, whether the transmission is under gear changing or not. If NO, that is, when the transmission is not under gear changing, the operation flow goes to step 122. At this step, a desired gear position corresponding to both the current vehicle speed "V" and the current throttle valve opening degree "TH" is determined based on a predetermined normal gear selection pattern. Then, at step 124, a judgement is carried out as to whether a gear change is necessary or not, that is, whether or not the desired gear position thus determined is coincident with the current gear position. If YES, that is, when the desired gear position does not agree with the current gear position, the operation flow goes to step 126 wherein the flag "FX" is set to "1" which indicates the "gear changing condition", and at step 127, instruction signals are fed to the first and second shift solenoids 64 and 66 to change their conditions for the purpose of achieving the desired gear position in the transmission. Then, at step 128, a judgement is carried out as to whether the inertial phase of the transmission has started or not.
It is to be noted that when the gear ratio of the transmission has started to change from a given gear ratio at a previous gear position toward another given gear ratio at a desired gear position, it is judged that the inertial phase of the transmission has started.
If NO at step 128, that is, when the inertial phase has not started yet, the operation flow goes to step 130 wherein a calculation "T1=T1+1" is carried out for counting an inertial phase starting time "T1" elapsed until the inertial phase will start, more specifically, elapsed from issuance of the gear change instruction to the time when the change of gear ratio starts. Then, the operation flow goes to step 132 wherein a judgement is carried out as to whether the transmission is under the inertial phase or not.
It is to be noted that when the gear ratio of the transmission is under changing from the given gear ratio at the previous gear position toward another given gear ratio at the desired gear position, it is judged that the transmission is under the inertial phase.
If YES at step 132, that is, when the transmission is under the inertial phase, the operation flow goes to step 134 wherein a calculation "T2=T2+1" is carried out for counting an inertial phase keeping time for which the transmission is under the inertial phase. More specifically, the inertial phase keeping time is the time elapsed from the time when, upon the gear change operation, the change of the gear ratio starts to the time when the change of the gear ratio ends. Then, the operation flow goes to step 136 wherein a judgement is carried out as to whether the inertial phase has ended or not. If NO, that is, when the inertial phase has not ended, the programmed operation ends. While, if YES at step 136, that is, when the inertial phase has ended, the operation flow goes to step 138 wherein the flag "FX" is reset to "0" and the other flag "FY" is set to "1". With this manner, the gear change is accomplished.
When thereafter a gear change is not carried out for a while, the operation flow goes through step 124 to step 140. At this step, a judgement is carried out as to whether "FY" is "1" or not. Because the "FY=1" has been established at the previous step 138, step 140 issues YES sign and thus the operation flow goes to step 142. At this step, from an after-described learning control, the correction value "ΔD" is corrected and renewed. Then, the operation flow goes to step 144 wherein the flags "FY", "T1" and "T2" are all reset to "0"
The detail of step 142 is shown in FIG. 7. That is, at step 142, a judgement is carried out as to whether "T1" (viz., the inertial phase starting time) is longer than a predetermined time "T0" or not. If YES at step 150, that is, when "T1" is longer than "T0", the operation flow returns. While, if NO at step 150, that is, when "T1" is shorter than "T0", the operation flow goes to step 152 wherein a judgement is carried out as to whether the time "T1" is longer than another predetermined time "T1S" or not.
It is to be noted that the above-mentioned predetermined time "T0" is longer than another predetermined time "T1S".
If YES at step 152, that is, when the time "T1" is longer than "T1S", the operation flow goes to step 154 wherein the correction value "ΔD" is increased by 2%. While, if NO at step 152, that is, when the time "T1" is shorter than "T1S", the operation flow goes to step 156 wherein the time "T2" (viz., inertial phase keeping time) is compared with a target time "T2S". If they are equal to each other, the operation flow returns. While, if the time "T2" is longer than "T2S", the operation flow goes to step 158 wherein the correction value "αD" is increased by 0.2%, and if the time "T2" is shorter than "T2S", the operation flow goes to step 160 wherein the correction value "ΔD" is reduced by 0.2%.
As will be understood from the above description, when the time "T1" (viz., the inertia phase starting time) is longer than the predetermined time "T0", correction to the correction value "ΔD" is not effected. With this, even when, due to for example a failure of the select position switch 304, a gear change instruction signal is issued with the transmission assuming N-range, it does not occur that the line pressure is increased.
FIG. 10 is a graph showing the characteristic curves of the time "T1" and the time "T2" with respect to the sum of the duty ratio "D" and the correction value "ΔD". As is seen from the broken line in the graph of FIG. 11, within a zone wherein the sum "(D+ΔD)" is relatively small and the line pressure is very low, the gear change takes place after adjustment of the line pressure and thus a marked shift shock is produced. Even in this gear change, the time "T2" is relatively short and thus a correction for reducing the correction value "ΔD" is effected assuming that the sum "(D+ΔD)" is too large. In order to avoid this undesired phenomenon, the steps 152 and 154 are employed. That is, when, at step 152, the time "T1" is judged longer than "T1S", the correction value "ΔD" is largely increased (viz., by 2%) for the purpose of instantly reducing the time "T1" to a level shorter than "T1S" . While, when, at step 152, the time "T1" is judged shorter than "T1S", the above-mentioned undesired phenomenon does not take place. Thus, in this case, the correction value "ΔD" is corrected (viz., increased or decreased) by only 0.2% by comparing the time "T2" with its target value "T2S". With this, when too low, the line pressure is raised, and when too high, the line pressure is reduced.
As is understood from the foregoing description, in accordance with the present invention, when, during the gear change operation, the inertial phase starting time "T1" exceeds a predetermined time "T1S", the control for quickly increasing the line pressure is suppressed. Thus, when, due to for example a failure of the selection position switch 304, the transmission is kept in N-range irrespective of issuance of D-range instruction signal, the learning control to the line pressure is not carried out. Accordingly, when the select position switch thereafter returns to work, the line pressure assumes a normal condition and thus undesired shift shock is not produced. | In a control system for an automotive automatic transmission having a friction element powered by a line pressure, a gear ratio provided by the transmission is measured. An inertial phase keeping time is measured, which is the time for which the transmission assumes an inertial phase. A line pressure adjuster is employed to adjust the line pressure in a manner to harmonize the inertial phase keeping time with a predetermined time. An inertial phase starting time is measured, which is the time elapsed until the inertial phase of the transmission starts. A line pressure increasing device is employed for increasing the line pressure irrespective of condition of the line pressure adjuster when the inertial phase starting time exceeds a first given time. An inhibitor is employed to suppress the operation of the line pressure increasing device in case wherein even when the inertial phase starting time exceeds a second given time longer than the first predetermined time, the change of the gear ratio does not occur. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to utilization of geothermal energy and more particularly to an improved system for maximizing the transfer of geothermal energy from a subsurface zone to the surface for utilization.
2. Description of the Prior Art
There exists, essentially untapped, massive quantities of heat available from magma which has migrated to zones close to the surface. Such conditions exist in large regions of the United States and in other locations throughout the world such as in Italy, New Zealand and Japan. Frequently, tectonic activity has produced fault lines which have permitted deep, subsurface waters to come in contact with magmatic rocks and return to the surface along fault lines as heated water, or in a few cases as steam. Similarly, tectonic activity below ancient subsidence areas, more recently overlain, have resulted in migration of heat into brine pools of varying salinity which lodged in these sinks. There are some 1.8 million acres in the United States which are designated as KGRA (Known Geothermal Resource Areas) and most of these KGRA are situated in the Western states.
The only operating geothermal plants in the United States are those operating at The Geysers, Sonoma, California, and others are formulating plants for geothermal power development in the Imperial Valley of California. The plants in operation in the United States and Italy rely on direct thermal fluid mining methods. Such methods have entailed serious problems due to the high salinity of the steam causing cavitation, abrasion, scaling and corrosion of the equipment over short intervals. Moreover, geological prospecting techniques are not very accurate and if a dry well results or a well with insufficient steam pressure the venture is a total loss. Drilling of adjacent thermal direct fluid recovery wells entails the risk of lowering the bottom hole pressure of the whole field. It is estimated that a brine pool exists in the Niland area of the Imperial Valley of California which occupies an area of 25 square miles. About a dozen geothermal wells have been drilled in the area, which produce as much as a million pounds per hour of brine per well for sustained periods. Flashing this brine would produce about 200,000 pounds per hour of steam which in turn could produce about 10,000 kW of electric power per well.
However, because of the high salinity of the brines, all attempts to utilize these brines have been unsuccessful. Since the discovery of these wells, several companies have spent millions of dollars trying to extract chemicals and generate power from the brines. Neither operation has been commerically successful because of the high operating costs and associated material costs necessary to withstand the corrosive and erosive environment and to dispose of the salt and concentrated salt bitterns.
Further to the South in Mexico, another brine pool exists of a size comparable to the Niland pool. The brine is lower in salinity in this pool. Exploratory investigation suggests the existence of seven or eight similar brine pools between Niland and the pool at Cerro Prieto in Mexico. In all, the power generating potential from geothermal energy in the Imperial Valley is estimated to be as high as 30,000 MW. Successful exploitation of this potential by conventional direct thermal mining methods would require either selective use of the lower salinity brine or disposal of vast amounts of salt and concentrated salt bitterns. Geothermal energy represents a clean, pollution free alternative to fossil fuel energy sources and does not entail the hazards or the environmentally unacceptable aspects of nuclear produced power.
The problems inherent in the conventional direct thermal mining approaches are avoided by use of the downhole heat exchanger disclosed in U.S. Pat. No. 3,470,943 since the geothermal brines remain in the pool and heat is extracted by in situ circulation of a clean, stable, secondary heat transfer fluid inside the downhole heat exchanger which is placed at the lower part of the casing within the geothermal zone. Thus, the downhole heat exchanger provides a means for utilizing the heat contained in the brine pools by extracting only the heat energy, leaving the brine recirculating in the underground pool. The advantages are many.
No saline fluids are brought to the surface; hence there are no disposal problems and reinjection wells are not required. The reservoir inventory and pressure is undisturbed. Except for extraction of heat, which is readily replenishable, nothing has been changed in the reservoir. Subsidence therefore will be avoided by this method.
Since the interior of the casing is contacted only by pure fluids, no corrosion or scaling will occur internally. The outside of the casing is in contact with the reservoir aquifer but the brine is at a pressure which does not allow the dissolved salts to precipitate. Hence, there is no abrasive action from the solids as in a flowing well. The convective currents within the aquifer are expected to be of insufficient velocity to result in abrasion. The low velocity should also promote the retention of a thin, passive coating of corrosion products which inhibit further corrosion.
The downhole heat exchanger system represents a truly non-polluting source of energy in that no pollution products are permitted to reach the surface. However, the energy capacity of a single well is not sufficient to justify the installation and operation of a generation plant. Therefore, multiple wells are required to develop sufficient steam to operate the turbine generator. This requires the utilization of a greater area of the surface for drilling the multiple wells and a greater investment cost to drill the well at each site. Furthermore, the separate location of the multiple wells requires water injection lines running to each well site and steam gathering lines running from each site to the generating plant. All of this involves capital investment and entails heat loss each time the steam or water is moved.
SUMMARY OF THE INVENTION
The multiple-completion geothermal system of the invention generally includes a plurality of geothermal wells, each having a first end converging toward and meeting at a first point and having a second end diverging from said point and terminating in a geothermal zone, each second end being spaced from any other second end of said geothermal wells. This system further includes a reservoir located at said first point receiving heated geothermal fluid from the second end of each well, outlet means connected to said reservoir for conducting the heated geothermal fluid in turn to separation means and energy conversion means. The system in accordance with the invention also may include control means for sequentially activating production from each of the plurality of wells in sequence to promote movement of hydrothermal fluids within the geothermal zone.
Depending on the condition of the geothermal zone, the system may require further structure. In a wet geothermal zone, the fluid will operate as a carrier for the heat energy to deliver it to the surface under pressure. In the case of a dry geothermal zone or one containing a molten brine pool with insufficient pressure, the implantation of closed end heat exchangers at the ends of the wells requires means for conducting heat exchange fluid to the heat exchangers which may be connected to the turbine to return the condensate to the heat exchanger in a closed cycle loop. Heat transfer to the heat exchanger in a dry geothermal zone may also be enhanced by injection of water into the zone external to the heat exchanger to create hot fluid to increase the transfer rate of heat to the outside surface of the heat exchanger.
It is apparent that the system of the invention minimizes the amount of surface area needed for access to the subsurface geothermal zone, the amount of surface area needed for collection and conversion of the goethermal fluid to electrical energy and minimizes the external piping conduits and energy loss that would be entailed in the separate spaced drilling of multiple wells to tap and mine the geothermal energy in a known geothermal resource area. The system of the invention also includes provision for controlled collection of the energy and in a manner to promote convection and movement of the hydrothermal fluids to increase the rate of energy recovery and to decrease the possibility of scaling and fouling the external portions of the wells being utilized for collection and transfer of heat.
These and many other objects and attendant advantages of the invention will become apparent as the invention becomes readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multiple-completion geothermal mining system in accordance with the invention;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a schematic view of a further embodiment of a mining system in accordance with the invention;
FIG. 4 is a top enlarged view of the system of FIG. 3;
FIG. 5 is an enlarged cross-sectional view of a closed end heat exchanger; and
FIG. 6 is a plan view of a geothermal mining system in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, the system includes a plurality of geothermal wells 10 each having a first, open, upper end 12 converging toward and meeting within a surface point bounded by a closed reservoir 14. The lower end 16 of each well terminates within a geothermal zone 18. The ends are positioned in a predetermined pattern such as those of wells 20 and 22 which are spaced vertically from each and the ends of wells 20 and 24 which are spaced horizontally from each other.
Each well contains a valve 26, suitably a servo-controlled valve such that production from each well can be individually controlled, suitably by a time sequencer controller 28 which activates or deactivates each valve 26 according to a predetermined program by sending signals through lines 30. The sequential production of wells 10, especially by rotating production in a circular pattern, will promote convective movement of the hydrothermal fluid 32 within the geothermal zone 18, and thus, increase heat transfer and recovery and decrease the possiblity of scale forming on the external surface 24 of the portion of the well casings within the zone 18.
The geothermal, heated fluid recovered from the wells collects within the reservoir 14. The reservoir may be located on the surface but is preferably recessed below the surface to take advantage of the insulating and warming effects of the subsurface strata. The reservoir is preferably a steel vessel 34 bounded by a concrete layer 36 and includes a removable lid 38 secured by bolts 40.
The collected steam is transferred through conduit 42 containing a pressure regulating valve 43 to a separator 45. Condensate and solids are removed through line 44 and the steam is delivered through line 46 to the power plant 48. The power plant can be a direct prime mover engine or a turbine generator. Condensate is removed through line 50 and may be recovered or recycled to the wells.
Geothermal fields are classified according to their production of hot water, hot water and steam, or dry steam. The system of FIG. 1 can be used for the recovery of geothermal heat values from all of these types of fields. Hot water fields typically produce temperatures between 60° and 100° C., with gradients of 30° to 70° C/km. Because of the low enthalpy, hot water fields are not now being used to generate electricity. They are being used instead for space heating and air conditioning. For electrical production most geothermal fields produce both water and steam at temperatures greater than 100° C. The highest temperature field in use to date is at Cerro Prieto, Mexico, at which temperatures have been measured up to 380° C. Similarly, the dry steam fields in commercial use have temperatures at 210° C. (The Geysers, U.S.) to 260° C. (Larderello, Italy).
The geothermal fields in production have the following basic geological characteristics:
1. A source of heat. In general, magmatic intrusions at shallow depths of 7 to 15 km provide a heat source at a temperature above 100° C., typically from 200° to 400° C. 2. A source of water. Commercial wells produce more than 20 tons/hour of water and steam. The best well, located in the Cerro Prieto field, produces 350 tons/hour. The water is believed to come from surface sources rather than being magmatic water. Therefore, it is probably replenishable at a rate determined by pressure, permeablility, source availability and other factors. Reinjection may be utilized to replenish the source and dispose of unwanted surface water such as condensate from the turbine. 3. A permeable rock aquifer. Almost any permeable rock can serve as an aquifer such as deltaic sand, volcanic turf, base salt flows, ignimbrite, greywacke, carbonate volcanics and limestone. Convection currents through the rock are believed to be the primary heat transfer mechanism between the magma and upper levels of the aquifer; these can be reached by drilling. Pressures in the aquifer may be as high as 2000 psi or more. Both thermal conductivity and permeability are critical parameters which limit the energy production of the well. 4. A cap rock. A rock layer of low permeability is required above the aquifer to limit the heat transfer by convection. The heat loss transfer through the cap rock to the surface primarily by convection is very low; this allows the system to remain hot. Many systems are believed to be self-sealing due to mineral, primarily silica, depositions of the hot water flashed and cold near the surface.
All of these geothermal aquifers can be mined by direct thermal mining methods in the system of the invention which will provide the same advantages of collection of the thermal fluid at a single point, thus reducing capital investment and well installation costs and the surface area needed for converting the fluid to mechanical or electrical energy. However, for the reasons previously discussed, the wet geothermal areas can more efficiently be mined by the downhole heat exchanger relation of the multiple-completion system of this invention. Dry geothermal areas may also be mined by either method. A man-made aquifer may be developed by explosion-stimulated methods. If the hole is hot and dry and not fractured, a large aquifer could be developed by hydrofracturing alone or in combination with explosive induced means. The downhole heat exchanger offers the opportunity to recover heat from the dry and hot geothermal area without the need to inject water to the zone to create a hydrothermal fluid.
If the system is hot, dry and fractured, water can be introduced from the surface internal of the well casing or external of the well casing and the resultant steam collected through the annulus of the well removed and harnessed to produce energy. If the system is hot, dry and unfractured, it may be utilized as such with the downhole heat exchanger to produce steam by indirect heat exchange methods or hydrofracturing and enhancement can be practiced through additional thermal stress fracturing or by the use of high explosive or nuclear devices to fracture large quantities of hot rock as described in my copending application Ser. No. 99,898, filed Dec. 21, 1970, which disclosed a system for producing a rubble cone cavity in a hot, dry rock geothermal zone, the disclosure of which is incorporated herein by reference.
Referring again to FIGS. 1 and 2, in a system for mining wet geothermal energy, the separator 45 would be a flash unit and the wet steam is delivered to the power plant 48 while the separated salts and condensate are removed through line 44. The salts may be separated into commercial salts for sale, may be concentrated and disposed or may be reinjected into the zone. In a system in which fairly dry steam is directly recovered, separation of solids may be required in a cyclone separator to minimize cavitation of the turbine blades.
Hydrothermal injection systems for mining a dry field are illustrated in FIGS. 3 and 4. Referring now to FIG. 3, an external water injection system is illustrated in which water is injected into the dry, porous geothermal zone 18 by means of a plurality of water injection wells 52. The wells are spaced about the periphery of the geothermal zone being mined and extend from the surface to the zone 18 and preferably extend below the level of the ends 16 of the geothermal wells 10, so as to form a rising body of pressurized, heated hydrothermal fluid. The water injection wells 52 can be supplied separately with water, or as illustrated can be supplied from a central storage tank 54 and pumped by means of pump 58 through line 36 to each of the injection wells 52.
The branch input conduit 60 to each injection well 52 contains a valve 62 so that production may be cycled to induce movement of the hydrothermal fluid. The hydrothermal fluid enters the ends 16 of the recovery wells 10, collects in reservoir 14 and is transferred through line 42 to the separator 45 and turbine generator 48. Condensate in lines 50 and 44 is recycled through line 64 to the storage tank 54 for reinjection in the zone 18 through wells 52.
A preferred injection-recovery system is illustrated in FIG. 4. In this system, water injection is internal of the recovery well casing. This again simplifies the installation, minimizes surface installation of long lengths of pipes and totally obviates the necessity of separate injection wells. A further incidental benefit is that the decending water is heated by the ascending geothermal fluid. As shown in the drawings, the delivery pipe 56 is connected to a single distribution ring 68 which may surround the outside of the casing for recovery wells 10 or may be positioned on the inside surface of the casings. The branch inlets 60 again contain a valve 62. The inlets 60 sealingly penetrate the casing of each well 10 and are connected to a water injection pipe 70. The end 72 of the water injection pipe preferably extends past the end 16 of the casing and into the porous or fractured geothermal zone 18 at a depth below the ends 16 of the casing 10.
All of the hydrothermal systems suffer from the common disadvantage of recovery of a saline hydrothermal fluid with the attendant problems of scaling and disposal. For the reasons discussed above, the downhole heat exchanger variant of the multiple-completion system is far preferable. Such a system is shown in FIG. 5.
In this system, the lower end 16 of each recovery well contains a plug 74 such as a metal-rubber layer over a cement layer. The terminal portion of the casing of each well contains or forms a closed heat exchanger 76. An injection pipe 78 delivers heat exchange fluid to the top 79 of the heat exchanger which is heated to form vapor therein. The vapor leaves through perforations 80 in the top 79 and rises through the annular space in each casing and collects within the reservoir 14 and after separation in separator 45 and conversion to electricity in turbine-generator 48 is recycled to storage tank 54 for reinjection as previously described.
The borehole is preferably cased with a metal casing which is in turn cased with a layer of concrete 81. For purposes of heat conduction to the heat exchanger 76, it is preferred that the metal surface 24 be directly exposed to the hydrothermal fluid. Referring again to FIG. 5, this installation is effected by lining the borehole with a metal casing 85. The casing is perforated at 77 at the location corresponding to the top of the heat exchanger 76.
The casing is then temporarily plugged directly below the perforations 77. Cement is delivered to the temporary plug area and squeezed through the perforations 77 to form a plug 81 in the annular area outside the casing 85. The upper casing 85 is then cased in cement. The temporary plug is then drilled out and the lower plug 74 is inserted and the top 79 of the heat exchanger is installed.
The closed-cycle system for extraction of heat from a geothermal zone provides a choice of heat exchange fluids such as isobutane or water. Demineralized water is the fluid of choice since its thermal and physical properties permit high heat transfer capabilities, and steam vapor is directly usable in conventional and economically available condensing steam turbines. Condensate is easily handled for return to the heat recovery zone. Also, demineralized water can be readily produced in conventional and economically available equipment and all of its physical properties and handling techniques are well known.
A schematic illustration of a more detailed embodiment of the downhole heat exchanger is illustrated in FIG. 6. FIG. 6 has been designed for the recovery of sufficient heat energy for the production of 50 megawatts (at the generator terminals) of electric power.
Referring now to FIG. 6, the system includes a plurality of downhole heat exchanger recovery wells 10 having a plugged end 74 within a geothermal zone 18. The upper ends 19 of the wells 10 converge to and meet in a reservoir 14. The steam output from the reservoir is delivered through line 42 to a vapor-liquid separator 45, condensed through line 46 to a turbogenerator 48. The low pressure steam from the turbo generator is delivered through line 50 to a condenser 80 which receives a continuous supply of cold water circulating through circuit 82 containing a cooling tower 84. The condensate from condenser 80 joins line 56 through line 88. Demineralized water from supply tank 54 and the condensate are pumped by means of power condensate pump 90 and preheat condensate pump 92 to the injection ring 68.
In this system, the steam is vaporized within the outer casing while it passes through the reservoir geothermal heat zone 18. The inner pipe returns the condensate from the above-ground power plant turbine condenser and vapor-condensate separator down to the well bottom to complete the heat exchange fluid transport circuit. The inner pipe also serves to preheat the condensate up to the boiling thermal equilibrium established during operation. The preheating requires vapor condensation. This condensate is separated from the power vapor fluid in a vapor-condensate separator and recycled. The power vapor is used in a conventional condensing type vapor turbine in a totally enclosed recycle system and thus the power fluid is conserved. The power vapor turbine has an indirect exhaust vapor condenser and condensate recycle pumping system.
The following calculations for feasibility of the system of the invention were based on a heat assumed to have generally constant temperatures unaffected by the heat recovered. The generalized heat zone conditions assumed were starting at 3,000 feet below grade with a temperature of 500° F. and extending 5,000 feet below grade to a temperature of 700° F. The heat zone was also assumed to be filled with hot brine under pressure, typical of the heat zone in the Niland area of the Imperial Valley. The geothermal zone 18 was assumed to be a porous sandstone filled with hot brine.
Under these conditions, the outside heat transfer from coefficients and fouling factors are the limiting elements for maximizing heat recovery from the brine into the heat exchange power fluid. The rate of heat removal is limited by heat zone porosity and permeability. If the assumed sand particle diameter is less than 0.039 inch (1 mm) in diameter, permeability rather than the outside-to-pipe film coefficient controls the rate of heat transfer.
On the basis of these criteria, the outer casing size of 13.375 inches O.D. is preferred since for the depth and temperature specified in the heat recovery zones this is about the largest size casing (heat transfer surface) which provides an economic weight (strength) per unit length required to withstand the internal and collapsing pressure encountered as well as the problems associated with offset drilling. The inner pipe will be selected to satisfy the overall system flow hydrodynamic requirements. It is expected that long life would be experienced with heavy wall carbon steel casings in the above conditions.
The same casing and cementing practices employed for other geothermal wells can be followed, the only difference being the closed end of the 133/8 inch casing which acts as a shell of the downhole heat exchanger. A further advantage of the directional slant drilling multiple-completion system of the invention is that it provides greater heat exchange area within the zone of heat collection, thus reducing the amount of wells necessary to produce a given amount of power. By slant drilling through the 3,000 to 5,000 foot zone under consideration, it is estimated that 10 wells must be drilled to provide the desired heat exchange surface area. The typical casing requirements will require about 8,000 feet of the casing within the zone forming the heat exchanger which will be connected to 1800 feet of cemented production casing and then to 50 feet of cemented 20 inch second string which in turn is then connected to 50 feet of cemented 36 inch conductor casing. The top end 19 of the wells can readily be separated by 25 to 150 feet and can be located in the surface zone bounded by a single reservoir 14.
Each well at the bottom should produce steam at 320 psia at a temperature of 423° F. The rising steam should maintain a pressure at the top after condensing the down-coming return condensate of 165 psia and a temperature of 366° F. At the vapor-liquid separator 45 such wells will provide 857,000 lbs. per hour vapor and 343,000 lbs. per hour of condensate. This vapor has an inert pressure of 130 psia and a temperature of 350° F. to provide a heat input to the turbogenerator of 1023 × 10 6 Btu/hour and a heat rate of 20,500 Btu/kWh gross at the generated terminals. This is sufficient to provide 15 megawatts at the generated terminals. The condenser returns this vapor as power condensate at a rate of 1714 gallons per minute at a temperature of 125° F. which combines with the preheat condensate at 773 gallons per minute to be returned to develop the necessary steam to power the system.
Feasibility was based on costs for well completion equipment, well gathering piping, condensate return piping, flash separator, flash water and condensate pumps. The estimate includes costs of all equipment, materials, direct and indirectly, freight taxes and insurance, engineering, contractors burden and profit and a 15% contingency and including costs of capital. The comparison of costs of energy produced with the system of the invention as contrasted with other sources is shown in the following table.
TABLE I______________________________________ $/Million Btus______________________________________Coal 0.25 - 0.30Oil (1% Sulfur) 0.65Natural Gas 0.42 - 0.48Synthetic Natural Gas 1.05 - 1.75Coal Based Synthetic Gas 1.10 - 1.25Van Huisen System 0.19 - 0.37 Gross at generator terminals*______________________________________ *Adjusted to heat rate equivalent of modern fossil fuel power plant rates of approximately 10,000 Btus/kWh.
Recent pollution regulations regarding maximum sulfur content in fuels of 0.3 to 0.5% have placed a considerable burden on refiners to produce low sulfur petroleum based fuels. It is estimated that the added processing may cost as much as $1.50 bbl or $0.24 per million Btus. Many coals run 3 to 4% sulfur and the only practical way to meet pollution standards is to desulfurize the stack gases which is estimated to add as much as $60-$70 kW in capital investment or $0.09-$0.11 per million Btus. Typical fuel costs in terms of mills/kWh for privately owned utilities as of 1969, run 3.5 to 6.5 mills/kWh. It is estimated that by 1975 fuel prices will roughly double and utilities will probably be paying 7.0 to 13 mills/kWh for fuel. The energy cost of 1.91 to 3.71 mills/kWh compares very favorably with competing fossil fuels for this module of power. No comparison could be made with nuclear fuel plants since nuclear fuel plants would be uneconomical to build in the range of 50 MW/150 MW.
It is to be realized that only preferred embodiments of the invention have been described and that numerous substitutions, alterations and modifications can readily be made by those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims. | A system for the mining of geothermal energy in which a plurality of geothermal wells radiate from a single surface site into a subsurface geothermal reservoir. The wells can be drilled by conventional slant drilling techniques and each may contain a closed end heat exchanger which receives water and generates steam. Some of the heat exchangers are disposed vertically and others are implanted horizontally. By alternating production of the wells in a programmed cyclical manner, convective movement of the hydrothermal fluid will occur within the geothermal zone. The generated steam is collected in a reservoir at the surface site and utilized to generate electricity. The condensate from the turbine can be recycled to the wells. | 4 |
This application claims benefit to Provisional Application No. 60/169,546 filed Dec. 7, 1997.
BACKGROUND
This invention was made with government support under grant No. 1R43DE13454 awarded by National Institutes of Health Office of Extramural Programs SBIR/STTR Grant Programs. The government has certain rights in the invention.
This invention relates to a method and apparatus for ensuring that small screws used to hold together dental implant components are tightened to the correct initial stress level, or “preload.” According to the National Institute of Health, among the factors involved in the design of a dental implant are the forces produced during implant loading, the dynamic nature of loading, and the mechanical and structure properties of the prosthesis in stress transfer to tissues. Unfortunately, accurate data on such parameters are incomplete. National Institutes of Health Consensus Development Conference Statement on Dental Implants. Jun. 13-15, 1988.
During the early 1970's the dental profession was very hesitant to use dental implants or fixtures surgically implanted into a patient's jawbone as a treatment option to replace missing teeth. However, success with implants in the past 30 years has replaced this skepticism. This is due to the efforts of P-I Brånemark and co-workers in Sweden who introduced the concept of osseointegration in humans. When the principles of osseointegration are followed, the anchorage of a non-biological titanium implant unit to living bone will occur, with approximately 95% and 85% implant survival rates for the lower and upper jaws, respectively. See, for example in U.S. Pat. Nos. 4,824,372, 4,872,839 and 4,934,935 to Jorneus et al., Brajnovic and Edwards, respectively.
One of most critical aspects in the replacement of missing teeth using dental implants is the ability of small screws positioned within the implant complex to hold the various implant parts together during loading and stress transfer. As any screw in the implant system is tightened, the initial stress level developed within the screw becomes critical to the maintenance of the joint stability between the parts the screw is clamping together. Owing to the high strain level that the assembled joint experiences in everyday life, this initial stress level called the preload is of paramount importance. Insufficient tightening of a screw in the implant system can result in the screw becoming loose rather quickly, and over time this looseness can lead to fracture of the screw and potentially failure of the implant reconstruction. This is particularly critical for screws that secure spacers or abutments to the implant or fixture.
The stability of the screw joint is considered a function of the preload stress achieved in the screw when applying the preload tightening torque to clamp the implant components together. The optimum preload torque is influenced by the geometry of the screw, the contact relationships between the screw and its bore, between the screw and its threads, and between the bearing surfaces of the components clamped together by the screw, friction, and the properties of the materials used. One example is the joint formed between the bearing surface of the implant and the bearing surface of the spacer or abutment. Another example is the joint formed between a prosthesis and an abutment, also held together by a small screw in the implant system.
When the screw joint experiences instability, the screw will either loosen or fracture. Screw joint failure occurs in two stages. The first stage consists of external functional loading applied to the screw joint that gradually leads to the effective erosion of the preload in the screw joint. Any transverse or axial external force that causes a small amount of slippage between the threads releases some of the stress, and therefore, some of the preload is lost. The greater the preload applied to a screw joint up to a maximum equal to the proportional limit), the greater the resistance to loosening and the more stable the joint. As long as the frictional forces between the threads remain large, a greater external force will be required to cause loosening.
Once the critical load exceeds the screw joint preload, it becomes unstable. The external load rapidly erodes the remaining preload and results in vibration and micromovement that leads to the screw backing out. Once this second stage has been reached, the screw joint ceases to perform the function for which it was intended and has failed.
Optimizing the preload of a screw used in a dental implant system is critical for implant screw joint stability. As was stated earlier, implant screw loosening and fractures are quite common. The fact that on average complications with implant screw will occur in one out of every four implants surgically placed is significant. The need for optimum preload in screw tightening at the initial stages of implant component assembly and completion of the final implant restoration cannot be left to chance. An instrument that scientifically records the preload established in these implant screws following tightening and prior to any external load applications is essential to implant performance and the quality of life of the patient who receives implants as part of their dental rehabilitations.
It has been reported by Patterson and Johns that to achieve the maximum preload possible in component screws for dental implants, it is necessary to apply the appropriate tightening torque to each screw. Torque tightening devices for implant screws arc discussed, for example, in U.S. Pat. No. 6,109,150 and 5,626,474. However, most screw torque-tightening devices lack accuracy because of a number of variables beyond the control of these conventional instruments. This means that the maximum stress developed in an implant screw tightened by conventional torque-tightening devices may be less than 70% of the yield strength of the screw itself and therefore well below the maximum possible preload for a stable joint. If the screw is loaded to the appropriate preload level one can be confident that the screw will not fail during the life of a patient when “normal” external loads are applied.
Ultrasound instrumentation has been used to measure the preload established in large bolts and screws in industrial applications. Thus far, however, it has not been applied to small screws the size of those used in implant systems. In industrial applications for large bolts and screws, the most common ultrasonic instruments for control of screw tension are called “pulse-echo” or “transit time” instruments. Bickford has described the use of this method with large bolts. A drop of fluid is placed on the head of the bolt to reduce the acoustic impedance between the transducer and bolt head. An acoustic transducer of some sort is placed against the bolt head. The instrument is then zeroed for this particular bolt because each bolt will have a slightly different acoustic length even if their physical lengths are the same. The zero load is recorded before tightening. Next, the bolt is tightened. If the transducer can remain in place during tightening, it will show the buildup of stretch or tension in the bolt during tightening. If it must be removed, it is repositioned on the bolt again after tightening to show the stress level achieved. If at some future time one wishes to measure the tension present within the bolt, the original data can be input to the instrument computer unit and after placing the transducer on the top of the bolt, the instrument will record the existing tension and the zero stress conditions.
In principle, the electronic instrument delivers a voltage pulse to the transducer, which emits a brief burst of ultrasound (typically five to seven or more cycles). This burst passes down through the bolt, echoes off the far end, and returns to the transducer. The electronic instrument measures very precisely the time delay required for the burst of sound to make its round trip in the bolt. As the bolt is tightened, the amount of time required for the ultrasound to make its round trip increased for two reasons: 1) the bolt stretches as it is tightened, so the path length increases, and 2) the average velocity of sound within the bolt decreases because the average stress level has increased. At low strain those functions can be approximated by linear ones of the preload in the bolt, so the total change in transit time is also a linear function of preload.
In dental implant technology, it is important to know what preload exists in implant screw joints at any time during implant therapy and throughout the life of the implant.
All of the currently used implant screws are fabricated from materials that are nontransparent and nonmagnetic. No other efficient technique for stress measurements of nonmagnetic and nontransparent materials is available. In contrast, a magnetic hysteresis curve can be used to infer the stress in magnetic materials, and also optical coherent methods can be used to infer the stress in transparent materials. However, the accuracy of this latter method is significantly lower than that of the ultrasonic TOF measurements, and as stated the implant screws are made of nonmagnetic materials. The use of mechanical methods for stress measurements requires exact measurements of the length of the implant parts, and with the 30 plus implant manufacturers throughout the world and their reluctance to provide this data, this method has definite limitations.
Ultrasonic measurement of the stress in a screw or bolt with a relatively big cross-section and length has been known for some time. Since the early fifties the technique has been theoretically and experimentally proven for a range of materials. Experimental and theoretical results obtained by Huges and Kelly on samples of rail steel with various load conditions have shown the proportionality between the uniaxial stress and velocity of acoustic waves. However, since then the method has been used for only relatively long and large cross-section components, partially due to an insufficient accuracy of TOF measuring devices. At present a digital oscilloscope's sampling rate ranging to several gigahertz makes possible a real time measurement of time intervals with the 10-100 picosecond accuracy. As to the dental implant screw in question, the ultrasonic evaluation of the stress via the time of flight measurement in principle is feasible. In practice the method is not straightforward and several factors have the potential to influence the accuracy, however, the whole performance is predictable. Difficulties reside in the small size transducer required (around 0.5 mm. active element diameter), and the small length inducing a low variation of the time of flight of the ultrasonic pulse. The smaller the transducer, the greater the exposure to a stronger mechanical stress. The smaller the length of the screw, the less variation in the time of flight and consequently the lower precision of the stress measurement obtained. Ambient temperature influencing elastic properties of materials, could also be a concern, which can be controlled.
The optimum preloads suggested for implant screw joints are a percentage of the yield strength of the screw. For example, 50-60% of yield has been suggested for average nongasketed joints, with “normal” safety or performance concerns. A 70-75% of yield has been suggested as the upper limit for nongasketed joints where “low preload” problems have been experienced in the past such as leaks, self-loosening, fatigue, etc. Joints which have had consistent “low preload” problems in the past, and where the need to avoid failure is significant and where service loads (or ignorance of service loads) make it unwise to take the screws any closer to the yield point, a 85-95% of yield has been suggested. Obviously, the preloads suggested for various screw joints demonstrate considerable variation, and depending on the joint requirements, the amount of preload achieved (% of the yield) would be significant in the performance of the joint. Furthermore, the amount of preload suggested depends on the accuracy of knowing the yield point of the screw. McGlumphy has reported significant differences between screws from several implant manufacturers even though the suggested tightening forces, and thus the preload achieved for these screws were the same. The force needed to cause failure in abutment screws for the systems as tested by McGlumphy ranged from 1.22 to 17.23 kg. However, even if the ultimate tensile strength of the screw, the proportional limit and the elastic range were known, neither the preload created by tightening using a torquing device suggested by the manufacturer for the particular screw nor the variability in the preload as a result of the tightening instrument used by the operator is known.
In summary, it would appear that a great deal of subjectivity exists in the tightening of implant screws. It isn't any wonder that screws loosen or fracture. The tightening instruments are a major variable. The quality and quantity of the tightening torque is in question. The “target” preload is uncertain. Finally, the achieved preload is unknown. In implant joints, which are very critical joint assemblies, the stability of the joint begins with knowing the exact preload achieved following the clamping together of the components. The Preload Measurement Gage will provide clinicians with that information.
SUMMARY OF THE INVENTION
This invention provides a method of determining the preload on a screw used in an implant system that secures a component to a fixture or to another component in a dental implant system which comprises the steps of transmitting a sonic impulse at a predetermined frequency to the head of the screw through a transducer when the screw is in an unstressed condition; measuring the delay between the first and second reflections through the unstressed screw, and establishing a baseline value for the unstressed screw; applying a preload of a predetermined value to the screw to secure the implant component in the implant system; transmitting a sonic impulse at a predetermined frequency to the head of the screw through a transducer; measuring the delay between the first and second reflections through the preloaded screw to establish a preload value; and determining the difference in the delay between the baseline value and the preload value, and comparing the difference with a predetermined table of values to determine the preload in the screw.
Transducers used in this invention may be any transducer that transmits and receives sonic impulses. Preferably, the sonic impulse is an ultrasonic impulse. The frequency of the impulse may vary depending on the material characteristics of the screw.
Screws used with this invention may be measured in this manner in the unstressed state before they are packaged and sold, and the baseline value may be provided with the sales information.
This invention also includes apparatus for determining the preload in a dental implant system that includes a fixture having one end adapted for osseointegration into a jawbone, the other end adapted to receive a spacer and including an internal bore that includes threads for engaging with a screw to secure the spacer to the implant, the spacer including an internal bore to receive the screw. The prosthesis may be attached to the implant system with a second screw. The apparatus comprises means for achieving a preload in the screw to secure the component in the implant system, which may be any conventional means, such as a hex wrench or screwdriver, as are commonly sold by companies such as Nobel Biocare, Implant Innovations, or others who market dental implants, abutments, and tools. The apparatus also includes means for transmitting a sonic impulse, which is preferably an ultrasonic impulse, at a predetermined frequency to the head of the screw through a transducer, which may be any apparatus that generates an ultrasonic impulse at the desired frequency. The frequency of the sonic impulse may vary, depending on the material and configuration of the screw. The apparatus also includes means for measuring the delay between the first and second reflections through the preloaded screw to determine a preload value, which may consist of a suitable measurement circuit, which may be in a separate control box, or part of a wand used to transmit and receive the ultrasonic impulse and pulses. The apparatus also includes means for determining the difference in the delay between a pre-established baseline value for the screw and the preload value, and comparing the difference with a predetermined table of values to determine the preload on the screw.
THE DRAWINGS
FIG. 1 is a sectional view of a dental implant installation of the prior art, adapted for purposes of this invention.
FIG. 1A is a sectional view taken along line A—A.
FIG. 2 is a block diagram of one embodiment of the apparatus of this invention.
FIG. 3 is a typical A-scan pattern of pulses generated by this invention.
FIG. 4 is a diagram that demonstrates the principal of the time of flight.
FIG. 5 is a depiction of a preload strain gauge program window for a computer program that may be used in the present invention.
FIG. 6 is a diagram showing configuration windows that may be used with the present invention.
FIG. 7 shows a diagrammatic depiction of a wand that may be used with the present invention.
FIG. 8 is a diagrammatic depiction of a second type of wand that may be used with the present invention.
DETAILED DESCRIPTION
Implant systems, which are well known in the art, generally consist of an implant or fixture, which is surgically implanted into a patient's upper or lower jawbone. As shown in FIG. 1 and FIG. 1A, the fixture 10 includes an externally threaded body 12 , which is surgically screwed into the jawbone. At one end of the body is a flange 14 , which has bearing surface 16 . Body 12 of fixture 10 includes an internal bore 18 , which extends from the flange 14 and which is at least partially threaded to receive an abutment screw (also known as a spacer screw) 22 , which includes a threaded portion 24 , and a head 26 . An abutment 30 includes a bearing surface 32 , which forms a joint 34 with the bearing surface 16 of flange 14 . Abutment 30 also includes an internal bore 36 to receive screw 22 and a flange 38 which is smaller in diameter than the head 26 of abutment screw 22 . The abutment screw 22 passes through the bore 36 of abutment 30 , and the threaded portion 24 of abutment screw 22 mates with the internal threads 20 of internal bore 18 of the fixture 10 . Abutment screw 22 is screwed into the internally threaded bore 18 of fixture 10 , and tightened to a predetermined preload to secure the abutment 30 to the fixture 10 .
Head 26 of the abutment screw 22 is provided with an internal bore 40 which has a geometric shape, such as an internal hex, adapted to receive a tool such as a hex wrench for tightening the screw. Other geometric shapes for tools arc well known in the art. The abutment screw used for practicing the invention is provided with a reflecting surface at the bottom 42 of bore 40 . A second reflecting surface 44 is provided at the opposite end of the screw. Each reflecting surface is preferably generally flat, and generally perpendicular to the line of transmission of the sonic pulse. Any number of screw head designs may be used, so long as each end of the screw (heads and ends) has a reflecting surface that is sufficiently perpendicular to the ultrasound propagation pathway in order to register and record at a sufficient amplitude the time of flight between two acoustical impulses traveling the length of the screw. All dental implant screw designs can potentially be modified to create a sufficiently reflecting area within and at the base of the head alteration and also at the end of the screw for this purpose. Alternatively, other forms of reflecting surfaces may be used.
In one embodiment of the invention depicted in FIG. 1, a small 20 MHz PZT element (transducer) 50 of 0.8 mm diameter is fixed to a flattened area 42 in the head 26 of a screw 22 . This transducer 50 provides the interface between the screw 22 and an acoustic source 70 (See FIG. 2) for the transmission of an acoustic pulse along the long axis of the screw.
As shown in FIG. 7 and FIG. 2., the acoustic source is a hand held wand 70 that is electronically connected to a control box 72 . The electronic connection may be hard-wired 74 , or it may be accomplished remotely, such as by infrared or by so-called “bluetooth” technology, so long as the wand is provided with appropriate infrared transmission and/or receiving means. Alternatively, the control box can be provided in miniaturized form through microelectronics entirely within the handle 76 of the wand 70 .
Within the control box 72 are the electronics needed to initiate an ultrasonic impulse from an acoustic source 78 near the small tip 82 of the wand 70 . The tip 82 of the wand 80 is placed in contact with the transducer element 50 in the head 26 of the screw 22 , which clamps together the abutment 30 and implant 10 to form the screw joint 38 of the implant assembly. A sound impulse is initiated from the tip 82 of the wand 80 and the sound is transmitted by the transducer 50 in the screw head 26 to the opposite end 44 of the screw 22 . Two clear sequential echo-pulses are reflected from the screw bottom (end) back to the transducer and ultimately across the interface to the wand.
The time of flight between pulses 1 and 2 can be determined independent of the acoustic contact variations. The time of flight of the wave propagation through the screw is registered by the transducer 50 and the information is transmitted and processed in the control box 72 by a computer microchip. Tightening of the screw will produced variations in screw length related to the elastic properties of the screw. Screw length variations influence the time of flight of the ultrasonic pulse along the long axis of the screw. The differences in the time of flight recorded before and after screw tightening are used to compute the stress within the screw as a function of screw tightening. The stress is computed by the control box electronics, and displayed both graphically and digitally at the control box 72 .
As shown schematically in FIG. 2, a system for preload measurement may include, for example, an embedded 20 MHz ultrasonic transducer 50 , an ultrasonic pulser-receiver USD-15 (Krautkramer) 72 , a digitizing oscilloscope TDS-520 (Tektronix) 73 connected to a GPIB port (IEEE488) 75 with computer 77 . As is discussed above, the implant screw is provided with a generally flattened surface inside the tool-receiving bore in order to accommodate a 1 mm diameter piezoelectric piston. A piezoelectric disk 50 is positioned inside the screw head and two wires soldered in order to provide the electric path. To protect the piezoelectric element and the wiring the head was molded with epoxy compound. The setup immediately provided two clear echo-reflections from the opposite end of the screw. To increase amplitude of the reflected signals the threaded end of the screw was slightly flattened. In FIG. 3 a typical A-scan is given. The basics of the measurement consist of determining variation of the delay between 1 st and 2 nd reflections. To measure the TOF between the two pulses zero cross-section method is used. The software seeks for the first minimum of both signals and then calculates the time coordinate of next zero cross-section linearly interpolating the signal between two consecutive samples for both first and second echo-pulses and finally estimates TOF as given by the following formula. TOF = 1 f sampl ( i - j + ( wfm ( i ) wfm ( i ) - wfm ( i + 1 ) - wfm ( j ) wfm ( j ) - wfm ( j + 1 ) ) ) , ( 1 )
where f sampl is the sampling frequency, wfm(k) is the digitized waveform data, i,j are samples around zero crossing (see FIG. 4 ). Better results are obtained at 1 GHz sampling rate. A real-time measurement provides ±0.2 ns precision, with 32-average mode the precision goes to 0.02 ns. This corresponds approximately to 0.025° C. temperature variation, or 0.6N force variation using for approximation elastic parameters of mild steel. Exact values of these uncertainties are to be calculated after the stress-TOF and temperature-TOF characteristics are studied for the material used in manufacturing the screw. This system results in excellent resolution of the method.
To realize the measurement method a software program may be used. Basic features of the program are transfer of the digitized A-scan from TDS520 to a personal computer, serial port communication, time delay compensation and measurement, and data storage. The outlook of a program window is given in FIG. 5 . Configuration windows for the preload gauge are shown in FIG. 6 .
In another embodiment, depicted in FIG. 8, wand 90 is designed to transmit and receive acoustic and time of flight data without the need for contact between the wand tip and a transducer located in the head of the screw. In this embodiment, the transducer 50 is positioned within the tip 92 of the wand, near enough to the end to transmit and detect sonic impulses. The wand also incorporates technology for digital analog signals to be transmitted and received in order to carryout the functions identified in the hard-wired control box. The information received and transmitted by the wand may be displayed in a remotely located display mode.
In another embodiment, the ultrasonic transducer may be located within the tool used to tighten the screw. Thus, a screwdriver may be used to tighten the screw and either simultaneously or at the end of the torquing procedure measure the stress within the screw. One end of the screwdriver is formed in a well known latch-type design for attachment to an electronic or manual tightening torque apparatus. At the other end of the screwdriver, the ultrasonic transducer is positioned within the screwdriver end in a position permitting it to transmit and detect sonic impulses. The transducer is electronically connected to the latch-type end by internal circuitry. The transducer is electronically connected to either the electronic or manual tightening torque handpiece by an electronic interface within the handpiece head. The screwdriver is positioned in the screw bore and brought into intimate contact with the screw. Following initiation of the sound impulse, the sound travels through the screw to the end of the screw. In the electronic tightening torque apparatus, the time of flight of the wave propagation through the screw is registered by the transducer in the screw driver, and the information is transferred electronically back to the tightening torque apparatus control boxes or an associated display unit. The elastic properties of the screw, which have been altered by the torquing force used to tighten the screw, are displayed both graphically and digitally at the control box ( 6 ) as the preload.
In the case of the manual tightening torque apparatus, the electronics for initiation of the wave impulse from the screwdriver, and data retrieval and processing are located in a modified handle for the tightening torque apparatus. The registration, recording and computation of the time of flight are performed using micro-processing technology and transferring the information from the electronic port in the manual tightening torque handle ( 2 ) as a digital analog signal to a remote display unit. | A method and apparatus are provided for determining the preload in a dental implant system. The preload is determined by transmitting a sonic impulse, which is preferably an ultrasonic impulse, at a predetermined frequency to the head of the implant screw through a transducer, which may be incorporated into the head of the screw, the head of a wand which generates the sonic impulse, or the transducer and pulse-generating instrumentation may be incorporated into a torque generating instrument used to tighten the screw. The preload is determined by measuring the delay between the first and second reflections through the preloaded screw to determine a preload value and comparing that value with a pre-established baseline value for the screw, and comparing the difference with a predetermined table of values to determine the preload on the screw. | 0 |
BACKGROUND
Basic hashing works by computing a hash index I=H(K), I ε S I , where K ε S K is the key and H( ) is a hash function that maps elements of key space S K into a smaller index space S I . I is used to index a hash table, which may either store one or more keys which hash to the same index directly, or a pointer to the key storage.
Hashing is frequently used as a mechanism to perform exact match searches of fixed- or variable-length keys. These searches may be performed to extract data from a results database that is associated with each stored key: e.g., Quality of Service (QoS) processing information for a packet flow which is defined by a key composed of certain packet header values. While hashing has good (O(1)) average search time, it has a worst case search time of O(N) for N keys, due to the possibility of hash collisions.
FIG. 1 is a graph 100 illustrating the probability of hash collision P for a new key inserted into a hash table as a function of the table's load, defined as tile ratio of already inserted keys N to the number of bins B in the hash table. Here, simple uniform hashing is assumed, that being where any key will hash into any bin with equal probability. In FIG. 1 , the results are plotted for B ranging from 100 to 10000000, and it is observed that the resulting curve is insensitive to the absolute value of B. Note that P is approximately proportional to α for small values of α. The collision probability P at load α is equivalent to the expected fraction of occupied hash bins at that load. This is also equal to the expected fraction of keys that collide with another key at that load. Hash collisions can be resolved through a variety of mechanisms, including chaining, double hashing, open addressing, coalesced hashing, 2-choice hashing, and 2-left hashing. Disadvantageously, none of these mechanisms offer a deterministic search time for every key.
An arbitrarily low ratio of colliding entries can only be achieved by operating at a low load; that is by making B large relative to N. However, this results in a waste of memory space.
Exact match searches for fixed- or variable-length keys in databases is a common problem in computer science, especially in the context of packet forwarding e.g., Ethernet Media Access Control (MAC) lookup, and Internet Protocol (IP) 6-tuple flow lookup. Often in these applications, tens of millions or hundreds of millions of searches must be completed per second. In the context of packet forwarding, the database key might be anywhere from 16 to 48 bytes in size. Conventional solutions often involve sophisticated memory technology, such as the use of binary or ternary content addressable memory (CAMs), or combinations of well-known hashing techniques with memory technology, to retrieve those keys which are not conveniently resolved by the hashing technique.
Conventional hash-based solutions cannot provide deterministic search time due to the need to resolve hash collisions, which in the worst case can be O(N) for N keys, whereas solutions which depend on sophisticated memory technology are typically expensive, have low density, and have high power consumption.
The concept of using multiple hash tables is known in the art. For example, it is a basic component of the well-known 2-choice hashing and 2-left hashing methods. The method described in U.S. Pat. No. 5,920,900 to N. Poole, et al., while it uses multiple hash tables for collision resolution, does not bound every search to at most two hash table lookups.
What is desired is a solution that provides deterministic search time, with bounded memory.
SUMMARY
The present invention relates to database access operations in computer systems. More particularly, and not by way of limitation, the present invention can be implemented in networking equipment, primarily in Ethernet switches and routers for wired networks which might be providing wireless traffic backhaul. Further, the present invention can be implemented in database search applications outside of networking equipment.
In the context of forwarding in packet networks, fields in packet headers are used to access one or more databases which may store forwarding, QoS, security, and accounting context necessary to process and forward, or discard, the packet. A search key composed of one or more packet header fields is generated, and a database is searched using either exact (binary) match, longest prefix match, or ternary match methods.
In an embodiment of the present invention, hash collisions in a base hash function are resolved in separate secondary hash tables. Further, if keys are inserted in the separate hash tables such that every key that collides in the base hash function is stored in the same secondary hash table, without collision with any other key stored in that table, then the identity of that table can be stored as a result of the base hash table search, bounding the maximum number of hash tables that need to be searched to two. The invention also considers the maximum amount of memory needed for the complete set of hash tables, as a function of the number of keys to store.
The present invention is novel over multiple hash tables as it is adapted to store keys such that the base hash function lookup can be used to resolve the secondary hash table where a particular set of keys (those that collide at a particular value in the base hash function) are stored.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following section, the invention will be described with reference to exemplary embodiments illustrated in the Figures, in which:
FIG. 1 illustrates the probability of hash collision P for a new key inserted into a hash table as a function of the table's load:
FIG. 2 is a data structure used in an embodiment of the present invention;
FIG. 3 is a flow chart illustrating the steps of an embodiment of the present invention; and
FIG. 4 is a flow chart illustrating the steps of searching for keys in an embodiment of the present invention:
FIG. 5 is a flow chart illustrating the steps of inserting keys in an embodiment of the present invention;
FIG. 6 is a flow chart illustrating the steps of deleting keys in an embodiment of the present invention; and
FIG. 7 is a block diagram illustrating the components of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As seen in the graph 100 of FIG. 1 , values of α ˜ 0.69 or less, P≦0.5 that is at least half of the bins are empty and at least half of the keys do not collide. By removing the keys that collide with hash function H( ) and hashing them using a second function and table, it is possible to achieve a deterministic search time for all those keys which don't collide in H( ). This process can be repeated using additional independent hash functions and tables, until all keys are hashed without collision. Given N≦0.69×B 0 (α≦0.69), the number of hash functions and tables needed will converge to a value <<N as long as the number of unstored, i.e., colliding, keys at each stage j is no greater than 0.69×B j+1 , where B j is the size of the hash table at stage j. Since the number of collisions is less than or equal to half of the remaining keys at each stage, the subsequent hash tables can each be half the size of the previous one. Assuming that B 0 =2 M+1 , then I 0 can be represented in M bits, and M hash tables can be realized, each half the size of the other, such that the total memory utilized for hash tables is 2×B 0 =2 M+1 times the space needed for each individual hash bin (either a pointer or a matching key).
Such a structure of hash tables should store at least 0.69×2 M keys without collision. In the worst-case, a database search for key K may require M independent hash searches. This worst-case can be reduced to a maximum of two hash searches using the method and system of the present invention.
In the present inventions when inserting a new key into the search database, all keys that it may collide with in the base (first) hash function H 0 ( ) must be stored in the same hash table T j [ ], jε{0, M−1}, without collision. This allows the use a table_id field in each entry of the base hash table to indicate which of the M hash tables a particular search key may be stored in. Then a worst-case search would consist of computing the base hash function for key K. I 0 =H 0 (K), checking the table_id field value j in the base hash table at index I 0 , j⊂T 0 [I 0 ], computing the jth hash function I j =H j (K) (assuming j≠0), and comparing the key stored, directly or indirectly, at T j [I j ].
The present invention has two embodiments: one which minimizes memory storage, and another which minimizes search time. The embodiment of the present invention which minimizes memory storage uses the data structures 200 of FIG. 2 .
The data strictures consist of three tables: an index_tbl 201 , a hash_tbl 202 , and a key_tbl 203 . The index_tbl 201 is of size B 0 =2 M , and each entry I stores a table_id value, which is used to indicate which of the AM hash tables the set of keys colliding in the base hash with value I are stored in. A special value of table_id (EMPTY) is reserved if there are no keys in the search database that hash to I in the base hash function, hash_tbl 202 is used to store the M hash tables, as pointers to the key storage in key_tbl 203 , hash_tbl 202 is of size 2×B 0 =2 M+1 : and each hash table is logically appended to the end of the previous one (at offset(T)=2×B 0 ×(1−2 −T ); e.g., offset(0)=0; offset(1)=B 0 ; offset(2)=1.5×B 0 : offset(3)=1.75×B 0 ). Each entry in hash_tbl 202 contains either NULL or a pointer to an entry in key_tbl 203 . Each key_tbl entry stores a key in the search database, a next pointer to another key_tbl entry, and a pointer to an entry in a results database, which stores the context information associated with the key_tbl entry. The next pointer is used to chain together all of the keys that collide in the base hash at a particular index, which is needed to facilitate insertions and deletions. When a key K does not collide with another key in the base hash, it is stored in the first hash table, i.e., in the top half of hash_tbl 202 ; otherwise it is stored in one of the secondary hash tables, i.e., in the bottom half of hash_tbl 202 . When K collides in the base hash function, the slot in hash_tbl 202 indexed by Ho(K) can be used to point to the key_tbl 203 entry which is the root of the linked list of key entries which collide with K in the base hash.
FIG. 2 shows the use of three keys (K 0 ,K 1 ,K 2 ), where K 1 and K 2 collide in the base hash. K 0 is (logically) stored in the first hash table (indicated by the table_id=0 at index H 0 (K 0 ) of index_tbl). At the corresponding index in hash_tbl 202 there is a pointer to the entry in key_tbl 203 storing K 0 , K 1 and K 2 are (logically) stored in the second hash table. The second hash function H 1 ( ) is used to generate indices for hash_tbl 202 , whose corresponding entries point to the key storage for K 1 and K 2 . Those two key entries are linked in a list whose root can be reached via a pointer stored in hash_tbl 202 at index H 0 (K 1 )=H 0 (K 2 ), key_tbl 203 need be only of size N (the maximum number of keys supported).
FIG. 3 is a flow chart 300 of the steps of an embodiment of the present invention, while FIGS. 4-6 are flow charts of the procedures for searching for, inserting, and deleting keys in an embodiment of the present invention.
In FIG. 3 , a method of performing exact match searches using multiple hash tables is provided. Step 301 comprises the step of storing in the same hash table, all keys that it may collide with in the base (first) hash function H 0 ( ), when inserting a new key into the search database, using a table_id field in each entry of the base hash table to indicate which of the M hash tables a particular search key may be stored in. Step 302 comprises the step of computing the base hash function for key K. I 0 =H 0 (K). Step 303 is the step of checking the table_id field value j in the base hash table at index I 0 , j=T 0 [I 0 ]. Step 304 is the step of computing the jth hash function I j =H j (K)(assuming j≠0); and step 305 is the step of comparing the key stored (directly or indirectly) at T j [I j ].
FIG. 4 is a flow chart 400 illustrating the steps of searching for key K:
401 : Compute I 0 =H 0 (K).
402 : Fetch T=index_tbl[I 0 ].
403 : If T=EMPTY, stop (K is not in the search database).
404 : Otherwise, compute I T =H T (K).
405 : Fetch P=hash_tbl[offset(T)+I T ] (shift I T into the correct hash table range in hash_tbl).
406 : Compare the key value stored in the key_tbl entry at address P to K. If they do not match, then K is not in the search database. If they do match, in step 407 , extract the results pointer. Note that searching is O(1) complexity.
FIG. 5 is a flow chart 500 illustrating the steps of inserting key K:
501 : Search for key K, determining I 0 .
502 : If it is found, stop.
503 : Allocate an entry in key_tbl (at address P), set the key value to K, and set the results pointer appropriately.
504 : Fetch T=index_tbl[I 0 ].
505 : If T=EMPTY, in step 506 , set index_tbl[I 0 ]=0. Otherwise, go to step 509 .
507 : Set hash_tbl[I 0 ]=P.
508 : Set the next pointer value in the key_tbl entry for K to NULL and stop.
509 : Otherwise (T≠EMPTY), compute I T =H T (K).
510 : Fetch Q=hash_tbl[offset(T)+I T ].
511 : If Q=NULL, in step 512 , store P at hash_tbl[offset(T)+I T ] and at hash_tbl[I 0 ]. Otherwise, go to step 514 .
513 : Link the key_tbl entry for K to the tail of the linked list whose root is reached via hash_tbl[I 0 ] (if T>0), terminate the list, and stop.
514 : Otherwise (Q≠NULL), take the list of keys colliding with K in the base hash, find a new U>T where they each can be inserted without collision with other pre-existing keys, and move them there.
515 : Set index_tbl[I 0 ]=U.
Return to step 513 : Link the key_tbl entry for K to the tail of the linked list whose root is reached via hash_tbl[I 0 ], terminate the list, and stop.
Insertion complexity as described here is O(M).
FIG. 6 is a flow chart 600 illustrating the steps of deleting key K:
601 : Search for key K, determining I 0 , T, I T , and P.
602 : Key found? If it is not found, stop.
603 : Delete the key entry stored in key_tbl at address P. If the entry is in the middle of a linked list of key entries, repair the list.
604 : If T>0, in step 605 , set hash_tbl[offset(T)+I T ]=NULL. Otherwise, go to step 608 .
606 : If hash_tbl[I 0 ]=P, in step 607 , change hash_tbl[I 0 ] to point to the first entry in the linked list in key_tbl previously storing key K and stop. If hash_tbl[I 0 ] does not=P, stop.
608 : If (T=0), set hash_tbl[I 0 ]=NULL.
609 : Set index_tbl[I 0 ]=EMPTY and stop.
There may be cases of pathological keys, where, for a static set of hash functions H i ( ), iε{0, M−1}, the keys collide in every hash function, or there is no hash table that can be found where there is not a collision with at least one other key. In this event, one or more of the hash functions can be permuted (e.g., by changing the seed value for the hash function) and the keys that were stored in the corresponding hash table reinserted. This may increase the insertion time substantially.
An embodiment of the method of the present invention which is optimized for search time would eliminate the need to perform step 405 of the search procedure by eliminating the separate hash_tbl, and extending key_tbl to size 2×B 0 . For large keys. e.g., larger than four bytes, this would typically result in an increase in memory usage as compared to the alternative embodiment.
The method of the present invention described above was implemented using random 16-byte keys. The Fowler/Noll/Vo FNV-1a hash function was used with different seed values to realize each hash function.
Two execution runs are shown in Tables 1 and 2, each with M=20, for α=0.69 (725000 keys) and α=0.90 (945000 keys)(α is relative to B 0 =2 M ). Table 1 shows the results of the former and Table 2 shows the results of the latter. Memory required for the first run was 23.937.184 bytes (assuming 16-byte keys) and for the second run, 28,337,184 bytes. The memory size difference was due to the greater size of key_tbl.
As can be seen, the results for α=0.69 use fewer hash tables than what would have been expected from the discussion above. The results for α=0.90 show that there are only a few bins left in the unused hash tables ( 126 ). It was also observed that some executions for α=0.90 did not converge (without permuting the hash tables).
TABLE 1
multi_hash execution for M = 20, α = 0.69 (725000 keys).
Hash
#keys
α of hash
Cumulative fraction of total keys
table
# bins
stored
table
stored
0
1048576
362620
0.34
0.50
1
524288
222543
0.42
0.80
2
262144
92949
0.35
0.93
3
131072
34794
0.26
0.98
4
65536
10345
0.15
0.99
5
32768
1661
0.05
0.99
6
16384
88
0.01
0.99
7
8192
0
0
1.0
8
4096
0
0
1.0
9
2048
0
0
1.0
10
1024
0
0
1.0
11
512
0
0
1.0
12
256
0
0
1.0
13
128
0
0
1.0
14
64
0
0
1.0
15
32
0
0
1.0
16
16
0
0
1.0
17
8
0
0
1.0
18
4
0
0
1.0
19
2
0
0
1.0
TABLE 2
multi_hash execution for M = 20, α = 0.90 (945000 keys).
Hash
#keys
α of hash
Cumulative fraction of total keys
table
# bins
stored
table
stored
0
1048576
384926
0.36
0.401
1
524288
289999
0.55
0.71
2
262144
139461
0.53
0.86
3
131072
67590
0.51
0.93
4
65536
33029
0.50
0.96
5
32768
15838
0.48
0.98
6
16384
7742
0.47
0.99
7
8192
3622
0.44
0.99
8
4096
1745
0.42
0.99
9
2048
759
0.37
0.99
10
1024
290
0.28
0.99
11
512
88
0.17
0.99
12
256
20
0.07
0.99
13
128
2
0.01
0.99
14
64
0
0
1.0
15
32
0
0
1.0
16
16
0
0
1.0
17
8
0
0
1.0
18
4
0
0
1.0
19
2
0
0
1.0
Referring now to FIG. 7 , a block diagram 700 illustrating the components of an embodiment of the present invention is presented. As seen therein, the present invention can be implemented using standard memory technology (e.g., DRAM). The search mechanism can be implemented either in software on a general purpose processor or network processor, or in computer hardware, such as a field programmable gate array (FPGA) or application specific integrated circuit (ASIC). The insertion and deletion mechanisms can be implemented in software on a general purpose processor. The total amount of memory required is on the order of twice the amount of memory needed to store the keys in the database (for 16 byte keys). Said system is adapted to perform exact match searches in deterministic time using multiple hash tables, and comprises means for storing in the same hash table, all keys that it may collide with in the base (first) hash function H 0 ( ), when inserting a new key into the search database, using a table_id field in each entry of the base hash table to indicate which of the M hash tables a particular search key may be stored in; means for computing the base hash function for key K, I 0 =H 0 (K); means for checking the table_id field value j in the base hash table at index I 0 , j=T 0 [I 0 ]; means for computing the jth hash function I j =H i (K)(assuming j≠0); and means for comparing the key stored (directly or indirectly) at T j [I j ]. The system of the present invention is further adapted to perform the above referenced steps of the method of the present invention.
Advantages of the present invention over conventional methods and systems include the ability to search both fixed-length and variable-length search keys, whereas the conventional methods and systems assume fixed-length keys. Note that variable-length keys could be stored in a fixed-length field along with a key length. These conventional methods and systems assume a single hash function, which computes a hash value that must map 1:1 with the search key of equal length. Subsets of this hash value are used as indices into each of the multiple hash tables. Conventional methods and systems assume that the implementation stores information in each hash table entry to extract subsets of the hash value to be used to index a secondary or tertiary hash table for collision resolution, whereas the present invention uses a label in the index table (indexed by the base hash function) to indicate a separate hash function (which could be computed in parallel with the first hash function when implemented in hardware). Also, conventional methods and systems define a method which does not guarantee a maximum search time, whereas the present invention guarantees a maximum search time of two hash lookups. Finally, the conventional method and system is much less memory efficient than the present invention.
As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a wide range of applications. Accordingly, the scope of patented subject matter should not be limited to any of the specific exemplary teachings discussed above, but is instead defined by the following claims. | A method and system to perform exact match searches for fixed- or variable-length keys stored in a search database. The method is implemented using a plurality of hash tables, each indexed using an independent hash function. A system implementing this method provides deterministic search time, independent of the number of keys in the search database. The method permits two basic implementations; one which minimizes memory storage, and another which minimizes search time. The latter requires only two memory accesses to locate a key. | 6 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The invention relates to an apparatus and method for the repair of failure areas in a previously set plug within a subterranean well.
[0003] (2) Brief Description of the Prior Art
[0004] Subterranean wells, such as oil, gas or water wells, are required to be “plugged” when they are abandoned, to assure that any slow flow of hydrocarbons or other fluids within the well do not escape and flow to the top surface of the well. As used herein the term “first plug” is intended to include such conventional plugs as hydraulically set, or mechanically set, or electrically set plugs, bridge plugs, packers and the like, as well as the use of cementious material, alone, or in combination with such other first plugs, as herein described, as typically used to plug off a well or zone in a well to be temporarily or permanently abandoned. These first plugs are many times intended to properly secure the well and prevent any flow of any fluids from within the well to the top of the well or into other formations within the well. Over time, and after exposure to high temperatures and pressures in the well, as well as a corrosive and acidic environment in the well, failures in such plugs occur, as the result of leaks, metallic pitting, loss of elastomeric seal integrity, and the like. It therefore becomes necessary to either mill out the first plug and provide a replacement plugging means of some sort or set additional cement plugs. These procedures are, of course, expensive and time consuming.
[0005] U.S. Pat. No. 6,474,414, entitled “Plug For Tubulars” is directed to the use of moltenl solder for providing a plug in a subterranean well which may be poured or otherwise applied directly upon a platform for the molten solder in the well.
[0006] U.S. Pat. No. 6,536,349, entitled “Explosive System For Casing Damage Repair” illustrates the use of liquid explosives to fragment damaged casing which has become an obstruction to proper flow of the well.
[0007] The present invention addresses problems, as above described.
SUMMARY OF THE INVENTION
[0008] The present invention provides a secondary plugging tool for use in a subterranean well for the repair of a first plug previously introduced into and set within the well. The plugging tool comprises an outer tubular housing including a ported lower end. The ports in the ported end may be initially closed by means of a thinner outer portion of the housing which also melts to open the ports during the ignition of the tool, or by a series of meltable eutectic plugs. Alternatively, small, open ports may be provided circumferentially around and immediate the lower end of the outer tubular housing. An inner tubular housing is concentrically positioned within the outer tubular housing. A low temperature melting eutectic metal alloy charge is deposited within the outer tubular housing. A thermitic reaction charge is deposited within the inner tubular housing immediate and covering the ported end. The thermitic reaction charge is also provided in a chamber in a lower housing member selectively and releasably secured to the outer tubular housing. The thermitic reaction charge in the chamber in the lower housing is provided to bake/melt the eutectic metal alloy charge after it is decanted from the upper chamber. Means are secured to at least one of the said housings for introducing, positioning and retrieving the plugging tool.
[0009] The igniting charge may be ignited by percussion means, such a dropping of a bar, or by electric signal or other known means.
[0010] In lieu of using a separate inner housing for purposes of receiving the thermitic reaction charge, the thermitic reaction charge and the eutectic metal alloy charge may be placed into one housing and separated simply by use of cardboard or plastic tubes or sheets, or the like. In such an arrangement, the thermitic reaction charge would be placed into an interior section, and exteriorally surrounded by the low temperature melting eutectic charge. Ports or port means are provided around the lower end of the housing for permitting flow of the molten eutectic charge upon melting of the eutectic.
[0011] The secondary plugging tool of the present invention may be introduced into the well and withdrawn there from on wire line, cable, electric line, or tubing. If it is desired that the secondary plugging tool not be retrieved from the well subsequent to use, it may be left in the well by providing a release mechanism, such as a shear release between the top of inner and outer housings and the line, cable, or tubing used to introduce the tool within the well. Alternatively, the now empty inner and outer tubular members may be separated from the lower housing by providing a releasing means, such as a shear pin connection, between the lowermost end of at least one of the outer tubular housing and the top of the lower housing. When the method is completed, the line, cable, or tubing is pulled until the shear pin mechanism shears and separates the inner and outer housings from the lower housing, and the line or cable or tubing may be retrieved from the well with the lower housing left in the well
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a vertical longitudinal sectional schematic view of the secondary plugging tool of the present invention carried into a well on an electric line and positioned just above a first plug previously placed in the well.
[0013] FIG. 2 is a view similar to that of FIG. 1 , illustrating the secondary plugging tool after it has been activated with the eutectic alloy charge flowing out of the openings through the lower end of the outer housing and upon the first plug.
[0014] FIG. 3 is an illustration of an alternative design of the present invention wherein the thermitic reaction charge and the eutectic charge are carried within a housing having concentric housing sections.
[0015] FIG. 4 is a further illustration of yet another alternative preferred embodiment wherein the eutectic metal alloy charge is secured, such as by casting, or the like, to the exterior of a tubular housing containing the thermitic reaction charge.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Now referring to FIG. 1 , there is shown a subterranean well W. The well W includes previously run and set first plug FP. The plug FP contains a number of abrasions, crevices, corrosive spots and electrometric failures, all generally identified as F. These failures F are believed to be the cause of well fluid leaks, previously detected at the top of the well W.
[0017] As shown in FIGS. 1 and 2 , the apparatus 100 of the present invention is preferably run into the well W (having casing C) on wire line 101 , of conventional and known nature. Alternatively, it may be run into the well W on tubing or electric line. If means other than electric line are used to run and set the apparatus 100 , an electric line 103 is provided form the top of the well W and connected to a source of electric energy at the top or other location in the well W and is connected at the lower end to a starter charge 104 within an upper section 105 within an inner tubular housing 106 , concentrically positioned within an outer tubular housing member 107 . The housing members 106 and 107 preferably are made of metal, such as an alloy steel or the like.
[0018] The lower end of the outer housing member 107 is ported, at ports 108 . Such ports may be provided by making the wall of the outer housing member 107 very thin in a series of circular or other geometric form, spaced radially around the outer housing member lower end, or even the bottom of the outer housing member 107 . If formed in this fashion, the extremely high heat resulting from the ignition of the thermitic reaction charge in the tool 100 will permit these thinned wall portions to give way and open, permitting the eutectic metal alloy charge, described below, in the outer housing to melt and pour through such openings. Alternatively, eutectic plugs may be sealingly placed into openings in the outer housing member 107 , such that melting of the eutectic plugs will transpose the plugged openings into the ports.
[0019] The inner housing 106 contains a thermitic reaction charge 109 , as hereinafter described. The housing 106 is in communication with the lower ends of each of the inner and outer tubular housings 106 and 107 as well as a lower housing 110 having a chamber 111 , also containing the thermitic reaction charge. A release joint 120 , or a shear pin connection 120 , of known construction and commercially available from a number of sources, secures the tubular housings 106 and 107 to the lower housing 110 . Alternatively, a meltable or shear release mechanism may be provided between the lower housing 110 and the outer housing 107 .
[0020] The invention contemplates use of two charges of materials. The first, or lower temperature melting eutectic metallic alloy LTA is deposited into the interior of the outer housing 107 . The eutectic composition LTA is an alloy, which, like pure metals, has a single melting point. This melting point is usually lower than that of any of the constituent metals. Thus, for example, pure Tin melts at 449.4 degrees F., and pure Indium melts at 313.5 degrees F., but combined in a proportion of 48% Tin and 52% Indium, they form a eutectic which melts at 243 degrees F. Generally speaking, the eutectic alloy composition LTA of the present invention will be a composition of various ranges of Bismuth, Lead, Tin, Cadmium and Indium. Occasionally, if a higher melting point is desired, only Bismuth and Tin or Lead need be used. The chief component of this composition LTA is Bismuth, which is a heavy coarse crystalline metal that expands when it solidifies. Water and Antimony also expand but Bismuth expands much more than the former, namely 3.3% of its volume. When Bismuth is alloyed with other materials, such a Lead, Tin, Cadmium and Indium, this expansion is modified according to the relative percentages of Bismuth and other components present. As a general rule, Bismuth alloys of approximately 50 percent Bismuth exhibit little change of volume during solidification. Alloys containing more than this tend to expand during solidification and those containing less tend to shrink during solidification. After solidification, alloys containing both Bismuth and Lead in optimum proportions grow in the solid state many hours afterwards. Bismuth alloys that do not contain Lead expand during solidification, with negligible shrinkage while cooling to room temperature. In summary, when reference herein is made to a low temperature alloy composition, or “a low temperature melting eutectic melting metal alloy”, we mean to refer to these exemplary compositions and to metallic compositions which melt at temperatures of no more than about 1,100 degrees F.
[0021] Most molten metals when solidified in molds or annular areas shrink and pull away from the molds or annular areas or other containers. However, eutectic fusible alloys expand and push against their container when they solidify and are thus excellent materials for use as plugging agents for correcting failure spots in well tubular conduits, such as casing.
[0022] The thermitic reaction charge TRC is deposited within a third chamber 130 in the inner housing 106 and within a second chamber 131 in the lower housing 110 . A first chamber 132 houses the LTA in outer housing 107 . The thermitic reaction materials used to prepare the charge will melt at temperatures of about 2,400 degrees F. or greater. An example of thermite, forming the thermitic reaction charge, is a mixture of powdered or granular aluminum or magnesium metal and powdered iron oxide or other oxides. The reaction is very exothermic. 1.
OPERATION
[0023] The apparatus 100 of the present invention is run into the well W on wire line 101 or other means well known to those skilled in the art to a depth just above the top of the first plug FP. The tool or apparatus 100 contains the thermitic reaction charge within the inner housing 106 , as well as in the lower housing 110 . The low temperature eutectic metal alloy charge LTA has been placed into the outer housing 107 . The tool 100 is activated by electric activation through electric signal in electric line 103 to activate the fuel charge 109 . The tool 100 may also be activated by a number of other known means such as by percussion means, the dropping of a heavy bar, or the like. Upon activating, the thermitic reaction charge will ignite and the temperature in the chamber outer housing 107 will increase quickly. Upon the outer housing 107 being heated to a temperature in excess of about 1,100 degrees F. i.e. the melting point for the low temperature eutectic metal alloy charge LTA is reached and the eutectic metal alloy charge begins to quickly form a molten mass. The low temperature eutectic charge LTA is permitted to flow through the ports 108 , into the well W and pass upon, through and across the exterior of the first plug FP. Upon cooling and solidification of the LTA within the well W, the tool 100 may be retrieved from the well, or left permanently in the well W and the electric line or tubing or the like disengaged from the tool 100 and removed from the well W.
[0024] Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | A secondary plugging tool is disclosed for use in a subterranean plug, such as in a plugged and/or abandoned well. The repaired plug may be of a cementicious material, or a mechanically, hydraulically or electrically set plug or packer. The plugging tool includes an outer housing containing an eutectic metal alloy. A thermitic reaction charge is contained within chambers within an inner tubular member and a lower housing. The lower end of the outer housing being ported circumferentially there around, the thermitic reaction charge activates the eutectic metal charge such that the eutectic charge melts and pours out of the outer housing and across and upon the initial plug to repair any failure areas therein. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of application Ser. No. 495,901, filed Aug. 8, 1974, which is a division of application Ser. No. 322,226, filed Jan. 9, 1973, now issued as U.S. Pat. No. 3,850,191. It is requested that all patent references cited in these cases be made of record in the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to means of limiting reverse fluid flow through conduits. More specifically, the present invention relates to a check valve assembly suitable for employment in a drill string in which drilling fluid or "mud" is being pumped downwardly through the string. The assembly is designed to limit upward flow of fluids when the drill bit enters a high pressure area.
2. Description of the Prior Art
When drilling a well, there may arise a need for a device to prevent the uncontrolled upward flow of the drilling fluid or "mud" in the drill string, e.g., should the drill bit enters a high pressure area. Under normal operating conditions, the device should allow unrestricted downward flow of the mud.
The prior art has suggested a number of valve assemblies designed to allow fluids or effluent materials to be pumped down through a drill string and to prevent reverse or upward flow therethrough. See, for example, U.S. Pat. Nos. 1,577,740 and 1,790,480.
If the valve elements are directly in the flow stream, the materials pumped down through the drill string may erosively wear the valve components, particularly when such materials carry abrasive particles. Previous check valve devices have employed a ball valve member and a seat member, along with a retainer or cage assembly. In these devices, the valve assembly is located directly in the flow stream and therefore subjected to the erosive action of abrasive material in the fluid. Such valves also restrict the downward flow of fluid and, with the valve assembly located directly in the flow stream, it is impossible for equipment to be lowered through the drill string past the assembly.
During drilling operations, the drill string may frequently be removed from the bore for maintenance of the drill bit. The valve assembly should allow fluid to empty from the drill string when it is raised from the bore. It is preferable that the valve assembly also allow fluid to flow at a limited rate upward past the assembly when the drill string is being lowered into the well bore. By allowing the drill string to fill from the bottom, fluid does not have to be pumped in at the top to lower the drill string and to prevent the drill string from collapsing because of pressure differentials. Valve assemblies previously used, either allow no reverse fluid flow, or a predetermined amount of flow at all times. The valve that allows fluid to flow all the time is undesirable. Such a valve works fine when lowering the drill string into the well bore; but, when the drill bit enters a high pressure area, the flow can never be completely stopped.
Other devices have been designed to control only the upward flow of fluid in well tubing and are not designed for use in a drill string, where fluid is allowed in both directions. These devices are used in production strings to shut off the flow of oil if damage occurs to equipment at the wellhead. Many of these devices have a ball valve located in a side pocket out of the flow stream and a movable inner sleeve for displacing the ball from the side pocket when the differential pressure is increased sufficiently.
In the aforementioned U.S. Pat. No. 3,850,191, a new and improved drill string check valve assembly is disclosed which provides an unrestricted flow path for unrestricted downward flow and passage of flowline equipment; but, which is provided with means for regulating the rate of reverse flow so that the drill string can be lowered into the well bore without having to pump fluid into the top of the drill string. In such a check valve, a tubular housing is provided, having a recess in its wall, for normally retaining a ball valve closure member out of the flow stream. Thus, the ball itself doesn't restrict the downward flow of fluid and is at least partially protected from erosion by abrasive material in the fluid. In its preferred form, the closed end of the ball recess may also communicate with the flowbore through a pressure equalizing passage by which the rate of reverse flow can be regulated. Although such a check valve assembly is superior to those of the prior art, the recess, and to some degree, the ball member itself, is still subject to some degree of erosion.
SUMMARY OF THE INVENTION
The present invention provides an improved version of the check valve assembly of U.S. Pat. No. 3,850,191. Its construction further reduces the effects of erosion, resulting in a more efficient and reliable check valve.
Like in the original embodiment, the check valve of the present invention comprises: a valve body having a longitudinal flowbore therethrough; seat means carried by the valve body at one end of the flowbore; and a ball closure means for disposal in a recess for movement into the flowbore for sealing engagement with the seat means, in response to a predetermined rate of reverse flow through the check valve assembly. However, instead of only one recess for disposal of the ball member, the present invention provides a pair of recesses in either one of which the ball member may be disposed. In a preferred embodiment of the invention, the recesses are symmetrically and directly opposed from each other relative to the flowbore. Thus, after entering the flowbore for seating against the seat member, the ball member, upon a reduction in reverse flow, may reenter either one of the recesses, without preference to either. This arrangement materially reduces erosion to the recesses upon continued operation, resulting in a check valve which has a longer life and greater reliability.
The closed end of each of the recesses may also communicate with the flowbore, via a pressure equalizing passage, so that changing of orifice bushings therein can regulate or determine the reverse flow rate at which the check valve will operate.
The foregoing and other features and advantages of the present invention will be more fully understood from the following specification, claims and related drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical elevation, in section, of a check valve assembly according to a preferred embodiment of the invention and illustrating the check valve in the opened or inoperative position;
FIG. 2 is a vertical elevation, in section, similar to FIG. 1 but showing the valve in its closed position for preventing reverse flow therethrough.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the check valve V of the present invention comprises a cylindrical body 1, having a longitudinal flowbore therethrough, divided into three distinct sections: a converging lower frusto-conical section 2, a restricted central throat section 3 and an upper cylindrical section 4. A threaded pin 5 at the lower end of the assembly and a threaded box 6 at the upper end of the assembly permit connection of the valve assembly V in a drill string above the drill bit (not shown).
Located at the upper end of flowbore section 4 is a valve seat bushing 7 having an annular seating surface 8 thereon. A resilient O-ring seal 9 encircles the bushing 7 and forms a fluidtight seal between the bushing 7 and body 1. To allow for replacement of the bushing 7 and to maintain the correct positioning thereof, an externally threaded lock nut 10 is positioned above the bushing. The lock nut 10 may be provided with slots 11 for engagement with any suitable tool to remove the lock nut for replacement of the bushing 7.
A pair of inclined cylindrical recesses or pockets 12 and 13 communicate with the flowbore near the junction of upper section 4 and central section 3. These pockets may be initially formed by inclined drilling from the outside of the valve body and replacing a portion of the drilled out area with plugs 14 and 15. The drilling, not only produces the recesses 12 and 13, but also provides transition guide areas 16 and 17 from the recesses to the flowbore.
Pressure equalizing passages 18 and 19 may be provided between the closed ends of the recesses 12 and 13 and the lower flowbore section 2. These passages may include a reduced diameter section threaded for receiving externally threaded orifice bushings 21 and 22. The positioning of the passages 18 and 19 may be such as to allow removal of the orifice bushing 21 and 22 from the lower flowbore section 2. It is the size of the orifice 21 and 22 which determines the reverse flow rate permitted.
During drilling operations, fluid is pumped down through the drill string, in which the valve assembly V is installed, through the flowbore sections 4, 3, and 2 and out the drill bit connected therebelow (not shown). The fluid assists the mechanical action of the drill bit and returns cutting to the surface of the well. In addition, when the drill string has to be removed from the well bore, the hydrostatic pressure of the fluid will seal the well bore.
When drilling resumes, after removal of the drill bit, the drill string must again be lowered into the well bore. The drill string is lowered by gravity, until the weight of the fluid displaced by the drill string equals the weight of the drill string. It is then normally necessary to either pump fluid into the top of the drill string to increase its weight or to have a valve assembly, such as the one described herein, to allow the drill string to fill from the bottom. Therefore, it is desirable to have a check valve assembly with reverse flow capabilities like the valve V of the present invention. But, the reverse flow rate must be regulated so that when the drill enters a high pressure area, the valve will completely close and prevent reverse flow or blowout of fluid.
If the pressure below the drill bit is greater than the pressure in the drill string, the fluid will start to flow upwardly through the drill string and when reverse flow reaches a predetermined rate, a ball member 23, which is disposed in either one of the pockets 12 and 13, will be displaced into the flowbore and forced into the contact with the valve seat 8 as in FIG. 2. The diameter of the ball 23 is slightly less than the diameter of the recesses 12 and 13 and the upper flowbore section 4.
The ball 23 is displaced because of a pressure differential created between the recesses and the restricted bore of throat section 3. This pressure differential exists because the entire hydraulic head within the recess is in the form of pressure energy, whereas the same hydraulic head in the throat 3 is in the form of kinetic energy embodied in the fluid flow. The pressure at the throat or intermediate section 3 is therefore lower than that in the recesses 12 and 13. This is in accordance with the well established principle outlined in hydraulic textbooks, e.g., "Fluid Dynamics" by Daily and Harleman (Addison-Wesley, 1966), and which is expressed quantitatively by the well known equation of Bernoulli.
When the orifice bushings 21 and 22 are blanked off so as to allow no communication of pressure, the initial pressure differential acting on the ball 23 will be at a maximum. However, if an orifice is fitted into the bushing, some reduction of pressure will take place in the recesses due to this communication. The larger the orifice the higher the flow rate required to cause the ball 23 to be displaced from its recess into the flowbore for engagement with the valve seat 8, as illustrated in FIG. 2.
Subsequently, when the pressure below the valve assembly V becomes less than the pressure above, the ball 23 will drop down through the upper flowbore section 4 and be guided by one of the guide areas 16 or 17 into one of the recesses or pockets 12 or 13 respectively. Since the recesses are symmetrically disposed about the axis of the flowbore, the ball does not prefer one to the other and depending on the fluids, the plumbness of the drill string and other variables may enter either one. Thx passages 18 or 19, or the clearance between the ball 23 and the recess in which it reenters, will allow the fluid displaced by the ball to escape from the recess. When the ball has returned to either one of the recesses 12 or 13, the drilling process can be resumed.
From the foregoing description, it can be seen that the check valve of the present invention offers several advantages. It permits some reverse flow of fluids, so a drill string can be lowered into the well bore without extra weight to overcome the buoyancy of the drilling mud therearound, yet it prevents excessive reverse flow which might occur upon drilling entry into an extreme high pressure area. The closure member is disposed in recesses out of the main flow stream, reducing erosion wear and by providing a pair of recesses for the closure member, erosion wear is further reduced. The resulting check valve assembly V is simple, effective and efficient.
Although only one embodiment of the invention has been described herein, many changes in the size, shape, materials, as well as the details of construction, may be made without departing from the spirit of the invention. It is therefore intended that the scope of the invention be limited only by the claims which follow. | A check valve assembly for use in a drill string to limit reverse flow of drilling fluid through the string while permitting such fluid to be pumped freely into the well under normal conditions. The assembly may include: a valve body having a longitudinal flowbore therethrough; a valve seat at one end of the flowbore; a pair of inclined cylindrical recesses in the valve body communicating with the flowbore; and a ball member normally disposed in either one of the recesses and movable into the flowbore for sealing engagement with the seat in response to a predetermined rate of reverse flow through the flowbore. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to elapsed time indicating devices and more particularly is concerned with a simple electrochemical timing cell which utilizes electrical current to anodize an electrode.
The prior art contains many examples of devices for measuring elapsed time by electrochemical means. One such system, such as described in U.S. Pat. No. 3,564,347 issued Feb. 16, 1971, employs dissimilar metal electrodes separated by an electrolyte which supports plating and/or deplating of ions at one of the metals. When one electrode is completely deplated with the metal of the other electrode, an electrochemical couple or voltage appears.
Another system providing a visual indication of elapsed time (offered by the Fredericks Company, Huntingdon Valley, Pa.) depends upon the plating out of copper ions from an electrolyte in a capillary tube as a function of current flow between anode and cathode.
Still another system, described in U.S. Pat. Nos. 3,045,178 issued July 17, 1962, and 3,665,308 issued May 23, 1972, provides a visual indication of elapsed time through the plating and deplating of two columns of mercury in a capillary tube separated by a small amount of electrolyte (a so-called gap) as a function of current flow.
These prior systems, while effective in certain applications, suffer from certain disadvantages. The dissimilar metal "switching" coulometers normally require expensive noble or rare metal elements and ions and are only suitable for indicating a specific "time-out" period--intermediate periods of time are not identifiable.
All of these systems depend upon the plating out of metallic ions.
It is an object of this invention to overcome the defects of prior elapsed time indicating devices.
It is a further object of this invention to produce a simple and low-cost elapsed time cell.
It is a still further object of this invention to provide an electrolytic cell that is capable of a continuous indication of elapsed time.
It is another object of this invention to provide a simple low-cost elapsed time indicator system.
It is yet another object of this invention to provide a low-cost elapsed time indicator system suitable for use in automobiles and other engine powered vehicles having a low voltage (e.g. 6 volt or 12 volt battery) source of electrical energy, which vehicles require special service maintenance at periodic running intervals.
SUMMARY OF THE INVENTION
An elapsed time indicating cell comprises a valve metal anode, a cathode being separated from the anode by a space, an electrolyte occupying the space, and a housing containing the electrolyte.
A series electrical circuit is formed including a resistor and the cell. The series circuit is terminated by two power supply terminals. A voltage sensing means is connected across the cell for producing a signal that is a function of the total time during which a D.C. power supply has been connected to the power supply terminals.
The invention recognizes the principle that an electrolytic cell having a valve metal anode is capable of exhibiting a changing impedance that is a function of the total electrical charge that has passed through it. It is further recognized that the cell may be connected in series with a resistor and a D.C. power supply causing the impedance of the cell to change as a function of the total time of energization. The larger the total time of energization, the greater becomes the resistance of the cell to D.C. current while simultaneously the capacitance decreases (capacitive reactance increases). Either or both of these impedance changes may be used to indicate the elapsed time of energization.
The invention is based upon the use of coulometric reaction energy required to anodize (oxidize) so-called valve metals by the process well known in the electrolytic capacitor art. However, in contrast to the latter, wherein the anode material is oxidized to an essentially fixed voltage level (20 to 500% higher than the capacitor operating voltage level), the present invention relates to a device in which the anode is not formed prior to use (other than a nominal initial voltage in some instances) and in which the device is "exhausted" prior to achieving a stable anodization voltage plateau.
The anodizable electrode should consist of a so-called valve metal selected from aluminum, titanium, niobium, vanadium, and tantalum. Tantalum and aluminum are preferred electrode materials since the electrolytically formed oxide layer is most stable, especially considering the "off-voltage" periods which characterize many of the applications of the invention. Aluminum is especially preferred because of its relatively low cost.
Anodic films formed on valve metal anodes for use as the dielectric films in electrolytic capacitors are as a practical matter assigned a maximum operating voltage that is from about 0.8 to 0.2 times the voltage at which they were formed. This insures an acceptably low leakage current in operation. Furthermore, the smaller factors are chosen for the smaller maximum rated operating voltages. For a rated operating voltage of 2 volts, for example, the anode formation voltage would typically be chosen to be at least as great as 4 volts and as high as 20 volts for very high quality capacitors.
For a given anode surface area, the CV product and the loss factor, tan δ, remain essentially constant as the formation voltage changes over a wide range, e.g. 10 volts to 300 volts. C is the capacitance. V is the rated maximum operating voltage. V is assumed for this purpose to be a fixed fraction of the formation voltage. Low formation voltages are desirable for maximizing the capacity. However, at low formation voltage, generally under about 10 volts, the CV product decreases and the tan δ goes up as the formation voltage decreases further. Thus, in this low voltage region of formation voltages the efficiency and quality of capacitors so formed being operated at any voltage tends to become very poor.
It is thus universally known in the electrolytic capacitor art to employ anode formation voltages greater than 3 volts regardless of the desired maximum rated operating voltage. The thickness of anodically formed aluminum oxide films is about from 11A/volt to 13A/volt while for tantalum oxide it is from 12A/volt to 20A/volt. Since no known electrolytic capacitors are formed at less than 3 volts there are no known capacitors having anodically formed dielectric films on their anodes which films are less thick than about 30 angstroms.
The anodes of an elapsed time indicating cell of this invention are preferably preformed prior to their assembly into the cell housing, but may be formed after assembly of the cell components. However, in use the indicating cell is subsequently further formed at a very slow rate during operation. The rate of formation during operation of cells of this invention expressed in volts per hour, are preferably no greater than 0.5 volts per hour whereas electrolytic capacitors are typically formed as much greater rates, namely greater than 5 volts per hour. The associated high rate of gas generation is not a problem since capacitor anodes are formed in operations prior to capacitor assembly.
The slow rate of formation during operation of a cell of this invention makes it possible for the low molecular weight gasses, mainly hydrogen, to diffuse through the sealing members of the cell at a rate commensurate with its slow generation in formation and to minimize internal pressures that may rupture the seal or housing.
It is preferred to provide an initial anodic film of a thickness corresponding to a formation voltage of about 2 volts in order to provide a more linear relationship between the elapsed time and the impedance of the cell (or the voltage drop across the cell). The initial thin anodic film has the additional advantage that the above-noted relationship is more uniform and predictable from cell to cell, since the initial film masks differences that may exist in the anode surfaces from cell to cell such as the degree of air oxidation and damage to the air oxidation film caused in handling.
Thus, an important structural feature of the electrolytic cell of this invention is an anodically grown film on the anode having a thickness corresponding to a formation voltage of less than 3 volts. In general, however, no anodic film need be provided at all.
For small area anodes of this invention, a machined or formed rod may be suitable, while for somewhat larger areas, a coiled wire anode or woven screen anode is useful. Where very large areas are desired, the surface of a foil or plate may be etched using known technology. Surface area increases on the order of 50 to 500 times the geometrically measured area may thus be achieved. A porous sintered anode may also be employed.
The cathode or opposing electrode, in the case of a D.C. timing cell should advisably have an equivalent area at least that of the anode area to reduce gassing and series capacitance effects. The cathode may be selected from a material exhibiting minimal polarizing effects, or depolarized, as for example a silver cathode with a platinized surface. In accordance with a limited embodiment of the invention, an aluminum cathode is employed with an effective surface area at least equal to that of the anode and may be preanodized to the same level as that of the anode, or to a higher voltage, although this effects a reduction in the effective capacitance of the cell.
If the current used to anodize the electrode(s) is of sufficient magnitude, the cell may be used directly to illuminate (activate) a lamp, a light-emitting diode, or any other visual indicator. Ordinarily, if the time to be measured is more than a few hours, for example, and the visual indicator connected in parallel with the cell is an incandescent filament bulb which is rated at 8 volts and draws 20 milliamperes, the cell should have a substantial electrode area, which may be accomplished by etching the surface thereof. In this system and example the visual indicator will gradually illuminate, as the cell voltage approaches 8 volts, thus giving a warning of the approaching of the time to be counted.
According to another embodiment of the invention, the series resistor, between the energy source and the timing cell, consists of a visual indicator, such as an incandescent lamp filament or a light-emitting diode rated at or slightly less than the voltage level of the energy source. During the period that the series resistance of the timing cell is low, owing to the anodization reaction therein, the series resistor-lamp will be illuminated, finally reducing its light output in accordance with the time design of the cell.
In accordance with another embodiment of the invention, the anode electrode material may comprise a thin evaporated layer of the valve metal, such as aluminum, on a carrier, typically a smooth plastic film of polyethylene terephthalate, regenerated cellulose, polycarbonate, or other materials which are stable in the process of the electrolyte. When using a thin evaporated film the thickness thereof should be greater than the thickness of metal oxidized during the timing operation in order to prevent discontinuities in electronic conduction to the terminal of the seal. Regenerated cellulose, as contrasted to the other referenced films, will absorb a glycol based electrolyte, thus permitting the oxidation to thick plates on both sides of the electrode surface. In such instances, it is preferred that the thickness of the metal be at least twice that amount to be oxidized.
In accordance with a limited embodiment of the invention, a reversible timing cell is produced wherein two anodes of normally equal surface area are employed instead of an anode and cathode element. In this construction the timing cell is reversible. After timing to a desired voltage level with one electrode connection as the anode, the terminal connections may be reversed and the cell operated in the reverse direction. This provides a dual timing function, although the cell still must be discarded after the second timing operation.
The elapsed time indicator of this invention, when connected through the ignition switch to, for example, an automobile battery, will advantageously provide a very low cost cumulative running time indicator, signaling the appropriate time for oil changes, tire rotation, and other maintenance service. It is particularly important that the preformation of the anode be less than 3 volts in such applications wherein the energizing voltage is low (e.g. a 12 volt auto battery), so that the potential time for the virgin cell to reach the predetermined alarm or indicating voltage (less than 80% of 12 volts) is still adequate.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a cross-section of a simple timing cell of the invention.
FIG. 2 shows a partial cross-section of one of the preferred embodiments of the invention.
FIG. 3 shows a schematic representation of an elapsed time indicator of this invention.
FIG. 4 shows representative curves indicating the relative magnitude of change of cell resistance and capacitance as a linear function of time that the cell is connected to a fixed voltage power supply in the circuit illustrated in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIG. 1, 10 is the metallic anode metal of the timing cell. It is selected from the class of metals known as valve metals which when connected to the positive polarity terminal of a current source and in intimate contact with an oxidizing electrolyte will become anodized or "formed" on its exposed surface to form a dielectric layer whose barrier characteristics inhibit the flow of current to the anode, and which dielectric layer provides capacitance between the anode and the electrolyte/cathode elements. Aluminum is our preferred anode material, although other metals of the class, such as tantalum and niobium may be employed. Aluminum and tantalum are especially valuable owing to the stability of the formed dielectric even on periods of remaining "off" voltage.
The metallic cathode 11 also serves as a container for the electrolyte 12. While many metals may be used, we prefer to use aluminum if the anode is aluminum. With tantalum anodes, a platinized silver cathode is effective. The effective area of the cathode preferably should be at least as great as the effective area of the anode although the system will operate, though with less absolute accuracy if the effective area is less.
When current flows in the cell, the electrolyte material 12 will oxidize the surface metal of the anode 10. Suitable formation electrolytes vary with the metal selected as the anode in order to provide a stable oxide film. For aluminum anodes, an electrolyte based on the borate anion, such as ammonium pentaborate, dissolved in an alcohol and/or water, such as ethylene glycol, is an excellent system. For tantalum, more active electrolytes can be used as tantalum is not as subject to corrosive action. Sulfuric acid, for example, may be used.
The seal 13 retains electrolyte within the cell. It consists of an insulating material such as glass, ceramic, plastic, or rubber. If a hermetic seal is desired, glass and ceramic are preferred, but must be chemically bonded to the metallic anode and cathode. More commonly, rubber--under compression--is used for the seal; it will permit the passage of low molecular weight gas, such as the hydrogen which is evolved on the surface of the cathode during the formation or anodizing process.
The gas pocket 14 is desirable as a cushion which can be compressed as additional gas is generated during the anodizing process. It is a feature of this invention that the pressure of this gas pocket should be less than that required to rupture the seal during the timing operation. At the time of sealing the timing cell, the gas may comprise air (nitrogen, oxygen, and carbon dioxide), or, preferably, an oxygen-free atmosphere to prevent pre-oxidation of the anode.
FIG. 2 shows a preferred embodiment of the timing cell of this invention (and one on which the examples following are based). In this figure 20 represents a wire of aluminum formed into a helical shape 25 to provide a substantial anode surface. Twenty-one is an aluminum can (cathode) which may be etched on its inside surface to increase the surface area, especially if the anode wire surface has been etched to increase its effective surface area.
The anodizing electrolyte 22 is contained in cathode can 21 by means of rubber seal 23. The gas pocket is shown as 24.
In order to achieve a seal free from the possibility of electrolyte 22 leakage, the rubber bung 23 is compressed around anode 20 through deformation of the can 21 into a bead or depression thereof, referred to as 26.
Referring to FIG. 3, 30 represents a D.C. power source, such as a battery connected to timing cell 32 at terminals 33 and 34 through a fixed resistor 35, which resistor although shown in the positive side of the circuit could be on the negative side. A sensing means 36 such as a C-MOS buffer/driver integrated circuit (RCA Type CD-4049B being typical) which can switch on or off at a particular voltage level appearing across timing cell 32. In the figure, lamp 36 will be ignited ("on") if the voltage across the cell 32, from voltage/current source 30, is 65% of source 30. If cell voltage exceeds 65% of source 30, lamp 38 is illuminated and lamp 37 is "off".
Alternately, the voltage sensing means 36 may simply be a lamp or preferably a volt meter providing a continuous indication of elapsed time.
FIG. 4 indicates the typical characteristics apropos resistance and capacitance of a cell of the invention (voltage characteristics being shown in the examples which follow). In this figure, cell resistance and capacitance values are shown on log scale against elapsed time on voltage. Typically, cell resistance which comprises the series resistance of the electrolyte and the dielectric oxide or other anodized film on the anode will increase by one, two, or more orders of magnitude as the source voltage level is approached.
Cell capacitance, normally very high on "virgin" or cleaned anode metal surfaces, decreases rapidly as the anode surface is formed or anodized. While the effect is most pronounced at low anodizing voltages, it is also significant at voltages of 500 volts and higher (in the case of aluminum anodes).
From FIG. 4, it will be evident that the reduction in capacitance and/or the increase in resistance of the timing cell may be employed to trigger or "switch" various electronic/electrical devices such as a Schmitt trigger circuit to indicate a predetermined "time elapsed" from the onset of current flow.
While in FIG. 3 a series and current-limiting resistor has been shown, the timing cells of the invention are not dependent thereon. If an extended timing period is desired, such as 100 hours, and the energy source is a low impedance, high capacity battery, a series resistor is desirable to permit small timing cells. However, if the energy source provides a low and essentially constant source of current (as for example a radioactive battery) the series resistor may be eliminated. Such a source, however, may be considered equivalent to a hard voltage source in series with a resistor.
In the following examples, two operating electrolytes were employed, prepared, and identified as follows:
A. Twenty grams of ammonium pentaborate dissolved in 80 grams of ethylene glycol at 71° C.
B. Thirty grams of ammonium formate dissolved in 150 grams of ethylene glycol at 70° C.
Resistivities of these electrolytes were 320 ohm cm. and 31 ohm cm. at 25° C, respectively, and 1200 and 81 ohm cm. at 2° C, respectively.
For the examples in which the anode was preanodized prior to assembly in other than the operating electrolyte, the formation electrolyte consisted of 20 gms. of ammonium dihydrogen phosphate dissolved in 200 gms. of water.
Except where otherwise indicated, the cathode consisted of a can drawn from aluminum alloy No. 3003 which was given a hot washing in a phosphate detergent followed by a deionized water rinse and drying before use. These cans have an inner diameter of 0.5 inch.
Anode materials used in the examples are identified as follows:
Wire: 0.062 inch diameter 99.99% purity aluminum wire, wound in a helical coil of 0.25 inch inner diameter.
Foil: 0.003 inch thick 99.99% purity aluminum foil 1 1/2 inches wide.
Met: 0.00035 inch thick polyethylene terephthalate film metallized with aluminum on one surface to a thickness corresponding to a resistance of 4 ohms per square.
The cell assembly consisted of dispensing electrolyte into the can, threading the lead portion of the anode through a tightly fitting hole provided therefor in a butyl rubber bung and compressing the open mouth of the can about the bung.
The power supply consisted of a 12 volt lead acid battery or a regulated low impedance D.C. power supply adjusted to a given output voltage corresponding to that of the lead acid battery; this voltage was 12.35 ± 0.15 volts.
The series resistors were fixed, stable film units with a resistance tolerance of 3% or better.
The performance data presented for each of the following experimental cells was accelerated by employing a relatively low value resistor in the series circuit. In most practical applications this resistor would have a value orders of magnitude greater. For a given cell and supply voltage a predetermined voltage level across the cell (e.g. 80% of the supply voltage) will be reached at an elapsed running time that is substantially proportional to the value of the resistor. Thus, the system is capable of indicating elapsed times of many thousands of hours if desired.
EXAMPLE 1
In this example, 20 inch long anodes were employed, utilizing operating electrolyte A and a can cathode. The anode of one cell was not preformed while the anode of another cell was preformed at 2.8 volts. The series resistor was 10,000 ohms in value. Cell voltages are given in Table I as a function of elapsed time.
Table I______________________________________Elapsed Time Control 2.8 VDC Pref-form(Minutes) (Volts) (Volts)______________________________________0.17 1.51 3.800.33 1.73 4.210.50 1.89 4.500.67 2.10 4.580.83 2.27 4.681.0 2.41 4.782.0 3.19 5.353.0 3.88 5.874.0 4.52 6.345.0 5.10 6.766.0 5.61 7.167.0 6.10 7.518.0 6.53 7.839.0 6.92 8.1410.0 7.28 8.41______________________________________
EXAMPLE 2
In this example for which data is given in Table II, 10 inch long coiled wire anodes were employed with electrolyte A and a cathode can, using a 147,000 ohm series resistor. The anodes were not preformed. The continuous unit was left on voltage at all times; the intermittent unit was subjected to voltage for ten minutes alternated with ten minutes of no voltage. Cell voltage readings are shown, indicating the lack of dependence on continuous exposure to voltage. "Off" periods of 24 hours or more appear to make no significant difference.
Table II______________________________________Elapsed Time Continuous Intermittent(Minutes) (Volts) (Volts)______________________________________10 3.14 3.1530 4.50 4.4950 5.42 5.4070 6.13 6.1390 6.69 6.72110 7.26 7.32130 7.74 7.82______________________________________
EXAMPLE 3
Cells of this example included a 10 inch long foil anode and electrolyte A. A 22,000 ohm resistor was employed.
Table III______________________________________ Elapsed Time in Minutes______________________________________Cell Voltage: 3.0 4.0 5.0 6.0 7.0 8.0 9.0Anode TreatmentNone 1.5 3.2 6.1 10.0 14.5 20.0 27.35% NaOH wash 2.9 4.5 6.7 9.2 12.0 16.9 23.0Electro-etched 3.1 6.0 9.6 14.7 21.5 29.7 40.5______________________________________
The above example demonstrates the substantial elimination of normal air formed surface oxide on the aluminum by caustic wash and the resulting "extra time" required for initial timing formation. Formation is more efficient, however, as evidenced by the acceleration in formation as the cell voltage approaches the power supply voltage.
The electro-etched anode was etched at a current of 200 milliamperes in a 10% solution of sodium chloride in water at 25° C for five minutes. The resulting increase in effective surface area in the timing cell substantially extended the time interval to reach different cell voltage levels.
EXAMPLE 4
In this example a 1 inch × 1 1/2 inches piece of metallized polyethylene terephthalate anode was placed in a beaker with electrolyte A and an aluminum foil cathode of comparable size, the anode and cathode being separated by approximately 0.25 inch The series resistor was 10,000 ohms. Performance data is shown in Table IV.
Table IV______________________________________Elapsed Time Cell Voltage(Minutes) (Volts)______________________________________ 0.17 2.351.0 4.652.0 6.483.0 7.834.0 8.835.0 9.576.0 10.127.0 10.548.0 10.859.0 11.0910.0 11.28______________________________________
EXAMPLE 5
In this example all anodes were 81/2 inches in length and prewashed in 1% NaOH in water at 80° C for 2 minutes, rinsed in deionized water, and dried before further treatment. The cathode can was as described earlier and the power supply was set at 12.35 VDC with a 10,000 ohm resistor in series with the timing cell.
The anodes indicated as "etched" were subjected to two minutes at 90° C in 18.8% strength hydrochloric acid, then rinsed and dried before assembly into the test cell. Table V gives the elapsed time in minutes to reach various cell voltages.
Table V______________________________________Anode Electrolyte 2.0 3.0 4.0 5.0 6.0 7.0Plain A 0.2 0.6 1.1 1.8 2.4 3.3Plain B 0.2 0.6 0.9 1.1 1.7 2.2Etched A 2.8 6.5 10.5 15.6 21.5 29.4Etched B 3.9 6.1 9.3 13.1 17.6 23.1______________________________________ | An elapsed time indicator includes an electrolytic timing cell in series connection with a resistor, which series circuit may be connected to a D.C. voltage. The cell is comprised of an aluminum can containing a liquid electrolyte with an aluminum anode immersed therein. During operation an aluminum oxide film is grown on the surfaces of the anode, the film thickness and resistance increasing with time. The voltage dropped across the cell of any instant is employed as an indication of the accumulated elapsed time during which the D.C. voltage has been connected to the circuit. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a mechanism in a magnetic recording/reproducing apparatus and, more particularly, to a mechanism for switching the mode of operations suitable for use in a magnetic producing/reproducing apparatus such as represented by a video cassette recorder.
In a magnetic recording/reproducing apparatus, it is necessary to switch the mode of various operations such as recording or reproducing mode, fast forward winding mode, etc. In response to the operation of selecting the switching to the desired mode of operation, a mechanism which as a tape withdrawing guide mechanism, a tape driving mechanism or a braking mechanism is actuated, and, U.S. Pat. No. 4,408,236 proposes utilizing a single power source from which the selected mechanism is commonly driven.
In such a proposed driving mechanism for selecting the mode of operations, the driving force is transmitted from a single power source to a selected driven member such as the brake, the driving roller through several members such as sliders and arms. Thus, it is necessary to assemble the respective power transmitting members so that they can be operated in timed relationship to each other in their operational phases, thereby causing difficult problems in assembling the same.
SUMMARY OF THE INVENTION
An object of the present invention is, therefore, to provide a mechanism for switching the mode of operations suitable for use in a magnetic recording/reproducing apparatus which is easy to assemble and accurate in operation, while it can be effectively made compact.
In order to achieve the above object, the present invention is constructed by driven members which are driven in response to the selected mode of operations, a ring-shaped operating cam formed with a plurality of cam portions corresponding to the respective driven members, and driving means driven by a single power source for rotating the ring-shaped operating cam. Position detecting means is provided in the ring-shaped operating cam for detecting the rotational position corresponding to each mode of operation so as to control the rotational position.
In the present invention, means may further be coupled with the above described single power source for commonly driving a tape loading mechanism to form a predetermined feeding passage of a magnetic tape which is withdrawn from a cassette.
According to the characteristic feature of the present invention, since each of the plurality of driven members is driven directly by a single ring-shaped operating cam in response to a selected mode of operation, the relative positioning of the respective driven members with respect to the ring-shaped operating cam is facilitated when the same is assembled. Further, the entire construction can be formed in the circular shape, while it is easy to make the size of the entire apparatus compact, because the plurality driven members can be actuated by the single ring-shaped operating cam.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing the main portions of a first embodiment of a video cassette tape recorder of the present invention;
FIG. 2 is an exploded perspective view showing the relative arrangement of a ring-shaped operating cam for switching the mode of operations, a driving ring for driving the same and a loading ring for the tape loading with respect to a chassis of the apparatus for the easy understanding of the arrangement;
FIG. 3 shows the rear side of the apparatus shown in FIG. 1;
FIG. 4 is a sectional view showing the arrangement of a motor for rotating the driving ring and the driving ring;
FIG. 5 is a sectional view showing the mechanism of power transmission gears for transmitting the rotation of the driving ring to the loading ring;
FIGS. 6A and 6B are a plan view and a side view, respectively, showing an example of a power transmission gear;
FIG. 7 is a fragmentary plan view showing the mechanism of the driving ring and the power transmission gears;
FIG. 8 is a fragmentary plan view showing the loading ring and the rotary head device;
FIGS. 9A and 9B are a plan view and a side view, respectively, showing the mechanism of a moving tape guide and a pinch roller lever portion;
FIGS. 10 and 11 show the arrangement of a guide roller on the loading ring with a portion in cross-section, FIG. 10 showing the loading operation in its intermediate state, while FIG. 11 shows the state at the end of the loading operation;
FIG. 12 shows an example of the construction of a catcher of the guide roller;
FIG. 13 shows a receiving plate secured to the guide roller engaging with the catcher; and
FIG. 14 is a fragmentary plan view showing the state of the driving ring and the power transmission gear immediately before the termination of the loading operation thereof; and
FIGS. 14A and 14B are sectional views taken along the lines XIVA--XIVA and VXB--VXB in FIG. 14, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 shows an embodiment of the mechanism for switching the mode of operations according to the present invention which is applied to a video tape recorder and, in particular, FIG. 1 illustrates the arrangement of various components such as reel supports for engaging with reels of the cassette tape, a rotary head device and a tape driving mechanism.
When the magnetic recording/reproducing apparatus is operated, a cassette 100 housing therein reels 102, 103 with a tape 53 wound thereon is loaded on the apparatus as shown by the two dot chain line in FIG. 1. FIG. 1 shows the apparatus in the standstill position before the tape 53 is withdrawn from the cassette. Main portions such as a cylindrical head drum 2 constituting the rotary head device, a capstan 3 for feeding the tape at a constant speed, reel supports 4, 5 with which the reels 102, 103 engage, respectively, a loading ring 6 and a pinch roller 57 are arranged on a disc-shaped chassis 1 as shown in FIG. 1.
The loading ring 6 is freely rotatably supported on the chassis 1 by three holding rollers 10, 11, 12 adapted to shiftably contact with the inner periphery thereof. Guide rollers 8, 9 are arranged on the loading ring 6 for drawing the tape out of the cassette cartridge and winding the same around the head drum 2 by a predetermined angle. The reel supports 4, 5 are freely rotatably supported on shafts 4-a, 5-a rigidly mounted on the chassis 1, respectively. A main brake 18 and sub-brakes 19, 20 are arranged near the outer periphery each of the reel supports 4, 5 for simultaneously controlling the two reel supports. These brakes are constituted by brake arms 18b-18e, 19b, 20b and brake shoes 18f, 18g, 19c, 20c which are rotatably mounted so as to be rotated about pins 14, 15, 16, 17 rigidly mounted on the chassis, respectively. An arm 25 mounting thereon an idler gear 24 and an intermediate gear 26 is freely rotatably supported between the reel supports 4, 5 so as to be rotated about a shaft 25b. The idler gear 24 is selectively meshed with either one of the reel supports 4, 5 so that the rotational driving force of a capstan motor (refer to FIG. 3) is transmitted to the reel support 4 or 5. A band brake 22 having one end thereof securely engaged with a pin 21 on the chassis is wound around the outer periphery of the supply side reel support 5 by a predetermined angle, and the other end of the band brake 22 is rotatably engaged with a pin on a tension arm 23.
FIG. 2 is an exploded perspective view showing the relationship of the mounting of the loading ring 6, a driving ring 27 and an operating ring 64. The loading ring 6 is formed entire outer periphery with gear teeth 6g and is arranged on the upper surface of the chassis 1. The driving ring 27 is formed in an inner peripheral portion thereof with gear teeth 27g, and is supported in contact with the lower surface of the chassis 1. The operating ring 64 is rotatably supported in the chassis 1 by holders 37 at a position further remote from the chassis 1 with respect to the driving ring 27. A plurality of cam surfaces 64a-64f are formed in the inner and outer peripheral surfaces of the operating ring 64 for operating the driven members. A groove 64' of a predetermined length is formed in the operating ring 64, and one end of the groove 64' is adapted to engage with a stationary pin 71 secured to the driving ring 27.
As shown in FIG. 3, the outer peripheral edge of the chassis 1 is formed with a peripheral wall extending in the direction toward the rear side as shown in FIG. 2 so that it provides a guard for the driving ring 27, the operating ring 64 along the entire periphery of the chassis 1. A flywheel 28 secured to an extension of the capstan 3 serves also as a rotor of a direct drive motor of the flat-type for driving the capstan 3. A driving force transmission belt 30 extends around a driving pulley 21a compressively fitted with the capstan 3 coaxilly with the flywheel 28 and an intermediate pulley 29 for transmitting the driving force of the reel supports to the idler gear 24. Power transmission gear 31 and a driving gear 66 mesh with gear teeth 27g formed in the inner periphery of the driving ring 27. Pins 19a, 20a, 58a, and 18a for actuating the sub-brakes 19, 20 arranged on the chassis, a pinch roller arm 58 and the main brake 18, respectively, extend through openings 1a-1d in the chassis to abut against the cam surfaces 64a-64f formed in the inner and outer periphery of the operating ring 64.
FIG. 4 illustrates the positional relationship of the mounting of the driving motor 65, the driving gear 66, the driving ring 27 and the operating ring 64. A worm gear 67 is attached to the tip of the driving shaft of the driving motor 65, and it meshes with one of the two gear portions formed on the driving gear 66, and the other gear portion of the driving gear 66 meshes with gear toothed surface of the driving ring 27. Thus, the driving ring 27 is rotated by the rotation of the driving motor 65 through the driving gear 66.
FIG. 5 shows a first transmission gear 31, a second transmission gear 38 and a third transmission gear 39 for transmitting the driving force of the driving ring 27 to the loading ring 6. As shown in FIG. 1, the third transmission gear 39 meshes with the loading ring 6 on the upper surface of the chassis 1, and is secured by a set screw 42 to one end of a shaft 41 fitted in a bearing 40 which is in turn secured to the chassis 1. The second transmission gear 38 is compressively fitted with the other end of the shaft 41 and the third transmission gear 39 on the upper surface of the chassis and the second transmission gear 38 on the lower surface of the chassis rotate in synchronism with each other.
As shown in FIGS. 6A and 6B, the first transmission gear 31 is formed with gear teeth along the entire outer periphery thereof and is constructed as a composite gear wherein a transmission gear 31a meshing with the driving gear 27 and the second transmission gear 38 is integrally secured by pins 43, 44 to a transmission gear 31b having a single tooth on the outer periphery with the remaining outer periphery being formed as a concentrical cylindrical surface of the same diameter as the dedendum circle of the transmission gear 31a. The first transmission gear 31 is rotatably supported by a shaft 46 secured to a boss 45 which is, in turn, secured to the chassis 1. In FIG. 6B, the single tooth of the transmission gear 31b located at the lower position is aligned with one of the teeth of the upper transmission gear 31a.
As shown in FIG. 7, the rotation of the driving ring 27 in the direction of the arrow A is transmitted to the loading ring 6 by the above described transmitting mechanism and it is converted into the rotation in the direction of the arrow B shown in FIG. 8. As shown in FIG. 8, the guide roller 8 on the loading ring 6 at the inlet side serves to wind the magnetic tape 53 around the inlet side of the head drum 2. A central shaft of the guide roller 9 is secured to the upper surface of the loading ring 6 so that the guide roller 9 acts as a tape guide at the inlet side of the head drum 2.
FIGS. 9A and 9B show the relationship of the driving system for the loading ring 6 and the pinch roller 57. In FIG. 9A, a portion of each of a guide arm 56 and a pinch roller arm 58 is shown as being broken away so as to show the arrangement of the parts beneath the broken-away portions. As shown in FIG. 9A the loading ring 6 is rotated in the direction of the arrow B, with the rotation being converted into the rotation of each of the intermediate gear 61 and the arm operating gear 60 in the directions as shown by the arrows in the figure, respectively. An arm operating pin 60a on the gear 60 urges a torsion spring 59 in the direction shown by the arrow FIG. 9A. In this case, the resilient force of the torsion spring 59 caused by the distorsion thereof acts to urge the guide arm 56 in the direction of the arrow C through one end 59a of the torsion spring 59. By virtue of this urging action, the guide arm 56 and a guide roller 55 and a winding pin 63 mounted on the guide arm 56 are rotated in the direction of the arrow C.
A projection 56a provided on the edge portion of the guide arm 56 acts to rotate the pinch roller arm 58 by the rotation of the guide arm 56 simultaneously therewith in the direction of the arrow C, so that the pinch roller 57 freely rotatably supported on the pinch roller arm 58 is also rotated in the direction of the arrow C.
By the operation of the apparatus as described above, the tape 53 is wound onto the head drum 2 at the outlet side. The movement each of the above described guide rollers 8, 9 and 55 continues until the guide rollers 8 and 55 reach catchers 13 and 54 shown in FIGS. 8 and 9A, respectively.
FIG. 10 is a sectional view showing the positional relationship between the inlet side guide roller 8 and the loading ring 6 during the movement thereof. The lower end of the central shaft of the guide roller 8 is formed with a threaded portion which is threadedly engaged with the threaded portion formed in a hole of a boss 48 is slidably engaged in an elongated hole 6-a formed in the loading ring 6. The securing of the guide roller 8 to the boss 48 is effected by a set screw 49 provided at the side of the boss 48. A flange is formed at the lower portion of the boss 48 thereby forming removal preventing means for the boss 48 from being moved out of the elongated hole 6a. A positioning plate 50 is press fitted onto the outer peripheral surface of the boss 48.
FIG. 13 is a perspective view schematically showing the configuration of the positioning plate 50. A pin 50a is provided at the rear portion of the positioning plate 50. The pin 50-a is adapted to receive a compression spring 51 as shown in FIG. 10 and it is coupled with a projection on the loading ring 6.
FIG. 11 shows the state of the guide roller 8 shown in FIG. 10 wherein it is moved to cause its boss 48 to abut a catcher 13.
FIG. 12 is a perspective view showing the construction of the catcher 13. V-shaped bearing surfaces are formed at the upper and lower side portions of the catcher 13, respectively, which engage with the cylindrical portion of the boss 48 so as to position the guide roller 8 on the plane of the chassis. An inclined surface 13b having a predetermined inclination angle with respect to the direction of advance of the loading ring 6 is formed at the lower side of the upper bearing surface of the catcher 13 and is adapted to compressingly engage with an inclined surface 50b formed in the front side of the positioning plate 50.
With the construction described above, a predetermined compressing force is generated between the boss 48 of the guide roller 8 and the V-shaped positioning surfaces of the catcher 13 by virtue of the fact that the compression spring 51 is compressed by a predetermined amount after the guide roller 8 commences contact with the catcher 13. The above described construction of the compressingly contacting portions may be applied to the case of the guide roller 55 at the outlet side and another catcher 54. In other words, another positioning plate 50c having an inclined surface 50d at the front side thereof is provided at the lower side of the guide roller 55 above the guide arm 56 as shown in FIGS. 9A, 9B. In this case, however, the outlet side guide roller 55 is compressingly contacted with the catcher 54 by the resilient compressing force of the torsion spring 59 instead of the compression spring 51.
The timed relationship between the compressing contacts of the guide rollers 8, 55 with the respective catchers 13, 54 is set to be synchronized with each other by adjusting the operating phases of the loading ring 6 and the meshing of the intermittent gear 61 with the arm operating gear 60. The operation of the driving ring 27 when these guide rollers 8, 55 are compressingly contacted with the respective catchers by the predetermined forces, respectively, will be described below.
FIG. 14 shows the positional relationship between the driving ring 27 and the first transmission gear 31 at the time point when the amount of compression of the compression spring 51 reaches a predetermined amount. The half of the thickness of the inner periphery of the driving ring 27 adjacent the chassis 1 is relieved from the toothed surface of the transmission gear 31a, as shown in FIG. 14B. This relieved portion begins at an end B of the toothed portion 27g and extends circumferentially away therefrom, so that no meshing engagement will take place between the relieved portions and gear 31a. Thus, only the single tooth surface of the transmission gear 31b will mesh with the last gear tooth of the toothed surface of the driving ring 27. When the driving ring 27 is further rotated in the direction of the arrow A beyond the above described state of the meshing engagement, the single tooth of the gear 31b is forcibly engaged with that part of the inner peripheral surface of the driving ring 27 which is adjacent to the end B of the toothed surface of the driving ring 27. Thereafter, no further transmission of the torque takes place from the driving ring 27 to the gear 31. The timing of this pushed-in position is set to be synchronized with the timing at which the predetermined compressing contact force is generated between the guide rollers 8, 55 and the catchers 13 and 54 by adjusting the relationship between the operational phases of the gears.
As described above, the pin 71 secured onto the driving ring 27 will move in the groove 64' in the operating ring 64 in the direction of the arrow A shown in FIG. 3 by virtue of the fact that the driving ring 27 is driven in the direction of the arrow A in FIG. 3 during the actuation of the loading ring. During the time when the pin 71 is moving, the operating ring 64 is maintained in its standstill state by the tension of a tension spring 69. When the operation of the loading ring terminates, the pin 71 on the driving ring 27 reaches the point 71' at the end of the groove 64' of the operating ring 64. When the driving ring 27 is further rotated in the direction of the arrow A beyond the condition of completion of the loading operation described above, the operating ring 64 is rotated in the direction of the arrow A by means of the pin 71 against the action of the tension spring 69. By the above described rotation of the operating ring 64, the cam surfaces 64a-64f are moved so that the apparatus can be operated in response to the selected mode of operation thereof.
In FIG. 3, a slide switch 68 is secured to the interior of the outer peripheral edge of the chassis 1, and the actuating portion of the switch 68 engages with a pin 72 provided on the operating ring 64 so that the mode of operation is detected according to the respective rotational angle of the operating ring 64. The cam surfaces 64a-64f formed independently from each other in the inner and outer peripheral surfaces of the operating ring 64 rotate also in response to the actuation of the driving ring 27. Thus, these cam surfaces will selectively urge the operating pins 18a, 19a, 20a, 58a, 25a of the main brake 18, the subbrakes 19, 20, the pinch roller lever 58 and the idler arm 25, respectively, which abut against these cam surfaces through the openings 1a-1d, respectively, so that these driven members are rendered to be operated in the well known manner in response to the selected mode of operation. This is achieved by virtue of the provision of the cam surfaces 64a-64f which are configured so as to correspond to the modes of operations detected by the above described slide switch 68. Further various operations such as the recording/reproducing, the fast feeding and the rewinding are effected by electrically controlling the head drum 2, the capstan 3 for selectively rotating them in response to the mode of operation detected by the slide switch 68. | A magnetic recording/reproducing apparatus for recording onto or reproducing from a magnetic tape housed in a cassette by using a rotary magnetic head having a tape withdrawal arrangement for winding a portion of the tape between the two reels in the cassette around the rotary magnetic head by a predetermined angle. A tape drive feed the magnetic tape at a constant speed, with a reel drive being provided for driving either one of the two reels so as to take up the magnetic tape in the reel driven by the reel drive, and with brake arrangement for braking the rotation of the reels. A ring-shaped cam operating member is provided in the outer peripheral surface or the inner peripheral surface thereof with cam surfaces each for effecting the operation of the respective elements in response to the mode of operation of the magnetic recording/reproducing apparatus. The selective operation is specifically determined by the rotational position of the ring-shaped cam operating member, and the rotational position is varied in response to the mode of operation. A detector is provided for detecting the rotational positions in the ring-shaped cam operating member. | 6 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The invention relates to apparatus for intravascular imaging structures and in particular to mechanical guided directional coronary atherectomy catheters.
2. Description Of The Related Art
Ultrasonic imaging catheters, such as the one set forth in U.S. Pat. 5,193,546, which is incorporated herein by reference, are well known and have been developed to provide cross-sectional structural images of blood vessels and their lumens such as arteries in the vicinity of the heart. Operation of mechanically driven types of imaging catheters involves the insertion of a protective sheath which surrounds a long thin rotatable cable assembly with a transducer subassembly attached to its distal end into the blood vessel of interest. This complete assembly is the imaging catheter. The operator positions the contained transducer subassembly at a location within the blood vessel near the structures to be imaged as is illustrated in the aforementioned patent.
Ultrasonic images of the inside of the blood vessel are formed by using a sonar-like technique. In such assemblies, the transducer subassembly includes a transducer element rotatably mounted within the subassembly, generating a series of pulses which are transmitted outward from the transducer as the transducer is moved through 360° of rotation. The transmitted and echo ultrasonic pulses are substantially able to pass through the material of the sheath. Echo pulses reflected from structures inside the blood vessel lumen and the wall are received between transmitted pulses by the transducer and collected by control apparatus coupled with the rotating transducer and cable assembly within the sheath and displayed as a cross-sectional ultrasonic image of the inside of the blood vessel as set forth in U.S. Pat. 4,917,097, which is incorporated herein by reference.
A directional atherectomy catheter, such as is set forth in U.S. Pat. 4,794,931, which is incorporated herein by reference, is structurally similar to the imaging catheter. A cylindrical cutter is attached to the distal end of a long thin rotatable cable assembly which is contained within a sheath. Attached to the distal end of the sheath is a metallic cylindrical housing which surrounds and contains the cutter. The housing has a cut-out section, hereinafter referred to as the window, which exposes a cutting edge of the contained cutter. Opposite the window, a balloon is mounted on the housing. In use, a physician or operator uses fluoroscopy to position and direct the housing window toward an atheroma blocking blood flow in the lumen of the blood vessel. The balloon is inflated to press the housing window against the atheroma. The cutter is mechanically rotated via the long thin cable assembly and advanced distally through the housing to cut any atheroma pressed inside the housing window and pushes the cut atheroma, for storage, into a nosecone mounted on the distal end of the housing. An atherectomy procedure may require many cuts, controlled balloon inflations/deflations and positionings of the housing and window to remove and collect the desired amount of atheroma.
Guided directional atherectomy adds a transducer in, or near, the cutter to give the directional atherectomy catheter the ability to ultrasonically image the blood vessel. The ability to image the blood vessel allows a more precise and efficient catheter positioning and cutting of the atheroma. The housing is generally constructed of a metallic material which will not substantially pass ultrasonic pulses. Therefore, the guided directional atherectomy catheter may only be used to image through the housing window. Generally, the window is cut in the housing surface at an angle of approximately 120° with respect to a center axis of the housing. Therefore, only a 120° section image view of the blood vessel adjacent to the housing window is obtained.
In a mechanically operated imaging or guided directional atherectomy catheter assembly, the transducer and cutter are located at the distal end of a long thin cable assembly generally comprised of a duplex spring assembly surrounding a coaxial cable extended through the sheath and connected at the proximal end to the control apparatus. The control apparatus rotates the proximal end of the cable assembly at a constant rate, typically 1800 RPM, and causes the transducer to generate an ultrasonic pulse at regular intervals, for example, approximately every 1.4° of rotation of the proximal end of the cable assembly. Thus, in the guided directional atherectomy catheter, approximately 85 transmit/receive cycles are generated as the transducer is transmitting pulses out of the housing window to create the 120° section image view of the blood vessel adjacent the housing window. The control apparatus operator can rotate the 120° housing window to view the entire inner surface of the blood vessel and move the transducer and cutter distally through the area of the housing window so as to remove the atheroma forced through the window by the catheter balloon.
A problem occurs in that the operator located at the proximal end of the catheter cable assembly is unaware of the precise position of the transducer and cutter within the catheter housing at the distal end of the cable assembly. Without the operator's knowledge, the transducer and cutter may be located at the rear, middle or front of the window area.
Accordingly, a need exists in the art for a guided directional coronary atherectomy catheter for use in determining the location and direction of travel of the to transducer and cutter in the window area of the distal ultrasound imaging catheter apparatus.
SUMMARY OF THE INVENTION
The foregoing problem and others that will be appreciated by those skilled in the art are solved by a guided directional coronary atherectomy ultrasound catheter apparatus having encoder structure formed thereon for indicating linear movement and travel direction of a transducer and cutter subassembly along a linear axis of the catheter apparatus.
It is an object of the invention to provide a guided directional coronary atherectomy ultrasound catheter having a housing mounting a rotating transducer and cutter subassembly positioned in a window formed in a housing surface for imaging a blood vessel and for removing a portion of a blood vessel atheroma. The catheter has a spiral encoder structure formed in the housing adjacent an area of the window for returning at least one echo pulse in response to transducer transmitted pulses at angles of rotation of the transducer and cutter subassembly defining linear movement and travel direction of the transducer and cutter subassembly along a rotational axis of the subassembly through the housing window area.
It is a further object of the invention to provide a guided directional coronary atherectomy ultrasound catheter, wherein the ultrasound catheter encoder spiral structure is formed as a plurality of indentations on the catheter housing and in an area adjacent the housing window at locations corresponding to angles of revolution of the catheter rotating transducer and cutter subassembly within the housing. The indentations are configured and positioned to return transducer pulse echoes defining the linear movement of the rotating transducer and cutter subassembly within the housing window along the rotational axis of the transducer and cutter subassembly.
It is a further object of the invention to provide a guided directional coronary atherectomy ultrasound catheter, wherein the ultrasound catheter encoder spiral structure is formed as a plurality of holes in the housing adjacent the housing window with each hole spaced apart from an adjacent hole. Each hole is positioned to define a predetermined angle of rotation of the transducer and cutter assembly and the plurality of holes defines linear movement and travel direction of the rotating transducer and cutter subassembly within the housing window along the rotational axis of the transducer and cutter subassembly.
It is yet another object of the invention to provide a guided directional coronary atherectomy ultrasound catheter, wherein the ultrasound catheter encoder spiral structure is formed as a channel in the housing adjacent the housing window and wherein the channel is configured to return echo pulses defining predetermined angles of rotation of the transducer and cutter subassembly in response to transducer transmitted pulses. The predefined angles each define a predetermined position of the rotating transducer and cutter subassembly within the housing window along the rotational axis of the transducer and cutter subassembly. When considered collectively, the predetermined angles provide an indication of the travel direction of the transducer and cutter subassembly.
In accordance with principles of the invention a guided directional coronary atherectomy ultrasound catheter for use with control Imaging apparatus comprises a transducer and cutter subassembly connected to a distal end of a cable used to couple the subassembly to the control imaging apparatus located at the proximal end of the cable. The transducer and cutter subassembly images an inside wall of the blood vessel and is controlled by an operator located at the control apparatus to remove a portion of an atheroma that may be blocking a flow of blood within the blood vessel.
A housing generally constructed of a material such as stainless steel is attached to the distal end of the cable for mounting the subassembly therein. The housing is configured to enable the control imaging apparatus by rotating and moving the cable to spin the subassembly about a rotational axis of the subassembly and to linearly move the subassembly along the subassembly rotational axis.
A window formed in a surface of the housing enables the transducer of the subassembly to transmit ultrasonic pulses under control of the control imaging apparatus toward the blood vessel wall.
Echo pulses returned from the blood vessel wall are received by the transducer and sent to the control imaging apparatus for imaging the blood vessel wall. The window may be rotated by means of the cable to provide a 360° view of the blood vessel wall and may be positioned to receive a portion of the atheroma to enable a cutter of the subassembly to remove the atheroma portion extending through the window.
An encoder structure formed in the housing adjacent an area of the window indicates linear movement of the transducer and cutter subassembly along the subassembly axis through the housing window area to the control imaging apparatus. The encoder is a spiral structure formed about the housing to extend from one end of the housing window to an opposite end thereof. The structure is configured to return at least one echo pulse in response to the transducer transmitted pulses to define at least one corresponding angle of revolution and linear movement of the transducer and cutter subassembly along the subassembly rotation axis.
In a first embodiment of the invention the encoder comprises a plurality of spiral indentations formed on the housing to have a depth so as to return a transducer pulse echo differing in time with respect to a transducer pulse echo returned from a wall of the housing. In another embodiment of the invention, the encoder may be a spiral conduit formed on the housing to have a depth so as to return a transducer pulse echo differing in time with respect to a transducer pulse echo returned from the housing wall. In other embodiments of the invention, the encoder may be formed as a spiral channel or a plurality of spiral holes in the housing with each hole spaced apart from an adjacent hole and positioned to define a predetermined angle of rotation of the subassembly and linear movement of the subassembly within the window area.
Another embodiment of the present invention is a catheter for use in a biological conduit, comprising:
a housing having an open window area;
a work element movably disposed within the housing, the work element having an imaging transducer mounted therein, the work element being attached to a distal end of a cable coupling the imaging transducer to an imaging apparatus; and
a linear encoder formed in a spiral configuration in an area of the housing other than the open window area.
When transducer signals emitted in a direction of the encoder are returned to the transducer as encoder signal echoes, the encoder signal echoes are uniquely identifiable by the imaging apparatus, and provide an indicia of linear position and travel direction of the work element within the housing.
The linear encoder may be a plurality of equally spaced holes disposed in a spiral configuration, a spiral groove, a plurality of equally spaced indentations disposed in a spiral configuration, or a plurality of equally spaced protuberances disposed in a spiral configuration. From these encoder signal echoes, the imaging apparatus may generate a graphical representation of a position and travel direction of the work element within the housing in real time, by calculating an angle between the edges of the encoder signal echoes and an edge of the window area.
BRIEF DESCRIPTION OF THE DRAWING
For a further understanding of the objects and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawing, in which like parts are given like reference numerals and wherein:
FIG. 1 is a view of mechanical guided directional coronary atherectomy catheter encoder apparatus in accordance with principles of the invention connected to control apparatus,
FIG. 2 illustrates another embodiment of the mechanical guided directional coronary atherectomy catheter apparatus of FIG. 1 in accordance with principles of the invention, and
FIGS. 3 and 4 set forth a partial configuration of the directional coronary atherectomy catheter housing in the area of the window incorporating encoder structure of the invention.
FIG. 5 shows a perspective view of the housing of an atherectomy catheter incorporating the encoder structure according to the present invention.
FIG. 6 depicts an end view of the housing of an atherectomy catheter according to the present invention, showing the relative positions of the holes of one embodiment of the encoder structure according to the present invention.
FIG. 7 schematically shows an ultrasonic image through 360 degrees of rotation of a conventional ultrasonic imaging atherectomy catheter.
FIG. 8a shows an ultrasonic image produced with the catheter according to the present invention, showing the ultrasonic transducer sweeping past one hole of an embodiment of the encoder structure according to the present invention.
FIG. 8b is a computer generated graphical representation of an atherectomy catheter, and shows the transducer and cutter apparatus in a position corresponding to the hole illustrated in FIG. 8a.
FIG. 9a shows an ultrasonic image produced with the catheter according to the present invention, showing the ultrasonic transducer sweeping past another hole of an embodiment of the encoder structure according to the present invention.
FIG. 9b is a computer generated graphical representation of an atherectomy catheter, and shows the transducer and cutter apparatus in a position corresponding to the hole illustrated in FIG. 9a.
FIG. 10a shows an ultrasonic image produced with the catheter according to the present invention, showing the ultrasonic transducer sweeping past yet another hole of an embodiment of the encoder structure according to the present invention.
FIG. 10b is a computer generated graphical representation of an atherectomy catheter, and shows the transducer and cutter apparatus in a position corresponding to the hole illustrated in FIG. 10a.
DETAILED DESCRIPTION
Guided directional coronary atherectomy ultrasound catheters shown generally by the numerals 10 and 20, set forth in FIGS. 1 and 2 respectively of the drawing, are used with control imaging apparatus 30 to provide cross-sectional structural images of blood vessel 50 and to remove atheromas 500 that may be present therein, blocking the flow of blood in the blood vessel 50 and their lumens such as arteries in the vicinity of the heart. In operation a sheath, not shown, is generally inserted into the brachial or femoral artery of a patient and advanced in a well known manner through the arterial tree towards the heart. The catheters 10, 20, connected to a distal end of a cable assembly, hereinafter referred to as the cables 103, 203, are inserted into the proximal end of the sheath and guided through the arterial tree by fluoroscopy to a position in the blood vessel 50 determined by the attending physician or system operator located at the control imaging apparatus 30.
The Catheters 10, 20 each have a subassembly with a cylindrical cutter 101, 201, and a transducer 102, 202 attached to the distal end of the cables 103, 203, respectively, for imaging an inside wall of the blood vessel 50 and for enabling an operator, located at the control imaging apparatus 30 connected to the proximal end of the cables 103, 203, to remove a portion of the atheroma 500 blocking a flow of blood within the blood vessel 50. The transducers 102, 202, located within and on the surface of the cutters 101, 201, respectively, provide the guided directional atherectomy catheters 10, 20 the ability to ultrasonically image the inside wall of the blood vessel 50 and thereby allow a more precise and efficient positioning of the cutters 101, 201 and cutting of the atheroma 500.
Ultrasonic images of the inside wall of the blood vessel 50 are formed by using a sonar like technique. The transducers 102, 202 generate a series of ultrasonic pulses which are transmitted outward from the transducers 102, 202 as the transducers 102, 202 are moved through 360° of rotation. Echo pulses reflected from the wall of the blood vessel 50 and the atheroma 500 are received between transmitted pulses by the transducers 102, 202 and collected by the control imaging apparatus 30 to be displayed as a cross-sectional ultrasonic image of the blood vessel 50.
Attached to the distal end of the cables 103, 203 are cylindrical housings 100, 200 mounting the transducer 102, 202 and the cutter 101, 201 subassemblies. The housings 100, 200 are formed of a metallic material such as stainless steel and are configured for enabling the control imaging apparatus 30 to rotate the subassemblies about a rotational axis of the subassemblies and to linearly move the subassemblies along the subassembly rotational axis. Since the transducer emitted ultrasonic pulses do not pass through the wall of the metallic housings 100, 200, cut-out sections, hereinafter referred to as the windows 106, 206, are formed in the housing walls to expose the transducers 102, 202 and the cutters 101, 201 of the subassemblies rotatably and linearly mounted in the housings 100, 200. Typically, the housing windows 106, 206 are formed in the surface of the housings 100, 200 at an approximately 120° angle with respect to the housing's center axis. Therefore, only a 120° section image view of the wall of the blood vessel 50 is normally visible through the windows 106, 206. However, catheter interface unit 304, may be operated by the attending physician to rotate the housing windows 106, 206 to obtain a 360° cross-sectional view of the blood vessel 50. In use, the physician uses fluoroscopy to position and direct the catheters 10, 20 toward an atheroma 500 which is blocking blood flow in the blood vessel 50. A balloon, such as the balloons 107, 207 mounted on the bottom of the housings 100, 200, is inflated by the physician using a balloon port of the catheter interface unit 304 coupled with the proximal end of the cables 103, 203 to press the housing windows 106, 206 against the atheroma 500.
The catheter transducer and cutter subassemblies, mechanically rotated by the long thin cable assemblies 103, 203 attached to a motor located in proximal patient interface unit 303, are advanced by operation of the proximal catheter interface unit 304 linearly along the rotation axis of the subassemblies through a window area of the distal housings 100, 200. Rotation of the distal cutters 101, 201 cuts off the portion of the atheroma 500 pressed inside the housing windows 106, 206 and pushes the cut atheroma, for storage, into the nosecones 105, 205 which are mounted on the distal ends 104, 204 of the housings 100, 200. This procedure, referred to as an atherectomy procedure, may require many cuts, controlled balloon inflations/deflations and positionings of the housing and window to remove and collect the desired amount of the atheroma 500.
In an exemplary embodiment, the control imaging apparatus 30, FIG. 1, comprises a processing system such as the well known HP Sonos 100 Imaging System. It will be appreciated that other systems which are equivalent thereto are within the spirit and scope of this invention. Such processing systems are well known and need not be described in detail for an understanding of the invention. In general, the control imaging apparatus 30 has a central processing unit 300 coupled via a patient interface unit 303 and a catheter interface unit 304 to the proximal end of the cable assemblies 103, 203. A data input device such as a keyboard 301 or other type of data input device, is connected with a central processing unit 300 so that data such as words, numerals and control information may be exchanged with the central processor unit 300.
The patient Interface unit 303 has a motor or other type of apparatus for rotating the catheters 10, 20 via the cables 103, 203 and circuitry which generates an index pulse at predetermined degrees of rotation of the proximal end of the cable assemblies 103, 203 for enabling the distal transducers 102, 103 to generate an ultrasonic transmit pulse. The control imaging apparatus 30 may also have a video, CRT monitor, a display terminal 302 or printer device to display an image of the inside of the blood vessel 50 and the atheroma 500 from image echo pulses received from the distal catheter transducers 102, 202.
In operation, programs controlling operation of the catheters 10, 20 and the control apparatus 30 are stored in a program memory of the central processing unit 300 to control operation of the catheters 10, 20.
In the mechanically operated guided directional atherectomy catheters 10, 20, the transducers 102, 202 are located at the distal end of the long thin cables 103, 203 generally comprised of a duplex spring assembly surrounding a coaxial cable and connected at the proximal end via catheter and the patient interface units 304, 303 to the control imaging apparatus 30. The patient interface unit 303, under control of the control imaging apparatus 30, rotates the proximal end of the cables 103, 203, at a constant rate, typically 1800 RPM, to spin the catheter transducer 102, 202 and the cutter 101, 201 subassemblies. The spinning transducers 102, 202, transmit ultrasonic pulses out of the 120° housing window to create a section image view of the blood vessel 50 and the atheroma 500 adjacent to the housing windows 106, 206. The control apparatus operator can rotate the 120° housing window by using the catheter interface unit 304 to view the entire inner wall of the blood vessel 50 and move the rotating transducers 102, 202 and the cutters 101, 201 linearly along the rotational axis of the spinning subassemblies distally through the area of the housing windows 106, 206 so as to remove the portion of the atheroma 500 forced through the window by inflation of the catheter balloons 107, 207.
The housings 100, 200 are provided with encoder structures 108, 208 formed adjacent the windows 106, 206 for indicating distal movement of the transducers 102, 202 and the cutter 101, 201 subassemblies along a linear axis of the housings 100, 200 through the area of the windows 106, 206. Each encoder structure 108, 208, is configured as a spiral structure formed about the housings 100, 200 to extend along the center axis of the housings 100, 200 from one end of the housing windows 106, 206 to an opposite end thereof. During catheter operation, the spiral encoder structures 108, 208 return one of the echo pulses in response to transducer transmitted pulses to indicate angles of revolution, thus defining the linear movement of the transducers 102, 202 and the cutters 101, 201 through the area of the housing windows 106, 206.
When the transducers 102, 202 are positioned in the area of the windows 106, 206, transmitted pulses travel through the windows 106, 206 and are reflected as echo pulses from the walls of the blood vessel 50 and the atheroma 500. During the time from transmission to receipt of an echo pulse, the distance traveled by the pulses is twice the distance from the transducers 102, 202, to the wall of the blood vessel 50 and the atheroma 500. Since the metallic housings 100, 200 do not pass a transmitted pulse, rotation of the transducers 102, 202 outside the windows 106, 206 result in the pulses being returned from the housing walls after having traveled twice the short distance from the transducers 102, 202 to the inner wall of the housings 100, 200.
The spiral encoder structures 108, 208 are configured to return one of the transmitted and echo pulses that travel a different distance than those returned from the blood vessel 50 and the wall of the housings 100, 200. Thus, the spiral configuration of the encoder structures 108, 208 causes distinct echo pulses in response to transducer transmitted pulses that define angles of revolution and the linear movement of the transducers 102, 202 and the cutters 101, 201 subassemblies through the area of the housing windows 106, 206.
In one embodiment of the invention, the encoder structure 108, FIG. 1, is a plurality of spiral indentations formed on the housing wherein the depth or height of each indentation extending either outwardly or inwardly with respect to the surface of the housing 100 results in the return of a transducer pulse echo differing in time with respect to a transducer pulse echo returned from a wall of the housing 100.
In another embodiment, the encoder structure may be a spiral configuration of a series of protuberances formed on the wall of the housing 100 that results in the return of a transducer pulse echo differing in time with respect to a transducer pulse echo returned from a wall of the housing 100.
In yet another embodiment of the invention, FIG. 3, the encoder structure 108 may have a line of holes in the housing 100 such that when the housing 100 is configured as a cylinder, the holes form a spiral configuration along the center axis of the housing 100 wherein each hole results in the return of a transducer pulse echo from the blood vessel 50 that differs in time with respect to a transducer pulse echo returned from a wall of the housing 100. The plurality of indentations, protuberances or holes forming the spiral encoder structure 108 are each spaced apart from an adjacent indentation, protuberance and hole and are positioned to define a predetermined angle of rotation of the transducer 102. The predetermined angle defines the linear position and movement of the spinning transducer 102 and the cutter 101 subassembly along their axis of rotation.
The spiral encoder structure 208, FIGS. 2 and 4, may also be a spiral conduit formed as a channel or protuberance on the housing 200 to have a depth or height so as to return a transducer pulse echo distinct in time with respect to a transducer pulse echo returned from a wall of the housing 200. Similarly, the encoder structure 208 may be a spiral channel formed in the housing 200 that is configured to return a transducer pulse echo from the blood vessel 50 to indicate a predetermined angle of rotation of the transducer 202 and the linear movement of the spinning transducer 202 and the cutter 201 within the area of the window 206.
An example of the operation of the guided directional coronary atherectomy catheter according to the present invention will now be explained, with reference to FIGS. 5-6, and 8a-10b.
FIG. 5 shows a schematic of a housing 500 incorporating an encoder structure 508. In the embodiment illustrated in FIG. 5, the encoder structure 508 comprises a plurality of holes formed in a spiral configuration through the wall of the housing 500. In the case illustrated in FIG. 5, seven equally spaced holes are shown, although a different number of holes may be used, depending on the positioning accuracy desired, or other considerations.
FIG. 6 depicts a cross-sectional diagram of the housing 500 of FIG. 5, showing the relative positions of the seven holes of the encoder structure of FIG. 5. The tissue viewing area, typically extending over a 120 degree arc, is referenced by numeral 602. The tissue viewing area corresponds to the window 106 of FIG. 1. As the holes of the encoder structure 508 are formed in a spiral, the relative positions of the holes 1-7 provide an indicia of the linear position and travel direction of the transducer and cutter assembly as it travels within the housing 500. In FIG. 6, hole number 7 can be said to occupy the 3 o'clock position, whereas hole number 1 can be said to occupy the 9 o'clock position, if the tick marks appearing on the figure were analogized to the hour marks on a standard analog clock face.
Prior art FIG. 7 schematically shows an ultrasonic image taken through 360 degrees of rotation, using a conventional guided directional coronary atherectomy catheter. Reference numeral 702 represents the tissue viewing area, and corresponds to the window area of a conventional housing. The true outline of the housing can be seen at numeral 704, whereas 706 graphically represents the ultrasonic ringing of the pulses sent from the transducer and the reflected echoes from the housing wall. As is apparent, no information can be extracted from such an image, other than from the tissue viewing area 702. Indeed, no positional or directional information of the transducer and cutter assembly can be inferred from the area exhibiting the ringing 706.
FIG. 8a shows an ultrasonic image produced from the catheter according to the present invention, as the transducer and cutter assembly 102, 101 of FIG. 1 is advanced to hole number 7. In FIG. 8a, the tissue viewing area is indicated at 802. However, FIG. 8a also shows an ultrasonic anomaly 804 at the 3 o'clock position. The anomaly 804 is produced as the transducer 102 of FIG. 1 is advanced to a position within the housing 100 of FIG. 1 corresponding to the 3 o'clock position. As was seen in FIG. 6, the 3 o'clock position corresponds to hole number 7 of the encoder structure 508 of FIG. 5. In that position, the ultrasonic pulse travels through hole number 7, and returns an echo from the arterial wall back through hole number 7, to be received by the transducer 102 of the cutter assembly 101. The anomaly 804, therefore, appears as a signal which is clearly distinct and uniquely identifiable from the ultrasonic ringing 706 of FIG. 7. This anomaly 804 could itself be used as a visual indicator of the linear position of the transducer 102 and cutter assembly 101 of FIG. 1. For example, the attending physician or operator could interpret an ultrasonic anomaly in the 3 o'clock position as an indication that the transducer 102 and cutter assembly 101 of FIG. 1 are in a proximal position within the housing 100 of FIG. 1. Alternatively, in a more sophisticated case, well known edge detection software could be employed to measure the angle α 7 , by counting the number of pulses between the edge of the tissue viewing area 802 and the leading edge of the anomaly 804. The angle α 7 could then be used to produce a computer generated graphical representation of the atherectomy catheter, with the transducer and cutter assembly in a linear position within the housing corresponding to the measured angle α 7 , as shown in FIG. 8b. Indeed, FIG. 8b shows the transducer and cutter assembly in a proximal position within the housing, which position corresponds to the position of hole number 7 of FIG. 6. This provides the attending physician with an immediately intuitive graphical representation of the position of the transducer and cutter assembly of the catheter within the housing, in real time.
As the transducer 102 and cutter assembly 101 is advanced to hole number 4, for example, the location of the ultrasonic anomaly shifts accordingly. This situation is shown in FIG. 9a, wherein the ultrasonic anomaly is referenced by numeral 904. The anomaly 904 is in the 6 o'clock position, and corresponds to hole number 4. The location of ultrasonic anomaly 904 may be used by the attending physician directly to infer the position of the transducer 102, cutter subassembly 101 of FIG. 1. Alternatively edge detection software may measure the angle 4, in the same manner as angle α 7 in FIG. 8a. From this information, a computer generated image of the atherectomy catheter may be formed, as shown in FIG. 9b. As shown in FIG. 9b, the linear position of the transducer 102, cutter 101 assembly corresponds to the relative position of hole number 4, as seen in FIG. 6. From FIG. 9b, the attending physician can immediately see that the transducer 102, cutter 101 assembly of FIG. 1 is approximately in the middle area of the housing 100 of FIG. 1.
In like manner, FIGS. 10a and 10b show the condition wherein the ultrasonic anomaly 1004 is produced at a position corresponding to hole number 1 in FIG. 6. Edge detection software may be used to measure the angle α 1 , which angle places the ultrasonic anomaly 1004 at the 9 o'clock position. The graphical representation of the position of the catheter is shown in FIG. 10b, wherein the transducer 102, cutter 101 assembly is shown in the distal-most linear position within the housing 100 of FIG. 1.
The direction of travel of the transducer 102, cutter 101 assembly of FIG. 1 may be calculated by determining whether the transducer 102, cutter assembly 101 are advancing toward higher hole numbers, or toward lower hole numbers. For example, if the ultrasonic anomaly is observed at time t 1 at hole 7, and observed at a time t 2 later than time t 1 at hole 4, it may be inferred therefrom that the transducer 102, cutter 101 assembly is being advanced in the distal direction, as shown by arrows 906, 1006 in FIGS. 9b and 10b, respectively. Conversely, if the ultrasonic anomaly is observed at time t 1 at hole 1, and observed at a time t 2 later than time t 1 at hole 4, it may be inferred therefrom that the transducer 102, cutter 101 assembly is being retracted in the proximal direction.
It is apparent from the foregoing that the facility, economy and efficiency of guided directional coronary atherectomy catheter apparatus is improved by encoder structures for use in determining the location and direction of travel of a transducer and cutter subassembly within the housing window area of the distal ultrasound imaging catheter apparatus. It is also apparent that the distal linear encoder structure according to the present invention may also be used to determine the linear position and travel direction of intravenous ultrasonic (IVUS) imaging catheters, whose working element, typically an ultrasonic transducer, does not comprise a cutter element, without departing from the spirit of the invention.
While the foregoing detailed description has described several embodiments of the guided directional coronary atherectomy linear encoder in accordance with principles of the invention, it is to be understood that the above description is illustrative only and is not limiting of the disclosed invention. Particularly other configurations of encoder structures that return pulse echo information defining angular and linear movement of the distal catheter transducer and cutter subassembly within the catheter housing to proximal control apparatus are within the scope and spirit of this invention. Thus, the invention is to be limited only by the claims set forth below. | Disclosed herein is a catheter device for use in a biological conduit having an encoder structure for indicating linear movement of the work element. The work element includes an ultrasonic transducer along a linear axis of the catheter. The catheter has a housing for insertion in the biological conduit. The transducer transmits ultrasonic pulses and receives echoes in response thereto for imaging an inside wall of the conduit. The housing has a window formed therein to image the conduit inside wall. An encoder structure adjacent an area of the window determines distal movement and travel direction of the transducer through the window area along a linear axis of the catheter housing. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a pharmaceutical composition suitable for a once-a-day dosing regimen comprising a combination of a biguanide and a sulfonylurea in the form of a multiparticulate, polyphasic system for the treatment of non-insulin dependent diabetes mellitus (NIDDM) and for improving glycemic control.
BACKGROUND OF THE INVENTION
[0002] Diabetes mellitus of type II is a progressive metabolic disorder with diverse pathologic manifestations and is often associated with lipid metabolism and glycometabolic disorders. The long-term effects of diabetes result from its vascular complications: the microvascular complications of retinopathy, neuropathy and nephropathy and the macrovascular complications of cardiovascular, cerebrovascular and peripheral vascular diseases. Initially, diet and exercise is the mainstay of treatment of type II diabetes. However, these are followed by administration of oral hypoglycemic agents. Current drugs used for managing type II diabetes and its precursor syndromes such as insulin resistance, include classes of compounds such as for example, biguanides and sulfonylureas, among others.
[0003] Biguanides, represented principally by metformin, phenformin and buformin, help in the control of blood glucose by decreasing hepatic glucose production and reducing intestinal absorption of glucose. Sulfonylureas, represented principally by glipizide, glimiperide, glyburide, glibomuride, glisoxepide, gliclazide acetohexamide, chlorpropamide, tolazamide, and tolbutamide, among others, help in controlling or managing NIDDM by stimulating the release of insulin from the pancreas.
[0004] Biguanides and sulfonylureas are commercially available in the form of tablets of the individual drugs, as either immediate release (IR) formulations or in some cases controlled release (CR) formulations, to be administered orally to patients in need thereof, in protocols calling for the single administration of the individual ingredient.
[0005] Biguanides, especially metformin, improves glucose tolerance but cannot stimulate insulin secretion. Sulfonylureas lower blood glucose levels acutely by stimulating the release of insulin from the pancreas, an effect dependent upon functioning beta cells in the pancreatic islets. They bind to sulfonylurea receptors on the beta cell plasma membrane, causing closure of ATP-sensitive potassium channels leading to depolarization of the cell membrane. This in turn opens voltage-gated calcium channels, allowing influx of calcium ions and subsequent secretion of insulin. A combination therapy of a biguanide and sulfonylurea has a synergistic effect on glucose control, since both agents act by different but complementary mechanisms.
[0006] The use of combinations of metformin (a biguanide) and glyburide (a sulfonylurea) has been demonstrated to be synergistic in clinical trials when compared with the use of the individual agents separately (see Physician's Desk Reference 2000, page 832). The monograph also advocates the use of combinations of metformin and sulfonylureas for patients not controlled on metformin alone. Pharmaceutical compositions having combinations of biguanides and sulfonylureas providing for controlled or immediate release of both of the drugs have been reported in the art. For example, a unit-dose combination of metformin and glipizde as an immediate release formulation is commercially available (Zidmin™ tablets, Wockhardt) and a combination dosage form of metformin and glyburide for immediate release is described in U.S. Pat. No. 6,303,146 to Bonhomme et al.
[0007] However, multiple medications for the prophylaxis or treatment of diseases usually result in patient inconvenience and consequently, patient non-compliance to the prescribed dosage regimen. The ease of using combination therapy for multiple medications as opposed to separate administrations of the individual medications has long been recognized in the practice of medicine. Controlled or sustained release pharmaceutical dosage forms help to maintain therapeutic serum levels of medicaments for an extended period of time. Such formulations provide therapeutic advantages for the benefit of the patient and the clinician, and also reduce symptomatic side effects through a possible reduction in the dose of the active medicament.
[0008] Extended release tablets, which employ either a biguanide drug alone or a sulfonylurea drug alone, have been described in the art. For example, International Patent application WO 96/08243 discloses a controlled release dosage form containing only metformin hydrochloride as the active ingredient, and employs a hydrogel to push the active ingredient from the dosage form. Similarly, U.S. Pat. Nos. 5,545,413, 5,591,454 and 5,091,190 disclose controlled release dosage forms containing only the drug glipizide and employ a hydrogel to push the active ingredient from the dosage form
[0009] U.S. Pat. Nos. 6,099,862 and 6,284,275, both to Chen et al., describe a combination composition for the simultaneous controlled release of a biguanide and a sulfonylurea. The composition comprises a core containing the two active agents along with other excipients and a semipermeable controlled release coating from which the release of the active agents is controlled by the presence of at least one passageway in the coat. Though the composition claims to achieve a controlled release of both the active agents, the composition suffers from certain drawbacks. The formation of a passageway in the coating requires expensive equipments such as a laser-hole drilling machine or an accurate mechanical drill for drilling the hole in the coat. The formation of the holes in the coat could also be achieved through the use of pore formers added into the coating itself. However, the use of a coated tablet composition is associated with the possibility of dose-dumping on coating failure resulting in toxicity to the patient. Both the coating process as well as the laser-hole drilling process are time-consuming and require great care to be taken for a number of processing parameters including the spray rate, polymer concentration in the polymer solution, grade of the polymer, the percentage weight gain, the type and percentage of plasticizer or pore former used, the diameter of the drilled hole, and such other parameters related to the formation of the coating, in order to achieve reproducible results. The compositions described in these patents are dependent completely on the coat and its characteristics, such as its thickness and permeability, the presence or absence of plasticizer(s)/pore former(s)/laser hole(s) and such other components, for the controlled release of the biologically active agents. Furthermore, these compositions release the biologically active agents immediately in the absence of the coating.
[0010] To achieve the clinical advantage of a combination of a controlled release sulfonylurea and a controlled release biguanide, for a synergistic effect in the treatment of NIDDM, the individual commercially available products have been heretofore administered together. There is no availability in clinical practice of such combinations for simultaneous controlled delivery of a biguanide along with a sulfonylurea, all in one physically and chemically stable dosage form for ready administration, and a need for such a dosage form exists. The availability of a dosage form that can provide therapeutic levels of a sulfonylurea and a biguanide from the same unit-dose composition over a period of 12-24 hours in a continuous and non-pulsating pattern would be extremely constructive in clinical practice for glycemic control in the treatment of NIDDM. Such a dosage form could then be administered once-a-day and provide both increased convenience and improved patient compliance resulting from the avoidance of missed doses through patient forgetfulness and through a reduced dosing frequency. There is also the possibility of a significant reduction in the doses of the drug substances used in combination because of the synergistic action and thus a possible reduction in toxicity.
[0011] The antidiabetic unit-dose combinations and processes for the preparation of such combinations for the simultaneous controlled release of a sulfonylurea such as for example, glipizide, which is a low-dose (less than 20 mg) low aqueous solubility (insoluble, or 1 part of solute soluble in 10,000 parts of solvent or greater) antidiabetic agent, and a biguanide such as for example, metformin hydrochloride, which is a high-dose (more than 250 mg) high aqueous solubility antidiabetic agent (>300 mg/ml) from the same matrix, over a period of 12-24 hours are not known in the art.
[0012] Combinations of biologically active agents are especially difficult to formulate because of the inherent differences in physicochemical properties, the possible drug-drug interactions between the drugs and also in the ingredients used for formulation of the combination composition. This is a particularly challenging task for the pharmaceutical formulation scientist because of issues such as the uniformity of content of the low dose drug in the matrix and the amounts of excipients that can be used to formulate such a dosage form.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to provide a pharmaceutical composition for oral administration of a biguanide and a sulfonylurea suitable for a once-a-day dosing regimen.
[0014] It is a further object of the present invention to provide a pharmaceutical composition for a combination of a biguanide and a sulfonylurea that provides continuous and non-pulsating therapeutic levels of both of the drugs to humans in need of such treatment over a twelve-hour or twenty-four hour period.
[0015] It is another object of the present invention to provide a composition comprising a core having a multiparticulate polyphasic system of biguanide and sulfonylurea and a coating on the core with a rupture time of not more than about 1 hour.
[0016] It is a further object of the present invention to provide a multiparticulate polyphasic core for the combination of biguanide and sulfonylurea such that both drugs constitute two different phases and the particulate phases are uniformly dispersed in a hydrophilic water-swellable polymer.
[0017] It is also an object of this invention to provide a method of administering these compositions for the treatment of diabetes.
[0018] These objects are achieved by virtue of the present invention, which relates to a pharmaceutical composition that provides a simultaneous controlled release of a combination of a biguanide and a sulfonylurea over a prolonged period of time.
[0019] In one embodiment of the present invention, a pharmaceutical composition for the once-a-day administration of drugs for the treatment of non-insulin dependent diabetes mellitus in humans includes a core comprising a multiparticulate polyphasic system wherein, a first particulate phase comprises a biguanide drug, a binding agent and a hydrophilic water-swellable polymer, a second particulate phase comprises a sulfonylurea drug, a wetting agent, a cyclodextrin polymer and a hydrophilic water-swellable polymer, and a third phase comprises a hydrophilic water-swellable polymer; and a coating on the core having a rupture time of not more than about 1 hour.
[0020] According to an embodiment of the present invention, a first particulate phase comprising a controlled release biguanide and a second particulate phase comprising a controlled release sulfonylurea are prepared and intimately mixed with a third polymeric controlled release phase. The particulate polyphasic mix is then subjected to compression followed subsequently by a coating.
[0021] An embodiment of the present invention includes a polyphasic unit-dose combination of a biguanide and a sulfonylurea for the simultaneous controlled release of both of the drugs. The term “polyphasic” as used herein is intended to mean the different particulate phases that form the combination composition and does not refer to the different phases in the release of drugs from a drug delivery system.
[0022] An embodiment of the present invention provides a multiparticulate polyphasic core for the combination of a biguanide and a sulfonylurea such that both drugs constitute two different hydrophilic polymeric phases and the particulate phases are uniformly dispersed in a hydrophilic water-swellable polymer.
[0023] In this embodiment of the invention, the three phases comprise hydrophilic water-swellable polymer. The polymer being hydrophilic in nature hydrates to form a gel layer on exposure to aqueous fluids, which thereafter slowly dissolves to release the medicament. The effective release of the drug is regulated by the diffusion and slow erosion of this polymer. The polymers recognized in the art of pharmaceutical compounding for release retarding properties form the controlled release matrix in different phases. The drug is entrapped within this polymeric matrix. The rate of release of drug from such a system is primarily dependent on viscosity of the polymer, rate of water imbibition, resultant rate of swelling of matrix, drug dissolution and diffusion from the matrix.
[0024] To obtain the desired and optimal release profile from each particulate phase and depending on the solubility characteristics of each drug, excipients, such as for example, a binding agent, a wetting agent and cyclodextrin are incorporated therein with discretion.
[0025] Another embodiment of the present invention includes a pharmaceutical composition in the form of, for example, beads, pellets, granules, tablets or capsules, incorporating drugs in a polymeric matrix and optional pharmaceutical adjuvants, such as for example, swelling agents, diluents and binders, coated with polymer film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 shows the simultaneous controlled delivery of glipizide and metformin hydrochloride from an embodiment of a unit-dose combination of the present invention.
DETAILED DESCRIPTION
[0027] An embodiment of the present invention includes a pharmaceutical composition comprising a core comprising a multiparticulate polyphasic system and a coating over the core having a rupture time of not more than about 1 hour characterized in that the core includes as the first phase, a controlled release bigauanide phase, the second phase being a controlled release sulfonylurea phase, and the two phases are uniformly dispersed in the third water-swellable polymer phase.
[0028] The Controlled Release Biguanide Phase:
[0029] The biguanides that could be used in accordance with the processes and compositions of the present invention include, but are not limited to, metformin, phenformin, buformin and other medicinally active and pharmaceutically acceptable forms from the biguanide class of compounds, including their salts, solvates, hydrates, polymorphs, complexes and such other products. In accordance with the present invention, metformin is a particularly preferred biguanide because of its proven clinical use. Different salts of metformin that could be used in the present invention include hydrochloride, acetate, maleate, fumarate, succinate and other salts, such as the different salts of metformin described in U.S. Pat. No. 6,031,004, which is incorporated herein by reference in its entirety. It is also to be understood that the same or similar salts could be prepared for buformin and phenformin and other compounds from the biguanide class of compounds.
[0030] The biguanide of the invention is preferably present in an amount of from about 25% to about 60% by weight, more preferably from about 30% to about 50% by weight, of the total composition.
[0031] According to an embodiment of the present invention, in addition to the biguanide, this phase can also contain a binding agent so as to form a cohesive mass of the powder blend. A suitable binding agent includes any pharmaceutically acceptable, non-toxic, water soluble and/or water insoluble agent showing binding properties. For example, the composition may contain a binder selected from among several applicable substances, such as starch, polyvinylpyrrolidone (Kollidon™, BASF) having a weight average molecular weight of 30,000 to 3,000,000, methyl cellulose, hydroxypropyl cellulose (HPC) having molecular weights from 80,000 to 1,150,000, carbomers (more popularly known as CARBOPOL™, BF Goodrich) in all different viscosity or molecular weight grades, and other such materials routinely used in the art of solid dosage form manufacturing for the purposes of binding and preparation of granules.
[0032] The requisite amount of binding agent used in the invention is an amount needed to obtain a cohesive mass of desirable strength that allows for the formation of granules or tablets of optimum hardness. The binding agent is preferably present in an amount of from about 1% to about 10% by weight, and more preferably from about 1.5% to about 7.5% by weight, of the total composition.
[0033] According to an embodiment of the present invention, the first particulate phase also contains a hydrophilic water-swellable polymer that regulates the release of the drug. Such polymers, which are amenable to controlled release therapy utilizing the novel therapeutic delivery system of the present invention, include any of those suitable for oral administration. The hydrophilic polymer forming the matrix in accordance with the invention is any such polymer that is non-toxic, swells upon imbibition of water and provides for controlled release of the drug. The hydrophilicity of these polymers causes the drug-containing matrix to swell upon ingress of water. Examples of polymers which can be used in accordance with the present invention include hydrophilic water-swellable polymers exemplified by cellulose ether, dextrin, starches, carbohydrate based polymers, acrylic polymers, natural or hydrophilic gums such as xanthan gum, karaya gum, locust bean gum, guar gum, gelan gum, gum arabic, tragacanth, carrageenan, pectin, agar, alginates, gelatins and the like. When cellulose ether derivatives are used as the hydrophilic controlled release polymers, any of the alkyl or hydroxy alkyl derivatives of cellulose are acceptable. Such cellulose derivatives include, but are not limited to, methyl cellulose, hydroxycellulose, hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), hydroxyethyl methylcellulose, hydroxypropyl ethylcellulose, hydroxypropyl cellulose (HPC), hydroxymethyl cellulose (HMC), sodium carboxymethyl cellulose (CMC) and other pharmaceutically acceptable derivatives in the different viscosity grades used in the processing of pharmaceutical solid dosage forms. A preferred cellulose derivative is HPMC available in the viscosity grades from 15,000-100,000 cps
[0034] It is also to be understood in the foregoing discussion that blends and mixtures of two or more binders, or two or more release-controlling hydrophilic water-swellable polymers, is completely within the scope of the invention. Also included within the scope of the invention is the use of mixtures of the same polymer in different viscosity grades.
[0035] The Controlled Release Sulfonylurea Phase:
[0036] According to an embodiment of the present invention, the second particulate phase contains a sulfonylurea. Suitable sulfonylureas include, but are not limited to, glipizide, glibomuride, glyburide, glisoxepide, gliclazide, acetohexamide, chlorpropamide, tolazamide, tolbutamide, and others, as well as other medicinally active and pharmaceutically acceptable forms from the sulfonylurea class of compounds, their salts, solvates, hydrates, polymorphs, complexes and such other products. For example, suitable sulfonylureas for use in the present invention are described in U.S. Pat. Nos. 5,674,900 and 4,708,868, both of which are incorporated herein by reference in their entireties. A preferred sulfonylurea for use in the present invention is glipizide.
[0037] The sulfonylurea is preferably present in an amount from about 0.1% to about 3.5% by weight, more preferably from about 0.2% to about 2% by weight, of the total composition.
[0038] According to a further embodiment of the present invention, the sulfonylurea may essentially be of a uniform particle size for uniform distribution in the final controlled release matrix. The particle size of the sulfonyurea present in the composition preferably varies from about 5 to about 100 μm, and even more preferably from about 5 to about 50 μm.
[0039] According to an embodiment of the present invention, the second particulate phase may also contain a wetting agent to facilitate wettability and dissolution of the drug. The wetting agent regulates the release of the highly water-insoluble sulfonylurea from the polymeric matrix. The wetting agent also aids in the uniform distribution of the drug within the particulate phase and reduces the actual particle size of the drug through surface solubilization. A suitable wetting agent could be chosen from, for example, surfactants, emulsifiers, bile salts, phospholipids and such other materials known to possess properties for wetting enhancement. For example, the Handbook of Pharmaceutical Excipients (1994), Handbook of Pharmaceutical Additives (1995) and International Patent application WO 99/42016 provide a more detailed listing of different emulsifiers useful in pharmaceutical formulations which could be used in accordance with the present invention, and they are all incorporated herein by reference in their entireties. A more detailed description of the different wetting agents that are suitable for use in preparation of the present compositions is provided in U.S. Pat. No. 6,248,363 to Patel et al. which is incorporated herein by reference in its entirety. Preferably, the wetting agent could be chosen from the group consisting of sodium lauryl sulphate, polyoxyethylene-polyoxypropylene copolymer, polysorbates, and mixtures thereof. The composition of the invention may contain a wetting agent preferably in an amount of from about 1% to about 5% by weight of the total composition.
[0040] The sulfonylurea particulate phase according to the present invention may also contain a cyclodextrin polymer. The cyclodextrin polymers could be chosen from, for example, α-cyclodextrin, β-cyclodextrin, their derivatives and other cyclodextrins as described in the art, including those cyclodextrins of varying water-solubility (less than 2% to higher than 50%). In a preferred embodiment of the invention, the cyclodextrin is β-cyclodextrin. The cyclodextrin is preferably present in an amount of from about 10% to about 30% by weight of the total composition.
[0041] According to an embodiment of the present invention, the second particulate phase may further comprise a water-dispersible diluent. Water-dispersible diluents refer to water insoluble pharmaceutical excipients that disperse readily in water, including but not limited to, calcium carbonate, dicalcium phosphate, tribasic calcium phosphate, calcium sulphate, magnesium trisilicate, and the like. The water-dispersible diluents are preferably present in an amount of from about 5% to about 25% by weight of the total composition.
[0042] According to an embodiment of the present invention, the second particulate phase may optionally contain a binding agent and/or a hydrophilic water-swellable polymer chosen from the pharmaceutically acceptable binding agents and the hydrophilic water-swellable polymers described previously for the first biguanide particulate phase. These two components could be the same or different from those used in the first particulate phase. As would be understood by one of ordinary skill in the art, mixtures of the different materials could also be used.
[0043] The Controlled Release Water-Swellable Polymer Phase
[0044] According to an embodiment of the present invention, the third phase is a controlled release hydrophilic swellable polymer phase. This polymer phase contains water-swellable polymers chosen from those described in the controlled release biguanide phase. The polymer in this third phase could be the same as that used in the first and second particulate phases, or it could be an altogether different hydrophilic water-swellable polymer.
[0045] The amount of polymer relative to the drug in the pharmaceutical composition of the present invention may vary depending on the release rate desired, nature of the polymers, their physicochemical characteristics, and other auxiliary components that may be present as an integral part of the formulation. Accordingly, the hydrophilic water-swellable polymer together in the three particulate phases of the core is preferably present in an amount of from about 5% to about 35% by weight of the total composition.
[0046] According to an embodiment of the invention, the three phases as described above comprise the core of the controlled release composition. The core can be prepared by any method of preparing solid oral dosage forms known to one of ordinary skill in the art of manufacturing solid oral dosage forms.
[0047] According to a further embodiment of the invention, other commonly known excipients may optionally be included into the core, such as a filler, binder agent, disintegrating agent, glidant, lubricant, pigment or dye, and mixtures thereof.
[0048] The Water-Soluble Coating Layer:
[0049] In accordance with an embodiment of the present invention, a coating layer is provided over the core formulation. The coating preferably varies from about 3% to about 12% by weight of the total composition. Preferably, the coating is intended to control the release of the active agents from the core only for a period of about one hour. Thus, a coating which has a film-rupture time of less than about 1 hour, such as for example, about 50 minutes, is preferred. The polymers used for the coating could be of varying molecular weight or viscosity range such that the desired film-rupture time could be attained. The polymers comprising the coating include, but are not limited to, insoluble cellulose derivatives such as ethyl cellulose, methacrylic acid copolymer, shellac, hydroxypropyl methyl cellulose and mixtures thereof. Other coating materials routinely used in the art of manufacturing coated pharmaceutical solid oral dosage forms could also be used in accordance with the invention.
[0050] In accordance with an embodiment of the present invention, the core could be coated by any method of preparing solid oral dosage forms known to one of ordinary skill in the art of manufacturing solid oral dosage forms. Such methods include, but are not limited to, pan coating, fluidized bed coating, and such other methods.
[0051] The present invention is not to be construed as being limited to any particular excipient or class of pharmaceutical excipients. The choices of excipients and the amounts to be used such that the composition is suitable for once-a-day dosage regimen are considered to be within the purview of one of ordinary skill in the art.
[0052] The pharmaceutical composition of the present invention may be prepared in a variety of forms, including but not limited to pellets, beads, granules, tablets and capsules.
[0053] It is to be understood, however, that for any particular subject being treated, e.g. a mammal, specific dosage regimens should be adjusted according to the individual need as would be understood by one of ordinary skill in the art. Thus, a unit-dose composition comprising 1-20 mg of glipizide and 250-2000 mg of metformin hydrochloride are all within the scope of the invention. Preferably, the unit-dose controlled release composition will contain 2.5, 5 or 10 mg of glipizide along with 250, 500 or 1000 mg of metformin hydrochloride. It is further to be understood that the dosages set forth herein are examples only and that they do not to any extent limit the scope of the present invention.
[0054] According to an embodiment of the present invention, the composition releases the biguanide and the sulfonylurea simultaneously in a controlled pattern, as demonstrated in the examples provided below when tested as per established analytical methods for the testing of controlled release dosage forms. As known in the art, the release profiles would vary based on the composition of each such combination dosage form formulated.
[0055] The present invention will now be described in detail with respect to showing how certain specific representative embodiments thereof can be made, the materials and process steps being understood as examples that are intended to be illustrative only. In particular, the invention is not intended to be limited to the methods, materials, conditions, process parameters, apparatus and the like specifically recited herein.
EXAMPLE
[0056] This example illustrates the present invention in the form of a controlled release tablet containing metformin hydrochloride and glipizide as the active ingredients.
[0057] Core:
Phase I: Particulate phase containing a biguanide % Weight of the Ingredients composition Metformin hydrochloride 41.84 Hydroxypropyl 3.01 methylcellulose (K15M) Polyvinylpyrrolidone (K-90) 1.93 Magnesium stearate 0.25
[0058] In this example, metformin hydrochloride and hydroxypropyl methylcellulose were blended and granulated with an aqueous dispersion of polyvinylpyrrolidone. The wet mass was dried and sifted through a 850 μm mesh (British Standard Sieve (BSS) no. 18). The sized granules were then lubricated with magnesium stearate.
Phase II: Particulate phase containing sulfonylurea % Weight of the Ingredients composition Glipizide 1.10 Hydroxypropyl cellulose (Klucel 1.31 LF) Sodium lauryl sulphate 1.64 β-Cyclodextrin 19.91 Dicalcium phosphate dihydrate 15.88 Hydroxyethyl cellulose (Natrosol 6.37 250 M) Stearic acid 0.45 Magnesium stearate 0.22 Colloidal silicon dioxide 0.04
[0059] A blend of β-cyclodextrin and dicalcium phosphate was sifted through a 355 μm mesh (British Standard Sieve (BSS) no. 44). This blend was granulated with an aqueous dispersion of mixture of glipizide and sodium lauryl sulphate and further mixed with hydroxypropyl cellulose and hydroxyethyl cellulose. The wet mass was passed through a multimill using 6 mm perforator and granules were dried and screened through a 850 μm mesh (British Standard Sieve (BSS) no. 18). Stearic acid, magnesium stearate and colloidal silicon dioxide were sieved through a 355 μm mesh and blended with the above granules.
Phase III: Hydrophilic polymer phase % Weight of the Ingredients composition Hydroxypropyl methylcellulose 6.06
[0060] Hydroxypropyl methylcellulose was blended well with the mixture of Phases I and II prior to the compression into tablets.
[0061] Coating:
% Weight of the Ingredients composition Ethyl cellulose (10 cps) 3 Hydroxypropyl methylcellulose 5 (5 cps) Polyethylene glycol 400 1 Titanium dioxide 1
[0062] Ethyl cellulose, hydroxypropyl methylcellulose and polyethylene glycol were dissolved in methylene chloride and isopropyl alcohol. Titanium dioxide was then dispersed in the above solution and homogenized. The core tablets were then coated with this coating solution to a desired weight gain.
[0063] The tablets were characterized for drug release in 900 ml of phosphate buffer of pH 7.5. The USP apparatus Type I with basket speed at 100 rpm was used for the study. The samples of the media were periodically withdrawn and analyzed for drug content. The dissolution results are recorded in Table I and the profiles are given in FIG. 1.
TABLE 1 Cumulative percent drug released Time Metformin (Hours) Glipizide Hydrochloride 1 6.5 28.83 2 16.6 49.59 3 27.1 64.74 4 33.9 78.09 5 41.5 88.49 6 47.3 93.26 8 55.4 97.29 10 67.9 100.01 12 75.2 103.93 15 85.8 105.57 18 93.0 105.92 21 99.4 105.99 24 102.5 106.47 | A pharmaceutical composition suitable for a once-a-day dosing regimen includes a combination of a biguanide and a sulfonylurea in the form of a multiparticulate, polyphasic system for the treatment of non-insulin dependent diabetes mellitus (NIDDM) and for improving glycemic control. | 0 |
This application is a continuation-in-part application of Ser. No. 10/407,285 filed on Apr. 4, 2003.
BACKGROUND OF THE INVENTION
The invention relates generally to a mixture of antioxidants and, more specifically, to lipid-soluble formulations that contain a mixture of both lipid- and water-soluble antioxidants.
Lipid autoxidation is the chemical term for a series of destructive processes that readily occur in organic materials by the reaction with molecular oxygen (Lipid Oxidation, E. N. Frankel, Chapter 1, The Oily Press, Dundee, 1998). There are three separate steps in the lipid autoxidation scheme. In the first step (initiation phase) free radicals are gradually formed. Radicals can be formed spontaneously or they can be produced by the thermal or metal catalyzed decomposition of hydroperoxides. The initiation phase in lipid oxidation mainly depends on the fatty acid composition expressed by the degree of unsaturation and the level of metal contamination. In the second step or propagation phase free radicals react with oxygen to form peroxyl radicals. The rate of oxidation accelerates which indicates the autocatalytic nature of the reaction. There is a rapid absorption of molecular oxygen and peroxides are progressively formed. The third step or termination phase, comprises the recombination of various radical species and the lipid autoxidation reaction slows down.
Oils and fats are major constituents in human and animal nutrition. Due to the autoxidation process, lipids will become rancid and undesirable flavor and odor components will be formed. Oxidized oils and fats will become unpalatable and the ingestion of highly oxidized vegetable fat results in a loss of appetite. In addition lipid oxidation will result in a rapid destruction of vitamins and other dietary components reducing the nutritional value of the food and feed matrix. Taking into account all these factors, it is important that effective measures are taken to stabilize oils and fats against oxidation.
The lipid autoxidation process of oils and fats can be delayed by phenolic antioxidants (Lipid Oxidation, E. N. Frankel, Chapter 8, The Oily Press, Dundee, 1998). Inhibition of the free radical autoxidation process by antioxidants is of considerable importance to preserve lipids from oxidative deterioration. Antioxidants inhibit or delay lipid oxidation by capturing lipid radicals and peroxyl radicals. Phenolic compounds with bulky alkyl substituents are effective chain breaking antioxidants because they produce stable and unreactive antioxidant radicals. These antioxidant radicals do not have enough energy to react with the fat to form new free radicals and therefore these antioxidants are called free radical scavengers or primary antioxidants.
Over the past decades especially, synthetic antioxidants such as BHA, BHT, and ethoxyquin have been used extensively in human food and animal feed. An increased concern regarding the application of these synthetic antioxidants has been observed over the last decades, due to the possible mutagenic and carcinogenic character of these products (Toxicology and Biochemistry of Butylated Hydroxyanisole and Butylated Hydroxytoluene, Journal of the American Oil Chemist's Society, Branen, pp. 59-63, 1975).
There has accordingly been an increased amount of attention directed towards natural antioxidants tocopherols, extract of herbs, spices and hulls (e.g., gallic acid, rosemary, sage and thyme), flavones, carotenoids, anthocyanidins, and others (Lipid Oxidation, E. N. Frankel, Chapter 8, The Oily Press, Dundee, 1998). However these natural antioxidants are more expensive compared to synthetic antioxidants, and in sectors where price is an important issue natural antioxidants are not often used.
In this respect semi-synthetic antioxidants can offer a solution. The most commonly used semi-synthetic antioxidants are esters of gallic acids such as propyl gallate and octyl gallate. The distribution and application of these semi-synthetic antioxidants is becoming more and more important.
However, the production of antioxidant formulations based on natural and semi-synthetic antioxidants is more difficult. Generally, those phenolic compounds, such as gallic acid and derivatives, flavones, phenolic di- and tri-terpenes, extract from sage, rosemary, thyme, and others, consist of polar groups which do not dissolve in a lipid system. While these antioxidants dissolve in a polar carrier, such as monopropylene glycol, glycerol, water, and others, such a polar carrier does not dissolve in an apolar lipid system. Mixing of an antioxidant formulation based on such a polar carrier in a lipophillic matrix immediately results in the separation of the antioxidant formulation and a homogeneous distribution of the antioxidant formulation is not achieved.
The inclusion of a metal chelator such as citric acid, phosphoric acid, and others in an antioxidant formulation is advantageous for its metal chelating activity (Lipid Oxidation, E. N. Frankel, Chapter 7, The Oily Press, Dundee, 1998). However, metal chelators only dissolve in polar solvents as well. As a consequence it is a challenge to formulate an antioxidant formulation which combines the inclusion of a metal chelator with oil solubility.
Due to the hydrophilic groups present in phenolic compounds and metal chelators they are either totally insoluble or very sparsely soluble in fatty systems. These polar compounds can be rendered fat-soluble by several methodologies.
The traditional procedure to render polar compounds lipid soluble is by synthesis (Drug Formulation, I. Racz, Chapter 4, John Wiley and Sons, 1989 and Dufour et al. J. Agric. Food Chem., 2002, 50, pp. 3425-3430). This is carried out by addition of an aliphatic side chain in order to increase the lipophylic character of the product. Esterification with a suitable fatty acid is a common practice to increase the lipid solubility. For example propyl gallate, octyl gallate and dodecyl gallate are derived from gallic acid and ascorbyl palmitate is derived from ascorbic acid. While these derived compounds have significantly increased lipid solubility, long mixing times at elevated temperatures are still required in order to make these compounds completely soluble into an oil and fat matrix.
Liposomes have also been used to introduce polar compounds into an oil and fat system. Liposomes consist of one or more concentric spheres of lipid bilayers surrounding an aqueous compartment. If liposomes are incorporated in a fatty system, the hydrophilic compounds remain separated from the fatty system because the hydrophilic compounds do not dissolve and are present as a heterogeneous dispersion. The use and success of liposomes has been rather limited (see “Drug Targeting and Delivery”, Chapter 6, edited by H. E. Junginger, Ellis Horwood 1992).
Another possibility is the formation of solid antioxidant particles of small particle size (e.g. micron size), which suspend easily in oils and fats. This procedure has been carried out with ascorbyl palmitate (U.S. Pat. No. 5,314,686).
A variety of commercial products are available, but none have the advantages of the present antioxidant system. Oxitrap ME (Nordos, Belgium) is a product based on BHA, propyl gallate and fatty acids esterified with citric acid. This product does not contain a synergistic combination with other gallates. Gallic acid itself will not dissolve in this type of product. Citric acid is present as an ester, which significantly reduces the chelating activity.
Loxidan TL 400 (Lohmann Animal Health GmbH, Germany) is a product that contains 26% ethoxyquin, 7% propyl gallate and 4% citric acid. Again this is a formulation is without a synergistic combination with other gallates. The formulation contains ethoxyquin, an antioxidant that can also function in part as a solvent for gallates. Formulations without ethoxyquin will be less effective in dissolving propyl gallate and citric acid. This limits the application because ethoxyquin is becoming less widely accepted.
Eurotiox L32 (Eurotec Nutrition, S.I., Spain) is a product that contains BHA, citric acid and propyl gallate, but the solvent is polyethylene glycol, which is not allowed in the European Union. This formulation has no synergistic combination with other gallates.
Ban-ox (Alltech, Inc., U.S.) is a product that does not contain a synergistic combination of gallates. This product also contains high amounts of iso-propanol, a flammable compound. Most antioxidants are used during the processing of fats and oils. This processing often occurs at higher temperatures, which means that flammable formulations cannot be used.
Liquid antioxidant formulations have been used for a long time in the food and feed industry. A liquid antioxidant formulation has the advantage of dissolving easily into the lipid system. The carrier used in an antioxidant formulation should dissolve the antioxidant in a considerable concentration (generally up to 10-30% antioxidant) and upon introduction into the lipid system disperse easily. An antioxidant formulation based on BHT or BHA can easily be based on a vegetable oil as carrier with good solubility in an oil system.
There has been a need in the market for an antioxidant formulation that could protect vegetable oils more efficiently than the current available formulations. This need is particularly important in the European Union because the use of animal fats in feed production decreased very rapidly after the “Mad Cow Disease” (bovine spongiform encephalitis) crisis in Europe. Feed ingredients from an animal source were replaced with ingredients from a vegetable source. Because vegetable oils are more unsaturated, an antioxidant formulation that was especially potent in this type of lipid matrix was needed.
SUMMARY OF THE INVENTION
The invention consists of an antioxidant system which incorporates phenolic antioxidant compounds into a liquid formulation that is readily dispersible in lipid matrices, such as oils and fats. The products of the invention include a phenolic antioxidant, a liquid carrier, an emulsifier and a polarity modifier. Preferably, a water-soluble antioxidant compound is also used in the products. The invention involves the mixing of antioxidants of different polarities, polar and non-polar, such that they are combined in a monophase liquid composition which readily dissolves in oil and fat matrices but contains substantially no oil or fat prior to that addition. The phenolic antioxidant compounds include gallic acid, gallic acid esters, flavones, phenolic di- and tri-terpenes, and phenolic extracts of sage, rosemary and thyme. The carrier includes water, monopropylene glycol, polyethylene glycol, and glycerol. The emulsifier includes acylglycerides, di-acylglycerides, phospholipids, and lysophospholipids. The polarity modifier includes short chain fatty acid such as propionic acid, butyric acid and acetic acid. The products also preferably include a metal chelator. Natural antioxidants that may be used in the products include gallic acid, tocopherols, carotenoids, anthocyanidins and non-phenolic extracts of herbs, spices and hulls. In a preferred embodiment, the invention comprises about 5% citric acid, between 25-30% monopropylene glycol, between 15-25% propionic acid and between 25-30% monoglycerides.
The developed antioxidant formulation contains a single homogenous phase which is not a microemulsion. Emulsions are a poor system for applying antioxidants to an oil/fat matrix because in an oil-in-water emulsion the oil phase (including oil soluble antioxidants) will dissolve readily in the continuous oil phase of the matrix one is trying to protect against oxidation, and the water droplets may assemble resulting in larger droplets which will sink to the bottom of the vessel containing the lipid matrix. Consequently the water soluble antioxidants cannot be effective because they do not dissolve in the oil and they are not available at the oil/air interphase where most oxidation takes place as the water phase with the water-soluble antioxidants always sinks to the bottom of the vessel.
The developed antioxidant system is a powerful antioxidant with special characteristics and is adaptable to provide a wide range of antioxidant products. The present antioxidant system addresses problems in the marketplace associated with stabilization of vegetable oils, replacement of ethoxyquin, and development of more potent antioxidant formulations. The present formulations provide a synergistic effect that is particularly surprising because all gallates have the same basic molecular skeleton leading one skilled in the art to expect that the mode of action would be identical for all these molecules. This could only be expected to lead to a linear additive effect and not to synergism.
Until the present invention, no known products based on gallic acid have been available.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The antioxidant formulation of the invention comprises the introduction of natural antioxidants, a semi-synthetic antioxidants and a metal chelator in a liquid carrier having good dispersability in diverse oils and fat matrices. The invention is a single-phase In a preferred embodiment, the natural antioxidant is gallic acid, the semi-synthetic antioxidants are propyl and octyl gallate, the metal chelator is citric acid, and the oil and fats matrices comprise soybean oil, rapeseed oil, corn oil, sunflower oil, lard, tallow, palm oil, cacao butter, coconut oil, methyl esters of fatty acids, and others.
The antioxidant system of the present consists of four main components. The combination of these four components into the final antioxidant system provides a homogenous single-phase product that is substantially free of fats or oils and maintains excellent solubility in a lipophilic system independent of the temperature:
(1) Natural, semi-synthetic and synthetic antioxidants can be combined in the formulation at high levels. In addition, an organic acid such as ascorbic acid and/or citric acid can be included in the formulation.
(2) The antioxidant system is a liquid carrier which is able to dissolve the antioxidants and organic acids. Due to the polar character of gallic acid and propyl gallate a polar carrier is required. Suitable polar carriers include water, monopropylene glycol, glycerol, polyethylene glycol, and the like.
(3) An emulsifier is necessary in order to make the liquid carrier soluble in a lipophilic system. Suitable emulsifiers include mono acylglycerides, di-acylglycerides, (lyso)-phospholipids, and the like.
(4) In addition, a polarity modifier such as an organic acid of short chain fatty acids is required to optimize the polarity of the formulation. Suitable polarity modifiers include propionic acid, butyric acid, acetic acid, and the like. The polarity modifiers are typically a relatively polar ingredient. Upon dissolving the antioxidants in the carrier and the emulsifier, the polarity of this combination will change, making it necessary to use a polarity modifier to assure the stability of the formulation and avoid precipitation or segregation of the system.
Products of the invention can be produced in a simple liquid mixer. Stirring is sufficient to produce the formulation. The concentrations of all ingredients can be changed independently in that all of the ingredients can be obtained in a chemically pure form. This allows the formulator to modify the formulation in order to obtain the best possible protection and synergism for a given lipid matrix. Further, there is no production step in the production process of these formulations which requires energy, such as e.g. evaporation of solvents, and all ingredients and the solvent system are allowed by law for use in animal feed. The combination of the ingredients has a synergistic effect on the improvement of oxidative stability of vegetable oils and other lipid matrices.
A lower concentration is needed to reach a certain level of protection of the lipid matrix. This is cost-efficient and also the level of the additive is reduced. This reduces the chance that the additive has an effect on other product characteristics such as taste or color. This makes the formulations very useful to protect feed and food.
Further the product is readily soluble in lipid matrices. This means that it can be applied very easily, just by gentle stirring. No emulsification or high shear mixing is needed.
Composition of Active Ingredients: Antioxidants and Metal Chelators
(1) Gallic acid, propyl gallate and ascorbic acid hardly dissolve in carriers commonly used in antioxidant formulations based on apolar carriers (e.g., vegetable oils).
(2) An antioxidant formulation solely based on emulsifiers does not allow the introduction of gallic acid and propyl gallate into a lipid system as gallic acid and propyl gallate have a limited solubility in emulsifiers. As a consequence, a polar carrier is required which does not dissolve directly into a lipid system.
(3) Natural antioxidants, derived semi-synthetic antioxidants and synthetic antioxidants (e.g., butylated hydroxyltoluene [BHT], and butylated hydroxyanisole [BHA]) can be combined in a single system in order to obtain a synergistic effect between the different antioxidants.
(4) A metal chelator is included in the antioxidant formulation.
(5) All ingredients should be mixed in a proper order and the right combination in order to prepare a stable antioxidant system.
(6) The antioxidant formulation is stable upon prolonged storage, even at refrigerator temperatures.
Solubility
The antioxidant system proposed in the invention is based on a liquid carrier, which is directly dissolving into a lipid system. Neither heating nor high shear mixing is required to dissolve the proposed antioxidant system into an oil and fat system independent of its temperature. As a consequence, the proposed formulation does not require special equipment or investments in order to introduce the antioxidants into the lipid system.
Description of the Experimental Conditions
Evaluation of Oil Solubility.
Following visual test was carried out to evaluate the oil solubility of the developed antioxidant systems. The water-soluble coloring agent Ponceau 4 Red was introduced in order to color the formulation. Mixing of the colored antioxidant formulation into a lipid system directly resulted in a homogeneous coloring of the lipid system.
Evaluation of Antioxidant Stabilization.
Oils and fats have a resistance to oxidation which depends on the degree of oxidation, presence of antioxidants, pro-oxidants etc. At room temperature oxidation is a slow process and takes several months. In order to evaluate the oxidative stability of an oil or fat sample an accelerated method is developed to speed up the oxidation process. This test was carried out with the Oil Stability Index (OSI) according to the AOCS Official Method Cd 12b-92 (American Oil Chemist's Society, Illinois, 1996). This method is particularly suited to evaluate the effect of antioxidant stabilization of oils and fats.
Before oils and fats start to oxidize a resistance has to be overcome, after which the oxidation accelerates and becomes very rapid. The length of time before this rapid acceleration of oxidation is a measure of the resistance to oxidation and is commonly referred to as the ‘induction period’. In the Oil Stability Index (OSI method) the oxidative stability and the effect of antioxidant stabilization of oils and fats is determined. A stream of purified air is passed through a sample of oil, which is held in a thermostatic bath. In this experimental test the OSI was carried out at a temperature of 98° C. The effluent air from the oil or fat sample is then bubbled through a vessel containing deionized water. The conductivity of the water is continually monitored. The effluent air contains the volatile organic acids formed upon oxidizing the oil. The Oil Stability Index is defined as the point of maximum change of the rate of oxidation, or mathematically as the second derivative of the conductivity curve. As a consequence the induction point is a measure for the oxidative stability of the oil or fat system. The higher the induction point the higher the oxidative stability of the oil.
Example 1—Preparation of a Stable Liquid Antioxidant Formulation
An example of an antioxidant formulation is a combination of the synthetic antioxidants gallic acid, propyl gallate and octyl gallate and citric acid as metal chelator. In order to dissolve gallic acid and propyl gallate, enough carrier, in this case, monopropylene glycol, is required. In order to introduce the active antioxidants easily into an oil or fat system, an appropriate range of emulsifiers, such as monoglycerides, and organic acids, for example, propionic acid, are needed. The active ingredients are formulated in a single liquid antioxidant system without harming the product stability and mixing properties of the formulation into a lipophilic carrier. Based on this concept, several different combinations can be prepared by altering the level of the different ingredients.
A first formulation, Formulation 1, comprises, by weight, 7% gallic acid, 10% propyl gallate, 3% octyl gallate, 5% citric acid, 27.5% monopropylene glycol, 19% propionic acid, 26.5% monoglycerides, and 2% phospholipids. Evaluating Formulation 1 on soybean oil in OSI resulted in an induction time of 27.9 h at a level of 500 ppm and 37.0 h at a level of 1000 ppm. The control soybean oil not treated with an antioxidant had an induction time of 14.8 h. These data indicate the effectiveness of the developed antioxidant to stabilize diverse oils and fats.
Example 2—Influence of Gallic Acid in the Antioxidant Formulation
An antioxidant formulation which contains gallic acid, specifically comprising 7% gallic acid, 10% propyl gallate, 2% octyl gallate, 5% citric acid, 27% monopropylene glycol, 20% propionic acid, and 29% monoglycerides, was designated Formulation 2. It was compared with a formulation in which gallic acid was interchanged with propyl gallate, specifically, 17% propyl gallate, 2% octyl gallate, 5% citric acid, 27% monopropylene glycol, 20% propionic acid, and 29% monoglycerides, herein designated as Formulation 3. Note that the total antioxidant level remained unchanged at a level of 20%. According to the OSI induction time of both formulations tested in soybean oil, it is observed that the antioxidant system containing gallic acid (Formulation 2), which gave an OSI induction time of 26.7 h at a level of 500 ppm and an OSI induction time of 34.2 h at a level of 1000 ppm, has a higher antioxidant stability and longer OSI induction times compared to the formulation based on propyl gallate (Formulation 3), which gave an OSI induction time of 24.6 h at a level of 500 ppm and an OSI induction time of 32.9 h at a level of 1000 ppm. This evidences a synergistic effect between gallic acid and propyl gallate and demonstrates the beneficial effect of gallic acid as an effective antioxidant in the formulation.
Example 3—Influence of Octyl Gallate in the Antioxidant Formulation
The beneficial effect octyl gallate in the antioxidant system is demonstrated in this example. Octyl gallate was removed from the antioxidant formulation of Formulation 1; specifically, the composition comprises 7% gallic acid, 10% propyl gallate, 5% citric acid, 27% monopropylene glycol, 20% propionic acid, and 29% monoglycerides, denominated herein as Formulation 4, and the antioxidant mixture was tested in soybean oil. Formulation 4 gave an OSI induction time of 24.0 h at a level of 500 ppm and an OSI induction time of 30.0 h at a level of 1000 ppm. Removal of octyl gallate from the formulation significantly reduces the OSI induction time, which indicates a reduced antioxidant activity of Formulation 4 compared to an antioxidant formulation containing octyl gallate, Formulation 1.
Example 4—Inclusion of Other Synthetic Antioxidants in the Antioxidant Formulation
In the developed antioxidant formulation, synthetic antioxidants such as BHT, BHA, and others can be included as well. An example of an antioxidant formulation including BHT is given in Formulation 5, comprised of 7% gallic acid, 10% propyl gallate, 3% octyl gallate, 5% citric acid, 30% monopropylene glycol, 19% propionic acid, and 26% monoglycerides. An example of an antioxidant formulation including BHA is given in Formulation 6, comprising 7% gallic acid, 12% propyl gallate, 5% BHA, 5% citric acid, 27% monopropylene glycol, 20% propionic acid, and 29% monoglycerides. Formulation 5 gave an OSI induction time of 26.3 h at a level of 500 ppm and an OSI induction time of 34.5 h at a level of 1000 ppm. Formulation 6 gave an OSI induction time of 25.2 h at a level of 500 ppm and an OSI induction time of 34.9 h at a level of 1000 ppm. Formulation 5 and 6 are less active compared to Formulation 1, which contains octyl gallate in the antioxidant mixture. These data indicate the superior activity of the semi-synthetic octyl gallate above synthetic antioxidants.
Example 5—Efficacy of the Proposed Formulation
The efficacy of Formulation 1 was compared with antioxidant formulations based on single antioxidants; BHT, BHA, gallic acid, propyl gallate and octyl gallate as reference. Data of the antioxidant system of Formulation 1 was also collected. All antioxidant formulations were prepared based on a similar level of total antioxidants of 20%. Testing of their antioxidant efficacy was carried out on soybean oil. The OSI data are presented in Table 1.
TABLE 1
OSI induction time (h) of formulations based on single antioxidants
Concentrate: 250 ppm of antioxidant formulation
Propyl
Replicate
BHA
BHT
Gallic acid
gallate
Octyl gallate
Formula 1
1
14.0
15.5
21.6
19.5
19.3
21.3
2
14.2
15.4
20.7
21.5
19.3
21.2
3
14.5
15.0
22.0
20.1
19.5
21.6
Antioxidant formulations were based on 20% active antioxidant dissolved in the same carrier as used in Formulation 1.
According to the experimental data the antioxidant formulation of the invention stabilizes the oil significantly better compared with single antioxidants. BHA and BHT are frequently used as antioxidants in the food and feed industry, however compared with gallic acid, propyl gallate and octyl gallate, they are significantly less effective.
The proposed antioxidant formulation of the invention, for example, Formulation 1, performs significantly better compared to an antioxidant formulations based on single antioxidants gallic acid, propyl gallate, and octyl gallate. This superior activity of the proposed mixture may be explained by a synergistic effect of several antioxidants.
Example 6—Efficiency of the Liquid Antioxidant Formulation Compared with Pure Antioxidants
Pure crystalline antioxidants (BHA, BHT, propyl gallate and octyl gallate) are essentially insoluble in a lipid matrix without heating. Consequently, the application of a liquid antioxidant formulation is beneficial for an adequate mixing of the antioxidant into the oil matrix without an additional heating of the lipophylic medium. Antioxidant activity of single antioxidants directly dissolved in soybean oil was tested at a level of 250 ppm, 500 ppm and 1000 ppm.
TABLE 2
OSI induction time of soybean oil stabilized with synthetic antioxidants
Experiment carrier out at 98° C., control soybean oil had
induction time of 14.8 h
Antioxidant
concentration (ppm)
Antioxidant
250
500
1000
Ethoxyquin
14.4
12.5
BHA
14.0
15.5
21.5
BHT
17.9
20
25.6
Gallic acid
30.6
41.8
47.4
Propyl gallate
35.8
44.5
53.1
Octyl gallate
29.6
38.6
47.6
Formulation 1
21.6
27.9
37.0
The developed antioxidant formulation, Formulation 1, has a high antioxidant capacity. As the antioxidant Formulation 1 is only based on 20% active antioxidants, the level of active antioxidants is consistently lower. For example, 1000 ppm of antioxidant Formulation 1 only represents 200 ppm active antioxidants.
At all tested concentration levels, 250, 500 and 1000 ppm, the proposed antioxidant Formulation 1 performs significantly better compared with single synthetic antioxidants, for example, ethoxyquin, BHA, and BHT. For example at a level of 1000 ppm the antioxidant Formulation 1 stabilizes the soybean oil for 37 h in OSI, whereas 1000 ppm of ethoxyquin, BHA and BHT only give a stabilization ranging between 12.5-25.6 h in OSI.
At a level of 1000 ppm, the developed antioxidant Formulation 1 stabilizes the soybean oil significantly better compared with 250 ppm of single gallic acid antioxidants, gallic acid, propyl gallate and octyl gallate.
This demonstrates the higher activity of the presented antioxidant system due to what is believed to be a synergistic activity of the different antioxidant mixtures and their excellent distribution in the lipid matrix. In addition, the proposed liquid antioxidant formulation has the advantage of dissolving directly in oils and fats, even at room temperature.
Although the invention has been described with respect to a preferred embodiment thereof, it is to be also understood that it is not to be so limited since changes and modifications can be made therein which are within the full intended scope of this invention as defined by the appended claims. | A substantially oil- and fat-free single phase, homogenous antioxidant formulation that is readily dispersible in lipid matrices at ambient temperature by gentle stirring. The formulation includes a phenolic antioxidant compound, a liquid carrier, preferably a metal chelator, an emulsifier, and a polarity modifier. In preferred embodiment, a combination of lipid-soluble and water-soluble antioxidant compounds is included to provide an improved antioxidant effect. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to multi-tone data communication systems and methods, and more particularly to applicability of “bit loading” techniques in wireless local area networks (WLANs).
[0003] 2. Description of the Prior Art
[0004] Multi-tone communication systems have been widely adopted in applications such as DSL, broadband wireless access, and wireless local area networks. A frequently quoted motivation for the use of multi-tone systems is their performance in channels that experience frequency-selective fading. A key feature of multi-tone communication as applied in DSL and broadband wireless access systems is “bit loading”, a technique that combats frequency-selective fading effectively. In bit loading, the transmitter uses estimates of the current channel between it and the receiver, and sends less information on severely faded tones than on strong tones. This results in a large performance advantage over a system in which the same amount of information is sent on every tone.
[0005] Wireless local area networks standards such as the IEEE 802.11a and HiperLAN 2 standards have incorporated multi-tone PHY layer systems; and these systems are also part of the current incarnation of the IEEE 802.11g draft standard. In these systems, however, no bit loading is incorporated. This has the redeeming advantage that in a channel that changes dynamically from packet to packet, there is no danger of using out-of-date channel information from previous packets in combination with bit loading. This is one justification for the route taken by the standard. Whatever the motivation, however, there is a large performance penalty in the lack of bit loading capability. This affects achievable throughputs, reliability of transmission, and range, which are key desirable attributes of WLAN systems.
[0006] Of course it is possible to introduce a proprietary system that uses the general framework of these standards, but adds bit loading, along with suitable channel measurements or feedback from the transmitter to enable it. This, however, creates many potential problems of coexistence with existing standards-compliant networks. In such networks, many devices share the transmission medium, and employ elaborate protocols to ensure coexistence and overall efficient use of the medium. The transmission of signals that are not strictly compliant with the standard, and that therefore will not be recognized by other devices, creates many coexistence problems and presents a significant barrier to acceptance of the mode. In some domains, there may be regulatory barriers to the transmission of such signals.
[0007] It is therefore advantageous and desirable to provide a way to incorporate bit loading techniques into a proprietary or other nonstandard mode, but with the constraint that all transmitted signals are valid packets that adhere to the standard in the sense that the transmitted signals could all arise in the regular standard. That is, it is desirable to confine the nonstandard nature of the transmission to the mapping of data bits to the transmitted waveform, rather than allow new transmission waveforms.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to “bit loading” techniques associated with wireless local area networks (WLANs). A method is provided to incorporate bit loading into a proprietary or other nonstandard mode, but with the constraint that all transmitted signals are valid packets that adhere to the standard in the sense that the transmitted signals could all arise in the regular standard. That is, it is desirable to confine the nonstandard nature of the transmission to the mapping of data bits to the transmitted waveform, rather than allow new transmission waveforms.
[0009] According to one embodiment, a method of bit loading in a multi-tone wireless local area network (LAN) comprises the steps of identifying the weakest data tone associated with a desired standards-compliant air interface for a multi-tone wireless LAN; determining if any data bit(s) associated with the requisite communication protocol will be inserted into a weak tone subsequent to processing; and inserting a dummy bit if a data bit will be inserted into a weak tone subsequent to processing, such that the processed bit will be a zero.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Other aspects and features of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same become better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:
[0011] The FIGURE is flowchart depicting a method of pseudo-bit-loading according to one embodiment of the present invention.
[0012] While the above-identified drawing FIGURE sets forth a particular embodiment, other embodiments of the present invention are also contemplated, as noted in the discussion. In all cases, this disclosure presents illustrated embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The present invention is best understood with reference first to a main motivating example. This example is formulated in terms of IEEE 802.11a systems, but in almost all respects carries over to similar related systems. In the highest rate, 54 Mbps, mode in IEEE 802.11a systems, the data bits to be transmitted are first fed through a data scrambler, mapping the data sequence to a different data sequence. The scrambled data sequence is then fed through a rate ½ convolutional code. The coded output bits are punctured (a process in which some of the coded bits are thrown away). The punctured coded bits are then fed through an interleaver. The interleaved, punctured coded bits are then grouped into blocks of 6 bits, and mapped to signal points from a 64-QAM constellation, with one 64-QAM constellation per each of 48 data tones. With some final processing, these 48 data tones are assembled into one OFDM “symbol” waveform, and the symbol is transmitted across the channel. An 802.11a packet consists of a header followed by one or more OFDM symbols.
[0014] With reference now to the example described herein above, the most elementary version of a pseudo-bit-loading scheme 10 in accordance with one embodiment of the present invention as shown in the FIGURE, works as follows. The transmitter identifies the weakest data tone out of the 48 as shown in block 12 . This identification of the weakest data tone may be accomplished either by examining the last packet received from the other party, exploiting the symmetry of the channel seen in either transmission direction, or by the local receiver sending an explicit message indicating which tone it finds as weakest. Note that the number of coded bits sent on this weakest tone equals six times the number of OFDM symbols in the packet. A simple form of bit loading, for illustrative purposes, is to send zero bits of information on this tone, and for other tones to send the normal number of information bits for this mode. Conceptually, this can be achieved by modifying the input data stream in such a way that the eventual (scrambled, coded, punctured and interleaved) stream has six zeros assigned to each 64-QAM symbol mapped to the weakest tone. Considering a bit-by-bit representation of the overall encoding process, in which as data bits arrive one by one, the eventual position and 64-QAM symbol label component corresponding to the output processed bits are immediately calculated. As used herein, a “processed” bit is defined as a bit at the output of the composite scrambling-encoding-puncturing-interleaving operation. Before inserting a data bit into the system where the resulting processed bit or bits will end up, an immediate calculation is then first made to ensure these data bits will not end up in a weak tone that is inserted into the system as shown in block 14 . If, however, one of the processed bits ends up on a weak tone, a dummy data bit is then inserted into the system in such a way as to produce a 0 at the output of the processing as shown in block 16 . Since the channel code used in the IEEE 802.11a protocol has the property that the two output coded bits each vary with the input bit, it is always possible to choose the input dummy bit so as to set the desired output processed bit to 0. (The case in which there are two output processed bits, each is constrained to a target tone, and they cannot both be set to 0, is discussed herein below.)
[0015] The net result of this process is that the input data stream will have been corrupted by the insertion of redundant dummy bits; and the overall rate of the system will have been lowered slightly. On the other hand, there is the desired benefit that the new, corrupted data stream maps to a transmitted waveform that has all zeros on each weak tone, but is also a valid transmitted waveform of the IEEE 802.11a protocol: in fact, it is the valid waveform that would result if the user had happened to want to send the corrupted data, rather than the original data.
[0016] At the decoder, the effect of the data corruption can be compensated for in the following way. The special mode is signaled by the use of appropriate header bits, so that the receiver is aware that the transmission has been modified, and is aware of where the modified bits occur. The received waveform, which consists of the transmitted waveform modified by the frequency-selective fading channel, with added noise, is processed in the normal way. However, in the decoder for the convolutional code, all bits corresponding to the weak tones have been constrained to be zero in the transmitted sequence, and so the decoder forces corresponding trellis transitions in the decoding process. This method of allowing for the presence of known bits in decoding a convolutional code is a standard procedure known as “state pinning” and is well understood to those skilled in the art. This method is known to be effective in maintaining high decoder performance. The resulting decoded stream of bits at the output of the normal receiver process is then the receiver's best estimate of the transmitted, corrupted data sequence. The receiver, knowing the weakest tone from its own estimate of the channel, or by agreement with the transmitter, can reverse the dummy bit-stuffing process to identify the dummy bits added to the transmitted stream and recover the original data bits.
[0017] Effectively, when all goes well, the system has managed to communicate while avoiding the weakest tone, and still communicating all required information, using a waveform that complies with the air-interface format of the standard.
[0018] The present invention is not so limited however, and those skilled in the art will understand the embodiments discussed herein before may be extended in an obvious way to cover more tones, and varying numbers of information bits per tone.
[0019] In practice, there are reasons why it is not desirable for the weakest tone always to map to exactly the same bit sequence: this produces undesirable radio effects. To combat this, the transmitter and receiver may agree in advance on a rotating known sequence of fixed bits patterns for the target tones. This produces no essential change to the operation of the proposed scheme.
[0020] According to one embodiment of this scheme, the CRC checksum (an overall check to ensure the reliability of the final data) can be modified by masking with a pre-agreed known non-zero pattern. This, being pre-agreed between the transmitter and receiver, will have no adverse effect on reception by the intended recipient. Unintended recipients that conform only to the existing standard, however, will decode the packet in the normal, standards-compliant way, without compensating in the required way for the padded dummy bits. The modification to the overall CRC check will ensure that with very high probability the unintended recipient will produce a CRC error and discard the packet as unreliable. The purpose of this is not security against unauthorized reception, but rather to ensure that the unintended recipient does not utilize information from the decoded MAC header part of the payload to perform any standards-compliant function.
[0021] This is important as this information is sometimes used by other devices in the network, and there would otherwise be the danger that these other devices could “decode” a deliberately-corrupted packet and use the corrupted data for network update purposes, with undesirable consequences.
[0022] As stated herein before, it is possible that there will be two output processed bits at the next time unit, both to be assigned to restricted tone bits, and that there is no way to specify both simultaneously. This situation can be handled in a number of ways. One way is to choose the input dummy bit to assign the first output processed bit in the normal way, then subsequently reverse the understanding of 0's and 1's. This takes care of the second bit; note that the receiver can reverse-engineer all these steps and recover the intended bits.
[0023] In view of the above, it can be seen the present invention presents a significant advancement in the art of “bit loading” techniques associated with wireless local area networks (WLANs). Further, this invention has been described in considerable detail in order to provide those skilled in the WLAN art with the information needed to apply the novel principles and to construct and use such specialized components as are required. In view of the foregoing descriptions, it should be apparent that the present invention represents a significant departure from the prior art in construction and operation. However, while particular embodiments of the present invention have been described herein in detail, it is to be understood that various alterations, modifications and substitutions can be made therein without departing in any way from the spirit and scope of the present invention, as defined in the claims which follow. | A method 10 is provided to incorporate bit loading into a proprietary or other nonstandard mode, but with the constraint that all transmitted signals are valid packets that adhere to the standard in the sense that the transmitted signals could all arise in the regular standard. That is, it is desirable to confine the nonstandard nature of the transmission to the mapping of data bits to the transmitted waveform, rather than allow new transmission waveforms. | 7 |
FIELD OF THE INVENTION
The present invention relates to the allocation of bandwidth in constrained topology ethernet networks.
BACKGROUND OF THE INVENTION
Ethernet has become the most popular physical layer for local area networks and is finding a market in larger data networks (i.e. metropolitan area and wide area). The popularity of ethernet is due in part to the good balance found between cost, speed and installation and maintenance difficulty.
The desire to reduce operating costs in networks of all sizes has produced the movement towards networks that can provide multiple services, such as carrying voice, video and data. Many of the current solutions to this problem have relied on ATM switching to map multiple services onto a network. These ATM networks typically operate at speeds between DS-1 (1.544 kbps) to OC-48 (2.5 Gbps) but the cost resulting from the higher speed complex processing leads to expensive network solutions. In addition, as traffic demands grow the evolution to faster ATM products is very costly. Further, expensive equipment is required to connect to an ATM-based network.
While ATM cells are effective for controlling “first mile jitter” problems, they are inefficient for carrying both voice and data as the cells are too long for voice but too short for data.
The use of frame-based ethernet, especially Gigabit ethernet, as a solution for the problems encountered with data traffic using ATM switching has been capitalized in the metropolitan area network (MAN) by providers such as Yipes™ and Telseon™. However, current high-speed ethernet-based networks only provide a single data service.
As the transmission rate for ethernet has increased to 1 Gbps and 10 Gbps it becomes possible to mix real-time traffic with large data frames without incurring large delays since the real-time packets no longer incur a long delay waiting for the completion of the transmission of a large data packet. For example, a 1500 byte data packet only requires 1.2 microseconds on an Ethernet network where as at ATM OC-3 rates (150 Mbps) an ATM cell requires a similar order of magnitude time at 2.8 microsceonds.
Although ATM networks operate at slower speeds than other networks, for example ethernet-based networks, ATM provides a guaranteed level of service not provided by ethernet-based networks. ATM networks offer Quality of Service (QoS) that guarantees a throughput level on the network between origination and destination.
The advantage of ATM networks is that this QoS ensures that under traffic congestion conditions some users can be guaranteed that their traffic will never be discarded. This characteristics makes ATM attractive for real-time applications, such as circuit emulation, where even small amounts of information loss can severely impact the service. Ethernet networks on the other hand are only able to assign traffic to classes that have different traffic handling characteristics. Unfortunately, these classes do not guarantee that data within these classes is never discarded. If the total volume of traffic requests for a specific class exceeds the bandwidth assigned to that class traffic will be discarded.
Further, since the path taken by packets in an ethernet network is not known by the source and there is no switch by switch allocation of bandwidth on trunks, an ethernet network is not able to allocate bandwidth to specific data flows.
SUMMARY OF THE INVENTION
For assigning bandwidth in a constrained topology ethernet network there is presented a function that creates and manages a ledger of bandwidth requests over the ethernet network. The function, a bandwidth manager, tracks the total bandwidth of each link in the network and the bandwidth that has been reserved on each link. When traffic is granted reserved bandwidth the bandwidth manager notes this allocation in the ledger. The header of the traffic packets indicates that the traffic is of highest priority when the traffic has been given reserved bandwidth. In this manner the bandwidth manager can track and limit the amount of high priority traffic on the network.
In accordance with one aspect of the present invention there is provided a bandwidth manager for controlling bandwidth resources in an ethernet network having a plurality of nodes, selected pairs of nodes being separated by links of predetermined link bandwidth capacities, the ethernet network having a plurality of paths connecting at least two of the plurality of nodes together, each of said plurality of paths being composed of at least one link. The bandwidth manager includes: means for receiving a bandwidth reservation request including a requested bandwidth capacity, an origination point and a destination point; means for storing available bandwidth capacity for each link in the ethernet network; and means for reserving link bandwidth capacity on a selected one of the plurality of paths based on said bandwidth reservation request and said available bandwidth capacity for each link in the selected one of the plurality of paths.
In accordance with another aspect of the present invention there is provided a method of controlling bandwidth resources in an ethernet network having a plurality of nodes, selected pairs of nodes being separated by links of predetermined link bandwidth capacities, the ethernet network having a plurality of paths connecting at least two of said plurality of nodes together, each of said plurality of paths being composed of at least one link. The method includes the following steps: receiving a bandwidth reservation request including a requested bandwidth capacity, an origination point and a destination point; storing available bandwidth capacity for each link in the ethernet network; and reserving link bandwidth capacity on a selected one of the plurality of paths based on said bandwidth reservation request and said available bandwidth capacity for each link in the selected one of the plurality of paths.
In accordance with another aspect of the present invention there is provided a node on an ethernet network for controlling bandwidth resources, the ethernet network having a plurality of nodes, selected pairs of nodes being separated by links of predetermined link bandwidth capacities, a plurality of paths connecting at least two of the plurality of nodes, each of said plurality of paths being composed of at least one link. The node comprising: a receiver accepting a bandwidth reservation request including a requested bandwidth capacity, an origination point and a destination point; a data store containing available bandwidth capacity for each link in the ethernet network; and a request processor for reserving link capacity on a selected one of the plurality of paths based on said bandwidth reservation request and said available bandwidth capacity for each link of the chosen one of the plurality of paths.
In accordance with another aspect of the present invention there is provided a computer readable medium having stored thereon computer executable instructions for controlling bandwidth resources in an ethernet network having a plurality of nodes, selected pairs of said plurality of nodes being separated by links of predetermined link bandwidth capacity, the ethernet network having a plurality of paths connecting at least two of said plurality of nodes together, each of said plurality of paths being composed of at least one link. The computer executable instructions comprising the steps of: receiving a bandwidth reservation request including a requested bandwidth capacity, an origination point and a destination point; storing available bandwidth capacity for each link in the ethernet network; and reserving link bandwidth capacity for a selected one of the plurality of paths based on said bandwidth reservation request and said available bandwidth capacity for each link in the chosen one of the plurality of paths.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in conjunction with the drawings in which:
FIG. 1 illustrates a ring topology ethernet network having bandwidth allocation capabilities according to an embodiment of the present invention;
FIG. 2 illustrates a star topology ethernet network having bandwidth allocation capabilities according to an embodiment of the present invention;
FIG. 3 illustrates a system diagram of a bandwidth manager according to an embodiment of the present invention;
FIG. 4 illustrates a flow diagram of the bandwidth manager according to an embodiment of the present invention; and
FIG. 5 illustrates a system diagram of a bandwidth allocation interface for an ethernet bridge according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a network architecture diagram of a ring topology ethernet network 10 having bandwidth allocation capabilities according to an embodiment of the present invention. This invention enables bandwidth to be effectively assigned in the ethernet network 10 through a combination of a constrained topology network 10 and the use of a bandwidth manager 16 that creates and manages a ledger of bandwidth requests for the ethernet network 10 .
Ethernet bridges 12 connect data sources 24 to the ethernet network 10 . The data sources 24 may be individual data producing devices, such as computers, or the data sources may be other networks. The data sources 24 each have interfaces (not shown) at the ethernet bridges 12 connecting them and allowing them to send data between the data source 24 and the ethernet bridge 12 . Packets having headers that contain a data source address for the originator and a data source address for the destination are forwarded to the ethernet bridges 12 to be sent along the ethernet network 10 .
The ethernet bridges 12 are simple switching devices and do not contain routing functions. The ethernet bridges 12 learn what data sources 24 are connected to each ethernet bridge 12 by looking at the data source address for the originator in each data packet that passes through the bridge 12 and remembering the interface the packet arrived on. The ethernet bridges 12 all have data stores (not shown) that contain a listing of the data source addresses and corresponding interfaces that may be used for translating data source addresses for the destination into an interface to which a received packet may be forwarded.
Connected within the ethernet network 10 to the ethernet bridges 12 is a core switch 18 that interfaces the ethernet network 10 with a second network (not shown). The second network to which the core switch 18 is interfacing can be a network using a different communications protocol or physical layer than the ethernet network 10 . The core switch 18 examines the packets it receives and determines a destination point on the second network. The packet can then be forwarded to its destination point. The core switch 18 can also analyze the entire packet to look for errors that would keep the packet from propagating through the second network. The core switch 18 may employ a number of switching technologies, such as ATM, TDM cross-connects or MPLS switches. In all three cases, the core switch 18 would assign bandwidth to connections in the second network to ensure that the bandwidth requested in the ethernet network 10 is provided end-to-end for the packets.
The bandwidth management for a ring topology is described in network 10 . The bandwidth reservation and allocation capabilities in the network 10 are found in a bandwidth manager 16 and bandwidth allocation interfaces 14 . The bandwidth manager 16 may be a separate component attached one of the switches in the network 10 , or alternatively, the functions of the bandwidth manager 16 may be contained in one of the ethernet bridges 12 .
The bandwidth manager 16 is the single source in the network 10 for the allocation and reservation of bandwidth. When a data source 24 connected to one of the ethernet bridges 12 desires bandwidth reservation the bandwidth manager 16 is contacted and the request is made. The bandwidth manager 16 , once bandwidth availability for each link in the network 10 has been determined, reserves the requested bandwidth. The originating data source 24 is informed that the bandwidth has been reserved and prepares the packet headers accordingly.
The bandwidth allocation interfaces 14 are each connected to each of the ethernet bridges 12 to enable the bridges 12 to communicate with the bandwidth manager 16 . The bandwidth allocation interface 14 negotiates with the bandwidth manager 16 for bandwidth reservation. The role of the bandwidth allocation interface 14 is to accept requests for bandwidth from data sources 24 and to forward those requests to the bandwidth manager 16 .
For CBR (Constant Bit Rate) traffic, the packet headers have a priority status indictor noting that the traffic must be forwarded at the highest priority. Control traffic might run at a higher priority than CBR but since control traffic has a very low volume the bandwidth manager 16 includes control traffic in its highest priority allocation. To provide the required service for CBR traffic, the ethernet bridges 12 have an absolute priority queuing mechanism (“serve to exhaustion”) for the highest priority traffic. If the ethernet bridge 12 has a configurable bandwidth allocation mechanism, the bandwidth manager 16 must communicate back to each ethernet bridge 12 to modify the bandwidth to reflect the increase (or decrease if a connection is terminated) in requested bandwidth.
Only data sources 24 that are participating in the reservation mechanism are allowed to send packets with packet headers set to the highest priority to ensure only registered users have access to this service. This is controlled by both the bandwidth manager 16 and the bandwidth allocation interface 14 by comparing the source address in a packet header with a list containing those data sources 24 that have permission to reserve bandwidth on the network 10 .
The bandwidth manager 16 reserves the required bandwidth for traffic around the network 10 . This ensures that if there is a break in the network 10 , either due to failure of an ethernet bridge 12 or a cut in the link between a pair of ethernet bridges 12 , traffic can be forwarded in the opposite direction around the network 10 to reach the destination without concern for congestion, i.e. the bandwidth is allocated to all links around the entire network 10 . Since the network topology has been constrained to a ring in this case, the bandwidth can be allocated without explicit knowledge for each connection by each ethernet bridge 12 .
In the ring topology where all traffic is destined to the core switch 18 , link between the ethernet bridges 12 may have different link capacity. For example, the links furthest away from the core switch 18 may have a lower link capacity than those links closer to the core switch 18 .
FIG. 2 is a network architecture diagram of a star topology ethernet network 26 having bandwidth allocation capabilities according to an embodiment of the present invention. Ethernet multiplexers(muxes)/bridges 12 connect and multiplex multiple data sources 24 to the network 26 . Traffic from multiple data sources 24 , such as individual data producing devices or networks, are multiplexed together at the ethernet mux/bridge 20 to be passed to an ethernet switch 22 .
Each ethernet mux 20 is aware of all the data sources 24 that are directly connected to that mux 20 . Since the ethernet switches 22 are not interconnected all traffic flows from originating mux 20 to one ethernet switch 22 to destination mux 20 . That is, each ethernet mux 22 is connected to the same ethernet switch 22 as the destination mux 20 . In this constrained architecture each mux 20 operates a local instance of a bandwidth manager 16 to ensure that there is no congestion on the link to the ethernet switches 22 that would violate the bandwidth contracts requested by the data sources 24 . The bandwidth manager 16 , as in FIG. 1 is the source for allocation and reservation of bandwidth.
Traffic enters the ethernet mux 20 from a data source 24 that is participating in the reservation system. The traffic is inserted into an ethernet packet (e.g. circuit emulation over MPLS over ethernet) and the destination address is the address of a port on this or another ethernet mux 20 . The packet is forwarded from the mux 20 to the ethernet switch 22 where the destination address is examined and the packet is then forwarded onto the destination.
Multiple ethernet mux/bridges 20 are redundantly connected to multiple ethernet switches 22 . Each ethernet switch 22 is connected to the same ethernet muxes/bridges 20 . That is, each ethernet mux/bridge 20 is individually connected to each ethernet switch 22 . In this manner, if one of the ethernet switches 22 fails then the other ethernet switch 22 will take over the functions of the failed switch 22 .
The ethernet switches 22 are unaware of the bandwidth allocations made by the ethernet muxes 20 , making it possible for the ethernet switch 22 to forward a connection request to the mux 20 that exceeds the remaining bandwidth on the link between the mux 20 and the ethernet switch 22 . In this situation, the mux 20 will refuse the request back to the source mux 20 . In the star topology 26 , there is not a bandwidth allocation interface since the bandwidth manager 16 is operated in the mux 20 (i.e. not centralized as in the ring topology) and therefore there is no need to communicate with a remote bandwidth manager.
The core switch 18 in the star network 26 is connected to each of the ethernet routers 22 . The core switch 18 , as in FIG. 1 , interfaces the ethernet network 26 with another network. The network to which the core switch 18 is interfacing can be a network using a different communications protocol or physical layer than the ethernet network 10 .
FIG. 3 is a system diagram of a bandwidth manager 16 according to an embodiment of the present invention. Bandwidth request packets from the bandwidth allocation interfaces 14 requesting bandwidth are received at an I/O interface 40 and passed to a request processor 42 . The request processor 42 is responsible for coordinating bandwidth reservation request processing. The request processor 42 extracts the requested bandwidth capacity from the bandwidth request packet and consults a bandwidth ledger 44 to determine if there is sufficient bandwidth available on all links in the path to be taken by the traffic.
The bandwidth ledger 44 includes a main table 46 containing basic information on each of the links in the network 10 , 26 . The links are defined by the two endpoints on the link. As different links may have different bandwidth capacity, the total bandwidth for each link is noted with the allocated and available bandwidth. For the bandwidth that has been allocated an allocation table 48 provides details of each reservation for the link. Allocated bandwidth has an identifier that is assigned to the source of the traffic. This allows audit to be performed to ensure that bandwidth is not assigned to a source that no longer exists. Each identifier has an associated bandwidth amount that has been reserved and an associated priority level.
The bandwidth manager 16 may keep separate ledgers for different services such as CBR (Constant Bit Rate) and VBR (Variable Bit Rate). For CBR requests, the bandwidth manager 16 must ensure that the full bandwidth request is allocated to the requester since CBR guarantees that the sender can send at the requested rate with absolutely no loss of information. For VBR traffic, the bandwidth manager 16 may choose to allocate more bandwidth than is available since for VBR as the user is not given an absolute guarantee but a probability that they can send at the requested rate.
The request processor 42 has a bandwidth ledger interface 50 and a booking manager 52 . The bandwidth ledger interface 50 provides the request processor 42 with an interface to the bandwidth ledger 44 . The bandwidth ledger interface 50 enables the request processor 42 to access the tables 46 , 48 containing bandwidth capacity information. The information accessed by the bandwidth ledger interface 50 allows the request processor 42 to determine if there is enough bandwidth capacity of the links between the origination and destination points to complete a received bandwidth reservation request. The booking manager 52 receives an indication that there is sufficient bandwidth and reserves capacity on each link between the destination and origination points as indicated in a bandwidth reservation request.
The bandwidth manager 16 also contains a registered data sources table 50 that lists all data sources 24 that are registered to use the bandwidth reservation offered by the bandwidth manager 16 . Upon receiving a request for bandwidth reservation, the request processor 42 consults the data sources table 50 to ensure the data source 24 requesting the bandwidth reservation is registered to use the service.
FIG. 4 is a flow diagram of the bandwidth manager 16 according to an embodiment of the present invention. At initialization the bandwidth manager 16 would clear the bandwidth ledger 44 of allocated bandwidth to zero for all links in step 62 . A request for bandwidth reservation is received in step 64 at the bandwidth manager 16 from the bandwidth allocation interface 14 . The request contains the originator address, the priority level of the traffic and the amount of bandwidth requested. The information contained in the request is extracted in step 66 . The bandwidth manager 16 checks to confirm that the requesting data source 24 is registered to reserve bandwidth in step 68 . If the requesting data source 24 is not registered then the bandwidth allocation interface 14 that sent the request is informed that the request could not be completed in step 76 .
Based on the path through the network the traffic will follow the bandwidth manager 16 checks each link for the available bandwidth in step 70 . The path will be dependant on the topology of the network. For example, in a ring configuration the path is considered to be the entire ring network so bandwidth on every link in the network must be reserved. In a star configuration only bandwidth on those links between originator and destination ethernet muxes and a connecting ethernet switch needs to be reserved. The available bandwidth is compared in step 72 to the request for bandwidth to ensure there is sufficient available bandwidth for the requested reservation. If there is insufficient bandwidth on at least one of the links in the path then the bandwidth allocation interface 14 is informed in step 76 that the request for bandwidth reservation cannot be completed.
If there is sufficient bandwidth available on all links then the bandwidth manager 16 reserves the requested bandwidth for all links in the path in step 74 . This is accomplished by adding an entry to the allocation table 48 of each link in the route. Each new entry in each allocation table 48 for each link will contain identical information (i.e. originator address, bandwidth allocated and priority level of traffic).
FIG. 5 is a system diagram of a bandwidth allocation interface 14 for an ethernet bridge according to an embodiment of the present invention. An I/O interface 80 connects the bandwidth allocation interface 14 with the ethernet bridge 12 . The I/O interface 80 sends messages to the bandwidth manager 16 requesting a reservation of bandwidth.
The bandwidth reservation requests are prepared by a message packager 82 connected to the I/O interface 80 . The message packager 82 receives information from a bandwidth calculator module 84 , a priority level module 86 and a destination module 88 . The information received from these modules 84 , 86 , 88 is the basis for the bandwidth reservation request.
The bandwidth allocation interface 14 contains a registered data source table 90 having a list of all data sources 24 connected to the ethernet bridge 12 of the bandwidth allocation interface 14 that are registered to reserve bandwidth. The message packager 82 consults the registered data source table 90 to determine if a bandwidth reservation request should be forwarded based on whether or not the originator is listed as being registered to reserve bandwidth.
The bandwidth calculator module 84 , the priority level module 86 and the destination module 88 extract data from traffic coming into the ethernet bridge 12 that is destined for the network 10 . The destination module 88 examines all traffic coming into the ethernet bridge 12 to determine its destination point. If the detected destination point is accessible by the network 10 then the destination module 88 extracts the destination point from the traffic and forwards this information to the message packager 82 . This causes the priority level module 86 to be invoked to determine the traffic type. Based on the traffic type the priority level module 86 can determine whether or not bandwidth needs to be reserved. If the traffic is time-sensitive, such as voice, then the priority level module 86 informs the bandwidth calculator module 84 that bandwidth must be reserved. The priority level module 86 passes the priority level of the traffic to the message packager 82 . The bandwidth calculator module 84 determines the amount of bandwidth that needs to be requested and forwards this to the message packager 82 . Upon receipt of the bandwidth amount the message packager 82 creates a request for bandwidth that is transmitted to the bandwidth manager 16 .
It is apparent to one skilled in the art that numerous modifications and departures from the specific embodiments described herein may be made without departing from the spirit and scope of the invention. | For assigning bandwidth in a constrained topology ethernet network there is presented a function that creates and manages a ledger of bandwidth requests over the ethernet network. The function, a bandwidth manager, tracks the total bandwidth of each link in the network and the bandwidth that has been reserved on each link. When traffic is granted reserved bandwidth the bandwidth manager notes this allocation in the ledger. The header of the traffic packets indicates that the traffic is of highest priority when the traffic has been given reserved bandwidth. In this manner the bandwidth manager can track and limit the amount of high priority traffic on the network. | 7 |
This invention relates to fossil fuel boilers and more specifically to an improved overfire air injector for fossil fuel fired boilers.
BACKGROUND OF THE INVENTION
Overfire air (OFA) injection is a common technique for reducing NOx emissions from fossil fuel fired boilers equipped with reburn systems. An OFA system typically consists of overfire air injectors installed on the boiler walls; ductwork to route combustion air from the air supply to the injectors; and controls for modulating the overfire air flow rate. In many areas of the country NOx emissions control is a seasonal requirement, so that equipment must be designed with the understanding that it will be out of service for prolonged periods of time. For example, in a typical OFA injector, combustion air must be admitted to the injector when it is out of service in order to maintain the temperature of the injector components below the point at which they will be damaged by exposure to the radiant heat of the furnace. The cooling air flow results in operation of the burners at reduced stoichiometric ratios, and can lead to increased carbon loss and to furnace tubewall corrosion. The increased carbon loss and increased tubewall corrosion lead to increased operating costs and a significant loss of revenue.
The current solution to reduce the cooling air requirements is to design a water-cooled throat that provides conductive cooling to the OFA injector. This solution can reduce the cooling air flow as compared to a non-water-cooled throat design, but still results in OFA cooling flow rates that are in the range of 5-10% of the total combustion air.
There remains a need for a more effective way to protect OFA injectors with reduced use of combustion air as cooling air.
BRIEF DESCRIPTION OF THE INVENTION
This invention seeks to reduce the cooling air flow to below 5% when the OFA system is out of operation by shielding the OFA injector components from the radiant heat of the furnace. The OFA injector in accordance with an exemplary embodiment of the invention continues to utilize a water-cooled throat, but now includes a housing or damper box on the front end of the injector with actuated gates or doors that may be closed when desired to shield the injector hardware from the high temperature environment of the furnace. The OFA injector may have dual passages to extend the range of operation of the injector, but for some applications, only one passage may be required.
During normal operation, and when the OFA system is operating, the damper box doors are open. When the OFA system is not in operation, automatic actuators are used to close the doors and thereby shield the OFA injector. It is within the scope of the invention, however, to employ manual actuation if desired. The doors and interior surfaces of the damper box are also covered with refractory or other insulating material to provide additional protection from the high furnace gas temperatures.
Accordingly, in its broader aspects, the invention relates to a damper box for an orifice air injector, the damper box comprising front and rear faces with respective front and rear openings therein, a pair of sides, a top and a bottom; and a pair of gates pivotally mounted within the damper box and actuatable between open and closed positions.
In another aspect, the invention relates to a housing for an overfire air injector comprising a rearward portion adapted for connection to a supply duct and a forward portion having an attachment flange; a damper box secured to the attachment flange, the damper box having front and rear faces with respective front and rear openings therein, a pair of sides, a top and a bottom; and a pair of gates pivotally mounted within the damper box adjacent the front opening and actuatable to move the gates between open and closed positions.
In still another aspect, the invention relates to a method of shielding an overfire air injector in a fossil fuel fired boiler from heat during periods when the overfire air injector is not in use comprising: a) adding a damper box to a front end of a housing enclosing the overfire air injector, the damper box having a front opening and at least one gate actuatable between open and closed positions; and b) closing the front opening by moving the at least one gate to the closed position when the overfire air injector is not in use.
The invention will now be described in detail in connection with the drawing figures identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of a conventional fossil fuel fired boiler;
FIG. 2 is a perspective view of an overfire air injector in accordance with an exemplary embodiment of the invention;
FIG. 3 is a perspective view of a damper box for use with the overfire air injector of FIG. 2 ;
FIG. 4 is a lower left perspective view of the overfire air injector shown in FIG. 3 ;
FIG. 5 is a rear perspective view of the overfire air injector of FIG. 2 ;
FIG. 6 is a section view taken along the line 6 — 6 of FIG. 5 ;
FIG. 7 is a top plan view of the overfire air injector shown in FIG. 5 ;
FIG. 8 is a section view of a gland plate surrounding a pivot shaft in the damper box in accordance with the exemplary embodiment of the invention;
FIG. 9 is a section view taken along the line 9 — 9 of FIG. 6 ;
FIG. 10 is a perspective view of a damper gate of the type shown in FIGS. 1-7 ;
FIG. 11 is a plan view of the damper gate shown in FIG. 10 ;
FIG. 12 is a side elevation of the damper gate shown in FIG. 10 ; and
FIG. 13 is an end view of the damper gate shown in FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic depiction of a fossil fuel fired boiler 10 that includes a main combustion zone 12 , a reburning zone 14 , and a burnout zone 16 . The combustion zone 12 is equipped with a plurality of main burners 18 which are supplied with a main fuel, such as coal and air, through a fuel input 20 and an air input 22 , respectively. The main fuel is burned in burners 18 in the presence of air, to form a combustion flue gas 24 that flows in a downstream direction from combustion zone 12 to reburning zone 14 . In some arrangements, about 85% of the total heat input can be supplied by main burners 18 . The reburning fuel, such as natural gas, is injected through reburn fuel input 26 and provides the remaining heat input. Reburn fuel could also be any fossil fuel, i.e., coal, oil, orimulsion or propane gas. In burnout zone 16 , overfire air is injected through an OFA injector 28 to complete combustion, and the flue gas then passes through a series of heat exchangers 30 and out of the boiler via outlet 32 .
FIG. 2 illustrates a new OFA injector 28 in more detail, useable in the conventional boiler 10 . The assembly includes an elbow duct 34 that feeds the overfire air into a rectangular spool assembly housing 36 . The housing 36 supports three aspirators 38 , 40 and 42 on respective top and side walls of the housing. The internal injector hardware is not particularly relevant to this invention and, thus, no detailed description of that hardware is required. In addition, the upstream duct 34 as shown is exemplary only, and would have various cross-sectional shapes.
The present invention relates to a novel damper box construction to be added to the front face of the rectangular OFA injector housing 36 for protecting the OFA injector hardware when not in use.
With reference now to FIGS. 3-7 , an overfire air injector damper box 44 in accordance with this invention is shown. The damper box 44 includes a flat front face 46 , a flat rear face 48 , sides 50 , 52 , top 54 and bottom 56 . The sides 50 , 52 , top 54 and bottom 56 are reinforced by front-to-back webs 58 , 60 and side-to-side webs 62 , 64 . Thus, the damper box 44 is a generally square, hollow structure with a front opening 66 and a rear opening 68 . The rear opening 68 is surrounded by a rigid frame structure 70 utilized for mounting the damper box 44 to a similar frame 72 on the front face of the OFA injector 28 by means of holes 74 and bolts or other suitable fasteners.
Apertures 74 in the frame structure 70 facilitate attachment of the damper box to a wall of the boiler 10 .
Within the damper box 44 are a pair of doors or gates 76 , 78 located adjacent the front opening 66 and arranged to swing between open and closed positions vis-a-vis the front opening 66 . Other gate arrangements may be utilized, including the use of a single gate or door where space permits. Since the doors are mirror images of each other, only one need be described in detail. With reference also to FIGS. 8-11 , gate 76 is mounted on a hinge shaft 80 that is rotatably supported within the damper box. Specifically, the lower end of shaft 80 is journalled for rotation in a lower gland plate 82 fastened to the underside of the gate bottom 56 via fasteners 84 . Gland plate 82 includes packing 86 that permits the shaft to rotate relative to the plate. Similarly, the upper end of shaft 80 is journalled for rotation in an upper gland plate 88 fastened to the top surface of gate top 54 via fasteners 90 . The gland plate 88 is similar to plate 82 and also includes packing (not shown).
A pair of split, annular collars 94 , 96 are located on the shaft 80 under the gate top 54 and above the gate bottom 56 , respectively. Collar 96 is oversized and serves to isolate the shaft and lower gland plate 82 from dust. The lower collar 96 on the damper box bottom 56 is enclosed within a stainless steel cover 98 .
As best seen in FIGS. 10 and 11 , a gate hinge handle shaft 100 is telescopingly received within the shaft 80 with a transverse pin 102 located within a slot 104 in the tubular shaft 100 to insure that shaft 80 will rotate with the handle shaft 100 . A bolt 106 passes through the shafts 80 , 100 and is secured by nut 108 , just above collar 96 (within the cover 98 ) and serves to lock the shafts 100 to the shaft 80 .
A gate hinge handle 110 is fastened to the lower end of handle shaft 100 via bolt 112 and nut 114 . It will be appreciated that the handle 110 (and similar handle on the door 78 ) may be operated manually or operatively connected to suitable hydraulic, electrical and/or mechanical controls for automatically moving the doors 76 , 78 to open the doors.
With reference also to FIGS. 10-14 the door 76 is constructed of a first plate 116 and a transverse edge plate 118 welded at the hinge end of the door. A corner plate 120 includes mutually perpendicular sides 122 , 124 , with side 124 welded to the edge plate 118 such that a portion of plate 116 , edge plate 118 , and sides 122 , 124 of plate 120 surround three sides of the hinge shaft 80 , with plate 116 extending further across the interior face of the door. The back side 126 of plate 116 is reinforced by a rectangular configuration of horizontal stiffening ribs 128 , 130 , 132 and vertical stiffening ribs 134 , 136 . A refractory block 138 is secured to the front side of plate 116 via refractory anchor clips 140 , 142 and 144 . A second refractory block 146 is secured behind the corner plate 120 about the front of the hinge shaft 80 , and adjacent block 138 .
Similar refractory blocks are applied to the interior of the damper box as best seen in FIGS. 4 , 7 and 10 . Specifically, block 148 ( FIG. 7 ) is applied to the underside of top 54 with the assistance of one or more refractory anchors 150 . Refractory block 152 is applied to the interior side of bottom 56 via one or more anchors 154 . The block 152 is cut out and beveled around the covers 98 as best seen in FIG. 4 to allow for door removal and installation without having to also remove the block 152 . The refractory “blocks” noted above are preferably molded directly onto their respective supporting surfaces but other suitable application techniques may be employed.
Insulation board panels 156 , 158 are applied to the interior surfaces of sides 50 , 52 .
Refractory blocks 138 , 148 and 152 have a maximum service temperature of 3200° F., a density of 159 PCf @ 300° F., and a thermal conductivity of 11-43 (BTU-IN/HR—FT 2 ° F.). The refractory material is available under the trade name “Vesuvius Criterion 70 M.” Block 146 has as maximum service temperature of 2300° F., a density of 61 PCf @ 300° F., and a thermal conductivity of 2.4 (BTU-IN/HR—FT 2 ° F.) and is available under the trade name “Vesuvius Litewate 58.” Insulation board panels 156 , 158 have a maximum service temperature of 2600° F. and a density of 25 PCf @ 3000° F. Other refractory block, insulation board and refractory material with similar insulating properties suitable for this application may be employed.
By enabling effective heat shielding of the OFA injector hardware when not in use, less than 5% combustion air is required to maintain the injector components at an acceptable temperature.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A damper box for an orifice air injector, the damper box comprising front and rear faces with respective front and rear openings therein, a pair of sides, a top and a bottom; and a pair of gates pivotally mounted within the damper box and actuatable between open and closed positions. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to the commonly assigned, copending U.S. application Ser. No. 07/117,841, filed Nov. 9, 1987, and entitled "METHOD FOR MANUFACTURING A PERFORATED BODY, FRICTION SPINNING MEANS USING THE PERFORATED BODY AND A FRICTION SPINNING DEVICE USING THE FRICTION SPINNING MEANS", and the commonly assigned, co-pending U.S. application Ser. No. 07/119,497, filed Nov. 12, 1987, and entitled "OPEN END FRICTION SPINNING DEVICE FOR PRODUCTION OF A YARN OR THE LIKE AND METHOD FOR PRODUCTION OF FRICTION SPINNING MEANS" the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a friction spinning drum of the type comprising a hollow perforated drum designed for substantially radial throughflow of air.
Such friction spinning drums are used in known friction spinning processes or methods in which usually two cylindrical drums arranged adjacent each other rotate in the same direction, at least one of the two drums being a perforated drum as above described.
The purpose of such perforated drum is to take up fibers fed thereto in known manner by means of an airstream and to twist them into a yarn in the region of convergence of the two friction spinning drums. The yarn is withdrawn in a direction substantially at right angles to the direction of rotation of the friction spinning drums.
The airstream required to feed the fibers is drawn through the holes or perforations of the perforated drum by means of a suction nozzle provided in the interior of such perforated drum.
It therefore should be manifest that, on the one hand, the holes or perforations of the perforated drum must have a diameter which substantially prevents too many fibers being taken up or engaged by the holes or perforations during deposition on the perforated drum and then being either sucked away and hence lost, or at least being cut on the edge of the mouth of the suction nozzle and thereby undesirably shortened.
On the other hand, the energy consumption of such equipment must be held as low as possible, the airflow representing a significant proportion of the energy consumption. From this standpoint, it is desirable to design the holes or perforations of the perforated drum with the largest possible diameter to present the lowest possible resistance to the required throughflow quantity of air per unit time.
These two requirements placed on the diameter of the holes or perforations are diametrically opposed to each other.
In normal practice, and from patent publications, it is known that these holes or perforations generally have a diameter between 0.5 and 0.8 mm.
On the other hand, the perforated drums must have inherent stiffness or rigidity in order to avoid deformation during use, thereby requiring a minimum wall thickness of at least 1.5 mm in such perforated drums when made of brass with, for example, a drum diameter of 50 mm.
It is, however, clear that boring or otherwise fabricating such small holes in a material of 1.5 mm thickness or greater cannot be carried out without problems. Thus such operation is therefore expensive, particularly when the number of holes or perforations per perforated drum is of the order of several tens of thousands.
When additional demands are placed on the configuration or form of the holes or perforations, as disclosed in the German Published Pat. No. 2,919,316, the manufacturer of such perforated drums is confronted with special problems.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved construction of a friction spinning drum which is not afflicted with the aforementioned drawbacks and shortcomings of the prior art.
Another important object of the present invention is to provide a new and improved construction of a perforated drum which can be manufactured economically with adequate inherent stiffness or rigidity and low airflow resistance.
Yet a further significant object of the present invention resides in economically fabricating a friction spinning drum composed of two parts wherein the holes or perforations of the friction spinning drum are particularly structured to comply as well as possible with the conflicting demands of reduced airflow resistance through the holes or perforations and avoidance to the extent possible of undesired sucking in or engagement of the fibers deposited upon the outer surface or fiber receiving surface of the friction spinning drum.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the friction spinning drum of the present development is manifested by the features that it comprises an inner perforated support body or support and an outer perforated body secured thereto.
Advantageously, the holes or perforations of the inner perforated support body exhibit a larger cross-sectional area or cross-section than that of the holes or perforations of the outer perforated body. Furthermore, it is advantageous for the manufacturing operation if the inner perforated support body comprises a rigid hollow body or body member and the outer perforated body is a flexible body or body member mounted on the inner perforated support body. This outer perforated body or body member can comprise a metal band mounted on the inner perforated support body in a spiral or helical configuration, or a rectangular foil mounted on the inner perforated support body. Equally, the outer perforated body can be mounted on the inner perforated support body in the form of a tubular foil.
The holes or perforations in the inner perforated support body and the holes or perforations in the outer perforated body can be coaxially arranged.
Certain of the more notable advantages of the present invention reside in the features that, on the one hand, the small diameter holes or perforations, which are difficult to fabricate, can be formed in a relatively thin or thin-walled material while the relatively thick or thick-walled support body or body member can be provided with holes or perforations which have a cross-section or cross-sectional area which is selected more appropriately in accordance with the greater wall thickness.
A further advantage of the present invention resides in the fact that the outer perforated body or body member can be constituted by a band or foil capable of being mounted or drawn on (even when a foil in a second operation is joined to make up a tubular perforated body). The side of the perforated foil having burrs or the like can then be arranged as the external face or surface of the outer perforated body. If a galvanic coating is then subsequently applied, this affords the further advantage that the holes or perforations widen or enlarge from the outside towards the inside. This hole widening or enlargement is advantageous not simply in relation to the pneumatic resistance of the individual hole or perforation; dirt particles which possibly penetrate into one of the holes or perforations cannot jam in the adjoining hole or perforation section or region.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings, there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 illustrates a front view of a friction spinning drum constructed in accordance with the present invention;
FIG. 2 illustrates an enlarged detail of the region of the friction spinning drum within the circle A depicted in FIG. 1 and illustrated in sectional view;
FIG. 3 illustrates an enlarged detail of the region of the friction spinning drum within the circle B depicted in FIG. 1 and taken from the surface of the friction spinning drum of FIG. 1;
FIG. 4 illustrates a modification of the surface of the friction spinning drum shown in FIG. 3; and
FIGS. 5, 6 and 7 illustrate respective views of possibilities of use of a friction spinning drum according to FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the structure of the friction spinning drum has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of the present invention. Turning now specifically to FIG. 1 of the drawings, the friction spinning drum 1 illustrated therein by way of example and not limitation, will be seen to comprise an inner support body or body member 2 with an outer perforated or sieve body or body member 3 mounted thereon. The form or structure of this outer perforated body or body member 3 will be described hereinafter.
The inner support body or body member 2 is designed as a hollow body and is firmly connected at one end with a stub-shaft 4 or equivalent structure. A shaft 5 operatively associated with the stub-shaft 4 serves to receive a roller bearing 6 or the like by means of which the friction spinning drum 1 is rotatably supported. As a means for driving the friction spinning drum 1 there can be provided, for instance, a drive belt 7 which engages the shaft 5.
As shown in sectional view in FIG. 1, the outer perforated body 3 has holes or perforations 8 and the inner support body 2 has throughbores or throughholes 9. A suction nozzle 10 or equivalent structure provided at the opposite axial end of the friction spinning drum 1 projects in known manner into the inner support body 2 and draws or sucks in air through the holes or perforations 8 and throughbores or throughholes 9 by means of a suitable nozzle mouth (not shown) of the suction nozzle 10 and which suction nozzle mouth is arranged close to the cylindrical internal wall of the inner support body or body member 2. This suction nozzle or suction arrangement 10 is well known from friction spinning technology and is therefore not here described in further detail, particularly since such is unimportant in terms of the teachings and the principles of the present invention.
The holes or perforations 8 and the throughbores or throughholes 9 are respectively provided in the inner support body 2 and the outer perforated body 3 within a perforated region as indicated in dot-dash lines. The holes or perforations 8 and the throughbores or throughholes 9 collectively form the holes or perforations 8,9 of the perforated friction spinning drum 1.
FIG. 2 shows a detail of the inner support body 2 and the outer perforated body 3 indicated at the region of the friction spinning drum 1 enclosed within the circle A in FIG. 1. The wall thickness of the inner support body 2 is designated W and the wall thickness of the outer perforated body 3 is designated V.
It is further apparent that the manufacturing burrs 11 (which have been exaggerated for clarity of illustration and comprehension) are directed towards the exterior or outer surface of the friction spinning drum 1. Further, the outer perforated body 3 is coated on its outer cylindrical surface, defining a fiber receiving surface, with a galvanic coating or layer 12, which may be roughened in any suitable manner, and which for physical reasons builds up more strongly around the burrs 11 than in the adjacent surface portions or regions. In addition, with a coating thickness which is predetermined in relation to the wall thickness V of the outer perforated body 3, the galvanic coating 12 also builds up, as shown in FIG. 2, in such manner in the depth of the holes or perforations 8 that such holes or perforations take on a form similar to a diffusor. This affords the advantages discussed in the introductory portion of this disclosure, namely that, on the one hand, the diffusor-like form or configuration provides an airflow advantage and, on the other hand, dirt particles or other contaminants sucked into the holes or perforations 8 cannot jam therein.
A further advantage of the stronger or more pronounced build-up of the galvanic coating 12 or the like around the manufacturing burrs 11 is that a small annular projection is created around each hole or perforation 8. This desirably improves the friction properties of the outer or fiber receiving surface of the outer perforated body 3.
The wall thickness W (FIG. 2) of an inner support body 2 made of, for instance, brass can, for example, lie in the range 1.5 to 2 mm, and the wall thickness V of an outer perforated body 3 made of, for instance, nickel-chrome alloy can be 0.5 to 0.8mm. The thickness of the galvanic coating 12 is about 0.2 mm in the surface regions between the annular projections. There also may be applied a plasma coating or layer upon the galvanic coating or layer 12.
Further, it will be seen from FIGS. 2 and 3 that the throughbores or throughholes 9 have a larger cross-section or cross-sectional area than the smallest cross-section or cross-sectional area of a hole or perforation 8. In the case where the holes or perforations 8 are round, the smallest cross-section or cross-sectional area of each hole or perforation 8 can, for example, have a diameter of 0.5 mm and the diameter of the throughbore throughhole 9 can be 0.8 to 1mm, depending upon the hole spacing, so that the inner support body 2 still provides sufficient material between the throughbores or througholes 9 to enable it to fulfill its purpose as regards strength.
This affords the advantage that, as a result of the small wall thickness V, the holes or perforations 8 of the outer perforated body 3 can be bored or otherwise appropriately machined without problems using conventional boring, punching or electron beam boring technology. As a result of their significantly greater diameter, the throughbores or throughholes 9 of the inner support body 2 can be bored without problems using conventional boring techniques even when the wall thickness is 2 mm or more.
As is also apparent from FIGS. 2 and 3, the holes or perforations 8 are arranged coaxially with respect to the throughbores or throughholes 9, although this is not absolutely necessary. It is possible to use significantly larger throughbores or throughholes 9 which do not have the same gauge as the holes or perforations 8; the term "gauge" refers in this disclosure to the spacing of the hole centers.
Furthermore, the sum of all cross-sectional areas of the holes or perforations 9 in the inner support body 2 represents a greater proportion of the total surface of the perforated region a than the sum of all cross-sectional areas of the holes or perforations 8 of the outer perforated body 3.
In addition, it can be seen from FIG. 4 that the holes or perforations 8 in the outer perforated body 3 do not necessarily have to have a round section. Other hole forms or configurations are possible, especially when a punching technique is used during manufacture. In FIG. 4, four-sided holes or perforations 8 have been shown, but holes or perforations with other forms could also be used. The same applies to the throughbores or throughholes 9 in the event that another fabrication technique is used in place of boring to produce the throughbores or throughholes 9 in the inner support body 2, for example injection molding.
FIGS. 5, 6 and 7 show various ways in which the outer perforated body 3 can be formed and mounted on the inner support body 2.
FIG. 5 illustrates an outer perforated body, here designated by reference character 3a, in a band-form, for instance formed of any suitable metal, and which is spirally or helically wound on the inner support body 2 and connected thereto by any suitable connecting means. The connection can be effected, for example, by a suitable adherance or adhesion technique in that the start and finish of the band-form or band-shaped outer perforated body 3a is adhesively bonded to the inner support body 3 in the zones located outside the perforated region a. The spiral winding is carried out in such manner that the turns or coils 30 of the band-shaped outer perforated body 3a contact or abut each other in order to prevent throughflow of air at the region of the joins or joints 13. Furthermore, there exists the possibility of welding the band turns or coils 30 together at the region of the joins or joints 13 by a laser beam.
In FIG. 6, the outer perforated body, here designated by reference character 3b, consists of a rectangular foil 32 mounted on the inner support body 2 and engaging sealingly thereon without forming any spaces at the joins or joints 14. Furthermore, the joins or joints 14 can also be welded by means of a laser beam.
In FIG. 7, the outer perforated body, here designated by reference character 3c, comprises a hollow body 34, such as a tubular foil, made of a material having a lower coefficient of expansion than the inner support body 2, i.e. since the selection of the material for the outer perforated body 3c takes precedence, the material of the inner support body 2 is selected to exhibit a greater coefficient of expansion than the outer perforated body 3c. For mounting of the outer perforated body 3c, such outer perforated body 3c and the inner support body 2 are cooled to a temperature substantially below normal ambient so that the inner support body 2 shrinks during cooling to a greater extent than the outer perforated body 3c. This enables problem-free mounting of the outer perforated body 3c on the inner support body 2. The external diameter of the inner support body 2 is so selected in comparison to the internal diameter of the outer perforated body 3c that upon warming to normal temperature (not as high as operating temperature) the outer perforated
3c seats firmly and without rotation on the inner support body 2. During warming to operating temperature, a predetermined pretension is generated in the outer perforated body 3c.
The manufacture of a hollow body of this type can be performed galvanically and is disclosed in the previously mentioned commonly assigned, copending U.S. application Ser. No. 07/117,841, filed Nov. 9, 1987, and entitled "METHOD FOR MANUFACTURING A PERFORATED BODY, FRICTION SPINNING MEANS USING THE PERFORATED BODY AND A FRICTION SPINNING DEVICE USING THE FRICTION SPINNING MEANS"
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY, | In the manufacture of friction spinning drums, in order to be able to select the size of the holes or perforations, on the one hand, to oppose technological fiber loss and jamming of sucked in foreign particles and, on the other hand, to provide airflow advantages, it is proposed to manufacture the friction spinning drum from a thick-walled support and a thin-walled perforated body. As a result, holes or perforations having a sufficiently small cross-section to counteract the above-mentioned fiber loss can be formed in the thin-walled perforated body. On the other hand, holes or perforations having a large enough cross-section to prevent jamming of sucked in foreign particles or other contaminants can be provided in the thick-walled support. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application No. 60/602,376, filed Aug. 18, 2004. The contents of these applications are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY FUNDED RESEARCH AND DEVELOPMENT
N/A
FIELD OF INVENTION
The present invention relates to the field of fluid handling devices.
BACKGROUND OF THE INVENTION
The present invention is directed to devices for handling fluids under pressure. For example, without limitation, embodiments of the present invention have application for pumps and valves that produce or control fluids under pressure. Devices for handling high pressures are built with parts and components with closely controlled tolerances. Such parts and components are also expensive to manufacture. It is desirable to be able to design components and parts which exhibit wear such that the worn parts and components can be replaced. And, it is desirable to reuse parts and components with closely controlled tolerances.
Unfortunately, worn parts and components may cease functioning prior to replacement. The function of many parts and components of fluid handling devices is to contain fluid under pressure. For example, the failure of seals in a valve or pump may release fluid into sections of the device which can not withstand the pressure and/or pulsation of the fluid. The parts and components to which a pressurized fluid is inappropriately applied may work free or change alignment from other components and parts. Specialized pumps for performing chromatography often have sapphire pistons. Mis-aligned pistons may gouge precision surfaces of such pumps. The pistons may be scratched or otherwise damaged. Parts and components to which inappropriate pressure is applied may permanently deform.
In the field of chromatography, there is an interest in operating at elevated pressures. Conventional pressures for performing high performance liquid chromatography are up to approximately 3,000 pounds per square inch (psi). Pressures for performing ultra performance liquid chromatography may reach 15,000 to 20,000 psi. With greater pressure, the potential for seal failure is greater and the potential for damage is greater.
It would be desirable to have parts and components of fluid handling devices convey fluids to the exterior of the device in a manner that does not allow inappropriate pressure to be applied to parts and components.
SUMMARY OF THE INVENTION
Embodiments of the present invention are directed to devices and methods for directing fluids away from surfaces with closely controlled tolerances to prevent damage in the event of a leak. One embodiment of the present invention is directed to a device for producing or conveying fluids under pressure. The device comprises a housing having a housing exterior, cap abutment surface, a chamber and a bore opening. The chamber is for containing fluid under pressure. The cap abutment surface is an area of the housing apart from the exterior that surrounds the bore opening for receiving a cap. The bore opening extends from the cap abutment surface to the chamber. The bore opening has a sealing surface and at least one housing seal compression surface. A seal is held in the bore opening. The seal has a seal opening and a housing engagement surface, said seal opening for receiving a shaft extending axially there-through. The seal sealing engaging said housing engagement surface against said sealing surface upon axial compression of the seal against said seal compression surface. The device further comprises a shaft having a shaft axis and mounted in the seal opening of the seal. The shaft is for rotation about the shaft axis or movement along the shaft axis. The device further comprises a cap having a cap exterior, housing abutment surface, a cap opening and a cap seal compression surface. The cap is affixed to the housing with the housing abutment surface engaging the cap abutment surface. The shaft extends through the cap opening and the cap seal compression surface is pressed against the seal compelling the seal against the seal compression surface to sealing engage the housing engagement surface against the sealing surface. The device further comprises a passage means for receiving and conveying fluid from said housing engagement surface to at least one of the cap exterior or the housing exterior and away from the cap abutment surface and the housing abutment surface.
Typically, the cap abutment surface and housing abutment surface influence the relationship of other components and parts. For example, the misalignment of the cap with respect to the housing will cause a corresponding misalignment of the shaft in the seal opening, cap opening and the bore opening. This misalignment can lead to undue expensive wear and damage to the these components. The passage means of the present invention directs fluids which are under pressure, away from this sensitive area.
The passage means of one embodiment of the present invention is a channel in at least one of the housing or cap. A preferred passage means is incorporated in the seal. Preferably, the seal has a flexible body section and a seal compression pad. The body section is for engaging the housing engagement surface. The seal compression pad has less flexibility than the flexible body section to compress the flexible section against said seal compression surface. Preferably, the seal compression pad has a cap engaging surface. A preferred passage means is at least one channel in the cap engaging surface. The channel preferably extends radially across the cap engaging surface from the cap opening.
In the alternative, one embodiment of the present invention has at least one channel in said seal compression surface of the cap.
The device of the present inventions may comprise a pump, wherein the housing is a pump housing, or a valve, wherein the housing is a valve housing. In pump applications, the shaft may rotate or move in or out of the chamber to compel fluid movement. For example, without limitation, the shaft may comprise a reciprocating piston within the chamber.
The device of the present invention has particular utility in pump and valve applications with fluids under high pressure and ultra high pressure.
A further embodiment of the present invention comprises a method of producing or conveying fluids under pressure. The method comprising the steps of providing a device having a housing having a housing exterior, cap abutment surface, a chamber and a bore opening. The chamber is for containing a fluid under pressure. The cap abutment surface is a area of the housing apart from the exterior surrounding the bore opening for receiving a cap. The bore opening extending from cap abutment area to the chamber. The bore opening has a sealing surface and at least one housing seal compression surface.
The device further comprises a seal held in the bore opening. The seal has a seal opening and a housing engagement surface. The seal opening is for receiving a shaft extending axially there through. The seal sealing engages the housing engagement surface against said sealing surface upon axial compression of the seal against said seal compression surface. A shaft, having a shaft axis, is mounted in the seal opening of the seal for rotation about said shaft axis or movement along a shaft axis.
A cap having a cap exterior, housing abutment surface, a cap opening and a cap seal compression surface, is affixed to the housing with the housing abutment surface engaging the cap abutment surface. The shaft extends through the cap opening. The cap seal compression surface is pressed against the seal compelling the seal against the seal compression surface to sealing engage the housing engagement surface against the sealing surface. The device provides passage means from the housing engagement surface to at least one of the cap exterior or the housing exterior and removed from the cap abutment surface and the housing abutment surface.
The method further comprises the step of operating such device such that fluid from the housing engagement surface is directed to the exterior of the cap or the exterior of the housing and away from the cap abutment surface and the housing abutment surface.
The passage means may take several forms. For example, the passage means may comprise a channel in at least one of the housing or cap. Or, the passage means may be incorporated in the seal. A preferred seal has a flexible section and a seal compression pad. The flexible section is for engaging the housing engagement surface. The seal compression pad has less flexibility than the flexible section to compress said flexible section against said seal compression surface. A channel is provided in the seal compression pad to direct fluids to the exterior of the housing or cap. Where the housing is a pump or valve housing, embodiments of the present invention prevent major damage in the event seals leak.
A further embodiment of the present invention is directed to a seal for use in a device for producing or conveying fluids under pressure. The seal comprises a seal body constructed and arranged to be received in a bore opening of a housing. The housing has a housing exterior, cap abutment surface, a chamber and a bore opening. The chamber is for containing fluid under pressure. The bore opening extends from the cap abutment surface to the chamber. The bore opening also has a sealing surface and at least one housing seal compression surface. The cap abutment surface surrounds the bore opening for receiving a cap. The seal body has a seal opening for receiving a shaft extending axially there-through. The shaft has a shaft axis and is constructed and arranged to be mounted in the seal opening of the seal for rotation about the shaft axis or movement along a shaft axis. The seal body has a housing engagement surface, a seal pad and a seal surface. The housing engagement surface is constructed and arranged for engaging the housing seal compression surface. The seal surface, upon axial compression of the seal body against the seal compression surface, sealing engages the sealing surface of the bore opening. The seal further comprises a cap pad affixed to the seal body. The cap pad has a cap pad opening constructed and arranged to cooperate with the seal body opening. The cap pad has a rigidity greater than the rigidity of the seal body to convey compressive force to the seal body. The cap pad has a cap engaging surface for receiving a cap seal compression surface of a cap. The cap has a cap exterior, housing abutment surface, a cap opening and a cap seal compression surface. The cap is constructed and arranged to be affixed to the housing with the housing abutment surface engaging the cap abutment surface and the shaft extending through said cap opening. The cap seal compression surface is pressed against the cap engaging surface compelling the seal surface to engage said housing engagement surface against the sealing surface. The seal further comprises passage means for receiving and conveying fluid from the housing engagement surface to at least one of the cap exterior or the housing exterior and away from said cap abutment surface and said housing abutment surface.
A preferred passage means is at least one channel in the cap engaging surface.
Embodiments of the present invention provide a defined path for fluids which leak past seal surfaces and prevent the build up of pressure between parts of pumps and valve assemblies. This build up of pressure can result is miss-aligned parts and components which parts and components may be subject to stresses which they can not withstand or result in wear.
These and other features and advantages will be apparent to those skilled in the art upon viewing the drawings and the detailed description that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts, in cross section, a device incorporating features of the present invention.
FIG. 2 depicts, in cross section, the pump assembly of a device depicted in FIG. 1 .
FIG. 3 depicts, in cross section, a seal incorporating features of the present invention.
FIG. 4 depicts an angled view of the seal depicted in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will now be described with respect to the Figures with the understanding that the embodiments described are preferred embodiments. For example, without limitation, the following discussion will describe a pump assembly with the understanding that the invention applies to valves and other fittings as well.
Turning now to FIG. 1 , a device, in the form of a pump, generally designated by the numeral 11 is depicted. The device 11 has a housing 13 , a seal 15 , a cap 17 , shaft 19 and passage means 21 a , 21 b , and 21 c as best seen in FIG. 2 . Returning now to FIG. 1 , device 11 , as a pump, produces fluids under pressure. However, features of device 11 may be modified such that the device could direct fluids to different fluid paths in the nature of a valve or fitting.
The housing 13 is part of a pump assembly 25 having a motor 27 and spindle mechanism 29 . Those skilled in the art will recognize that housing 13 could be described as a housing for a valve [not shown] in which the spindle mechanism 29 would normally comprise suitable gearing and the like. As depicted, spindle mechanism 29 is mechanically linked to a shaft 19 .
Housing 13 is depicted in greater detail in FIG. 2 . Housing 13 has a housing exterior 31 , a cap abutment surface 33 , a chamber 35 and a bore opening 37 . The cap abutment surface 33 comprises an area of the housing 13 , separate from the exterior 31 , surrounding the bore opening 37 , for receiving a cap 17 . The housing 13 has a cap recess 39 to align the cap 17 .
Chamber 35 is for containing fluid under pressure. As a pump, the shaft 19 moves in and out of the chamber 35 causing fluids to move. As a valve, it would be more common that the shaft 19 rotate and turn a rotor [not shown] fitted to a stator [not shown]. As depicted, chamber 35 has an inlet 43 and an outlet 41 for receiving and discharging fluids.
Bore opening 37 extends from the cap abutment surface 33 to the chamber 35 . Bore opening 37 may be substantially contiguous with chamber 35 . Bore opening 37 has a sealing surface 45 and at least one housing seal compression surface 47 . Sealing surface 45 is for creating a seal between the housing 13 and seal 15 . Housing seal compression surface 47 is for creating a compressive force on the seal 15 which will compel the seal 15 against the sealing surface 45 .
Seal 15 is held in the bore opening 37 . As best seen in FIGS. 3 and 4 , the seal 15 has a seal opening 49 and a housing engagement surface 51 . The seal opening 49 receives shaft 19 extending axially there-through. The surface of the seal opening 49 sealing engages the shaft to prevent fluid from escaping the chamber 35 . The housing engagement surface 51 sealing engages the sealing surface 45 of the bore opening 37 upon axial compression of the seal 15 against the housing seal compression surface 47 .
Seal 15 has a seal body 55 and a seal compression pad 57 . The seal body 55 is a flexible section that engages the sealing surface 45 of the bore opening 37 . The seal body 55 has a canted coil spring 59 . Canted coiled spring 59 creates radial force directed inward and outward upon compression of the seal 15 against the housing seal compression surface 47 . This radial force facilitates the sealing engagement of the housing engagement surface 51 with the sealing surface 45 of the housing 13 . However, seal 15 , holding pressure up to 15,000 psi, may fail. Upon failure, the fluid leaks to areas of the pump until an outlet is reached, or if confronted with a sealed area, the fluids will build up pressure. However, the pressure may build in areas of the device 11 which are pressure sensitive.
Seal compression pad 57 has less flexibility than seal body 55 to compress the seal body 55 against the housing seal compression surface 47 . The seal compression pad 57 is made of plastic, such as, by way example, without limitation, polyethylene ether ketone, (PEEK). The seal body 55 is made of rubber or rubber-like materials. The seal compression pad 57 has a cap engaging surface 61 for engaging the cap 17 . It will be recognized by those skilled in the art, that the seal compression pad 57 may represent a area of a seal body that is more rigid than sections of the seal body performing sealing functions. That is, the seal cap 57 may be integral with the seal body 55 .
Returning now to FIG. 2 , shaft 19 has a shaft axis 63 extending lengthwise along the shaft. The shaft 19 is generally cylindrical and shaft 19 and seal 15 are constructed and arranged such that shaft 19 fits seal opening 49 . Shaft 19 is mounted in the seal opening 49 of the seal 15 for rotation about said shaft axis 63 or reciprocating movement along a shaft axis 63 .
Cap 17 has a cap exterior 67 , housing abutment surface 69 , a cap opening 71 and a cap seal compression surface 73 . The cap exterior 67 is that part of the cap 17 other than housing abutment surface 69 , cap opening 71 and cap seal compression surface 73 . Cap 17 is affixed to the housing 13 with the housing abutment surface 69 engaging the cap abutment surface 33 . The relationship of the housing 13 to the cap 17 is important. The cap 17 is secured to other components as depicted in FIG. 1 . Misalignment of the cap 17 with the housing 13 may cause extreme wear of moving components and may alter the shape of components not designed for pressure.
Returning now to FIG. 2 , shaft 19 extends through the cap opening 71 . Cap seal compression surface 73 is pressed against the seal 15 at the cap engaging surface 61 of the seal compression pad 57 . The seal 15 is compelled against the seal compression surface 47 by the seal compression pad 57 to sealing engage the housing engagement surface 51 against the sealing surface 45 .
Device 11 has passage means 21 for receiving and conveying fluid from the housing engagement surface 51 to at least one of the cap exterior 67 or the housing exterior 31 and away from the cap abutment surface 33 and the housing abutment surface 69 . Passage means 21 may take several forms. For example, without limitation, one embodiment of passage means 21 is at least one channel 21 b in a cap engaging surface 61 of the seal 15 , and in particular, the seal compression pad 57 as best seen in FIG. 4 .
In the alternative, channels [not shown] can be provided in the cap seal compression surface 72 of the cap 17 . As a further alternative, returning again to FIG. 2 , passage means 21 is a channel 21 b in the housing 13 . As a further alternative, a channel 21 c is provided in the cap 17 .
Embodiments of the present device prevent critical wear and damage to parts of a valve and/or pump or other fluid containing device in the event of a seal failure. These advantages and features may be realized with a seal 15 having a seal body 55 having channels 21 a in a cap engaging surface 61 for pumps, valves and fittings.
Embodiments of the present invention directed to a method are discussed herein with respect to the manner of operation. One method of the present invention is directed to a method of producing or conveying fluids under pressure. The method comprises the steps of providing a device 11 having a housing 13 having a housing exterior 31 , cap abutment surface 33 , a chamber 35 and a bore opening 37 . The chamber 35 is for containing fluid under pressure. The cap abutment surface 33 comprising an area separate from the housing exterior 31 and surrounding the bore opening 37 for receiving a cap 17 . The bore opening 37 extends from the cap abutment surface 33 to the chamber 35 and has a sealing surface 45 and at least one housing seal compression surface 47 . The device further comprises a seal 15 held in the bore opening 37 . The seal 15 has a seal opening 49 and a housing engagement surface 51 . The seal opening 49 receives a shaft 19 extending axially there through. The seal 15 sealing engages the housing engagement surface 51 against the sealing surface 45 upon axial compression of the seal 15 against the seal compression surface 47 . The device 11 further comprises a shaft 19 having a shaft axis 63 and mounted in the seal opening 49 of the seal 15 for rotation about the shaft axis 63 or movement along a shaft axis 63 , for example a reciprocating inward and outward movement. The device 11 further has a cap 17 having a cap exterior 67 , housing abutment surface 69 , a cap opening 71 and a cap seal compression surface 73 . The cap 17 is affixed to the housing 13 with the housing abutment surface 69 engaging the cap abutment surface 33 and the shaft 19 extending through the cap opening 71 . The cap seal compression surface 73 presses against the seal 15 compelling the seal 15 against the seal compression surface 47 to sealing engage the housing engagement surface 51 against said sealing surface 45 .
The device 11 further has passage means 21 a , 21 b or 21 c from the housing engagement surface 51 to at least one of the cap exterior 67 or the housing exterior 31 and removed from the cap abutment surface 33 and the housing abutment surface 69 .
The method further comprises the step of operating the device 11 such that fluid from the housing engagement surface 51 is directed to the cap exterior 67 or the housing exterior 31 and away from the cap abutment surface 33 and the housing abutment surface 69 .
The method of the present invention can be performed by providing a device 11 or providing a seal 15 in a device 11 . One further embodiment of the present invention is directed to such a seal 15 . The seal 15 comprises a seal body 55 constructed and arranged to be received in a bore opening 37 of a housing 13 . The bore opening 37 and the housing are as described previously. The seal body 55 has a seal opening 49 for receiving a shaft 19 extending axially there-through. The shaft 19 is a previously described. The seal body 55 has a housing engagement surface 51 for engaging the housing seal compression surface 47 of the housing 13 upon axial compression of the seal body 55 . The seal 15 further comprises a cap pad 57 affixed to the seal body 55 or integral with the seal body 55 . The cap pad 57 has the seal opening 49 extending there through for receiving the shaft 19 . The cap pad 57 has a rigidity greater than the rigidity of said seal body 55 to convey compressive force to the seal body 55 . The cap pad 57 has a cap engaging surface 61 for receiving a cap seal compression surface 73 of a cap 17 . The features of the cap 17 are as previously described. And, such seal 15 comprising passage means 21 a for receiving and conveying fluid from the housing engagement surface 51 to at least one of the cap exterior 67 or the housing exterior 31 and away from the cap abutment surface 33 and the housing abutment surface 69 .
A preferred passage means is at least one channel 21 a in the cap engaging surface 61 .
Thus, while the preferred embodiments of the present invention have been described with respect to the Figures, those skilled in the art will recognize that the present invention is capable of being modified and altered without departing from the teaching of the present application. Therefore, the present invention should not be limited to the precise details herein but should encompass the subject matter of the following claims. | Embodiments of the present invention are directed to methods and devices for conveying or containing fluids under pressure in which seals are provided with a defined path to vent fluid in the event of a seal failure. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Patent Application No. 60/107,494 filed Nov. 6, 1998, entitled, “Compressed Portable Tufting Creel,” U.S. Patent Application No. 60/107,495 filed Nov. 6, 1998, entitled, “Alignment Header for Burning-In Process,” and U.S. Patent Application No. 60/134,589 filed May 17, 1999, entitled, “Compact Creel,” all which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates in general to the field of carpet production, and in particular, to carpet yarn creels.
BACKGROUND OF THE INVENTION
[0003] Carpet tufting machines are relatively compact devices. However, substantial space within a carpet production facility is required for the entire tufting process. In addition to the space occupied by a tufting machine (i.e. the tufter) itself, there must be roll-up or additional processing equipment, or both, positioned downstream from the tufter.
[0004] Substantial additional space is required to supply yarn to the tufter. Yarn is typically supplied directly to the tufter by one of two methods. It may come from a “creel,” which is a rack holding large bobbins or packages of yarn that spool off of the bobbins and into the tufter. Conventional creels occupy substantial floor space “upstream” from the tufter because of the size of the packages or bobbins of yarn and the space needed to hold them so that the many separate strands of yarn can be pulled off the bobbins and fed into the tufting machine. The floor space required by a standard warper and creel is on the order of 2,000 square feet.
[0005] Alternatively, yarn can be fed to the tufting machine from a “beam,” a large horizontal mandrel onto which multiple strands of yarn of the needed colors are wound in advance. The yarn strands are then unwound simultaneously from the beam into the tufter. While beams typically require substantially less space immediately in front of the tufter than conventional creels, substantial space is needed, and significant work is required to prepare the beam, because in order to position yarn on a beam, bobbins or yarn packages must be positioned on creels to “feed” the beam, much as the yarn packages would be positioned to feed a tufter directly.
[0006] A significant challenge to carpet manufacturers is to reduce the amount of yarn waste occurring in the manufacturing of carpet. Wasted yarn can occur in several stages during the manufacturing process. For example, there can be yarn waste due to tufting beam waste, production beam waste and/or warping beam waste. A cause of waste is the inability to effectively determine the amount of yarn that is needed for a particular piece of carpet. As yarn is fed into a tufting machine it may be realized that yarn length for one color in a pattern is too short while yarn length for another color in the pattern is too long, resulting in wasted yarn. Large bobbins of yarn or beams of yarn compound the problem due to the sheer size of the yarn contained. A compact creel with smaller yarn packages reduces waste in the manufacturing process. Another significant problem is carpet overrun overage.
[0007] Therefore, a need exists for a compact creel that occupies less space on the manufacturing floor and reduces yarn waste in the manufacturing process, while enabling the same quantities of carpet production as that produced from a conventional creel.
SUMMARY OF THE INVENTION
[0008] This invention is a highly mobile, compact creel that utilizes frames for holding yarn packages (or bobbins), where the packages may be in the form supplied by the yarn supplier (typical sizes are initially about 6 inches or about 10-11 inches in diameter). Each frame can hold yarn packages facing front and back. Each creel frame can hold, for instance, about 416 yarn packages, for a total of approximately 832 yarn packages, so that the two sides of the frames together hold sufficient yarn ends for a typical carpet tufting machine. Other numbers of packages can also be accommodated, and multiple frames can be used to feed a single tufting machine.
[0009] A header having adjustable bars and slots for the yarn mates and affixes to the frame. This header provides for aligning all of the yarn ends in the same plane in order to join them to ends already threaded into the tufting machine.
[0010] In operation, yarn spools off of the end of the yarn package, through an eyelet (or yarn eye), through a rigid tube affixed to the frame (and inside the hollow yarn package), and through a flexible tube leading to the top of the frame, and into the header. The flexible tube typically passes through the rigid tube on which the package rests and a yarn eye at the end of the rigid tube can be formed on the end of the flexible tube. The floor space required for two 16 foot frames of the compact creel of this invention is on the order of 160 square feet.
[0011] A yarn reclamation procedure of this invention strips the yarn packages without unloading the yarn packages from the creel. The ends of the yarn tie from head to tail. The portable creel is placed in front of a backwinder head, and skinner yarn pieces wind onto one package or a few packages.
[0012] Objects of this invention include:
[0013] To provide a compact creel that reduces yarn waste in the tufting, production and warping processes.
[0014] To provide an alternative use for warping beam yarn, other than overrun carpet or beam waste.
[0015] To provide a compact creel that increases the quality of the finished product by reducing slack ends.
[0016] To provide yarn inventory reduction and decreased amounts of material handling.
[0017] To provide a compact creel that requires less floor space.
[0018] To provide an efficient reclamation procedure.
[0019] To provide a compact creel that reduces the labor required in the warping process.
[0020] To provide simplified scheduling and increased plant through-put time.
[0021] To provide all the same features for sample production and carpet development.
[0022] As the following description and accompanying drawings make clear, these and other objects are achieved by this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a perspective view of both sides of a compact creel of this invention including a frame, a header, yarn packages on hollow supports and flexible tubing.
[0024] [0024]FIG. 2 is an exploded perspective view of a portion of the compact creel of FIG. 1, including a hollow support for a yarn package shown in broken lines and a support, a flexible yarn tube and a portion of the header.
[0025] [0025]FIG. 3 is a side elevation view of a front and rear portion of the creel of FIG. 1.
[0026] [0026]FIG. 4 is a side view, partially in section of the end of a package support tube and flexible tubing.
[0027] [0027]FIG. 5 is an end view, partially in section of the header.
[0028] [0028]FIG. 6 is a side elevation view of two of the creels of FIG. 1 showing the path yarn takes to enter a tufting machine with yarn from one creel traveling over the other creel.
[0029] [0029]FIG. 7 is a side elevation view of two yarn packages illustrating the problem of yarn falling from one yarn package to another yarn package and becoming entangled therein.
[0030] [0030]FIG. 8 is a side elevation view of two yarn packages and an air shunt in the flexible tubing for blowing air through the flexible tubing and a ring having lines for capturing any slack yarn to avoid the problem of the yarn becoming entangled as shown in FIG. 7.
[0031] [0031]FIG. 9 is a perspective view of the ring, threaded shank and line affixed to the overlay upright taken at oval “ 9 ” in FIG. 8.
[0032] [0032]FIG. 10 is a perspective view of the creel having the overlay upright, ring, shank and lines of FIG. 9 extending across the front and rear portions of the frame.
DETAILED DESCRIPTION
[0033] [0033]FIG. 1 is a perspective view of a compact creel 20 of this invention. The compact creel 20 includes a frame 22 having a front portion 24 and a rear portion 26 , multiple hollow supports 28 attached to the frame 22 for holding yarn packages 30 , and an attachable header 32 . Preferably, the frame 22 can hold about 832 yarn packages 30 with approximately 416 yarn packages 30 on each of the front 24 and rear 26 portions of a sixteen foot frame 22 . Generally, the yarn packages 30 have a diameter of about seven inches and are about twelve inches long. Preferably, the overall footprint of the compact creel 20 is on the order of 160 square feet or less. A variety of yarn packages 30 can be used with the compact creel 20 including yarn packages 30 containing yarn 33 , that is for instance, tightly twisted, loosely twisted and air entangled. Casters 34 , 36 , 38 , 40 , 42 and 44 placed on the bottom of the frame 22 provide for ease of movement of the compact creel 20 .
[0034] As illustrated in FIG. 1, the yarn packages 30 of the creel 20 are arranged in compact staggered rows. The hollow supports 28 holding the yarn packages 30 are closely spaced, for instance about one inch apart, so that side-to-side and above-and-below positions of yarn packages 30 are close. This configuration is an improvement over the existing arrangements that requires large bobbins of yarn occupying substantial space before feeding into a tufting machine, and a labor intensive set up process. The compactness of the yarn packages 30 , the large quantity of yarn packages 30 fitting on a creel 20 and reductions in set-up and labor costs provide for a more efficient system for delivering yarn to a tufting machine.
[0035] Preferably, the front portion 24 and the rear portion 26 of the frame 12 define a passageway 46 . Flexible anti-static tubing 50 affixes to the header 32 at one end 52 of the flexible tubing 50 and travels through the passageway 46 with the other end 54 (not shown) of the flexible tubing 50 positioned through the hollow support 28 . Yarn 33 feeds through the flexible tubing 50 to the header 32 , and through the slots 56 in the header to the tufting machine (represented by dash line 58 ). The arrangement of the header 32 and slots 56 ensures that yarns feeding into the tufting machine 58 lie in the same plane.
[0036] [0036]FIG. 2 shows a perspective view of the hollow support 28 . The hollow support 28 includes a tube 60 , a retainer spring clip 62 , and a connector 64 . The hollow support 28 can be configured, for instance, as a length of round or square pipe or metal tube. Preferably, the tube 60 is welded to the frame 22 , and the connector 64 having the retainer spring clip 62 attaches to the tube 60 . The connector 64 can attach to the tube by a variety of methods including, for instance, screwing, welding, and gluing. The tube 60 is hollow, allowing the flexible tubing 50 to be positioned therein. The yarn package 30 is removably placed on the hollow support 28 . An eyelet 66 formed by heat flaring the end 54 of the flexible tubing 50 .
[0037] During setup of the creel 20 , an end of a strand of yarn 33 is unwrapped from the yarn package 30 . The yarn 33 is blown through the flexible tubing 50 up to the header 32 . As yarn 33 spins off the yarn package 50 , the eyelet 66 serves to allow continuous feeding from the yarn package 30 through the flexible tubing 50 , aids the threading process and helps avoid wear as the yarn 33 is pulled through. Alternatively, a ceramic or ceramic-coated yarn eye may be attached to the end of the tube 60 . As shown in FIG. 2, the flexible tubing 50 snakes behind the frame 22 and traverses up to the header 32 . The other end 52 of the flexible tubing 50 that affixes to the header 32 can also be heat flared ensuring the flexible tubing 50 remains in place on the header 32 by the heat flared end 68 . Preferably, yarn 33 removal from the yarn packages 30 onto the tufting machine 58 is relatively slow, with little wear on the heat flared end of the flexible tubing 50 .
[0038] [0038]FIG. 3 is a side elevation view of the front 24 and rear 26 portion of the frame 22 of the creel 20 of FIG. 1. As shown in FIG. 3, the flexible tubing 50 travels from the hollow support 28 up the passageway 46 of the frame 22 to the header 32 . As shown, both portions 24 , 26 of the frame 22 contain a plurality of yarn packages 30 . Yarn 33 inside the flexible tubing 50 travels through the passageway 46 to the header 32 . Yarn 33 exiting the header 32 aligns to enter the tufting machine 58 .
[0039] [0039]FIG. 4 is an enlarged side elevation view of the end tube 60 . Tube 60 contains the flexible tubing 50 with an eyelet 66 at the end 54 of the flexible tubing. The eyelet 66 serves to hold the flexible tubing 50 in place within the tube 60 .
[0040] [0040]FIG. 5 is an enlarged side view of the header 32 . The header 32 includes a first plate 70 and a second plate 72 . The flexible tubing 50 threads through the first plate 70 . The heat flared end 68 of the flexible tube 50 serves to keep the flexible tubing 50 from coming out of the first plate 72 . The heat flared end 68 of the flexible tubing 50 abuts the second plate 72 . The second plate 72 attaches to the first plate 70 by any connecting methods such as, for example, bolts 74 .
[0041] [0041]FIG. 6 is a side elevation view of two creels 20 and 21 placed one in front of the other. Because of the portable nature of the compact creel 20 , more than one compact creel 20 , 21 can be used at the same time with a tufting machine 58 . After one compact creel 20 is set up and connected to the tufting machine 58 , the second compact creel 21 can be placed into position and attached to the tufting machine 58 . The first creel 20 is positioned closest to the tufting machine 58 . The second creel 21 placed behind the first creel 20 has all the elements of the first creel 20 with an additional feature. The second creel 21 includes a yarn guide 74 for directing the yarn 33 exiting the header 32 over the first creel 20 and into the tufting machine 58 . The yarn guide 74 creates an angled path for the yarn 33 to traverse, as illustrated by directional arrow A-A to insure that the yarn 30 does not travel a path that would interfere with the operation of the first creel 20 . The yarn 33 exiting the first creel 20 travels path B-B which is a separate path from path A-A.
[0042] In an alternative embodiment, the yarn guide 74 includes a yarn slide that is placed across the top of the compact creel 21 . The yarn guide can include a bar affixed to and positioned above an upper portion of the frame 22 . So that yarn coming from the header 32 of the second compact creel 21 into the tufting machine 58 is not damaged or broken when the first compact creel 20 slides into position, the yarn slide acts as a “roof” that allows the yarn to slide along an upper portion of the yarn slide as the first creel 20 is placed in proper position.
[0043] [0043]FIG. 7 is a schematic side elevation view of two yarn packages 30 A and 30 B illustrating how yarn 33 A falls from one yarn package 30 A to another yarn package 30 B and becomes entangled. The hollow support 28 that supports the yarn packages 30 (including 30 A and 30 B) allows the yarn to spool off at a variety of speeds including high speeds of about 800 rpm. Yarn packages 30 having different tensions of yarn 33 on the yarn packages 30 such as loosely twisted or tightly twisted yarn 33 can spool off the yarn package 30 at different rates. Yarn packages 30 containing different types of yarn 33 placed above each other can cause the yarn from one package to become entangled with another package. FIG. 7 shows this situation where the yarn 33 A from the upper yarn package 30 A has fallen onto the tube 60 B of the lower yarn package 30 B. This problem causes the yarn 33 A to jam, requiring stopping the operation of the creel to untangle the yarn packages 30 A and 30 B which can negatively affect productivity.
[0044] [0044]FIG. 8 shows a method for addressing the yarn entanglement problem including a ring having a line for capturing any slack yarn to avoid the problem of the yarn becoming entangled as shown in FIG. 7. The ring 78 having a threaded shank 80 (shown in FIG. 9) received in an overlay upright 81 and held in place by a nut 82 . A line or strand 84 , such as, for instance, fishing wire or monofilament line, loops through the ring 78 and extends across the overlay upright 81 and attaches at the opposite end of the overlay upright 81 (shown in FIG. 10). The front portion 24 and rear portion 26 of the overlay upright 81 can contain such strands 84 . The placement of the ring 78 and strand 84 avoids the problem of yarn 33 A entanglement by supporting any loose yarn on the strand as shown at 86 . Further, even if yarn 33 A is very loose and falls down to the lower yarn package 30 B, the yarn follows the likely path shown at 87 and does not become entangled in the tube 60 B of the lower yarn package 30 B.
[0045] [0045]FIG. 8 also illustrates use of a shunt for blowing air through the flexible tubing 50 . Shunt 90 attaches to the flexible tubing 50 providing an alternative location for air entry to blow the yarn 33 through the flexible tubing 50 . In another alternative embodiment, multiple shunts can be fed by a single manifold so that air can simultaneously be blow through tubes 50 .
[0046] [0046]FIG. 9 is a perspective view of the ring 78 , shank 80 and strand 84 taken at oval “ 9 ” in FIG. 8. The wire 84 extends across the front and rear portions 22 , 24 of the frame 22 such that yarn 33 A from an upper yarn package 30 A does not become entangled with yarn 33 B from a lower yarn package 30 B.
[0047] [0047]FIG. 10 is a perspective view of the front portion 24 of a compact creel 85 having the strands 84 of FIG. 9 extending across overlay uprights 81 . The overlay uprights 81 contain a series of rings 78 for attaching strands 84 between each horizontal row of yarn packages 30 to prevent yarn 33 A from an upper yarn package 30 A from inadvertently wrapping around a tube 60 B of a lower yarn package 30 B entangling the yarn 33 A.
[0048] Yarn reclamation can occur by stripping the yarn 33 from the yarn packages 30 without unloading the yarn packages 30 from the creel 20 , 21 and 85 . The ends of the yarn 33 in adjacent packages 30 are tied from head to tail. The portable creel 20 , 21 and 85 is placed in front of a backwinder head, and skinner yarn pieces wind onto one package or a few packages.
[0049] An advantage of this invention is that it provides a compact creel that substantially reduces wasted yarn while making a comparable sized carpet.
[0050] Yet another advantage of this invention is that it provides for improved quality by reducing yarn slack ends.
[0051] Still another advantage of this invention is that it improves plant through-put time because the warping process is eliminated for smaller jobs.
[0052] Another advantage of this invention is that it increases output because it provides for placing yarns of different thickness having different lengths on yarn packages directly next to each other on the compact creel. This also increases carpet design flexibility.
[0053] Some other advantages of the compressed, portable, tufting creel include:
[0054] Tufting setup time reduction
[0055] Carpet overrun overage reduction and control
[0056] Usable plant floor space increases
[0057] Yarn warehouse inventory reduction
[0058] Improved skinner yarn reclamation
[0059] Simplified scheduling of plant personnel
[0060] Material handling labor reduction
[0061] Redirection of non-value added labor to value added labor
[0062] Enhanced sample production
[0063] While certain embodiments of this invention have been described above, these descriptions are given for purposes of illustration and explanation. Variations, changes, modifications and departures from the systems and methods disclosed above may be adopted without departure from the scope or spirit of this invention. | A highly mobile, compact creel that utilizes frames for holding yarn packages (or bobbins) for feeding yarn to a tufting machine. Each frame includes holders affixed to the frame for holding yarn packages facing front and back, a header attachable to the frame for directing yarn from the yarn packages to the tufting machine, and anti-static flexible tubing for leading yarn from the holders to the header. The header provides for aligning all the yarn ends in the same plane to join them to ends already threaded into the tufting machine. An optional frame overlay upright having a ring affixed thereto and strands threaded through the ring prevents yarn from upper yarn packages from falling onto tubes holding lower yarn packages causing yarn entanglement. | 3 |
This application is a continuation, divisional, continuation-in-part, of application Ser. No. 08/433,458 filed on Jun. 8, 1995 now abandoned which is a 371 of Ser. No. PCT/JP93/01622 filed Nov. 9, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for preparing difluoromethane (CF 2 H 2 ) which is used as a refrigerant and the like and is a substitute for a fluorinated gas.
2. Related Art
Methods for preparing CF 2 H 2 (hereinafter referred to as HFC-32 include a process of reducing CF 2 Cl 2 (hereinafter referred to as CFC-12), as described in UK Patent No. 732269; and a process of fluorinating CH 2 Cl 2 (dichloromethane), as described in Japanese Patent Kokoku Publication No. 3004/1967 (corresponding to U.S. Pat. No. 226447), and Japanese Patent Kokai Publication Nos. 225131/1984, 231029/1984, and 231030/1984.
The former process conduct the reduction with hydrogen at a temperature of 400 to 1,000° C. in the presence of a Pt, Pt alloy, Cu, Ag or Co catalyst. In the latter process, the catalyst used includes dichromium trioxide, chromium fluoride, aluminum fluoride and a mixture thereof.
HFC-32 draws attention as a substitute for CFC-12 (CF 2 Cl 2 , dichlorodifluoromethane) and HCFC-22 (CF 2 ClH, monochlorodifluoromethane). Accordingly, if HFC-32 can be prepared from the CFC-12 or HCFC-22 raw material, an existing apparatus can be effectively used. In this case, a reaction for reducing the raw material is necessary.
However, a hitherto known reduction method has a high reaction temperature of at least 400° C. and results in excess reduction in the case that each of HCFC-22 and CFC-12 is used as the raw material, whereby a large amount of evolved methane is produced so that the selectivity of HFC-32 is low. For example, if the reaction is conducted at the temperature of 720° C., the conversion of CFC-12 is 66% and a selectivity of HCFC-32 is only 13.2% (cf. UK Patent No. 732269).
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for preparing HFC-32 from a CFC-12 or HCFC-22 raw material so as to provide both a high conversion and a high HFC-32 selectivity.
The present invention provides a method for preparing difluoromethane (CF 2 H 2 , HFC-32) which includes reacting dichlorodifluoromethane (CF 2 Cl 2 , CFC-12) and/or monochlorodifluoromethane (CF 2 ClH, HCFC-22) with hydrogen in the presence of a palladium-based catalyst.
DETAILED DESCRIPTION OF THE INVENTION
The palladium-based catalyst is preferably a palladium (Pd) catalyst; or a catalyst in which at least one metal selected from the group consisting of vanadium (V), zirconium (Zr), calcium (Ca), magnesium (Mg), niobium (Nb) and tantalum (Ta) is added to palladium.
The above reaction (hydrogenation reaction) in the present invention is preferably conducted at a temperature of 120 to 400° C.
The palladium-based catalyst used in the present invention comprises a carrier and an active metal component. The active metal component is preferably a palladium metal or a combination of a palladium metal with at least one additional metal selected from the group consisting of vanadium, zirconium, calcium, magnesium, niobium and tantalum. An amount of palladium supported in the catalyst is preferably from 0.5 to 5% by weight. A molar ratio of the additional metal to Pd is usually from 0.01 to 4, preferably from 0.1 to 2. Since the large molar ratio does not give a significant effect on a selectivity and gives a decrease of reaction conversion, the molar ratio is preferably at most 4. A size of the catalyst is not limited and is usually from 1 to 6 mm. A powdery catalyst may be used.
The additional metal may be in the form of a salt. A nitrate salt, a metal oxide salt, an oxide and a chloride salt can be used. The carrier may be one usually used in conventional catalysts, such as active carbon and alumina. Since HF may evolve in the method of the present invention, it is undesirable to use a catalyst which has no resistance to HF.
One example of procedure for supporting the additional metal on the carrier is explained hereinafter. However, the present invention is not limited to this example. A salt of an additional metal is dissolved in water. Formalin and a powdery catalyst having Pd supported on active carbon are added to water and aged. The additional metal is dissolved in such amount that the desired molar ratio of the additional metal to palladium is achieved. Then, after water is evaporated, the catalyst is dried in air. Before the method of the present invention, the catalyst may be pretreated at 300-500° C. for 0.1-10 hours in a hydrogen stream.
In the reaction of the present invention, a molar ratio of hydrogen to CFC-12 or HCFC-22 is usually from 1 to 10. When the molar ratio is from 1 to 10, the selectivity is not adversely affected and the reaction seldom gives an excessively hydrogenated paraffin compound. The W/F (W: weight of catalyst (g), F: total flow rate of raw material and hydrogen (ml/sec at STP)) corresponding to a contact time is preferably from 0.01 to 10. When the W/F is up to about 10, the W/F gives an effect only on the reaction conversion with a slight change of the selectivity.
The method of the present invention is usually conducted in a gas phase. A reaction temperature is usually from 120 to 400° C., preferably from 200 to 300° C. A reaction pressure is usually from 1 to 10 atm, preferably from 1 to 5 atm. According to the present invention, when the reaction temperature is from 200 to 300° C., the reaction gives the result that a conversion from CFC-12 is 91% and a selectivity to HFC-32 is 81%.
In the reaction of the present invention, a raw material is either CFC-12 or HCFC-22; or combination thereof.
According to the method of the present invention, the reaction of CFC-12 and/or HCFC-22 with hydrogen in the presence of the palladium-based catalyst at the temperature of at most 400° C. gives a higher conversion and a higher HFC-32 selectivity.
PREFERRED EMBODIMENT OF THE INVENTION
The present invention will be illustrated by the following Examples.
EXAMPLE 1
An additional metal (namely, Zr) was supported on a catalyst material in which 5% by weight of Pd is supported on active carbon (a commercially available catalyst manufactured by N. E. CHEMICAL CATALYST) to prepare a catalyst. A molar ratio of Zr/Pd in the resultant catalyst was 0.5. 0.083 g of zirconyl chloride was dissolved in 30 ml of water. 2 g of the powdery catalyst material in which Pd is supported on active carbon and 0.2 g of formalin were added to water and aged at 50° C. for 2-3 hours. Then, water was removed by the use of a rotary evaporator and a solid material was dried at 100° C. for 12 hours in air. Before a hydrogenation reaction of CFC-12, the catalyst was treated at 400° C. for 2 hours so as to conduct a pretreatment of the catalyst.
A SUS-314 reaction tube having an internal diameter of 10 mm was filled with 1 g of catalyst. While keeping the reaction tube at a temperature of 250° C., a combination of 10 Nml/min of CFC-12 and 30 Nml/min of H 2 was passed through the reaction tube.
A conversion of CFC-12 was 91%. A selectivity was 81% of HFC-32, 14% of methane, 1% of ethane and 3% of HCFC-22.
EXAMPLE 2
The reaction was conducted in the same manner as in Example 1, except that the reaction temperature was 200° C. A conversion of CFC-12 was 75%. A selectivity was 82% of HFC-32, 13% of methane, 1% of ethane and 4% of HCFC-22.
EXAMPLE 3
The reaction was conducted in the same manner as in Example 1, except that the flow rates of CFC-12 and H 2 were 4 Nml/min and 9 Nml/min, respectively. A conversion of CFC-12 was 89%. A selectivity was 70% of HFC-32, 21% of methane, 5% of ethane, 2% of HCFC-22 and 2% of HFC-23 (CF 3 H).
EXAMPLE 4
The reaction was conducted in the same manner as in Example 1, except that the molar ratio of Zr/Pd was 0.2. A conversion of CFC-12 was 89%. A selectivity was 82% of HFC-32, 12% of methane, 2% of ethane and 4% of HCFC-22.
EXAMPLE 5
The reaction was conducted in the same manner as in Example 1, except that the molar ratio of Zr/Pd was 1. A conversion of CFC-12 was 62%. A selectivity was 67% of HFC-32, 20% of methane, 7% of ethane and 6% of HCFC-22.
EXAMPLE 6
The reaction was conducted in the same manner as in Example 1, except that the molar ratio of Zr/Pd was 1.5. A conversion of CFC-12 was 82%. A selectivity was 76% of HFC-32, 13% of methane, 6% of ethane, 4% of HCFC-22 and 1% of HFC-23.
EXAMPLE 7
The reaction was conducted in the same manner as in Example 1, except that ammonium metavanadate was used as the supported metal salt and the molar ratio of V/Pd was 0.2. A conversion of CFC-12 was 74%. A selectivity was 81% of HFC-32, 15% of methane and 4% of HCFC-22.
EXAMPLE 8
The reaction was conducted in the same manner as in Example 1, except that magnesium chloride was used as the supported metal salt and the molar ratio of Mg/Pd was 1. A conversion of CFC-12 was 40% and a selectivity of HFC-32 was 81%.
EXAMPLE 9
The reaction was conducted in the same manner as in Example 1, except that calcium chloride was used as the supported metal salt and the molar ratio of Ca/Pd was 1. A conversion of CFC-12 was 52% and a selectivity of HFC-32 was 78%.
EXAMPLE 10
The reaction was conducted in the same manner as in Example 1, except that niobium chloride oxide was used as the supported metal salt and the molar ratio of Nb/Pd was 1. A conversion of CFC-12 was 52% and a selectivity of HFC-32 was 78%.
EXAMPLE 11
The reaction was conducted in the same manner as in Example 1, except that tantalum chloride was used as the supported metal salt and the molar ratio of Ta/Pd was 0.5. A conversion of CFC-12 was 46% and a selectivity of HFC-32 was 82%.
EXAMPLE 12
The reaction was conducted in the same manner as in Example 1, except that a metal other than Pd was not supported in the catalyst. A conversion of CFC-12 was 64%. A selectivity was 74% of HFC-32, 19% of methane, 1% of ethane and 6% of HCFC-22.
EXAMPLE 13
The reaction was conducted in the same manner as in Example 7, except that HCFC-22 was used instead of CFC-12, the flow rates of HCFC-22 and H 2 were 10 Nml/min and 20 Nml/min respectively, the reaction temperature was 380° C., and the molar ratio of V/Pd was 1. A conversion of HCFC-22 was 62%. A selectivity was 76% of HFC-32, 22% of methane, 1% of ethane and 1% of HCFC-23.
EXAMPLE 14
The reaction was conducted in the same manner as in Example 13, except that the molar ratio of V/Pd was 0.5. A conversion of HCFC-22 was 63%. A selectivity was 73% of HFC-32, 24% of methane and 3% of HFC-23.
EXAMPLE 15
The reaction was conducted in the same manner as in Example 13, except that a metal other than Pd was not supported in the catalyst. A conversion of HCFC-22 was 43%. A selectivity was 72% of HFC-32, 24% of methane and 4% of HFC-23. | A method for preparing difluoromethane (CF 2 H 2 , HFC-32) by the use of reaction of dichlorodifluoromethane (CF 2 Cl 2 , CFC-12) and/or monochlorodifluoromethane (CF 2 ClH, HCFC-22) with hydrogen in the presence of a palladium-based catalyst can give difluoromethane at a high conversion and a high selectivity. | 2 |
BACKGROUND
[0001] The subject matter of the invention is a device and a method for changing embroidery patterns.
[0002] Modern sewing machines frequently include embroidery devices with an embroidery hoop that can be coupled to the sewing machine. For embroidering, the material to be sewn is set in tension in the embroidery hoop. This can be displaced in the two directions of the sewing plane by means of two independent drives. In the embroidery mode, the embroidery hoop, controlled by the sewing machine controller, is moved as a function of stored embroidery pattern data to the next stitching point, where a corresponding embroidery stitch is formed. The software controlling the movements of the embroidery hoop and the needle bar of the sewing needle is usually stored in a program memory of the sewing machine. The data for an embroidery pattern can also be stored in an internal memory of the sewing machine. Alternatively, the embroidery pattern data can also be stored in an external memory, e.g., a USB stick, which can be connected to the sewing machine.
[0003] There are many different formats for embroidery pattern data, e.g., “.ART” or “.EXP”. In principle, distinctions can be made between vector-based and stitching data-based formats. Stitching data-based formats are usually optimized for use on certain sewing machine models. In contrast, vector-based formats can be used universally, but require more complex data-processing devices. Computer programs are known that allow the conversion of embroidery pattern data from one format to the other. In addition, computer programs, e.g., “ARTE Engine,” are known, with which embroidery patterns can be created and/or modified.
[0004] For enlarging and/or reducing embroidery patterns, it is advantageous when the corresponding data is provided in a vector format, e.g., “.ART”. For changing the size of the embroidery pattern up to approximately ±20% of the original size, it is possible to change the stitch length (or their components into the two directions of movement of the embroidery hoop) according to the appropriate scaling, without significantly decreasing the quality of the embroidered image. This type of modification to the embroidery pattern is also designated as “resizing.”
[0005] For scaling values greater than approximately 20% to 25% in terms of magnitude, the stitches or the puncture points for the embroidery pattern to be created must be recalculated, with the number of puncture points usually increasing or decreasing, so that the stitching density quality is changed to be within tolerable limits. This type of modification to the embroidery pattern data is also designated as “recalculation.” For performing such a recalculation process, CAD software, e.g., “ARTE Engine” is necessary. Moreover, the embroidery pattern data must be provided in a suitable vector format, e.g., “.ART”. The recalculation of embroidery pattern data is computationally intensive and requires a computer with correspondingly high computing power. Therefore, in conventional sewing machines without powerful CAD software, sometimes alternative algorithms are used for the recalculation of embroidery pattern data. This has the result, especially for stitching data-based embroidery formats, e.g., “.EXP”, that the stitching density quality decreases for increasing sizes, and that fillings in the embroidery pattern can be lost.
SUMMARY
[0006] Therefore the object of the present invention is to create a device and a method for scaling embroidery patterns, with which qualitatively good, new embroidery pattern data can be calculated relatively quickly even for given scaling values above approximately 120% and below approximately 80%.
[0007] Another object of the invention is to construct the device and the method so that fillings of embroidery patterns are not lost even for embroidery pattern-based formats.
[0008] These are met by a device and by a method according to the invention.
[0009] With the method according to the invention and the device according to the invention, an embroidery pattern can be scaled and changed easily and quickly, without negatively affecting the quality of the embroidery pattern. For this purpose, several data sets are created, which represent the embroidery pattern with the associated stitching data for different fixed or adjustable scaling factors. (Because the invention can be applied not only to changes in size with constant proportions, but generally to parameterizable changes, from here on instead of the term “scale factor,” the term “change factor” will be used and instead of the term “scale value,” the term “change value” will be used.) The stitching data of each data set is optimized in terms of the stitching density quality. The given change factors are preferably dimensioned so that the enlargements or reductions of the embroidery pattern correspond to steps of approximately 20% of the original size.
[0010] For enlarging or reducing an embroidery pattern, the user can set or select the desired change value. The machine controller determines the change factor lying closest to the desired change factor with reference to this user input. With reference to the given stitching data of the associated data set, the machine controller calculates the actual stitching data for the desired change value. Thus it is not necessary to recalculate the arrangement of stitches for an embroidery pattern when a change in size greater than approximately 20% of the original size is desired for the embroidery pattern.
[0011] With the storage of embroidery pattern data according to the invention, embroidery patterns can be scaled or changed quickly and without additional software for calculating new stitching arrangements directly by the sewing machine controller within a large range. All possible filling patterns are preserved independent of the change value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will be described in more detail below. Shown are
[0013] FIG. 1 a simple embroidery pattern in the original size,
[0014] FIG. 2 a the embroidery pattern from FIG. 1 reduced by a change value with stitch intervals reduced according to the change value,
[0015] FIG. 2 b the reduced embroidery pattern from FIG. 2 a, but with modified stitch intervals,
[0016] FIG. 3 a flow chart,
[0017] FIG. 4 a transformation of a rectangle into a circle,
[0018] FIG. 4 a an embroidery pattern assembled from sub-patterns,
[0019] FIG. 4 b the embroidery pattern from FIG. 4 a with sub-patterns changed independently from each other.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1 shows, in a coordinate system with the reference axes x and y (these correspond to the independent displacement directions of an embroidery hoop), an example embroidery pattern 1 in the original size. The term “embroidery pattern 1 ” comprises, in connection with the present protective rights, a certain picture or motif, to which is allocated a sequence of discrete stitching or puncture points 3 according to the size and the desired stitching density quality of the pattern. The embroidery pattern 1 can be enlarged or reduced or scaled, wherein its form is preserved through proportional size changes, but the number and arrangement of the puncture points 3 can be adjusted.
[0021] The units of length of the coordinate system are represented on the reference axes x and y by tick marks. For better understanding, the embroidery pattern 1 is kept very simple. It represents the outline of a bird's head. The eye and the beak are filled with a simple filling pattern. The individual puncture points 3 are represented as small circular rings. The sewing yarn 5 between these puncture points 3 is represented as solid lines.
[0022] The embroidery pattern 1 can be stored, e.g., by storing coordinates (x i , y i ) in the sequence of sewing stitches to be formed for each cohesive object that can be formed by a continuous sequence of sewing stitches. The index i here corresponds to the number of relevant sewing stitches. The coordinates (x i , y i ) can be specified, e.g., relative to the origin or relative to each preceding sewing stitch (x i-1 , y i-1 ).
[0023] FIG. 2 a shows the embroidery pattern 1 from FIG. 1 . In comparison to the original size, however, this embroidery pattern 1 is approximately 40% smaller (the units of length of the coordinate system match those from FIG. 1 ). For vector-based sewing stitch coordinates (x i , y i ) the new coordinate values x i and y i in the present example can be calculated by multiplying the original coordinate values by a factor of approximately 0.6.
[0024] The puncture points 3 of the reduced embroidery pattern 1 thus lie closer together or the stitching density is increased relative to the embroidery pattern 1 in the original size.
[0025] FIG. 2 b corresponds to the embroidery pattern 1 from FIG. 2 a reduced by approximately 0.6 with puncture points 3 that have been recalculated or adapted to the new size. In comparison with FIG. 2 a, the embroidery pattern 1 in FIG. 2 b comprises fewer puncture points 3 , so that the stitching density quality corresponds approximately to that of the embroidery pattern 1 in the original size.
[0026] The optimized stitching data or coordinates (x i , y i ) for different change factors q j (the index j is a natural number) can be calculated, e.g., with corresponding algorithms in CAD software. For each of the change factors q j , a data set d j with the associated stitching data (x i , y i ) is calculated. The calculations are usually performed on a computer that is independent from the sewing machine. For a corresponding construction of the sewing machine, the calculations can obviously also be executed there. In a storage medium that can be accessed by the sewing machine controller, not only is the first data set d 0 stored with the stitching data or coordinates (x i , y i ) of the embroidery pattern 1 in the original size, but also one or more other data sets d j with the optimized stitching data or coordinates (x i , y i ) for one or more scalings or enlargements or reductions of the embroidery pattern 1 as well as the associated change factors q j . The number of such stored scaled embroidery pattern data sets of an embroidery pattern 1 or the value range of the index j can either be fixed or—in an alternative construction of the invention—can be selected freely.
[0027] FIG. 3 shows an example sequence for scaling an embroidery pattern 1 , wherein in addition to the first data set d 0 with the stitching data (x i , y i ) of the embroidery pattern 1 in the original size, nine other data sets d 1 to d 9 corresponding to change factors of q 1 =20%, q 2 =40%, q 3 =60%, q 4 =80%, q 5 =120%, q 6 =140%, q 7 =160%, q 8 =180%, and q 9 =200% are stored in the working memory of the sewing machine. For scaling the selected embroidery pattern 1 , in a first step S 1 the user can select, adjust, or set a desired change value v on a correspondingly constructed user interface. In the present example, v=67%. This can be set, e.g., by means of a rotary knob that can be set continuously or in steps on the sewing machine with corresponding values shown on a display. In a second step S 2 , processing software of the sewing machine stored in a program memory determines which of the stored change factors q j lies closest to the input, desired change value v, for example, by finding the minimum of the expression ¦v−q j ¦ from all of the stored change factors q j (including q 0 =1). In the example from FIG. 3 , the corresponding change factor q 3 and the associated data are outlined by bold lines.
[0028] As step S 3 , the associated data set d 3 with the coordinates (x 31 ,y 31 ), (x 32 ,y 32 ) . . . (x 3k ,y 3k ) of the corresponding puncture points 3 is selected. It is used as a basis for calculating the stitching data for the embroidery picture 1 enlarged or reduced according to the change value v. The sewing machine controller first calculates the value w:=v/q 3 . Then, in step S 4 the x and y coordinates of the puncture points 3 stored in data set d 3 are multiplied with this value w. This produces the desired coordinates of a target data set z with the optimized stitching data for the embroidery pattern 1 enlarged or reduced according to the change value v.
[0029] Alternatively, a different comparison criteria could also be used for determining the base data set d b (in the shown example, the index b=3) suitable for the scaling or change. For example, instead of the change factor q j lying closest to the selected change value v in terms of magnitude, the next larger or next smaller change factor q j could be selected.
[0030] The scaling of an embroidery pattern 1 corresponds to a special transformation or conversion, in which the stitching data coordinates (x i , y i ) in the embroidery pattern are enlarged or reduced proportionally. The form or the outline of the transformed embroidery pattern is preserved in the scaling.
[0031] Other special transformations are, e.g., compressions, extensions, distortions, rotations, reflections, or any combinations or sequences of such transformations.
[0032] In general, parameterizable transformations are understood as functions F, which assign one pixel F(x i , y i ) to each point (x i , y i ) of an embroidery pattern. Analogous to scaling an embroidery pattern, a transformation, which changes the shape of an embroidery pattern, can be divided into several intermediate steps. FIG. 4 shows, as an example, the transformation of a rectangle 7 into a circle 9 by means of a function F. This corresponds to a change factor of 100%. The function can be understood as a continuous transition from an original picture (rectangle 7 ) to a transformed picture (circle 9 ). Accordingly, intermediate functions F j can be calculated for one or more change factors q j lying between 0% and 100%. For the illustrated example, an intermediate function F 1 is shown for the change factor q 1 =33.3% and an intermediate function F 2 is shown for the change factor q 2 =66.6%. For two actual points (x i , y i ) and (x 2 , y 2 ), the assigned pixels F 1 (x 1 ,y 1 ), F 1 (x 2 ,y 2 ), F 2 (x 1 ,y 1 ), F 2 (x 2 ,y 2 ) und F(x 1 ,y 1 ), F(x 2 ,y 2 ) are listed.
[0033] Analogous to the proportional scaling of an embroidery pattern, the user can specify a desired change value v, wherein these values v must now lie between 0% and 100%. The control software determines from these value the two adjacent change values q j and q j+1 and calculates the desired pixels, e.g., through linear interpolation.
[0034] In another construction of the invention, embroidery pattern data from several different transformations or functions F can be stored in a memory that can be accessed by the sewing machine controller. It is also possible not to store any data sets for intermediate functions for one or more of these functions F. For example, for an embroidery pattern, in addition to the data set do with the stitching data of the original, data sets d j with stitching data of simple transformations, such as reflections or rotations by 45° or 90° can be stored and retrieved via a selection menu of the sewing machine.
[0035] In another alternative construction of the invention, an embroidery pattern can comprise several sub-patterns. The sub-patterns can be combined individually or into groups and scaled or changed with the same or different change values. For illustration, in FIGS. 4 a and 4 b, an embroidery pattern is shown, which comprises three sub-patterns, namely writing 11 a shown symbolically as the letter “A”, a square 11 b, and a star 11 c. Each of these sub-patterns has a unique coordinate system with a reference point 13 a, 13 b, 13 c. The sub-patterns can be stored individually in their original size and/or with optimized stitching data. For scaling or changing an embroidery pattern with sub-patterns, the sub-patterns can be changed according to the invention with the same change value or alternatively with different change values v. In addition, there is the possibility of rearranging the reference points of the scaled or changed sub-patterns when the embroidery pattern is changed.
LEGEND OF REFERENCE SYMBOLS
[0000]
1 Embroidery pattern
3 Puncture point
5 Sewing thread
7 Rectangle
9 Circle
11 a Writing
11 b Square
11 c Star
13 a,b,c Reference points | A method and the device for scaling or changing embroidery patterns ( 1 ) for sewing machines that allows a quick calculation of optimized stitching data. For one or more different change factors q j , data sets d j with optimized stitching data (x ji ,y ji ) are stored. A target data set z with stitching data changed according to a given change value v is determined by selecting one of the stored data sets d j and performing an extrapolation or an interpolation with the associated stitching data (x ji ,y ji ). For a pattern with several sub-patterns, these sub-patterns can be changed individually and combined to form a changed pattern. | 3 |
FIELD OF THE INVENTION
[0001] The present invention pertains to adjusting the weight of a sports implement, and more particularly to adjusting the weight of the barrel end of a baseball bat to allow the weight to be tailored to an individual batter.
BACKGROUND OF THE INVENTION
[0002] The size, weight, and shape of a baseball bat effects the kinematics of the swing of the baseball bat by a batter. The weight of the barrel end affects the ability of the batter to swing the bat rapidly enough to meet a pitched ball. A heavier barrel end requires greater strength to achieve the same barrel speed as a lighter barrel end. A heavier barrel end, however, carries greater momentum when a pitched baseball is struck. In addition to the weight of the barrel end of the bat, the length of the bat also affects the ability of a batter to both control the swing, as well as generate an effective barrel velocity at impact with a pitched ball.
[0003] Typical baseball bats are formed from a substantially homogenous material, such as wood or aluminum. Some bats are formed from multiple materials, such as using a fiberglass handle with an aluminum head. Notwithstanding, these bats are formed with a fixed weight of the barrel end, fixed length, and fixed grip size.
[0004] In addition to affecting the swing of the bat at a pitched ball, it is typical for a batter to desire a heavier barrel end of the bat for practice swings, to both build up and stretch the muscles used for swinging the bat. To this end, doughnuts may be provided. Doughnuts are toroidal shaped weights that may be placed around the barrel end of the bat to add weight to the barrel. The use of a doughnut precludes the ability of the batter to actually hit a ball when the doughnut is on the bat, since the doughnut does not provide a uniform hitting surface.
SUMMARY OF THE INVENTION
[0005] The present invention is a sports implement for hitting a pitched ball or the like. The contact end of the sports implement is adapted to allow the selective engagement of varying weights or contact extensions, hereinafter further referred to collectively as attachments, to the sports implement, allowing weight and/or length parameters of the sports implement to be varied as desired for individual users of the sports implement, or as desired at various times by an individual user.
[0006] The barrel end of the sports implement may be provided with a system for allowing weights in the barrel end of a baseball bat to be easily substituted to allow varying the barrel weight of a bat, without varying the hitting surface of the bat. Such a system may include weights having a smaller diameter than the contact surface of the sports implement, such that the weights nested within the end of the sports implement.
[0007] The attachment could also have an outer size and shape consistent with the sports implement, allowing the attachment to form a portion of the contact surface of the sports implement.
[0008] The attachment may be engaged to the sports implement by any method however the use of a threaded joint as a bayonet joint allows rapid engagement and removal of an attachment from the sports implement.
[0009] Biasing means may be provided to ensure that an attachment engaged to a sports implement remains engaged until such time as a user decides to remove the attachment. The biasing means may include an elastic element urging portion of the attachment and the sports implement into contact, or creating a friction or other retaining force to maintain engagement of the attachment to the sports implement.
BRIEF DESCRIPTION OF THE FIGURES
[0010] [0010]FIG. 1 illustrates a sports implement having a female socket receptacle for engaging a weight to the end of a sports implement.
[0011] [0011]FIG. 2 illustrates a weight for a sports implement where the weight nests in the end of the sports implement without forming a portion of the contact surface of the sports implement.
[0012] [0012]FIG. 3 illustrates a sports implement having a female socket formed within a weight for engaging a post on the end of a sports implement.
[0013] [0013]FIG. 4 illustrates a sports implement having a male post with retention pins nested within an end of a sports implement.
[0014] [0014]FIG. 5 illustrates a sports implement having a threaded socket on the end of the sports implement for receiving a male threaded post formed on a weight.
[0015] [0015]FIG. 6 illustrates the use of a pair of friction rings on the joint surfaces between an attachment and a sports implement, with the sports implement shown in cross section and the attachment shown in profile.
[0016] [0016]FIG. 7 illustrates the use of serrated surface features on the engagement faces between a weight and a sports implement.
[0017] [0017]FIG. 8 illustrates an intermediate engagement device formed to allow the engagement features to be added to an attachment or sports implement rather than formed integrally with the attachment or sports implement.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In FIG. 1, wherein like numbers represent like elements, there is shown a sports implement 2 in the form of a baseball bat 4 . The sports implement may have a grip end 6 and a contact end 8 . A weight 10 or other attachment may be provided with a method for engaging the weight to the contact end of the sports implement. In the configuration shown in FIG. 1, the method for engaging comprises a receptacle 12 formed in the tip end 14 of the sports implement. The receptacle may be a bore 16 drilled into the end of the sports implement, allowing a cylindrical portion 18 of the weight 10 to be engaged within the bore 16 . A retention pin 20 or pins may be provided on the sidewall 22 of the cylindrical portion 18 . A retention channel 24 may be provided on a sidewall 26 of the bore 16 . The retention channel 24 may have a first leg 28 and a second leg 30 , and a portion 32 connecting the first leg 28 and the second leg 30 . The first leg may extend to an opening 34 in the end of the bore 16 , allowing a retention pin 20 to slide into the retention channel 24 when the cylindrical portion of the of the weight is engaged into the bore. An elastic element 38 such as a spring may be provided at the bottom of the bore to resist engagement of the cylindrical portion of the weight into the bore. The second leg 30 of the retention channel may be parallel to the first leg 28 , without extending to the opening 34 , such that the cylindrical portion of the weight and the retention pin may be forced into the bore, and then twisted to move the retention pin 20 into the second leg 30 . Alternatively, the second leg 30 may be orthogonal to the long axis of the sports implement, such that when the retention pins are in the second leg, such that the engagement faces ( 26 , 28 ) remain in tight contact. The elastic element may then force the retention pin against the end of the second leg. As shown in FIG. 2, the weight may be formed such that it does not form a contact surface on the sports implement.
[0019] As shown in FIG. 3, the bore 32 may be formed into the attachment, shown as a barrel extension 34 , with a cylindrical post section 36 extending from the sports implement 2 . An elastic element 38 may be provided around the periphery of the engagement end of the sports implement to both provide a biasing function for engagement of the retention pin 40 into the retention channel 42 , as well as to provide a smooth exterior contact surface 44 .
[0020] As shown in FIG. 4, the attachment may be selected so as to have an outer diameter greater than the diameter of a pocket 402 on the end of the sports implement 2 . A post having retention pins 406 may be located in the pocket 402 , such that engagement of an attachment within the pocket 402 allows the attachment to nest within the end of the sports implement 2 . Alternately, the post 404 may be formed with male threads (not shown) on the exterior of the post, allowing an attachment having female threads to be threadedly engaged to the post 404 . A retention feature, such as a friction ring elastic element, or other device as described in this specification may be provided to ensure retention of the attachment onto the end of the sports implement.
[0021] As shown in FIG. 5, the attachment 500 may be joined to the sports implement using a threaded connection 502 . The attachment 500 may form a portion of the contact surface 504 of the sports implement 2 , such that varying the length of the attachment 500 allows variation of the length of the sports implement 2 , as well as variation of the area of the contact surface 504 of the sports implement. A bore 506 may be drilled and tapped with female threads 508 in the end of the sports implement 2 . A retention ring 510 , such as a rubber gasket, may be provided adjacent to the periphery of a contact face to provide sufficient friction between the attachment 500 and the sports implement 2 to prevent the attachment 500 from rotating and loosening the threaded connection in an undesired fashion. The attachment 500 may be provided with surface features 512 such as grooves or knurling (not shown) to allow a stronger grip on the attachment when attaching or detaching the attachment 500 from the sports implement 2 .
[0022] As shown in FIG. 6, when a bayonet fitting (retention pin and retention channel) is used for the connection between the attachment 600 and the sports implement 2 , care must be shown with regard to the design of the retention channel 602 . The retention pins 604 will exert a force against the retention channel 602 in an amount related to the mass of the weight and the speed and acceleration of the attachment 600 . Thus, the retention pins 604 must be of sufficient size and strength to prevent failure of the pins 604 , which could result in an undesired separation of the attachment 600 from the sports implement 2 .
[0023] Furthermore, the design of the retention channel 602 must address the force generated by the acceleration of the weight on the end of the bat, which may tend to force the attachment 600 away from the sports implement 2 , creating a gap between the attachment 600 and the sports implement 2 where the attachment 600 is used to form a portion of the contact surface 606 of the sports implement 2 . The use of an L-shaped retention channel 608 allows the attachment to be snugly mounted against the sports implement 2 , but may not provide a positive detent to ensure retention of the attachment 600 to the sports implement 2 . A friction ring 610 , such as a thin rubber washer or a pair of rubber washers may be added to the end surfaces 612 , 614 of the attachment 600 and/or sports implement 2 to improve the retention of the attachment 600 to the sports implement 2 . Alternately, serrated surface features 700 , such as shown in FIG. 7, may be implemented to provide a positive detent where the retention channel 702 is not shaped to provide such a detent. A serrated surface feature 704 , 706 formed from an elastic material, such as a spring steel, rubber, or other elastomer, may be provided on contact faces on the attachment 700 and sports implement 2 . Engagement of the serrated surface features may require the two serrated surfaces to deform to allow rotation of the retention pins into the lateral legs of the retention channel, such that the contact between the serrated surfaces provides an anti-rotation force when the attached 700 is engaged to sports implement 2 . Proper design of the serrated surface features allows a tight joint to be accomplished, allowing the weight to form a portion of the contact surface without an undesirable gap being present between the attachment and the sports implement 2 . The serrations may be saw tooth or wave shaped.
[0024] Although the engagement means has heretofore been illustrated as integral to the sports implement or to the attachment, the engagement means may be also formed through fabrication of an intermediary engagement device formed to be joined to the sports implement or to an attachment. As shown in FIG. 8, a male engagement device 802 may be provided with male threads 804 at one end and retention pins 806 at an opposite end. An attachment 800 may thus be formed with a bore 808 which is internally threaded 810 to receive the male engagement device 802 . This allows simpler forming tasks to be required to adapt the end of the sports implement 2 for engagement to an attachment 800 . Also, a female engagement device 810 may be formed having external threads 812 , and a central bore 814 having a retention through 816 and biasing element 818 , such as a spring. A sports implement 2 may thus be adapted for receiving the female engagement device 810 by drilling and threading 820 a bore in the engagement face 822 of the sports implement. The use of intermediate engagement devices 802 , 810 may allow the implementation of attachments according to the present invention to sports implements which were previously manufactured, by allowing basic machining (drilling and threading) to be used to adapt the sports implement and/or attachment for implementation of attachments according to the present invention.
[0025] As is apparent from the above description, the benefits of the present invention are not limited to baseball bats, but extend to other sports implements used to impact thrown or flying objects, such as, but not limited to, softball bats or cricket bats.
[0026] The present invention may be embodied in other specific forms than the embodiments described above without departing from the spirit or essential attributes of the invention. Accordingly, reference should be made to the appended claims, rather than the foregoing specification, as indicating the scope of the invention. | The present invention is a sports implement for hitting a pitched object. The sports implement includes attachments for a contact end of the implement allowing variation of the weight and/or length of the sports implement. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The field of the present invention is forging metallic or other suitable materials in accordance with cold, warm, or hot forging operations.
Background
As is well known, forging is a process by which a product is formed from a metallic or other suitable materials into a particular or desired shape. During the forging process, metallic materials, such as aluminum, may be subjected to conventional cold, warm, or hot forging operations to force the materials to assume a particular shape.
Although there are many different forging techniques, one particular type utilizes a die set including a holding portion, within which a workpiece is disposed. A punching portion of the die set is dropped down to press against the workpiece and force it to flow into a guiding portion of the die set and to assume a particular shape within the guiding portion. During this type of conventional forging process, the die set suffers damage. Also, there is stagnant buildup of dead material from abnormal flow of material.
FIG. 1a further illustrates the manner in which such a conventional forging process can generate damaging cracks. A workpiece W is disposed within the holding portion 4'(2') of the die set 2', which is integrally formed with the guiding portion 5'(2') of the die set 2' as a single unit. The punching portion 3'(2') is pressed against the workpiece W to accelerate the plastic deformation phase of the workpiece. This exerts extreme pressure on the die set 2'. As the workpiece W is pressed down, the portion of it that contacts an area of the guiding portion 5'(2'), as indicated by reference letter W1, pushes downward in the direction of the pressing action, as illustrated by the vertical arrows in Figure la. At the same time, the portion of the workpiece that contacts the wall of the holding die 4'(2'), as indicated by reference letter W2 pushes outward, exerting pressure on the holding die 4'(2') in a direction illustrated by the horizontal arrows in FIG. 1a. Consequently, at the corner C where the holding portion 4'(2') transitions into the guiding portion 5'(2'), forces are simultaneously exerted in two different directions, perpendicular to each other. The diverging forces at the corner C in this integrally formed configuration cause the die set 2' to tear and cracks to occur at the corner C. When such cracks occur, the die set 2' is damaged and rendered ineffective, requiring replacement.
To overcome this problem, in another configuration, the holding portion 4'(2') and the guiding portion of the die set are formed separately. Such a configuration is illustrated in FIG. 1b. This configuration is further reinforced from the outside to resist cracks. While this configuration, addressed the problem of alleviating the forces at the corner C that caused the cracks, it gave rise to yet other problems. For instance, as the punch die 3' presses down on the workpiece, there is a tendency for the workpiece material under pressure to escape into any space or clearance that may exist between the holding die 4' and the guiding die 5'. The material slipping into the clearance between the holding die 4' and guiding die 5' results in the formation of burrs. Gradually, with time and usage, the seepage increases, causing buildup of dead material that serves as a wedge, prying the holding die 4' away from the guiding die 5'. Additionally, the formation of burrs destroys the layer of lubricant that is applied on the workpiece prior to commencing the forging process. Once the lubricant is destroyed, the material is further obstructed from flowing along its intended path down into the guiding portion 5'.
In addition, as the workpiece W presses down along the inner walls of the holding die 4', material collects at the corner E where the holding die 4' and the guiding die 5' meet. The arrows in Figure lb illustrate the sluggish and abnormal flow patterns along the corner E, resulting in buildup of material at that location that ultimately remains there and stagnates. The stagnant material is essentially dead metal (indicated by reference numeral D) that prevents products from forming properly.
In a further attempt to address this problem and to prevent the buildup of dead material, the guiding die 5' is curved at the corner E, to provide a rounded surface, instead of sharp corners where the dead metal D once remained. But again, such a configuration not only resulted in the same problem where burrs occur, but, the same bidirectional forces at the curved portion also resulted, causing cracks.
SUMMARY OF THE INVENTION
The present invention relates to improved equipment and forging techniques that prevent damage to the die set while also preventing abnormal flow of the particular workpiece material used in the forging process.
According to a first separate aspect of the present invention, the forging equipment comprises a die set with a holding portion, constructed separate from the guiding portion. The holding portion is configured to accommodate the workpiece material and the punch portion as it is dropped down on the workpiece. At the corner where the holding portion and the guiding portion meet, the holding portion has a cavity formed in it that serves as a retaining cavity or cavity, which is sized to accommodate a metal sealing assembly.
In a second separate aspect, the metal sealing assembly of the first aspect has a horizontal body that slides into the retaining cavity formed within the holding portion. The body of the metal sealing assembly terminates at one end in a tapered head portion. The tapered head portion, at its upper end, abuts the inner wall of the holding die such that the workpiece material, when under pressure, is prevented from escaping into the retaining cavity. From its upper end to its lower end, the tapered head portion provides an angled surface that serves to guide the workpiece material. This surface, upon contacting the workpiece material, serves not only to guide it, but to guide it smoothly, along its intended path toward the center of the guiding die. By configuring the metal sealing assembly in this fashion, the bidirectional forces at the corner between the holding die and the guiding die of the die set are alleviated, as is the buildup of dead material at that location.
In a third separate aspect of the present invention, the upper end of the tapered portion forming the material guiding surface of the second aspect abuts an inner wall of the holding die above the retaining cavity. With such a configuration, even though the workpiece material exerts tremendous pressure in an outward direction on the metal sealing assembly, it cannot encroach into the holding die. If anything, the greater the forces against the metal sealing assembly, the more securely it adheres to the surface of the holding die and the guiding die.
In a fourth separate aspect, the body of the metal sealing assembly accommodated within the retaining cavity of the first aspect is sized to complement the size of the opening defined within the retaining cavity such that the body is forced into the retaining cavity with pressure. By this configuration, material is effectively prevented from migrating into any clearance between the holding die and the guiding die.
In a fifth separate aspect, the holding portion of the first aspect comprises a recessed area or cavity to accommodate the upper end of a tapered head portion of the metal sealing assembly. This feature prevents damage to the metal sealing assembly.
In a sixth separate aspect of the present invention, various combinations of the foregoing separate aspects are contemplated to provide system advantage.
Accordingly, it is an object of the present invention to provide improved forging equipment and methods. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which constitute a part of this specification, exemplary embodiments of the forgoing equipment and techniques are illustrated.
FIG. 1a illustrates a cross sectional view of conventional forging equipment, illustrating a problem that occurs during a forging technique using this type of equipment.
FIG. 1b illustrates a cross sectional view of other conventional forging equipment, illustrating yet another problem with a forging technique using this type of equipment.
FIG. 2a illustrates a cross sectional view of forging equipment with a metal sealing assembly.
FIG. 2b is an enlarged cross sectional detail view illustrating the metal sealing assembly.
FIG. 3 illustrates a cross sectional view of the metal sealing assembly and the holding die in accordance with a second embodiment.
FIG. 4a illustrates an exploded perspective view of the metal sealing assembly.
FIG. 4b illustrates an enlarged detail view of the metal sealing assembly of FIG. 4(a).
FIG. 5 is a cross sectional view illustrating, in conjunction with enlarged detail views shown in FIGS. 5(a), 5(b), and 5(c), a forging sequence.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 illustrates improved forging equipment and an improved method of forging. The improved forging equipment and method may be used to forge products from suitable materials such as aluminum. The forging equipment comprises, and the forging method utilizes; a die set 2 to form the workpiece W. The die set 2 comprises a holding portion or die 4 configured to hold the workpiece W. A punching portion or die 3 is dropped down on the workpiece W to apply pressure on it and force it through a plastic deformation phase until it assumes a desired shape. The desired shape is determined by a guiding portion or die 5 that restricts workpiece W within its bounds to assume the desired shape for the particular product being manufactured. At a corner along the line where the holding die 4 and the guiding die 5 meet, a metal sealing piece 6 is assembled within a retaining cavity 42 formed within the holding die 4. The metal sealing piece 6 is otherwise referred to as a metal sealing assembly 6.
The punch die 3 is more or less cylindrical in shape and is constructed to ascend and descend freely in an up and down motion. During the forging process, the punch die 3 is pressed or dropped down from above, and gradually travels through the holding die 4 as it applies pressure on the workpiece W. As it travels down farther into the holding die 4, it applies increasing pressure on the workpiece W, which is then forced into the guiding die 5.
The holding die 4 defines a retaining cavity 41 that holds the workpiece W. The retaining cavity 41 prevents the workpiece W from expanding outwardly when the workpiece W is subjected to pressure. As is better illustrated in FIG. 2(b), the holding die 4, at its lower extremity 10, comprises a retaining cavity or area 42 where an inner wall 12 substantially contacts (or is otherwise closely aligned proximate) an upper extremity 14 of the guiding die 5. The metal sealing assembly 6 is accommodated within the retaining cavity 42.
Referring now to FIG. 3, in accordance with one embodiment of the present invention, to prevent damage to an upper edge 16 of the metal sealing assembly 6, the retaining cavity 42, in its upper wall 18, defines a recessed area or contacting surface retaining cavity 43 for accommodating the upper edge 16.
Referring again to FIG. 2a, the guiding die 5 forces the material in its pressurized state to travel through its center. The guiding die 5 defines a forming area 51 where the workpiece W undergoes plastic deformation and assumes the desired shape required for the particular product being manufactured. In the embodiment illustrated in these drawings, the forming area 51 is cylindrical in shape for purposes of forming cylindrical products. It should be recognized, however, that depending on the particular shapes desired, the forming area 51 is appropriately configured. Also, one or more holes in the product may be created as required, as the product is being formed.
Referring now to FIG. 4(a), the metal sealing assembly 6, as illustrated, is configured in a circular ring-like shape, similar to the shape of the holding die 4. Once engaged within the retaining cavity 42 of the holding die 4, the metal sealing assembly 6 conforms along the inner circumference of the holding die 4.
Referring now to FIGS. 2, 3, and 4(b), the metal sealing assembly comprises a material guiding head section 61, somewhat triangular in shape (FIG. 4(b)), and a flange portion 62, somewhat rectangular (FIG. 4(b)) in shape. The flange portion 62 is press fit into the retaining cavity 42 by force applied by the workpiece material. To facilitate this action, the outer extremities of the flange portion 62 conform to the inner extremities of the retaining cavity 42. It should be noted that in the drawings, the clearance areas or spaces between the outer extremities of the flange portion 62 and the inner extremities of the retaining cavity 42 are somewhat exaggerated for illustration purposes. The material guiding head section 61 is wider and extends beyond the retaining cavity 42 to guide the workpiece W during the forging process.
The material guiding head section 61 has a material guiding surface 61a tapered from the upper edge 16 to a lower edge 19. The tapered configuration of the material guiding section 61, during the forging process, urges the material to flow smoothly toward a forming area 51 defined within the guiding die 5. The material guiding head section 61, opposite the material guiding surface 61a, comprises a peripheral wall contacting surface 61b that contacts or abuts the inner wall 12 or an area 12a of the inner wall 12, of the holding die 4.
The material guiding surface 61a contacts the workpiece W in its pressurized state and guides the workpiece material toward the guiding die 5. Referring particularly to FIGS. 2(b) and 3, the material guiding surface 61a abuts an area 12a of the inner wall 12 directly above the opening of the retaining cavity 42. In order to make the material flow smoothly, the material guiding surface 61a may be curved as better shown in FIG. 4(b).
The peripheral wall contacting surface 61b is configured to lie substantially perpendicular to the adjoining edge A of the material guiding surface 61a. Similar to the upper tip of the material guiding surface 61a, the peripheral wall contacting surface 61b contacts or abuts an area 12a of the inner wall 12 directly above the opening of the retaining cavity 42. With this configuration, despite extreme pressure exerted by the workpiece W in its pressurized state, the metal sealing assembly 6 resists being forced into any clearance areas between the holding die 4 and the guiding die 5. Therefore, the material guiding surface 61a always maintains its position, protruding beyond the retaining cavity 42.
The flange portion 62 projects horizontally outward from the material guiding head section 61. The body of the flange portion 62 is press fit into the retaining cavity 42 with pressure from the workpiece material applied against the material guiding surface 61a. The flange portion 62 is configured to minimize any clearance areas or spaces between its outer exterior O and the inner peripheral surface S of the retaining cavity 42. The pressurized material subjects tremendous outward pressure on the metal sealing assembly 6, therefore, minimizing the clearance is essential for an effective sealing arrangement. In accordance with one embodiment, a portion of the metal sealing assembly 6 may be severed, as illustrated at P in FIG. 4(a), to further assist the metal sealing assembly to absorb the outward forces. By severing the metal sealing assembly 6, it is designed to gradually give way and open when subjected to extreme pressure. Also, it should be recognized that although the metal sealing assembly 6 is shown as circular in shape in the illustrated embodiment, it may be variously shaped, depending on the shape of the holding die 4 and the desired product. For example, it may be rectangular, oval, etc. Also, in accordance with an alternative embodiment, if the metal sealing assembly 6 is configured to provide larger material guiding surfaces, depending on the product to be formed, it may not be necessary to provide the flange portion 62. Various other configurations may be possible along the principles of the embodiments explained here.
Referring now to FIG. 5, the method of forging is described, of course, using the forging equipment described above. FIG. 5 shows the punch portion 3 disposed directly above the workpiece W that is held within the holding die 4. Operation begins with the punch die 3 in this position. Referring now to FIG. 5a, at this stage of operation, when disposed within the holding die 4, the workpiece W contacts the material guiding surface 61a. As the punch die 3 is pressed against the workpiece W, it in turn presses against the material guiding surface 61a of the metal sealing assembly 6 and forces its flange portion 62 into the retaining cavity 42. With increasing pressure, the workpiece W is compressed gradually, which causes it to deform into a mass of pressurized material. The pressurized material exerts outward pressure on all neighboring objects and ultimately exerts pressure on the angled surface of the material guiding surface 61a that lies in contact with the workpiece W. Because of the angled configuration of the material guiding surface 61a of the metal sealing assembly 6 and support provided for it along its bottom surface, by the guiding die 5, the metal sealing assembly 6 is pushed outward along a horizontal axis. Due to the forces acting as they do, the metal sealing assembly 6 is pressed against the inner wall 12 of the holding die 4 such that the peripheral wall contacting surface 61b abuts an area 12a of the inner wall 12 of the holding die 4. This operation is illustrated in FIG. 5(b).
Despite the pressure forcing the metal sealing assembly 6 against the inner wall 12 as it does, no portion of the metal sealing assembly will slip through spaces between the metal sealing assembly 6 and the holding die 4. Moreover, the material guiding surface 61a, maintains its position, protruding beyond the retaining cavity. Continuous pressure against the material guiding surface 61a, forces the metal sealing assembly 6 toward the inner wall 12 until the metal sealing assembly 6 adheres closely to the inner wall 12. This eliminates materials from slipping into any space or clearance between the holding die 4 and the guiding die 5, thereby preventing any burrs from forming. Moreover, in the embodiment with a contacting surface retaining cavity 43, the peripheral contacting surface 61b is received in the contacting surface retaining cavity 43 that prevents any damage to the ends of the metal sealing assembly 6. By forming the contacting surface retaining cavity 43 at about the same level as the peripheral wall contacting surface 61b, material is prevented from seeking and escaping into any clearance areas. The dimensions of the contacting surface retaining cavity 43 are small enough so that it does not pose a hindrance in ejecting the workpiece W after it is formed.
As also illustrated by FIG. 5c, the workpiece material in its pressurized state first flows in a direction where it contacts the inner walls of the holding piece 4. At his stage of operation, the material remaining directly above the forming area 51 is pressed down easily into it. The material disposed proximate the inner walls 12 of the holding die 4 is pressed down along the surface of the inner walls 12 until the material is near the corner area between the holding die 4 and the guiding die 5. The material guiding surface 61a serves to deflect the material here by approximately 90 degrees, as illustrated by the arrows, directing it toward the center of the guiding die 5. This prevents any buildup of the material at the corner area and serves to guide all the material smoothly along its intended path. A smooth flow of material also prevents unusual forces from resulting that may damage the die set 2.
While the invention is susceptible to various modifications and alternative forms, specific examples of it have been shown by way of example in the drawings and are described here in detail. It should be understood, however, that is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following claims. | Forging equipment and techniques prevent damage to the die set while also preventing abnormal flow of the material used in the forging process. In one embodiment, the forging equipment comprises a die set with a holding portion, constructed separate from the guiding portion. The holding portion is configured to accommodate the workpiece material and the punch portion as it is dropped down on the workpiece. At the comer where the holding portion and the guiding portion meet, the holding portion forms a retaining cavity, which has a sufficient size to accommodate a metal sealing assembly. The metal sealing assembly at one end terminates in an angled material contacting surface that prevents formation of cracks and abnormal flow of material away from its intended path of flow. | 1 |
BACKGROUND OF THE INVENTION
Many of the medical care garments and products, protective wear garments, mortuary and veterinary products, and personal care products in use today are partially or wholly constructed of thermoplastic nonwoven web materials. Examples of such products include, but are not limited to, medical and health care products such as surgical drapes, gowns and bandages, protective workwear garments such as coveralls and lab coats, and infant, child and adult personal care absorbent products such as diapers, training pants, swimwear, incontinence garments and pads, sanitary napkins, wipes and the like. For these applications nonwoven materials provide tactile, comfort and aesthetic properties which can approach those of traditional woven or knitted cloth materials. Nonwoven web materials are also widely utilized as filtration media for both liquid and gas or air filtration applications since they can be formed into a filter mesh of fine fibers having a low average pore size suitable for trapping particulate matter while still having a low pressure drop across the mesh.
Nonwoven web materials have a physical structure of individual fibers or filaments which are interlaid in a generally random manner to form a fibrous web material. The fibers may be continuous or discontinuous, and are frequently produced from thermoplastic polymer or copolymer resins from the general classes of polyolefins, polyesters and polyamides, as well as numerous other polymers. Blends of polymers or conjugate multicomponent fibers may also be employed. Nonwoven materials formed by melt extrusion processes such as spunbonding and meltblowing, and formed by dry-laying processes such as carding or air-laying of staple fibers are well known in the art. In addition, nonwoven materials may be used in composite materials in conjunction with other nonwoven layers as in a spunbond/meltblown (SM) and spunbond/meltblown/spunbond (SMS) laminate materials, and may also be used in combination with thermoplastic films.
Nonwoven materials may be topically treated to impart various desired properties, depending on end-use application. For example, some applications such as components for diapers and other incontinence products and feminine hygiene products call for nonwoven materials which are highly wettable and will quickly allow liquids to pass through them. For these applications it is desirable to treat the nonwoven materials with surfactants or other chemicals to impart hydrophilicity. On the other hand, for applications such as surgical drapes and gowns, and other protective garments, liquid barrier properties are highly desirable, and specifically desirable are nonwoven materials which have a high degree of repellency to low surface tension liquids such as alcohols, aldehydes, ketones and hydrophilic liquids, such as those containing surfactants. Repellency to low surface tension liquids may be achieved by treating the nonwoven material with chemicals such as fluorochemical compounds known in the art. Topical treatments are available to impart other properties as well, such as antistatic treatments for example.
Topical treatments are typically applied to fibrous web materials such as nonwoven materials in the form of a treatment chemical carried in a liquid, often aqueous, medium as a solution, suspension or emulsion. Once the treatment has been applied to the nonwoven material it is generally necessary to remove the excess moisture in the nonwoven material sheet by drying. Conventionally, the moisture is removed by blowing heated air on the nonwoven material or by running the nonwoven material over and in contact with heated surfaces such as rollers or cans until it is dry or nearly dry. However, a wetted nonwoven material generally will not dry in all places at the same rate; therefore with conventional drying techniques certain areas of the nonwoven material will become completely dry while other areas still contain moisture, and these areas which dry first will experience continued and excessive heat from the drying process while the entire sheet of material is dried to a satisfactory level of residual moisture. This additional heating of the nonwoven material can deleteriously affect the material and degrade material properties such as by causing heat shrinkage of the material, reducing material tensile strength, causing the material to become embrittled and/or surface glazed and thereby unpleasant to the touch, and decreasing barrier properties in SMS laminate materials.
Consequently, there remains a need for an efficient treatment method that provides treated thermoplastic nonwoven materials without unduly negatively impacting the material and material properties compared with methods heretofore known.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an exemplary process for topically treating fibrous webs in accordance with the invention.
SUMMARY OF THE INVENTION
The present invention provides a method for treating a fibrous web material including the steps of providing a fibrous web material, treating the web material with a topical treatment which includes a treatment chemical and a liquid carrier medium, partially drying the treated web material such that after the partial drying step the web material has less than about 40 percent and at least about 10 percent by weight residual moisture and then passing the web material through a radio frequency energy field to further dry the web. After passing through the radio frequency energy field the web has less than about 5 percent by weight residual moisture, desirably less than about 2 percent, more desirably less than about 1 percent, and still more desirably less than about 0.5 percent by weight residual moisture.
The partial drying step may be performed by applying vacuum or external heat to the fibrous web material, and the fibrous web material may desirably be thermoplastic nonwoven web material or thermoplastic nonwoven barrier laminate material. The topical treatment may desirably be a liquid-repellent treatment, a hydrophilic treatment or an anti-static treatment. In certain embodiments, the web after partial drying has about 20 percent to about 10 percent by weight residual moisture. The radio frequency energy field may have a frequency ranging from about 10 megahertz to about 50 megahertz. Also provided are fibrous web materials obtained in accordance with embodiments of the method of the invention.
DEFINITIONS
As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps.
As used herein the term “polymer” generally includes but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to isotactic, syndiotactic and random symmetries.
As used herein the term “fibers” refers to both staple length fibers and continuous filaments, unless otherwise indicated.
As used herein the term “monocomponent” fiber refers to a fiber formed from one or more extruders using only one polymer extrudate. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for color, anti-static properties, lubrication, hydrophilicity, etc. These additives, e.g. titanium dioxide for color, are generally present in an amount less than 5 weight percent and more typically about 2 weight percent.
As used herein the term “multicomponent fibers” refers to fibers which have been formed from at least two component polymers, or the same polymer with different properties or additives, extruded from separate extruders but spun together to form one fiber.
Multicomponent fibers are also sometimes referred to as conjugate fibers or bicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the multicomponent fibers and extend continuously along the length of the multicomponent fibers. The configuration of such a multicomponent fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another, or may be a side by side arrangement, an “islands-in-the-sea” arrangement, or arranged as pie-wedge shapes or as stripes on a round, oval, or rectangular cross-section fiber. Multicomponent fibers are taught in U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 5,336,552 to Strack et al., and U.S. Pat. No. 5,382,400 to Pike et al. For two component fibers, the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratios.
As used herein the term “nonwoven web” or “nonwoven material” means a web having a structure of individual fibers or filaments which are interlaid, but not in an identifiable manner as in a knitted or woven fabric. Nonwoven webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, air-laying processes and carded web processes. The basis weight of nonwoven fabrics is usually expressed in grams per square meter (gsm) or ounces of material per square yard (osy) and the fiber diameters useful are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).
The term “spunbond” or “spunbond nonwoven web” refers to a nonwoven fiber or filament material of small diameter fibers that are formed by extruding molten thermoplastic polymer as fibers from a plurality of capillaries of a spinneret. The extruded fibers are cooled while being drawn by an eductive or other well known drawing mechanism. The drawn fibers are deposited or laid onto a forming surface in a generally random manner to form a loosely entangled fiber web, and then the laid fiber web is subjected to a bonding process to impart physical integrity and dimensional stability. The production of spunbond fabrics is disclosed, for example, in U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,802,817 to Matsuki et al. Typically, spunbond fibers or filaments have a weight-per-unit-length in excess of 2 denier and up to about 6 denier or higher, although finer spunbond fibers can be produced. In terms of fiber diameter, spunbond fibers generally have an average diameter larger than 7 microns, and more particularly between about 10 and about 25 microns.
As used herein the term “meltblown fibers” means fibers or microfibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or fibers into converging high velocity gas (e.g. air) streams which attenuate the fibers of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Buntin. Meltblown fibers may be continuous or discontinuous, are generally smaller than 10 microns in average diameter and are often smaller than 7 or even 5 microns in average diameter, and are generally tacky when deposited onto a collecting surface.
The term “staple fibers” refers to discontinuous fibers, which typically have an average diameter similar to that of spunbond fibers. Staple fibers may be produced with conventional fiber spinning processes and then cut to a staple length, typically from about 1 inch to about 8 inches. Such staple fibers are subsequently carded or airlaid and thermally or adhesively bonded to form a nonwoven fabric.
As used herein, “thermal point bonding” involves passing a fabric or web of fibers or other sheet layer material to be bonded between a heated calender roll and an anvil roll. The calender roll is usually, though not always, patterned in some way so that the entire fabric is not bonded across its entire surface. As a result, various patterns for calender rolls have been developed for functional as well as aesthetic reasons. One example of a pattern has points and is the Hansen Pennings or “H&P” pattern with about a 30% bond area with about 200 bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen and Pennings. The H&P pattern has square point or pin bonding areas wherein each pin has a side dimension of 0.038 inches (0.965 mm), a spacing of 0.070 inches (1.778 mm) between pins, and a depth of bonding of 0.023 inches (0.584 mm). The resulting pattern has a bonded area of about 29.5%. Another typical point bonding pattern is the expanded Hansen and Pennings or “EHP” bond pattern which produces a 15% bond area with a square pin having a side dimension of 0.037 inches (0.94 mm), a pin spacing of 0.097 inches (2.464 mm) and a depth of 0.039 inches (0.991 mm). Other common patterns include a diamond pattern with repeating and slightly offset diamonds and a wire weave pattern looking as the name suggests, e.g. like a window screen. Typically, the percent bonding area varies from around 10% to around 30% of the area of the fabric laminate web. Thermal point bonding imparts integrity to individual layers by bonding fibers within the layer and/or for laminates of multiple layers, point bonding holds the layers together to form a cohesive laminate.
As used herein, the term “hydrophilic” means that the polymeric material has a surface free energy such that the polymeric material is wettable by an aqueous medium, i.e. a liquid medium of which water is a major component. The term “hydrophobic” includes those materials that are not hydrophilic as defined. The phrase “naturally hydrophobic” refers to those materials that are hydrophobic in their chemical composition state without additives or treatments affecting the hydrophobicity. It will be recognized that hydrophobic materials may be treated internally or externally with surfactants and the like to render them hydrophilic.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a method for topically treating fibrous web materials such as thermoplastic nonwoven materials and nonwoven barrier laminate materials. The method includes providing the fibrous web material, topically treating the fibrous web material with a liquid-carried treatment chemical, partially drying the fibrous web material and then further drying the fibrous web material utilizing a radio frequency energy field.
Conventional topical treatment methods for fibrous webs include brushing or spraying liquid chemical treatment on the web, dipping or saturating the web in a liquid treatment bath and foaming a liquid chemical treatment and applying the foam to the web material.
The invention will be more fully described with reference to FIG. 1 . Turning to FIG. 1 , there is illustrated in schematic form an exemplary process line 10 which demonstrates an embodiment of the method of treating fibrous web materials. Fibrous web material 20 is shown being transported through process line 10 . Fibrous web material 20 may desirably be a thermoplastic nonwoven web material or laminate material including thermoplastic nonwoven web materials such as for example spunbonded materials, bonded carded webs, high-loft spunbond and through-air dried nonwovens, spunbond-meltblown-spunbond (“SMS”) laminates or spunbond-film-spunbond (“SFS”) laminates. As shown in FIG. 1 , fibrous web material 20 is topically treated at treatment station 30 . Treatment station 30 may desirably be one or more means of applying topical treatment as are known in the art such as for example a brush treater, spray treater, foam treater, or, as shown, a saturation treater such as a dip and squeeze bath.
For the purpose of describing the advantages of the invention, FIG. 1 and process line 10 will be described with reference to fibrous web material 20 being a nonwoven barrier laminate material such as for example a spunbond-meltblown-spunbond laminate or “SMS” laminate material which may be produced in accordance with U.S. Pat. No. 4,041,203 to Brock et al., incorporated herein by reference in its entirety. Because of their liquid barrier properties, SMS laminate materials are highly suitable as protective fabrics and are used as or as part of surgical suite wear such as patient drapes and surgical gowns, and also may be used in protective or industrial workwear. However, in order to more fully protect the wearer from harmful exposure to contaminants the laminate material should have a high degree of repellency to low surface tension liquids such as surfactant containing aqueous solutions, alcohols, aldehydes and ketones. Repellency to low surface tension liquids may be imparted to the laminate material by use of a treatment chemical such as for example fluorocarbon compound treatments as are disclosed in U.S. Pat. No. 5,149,576 to Potts et al. and U.S. Pat. No. 5,178,931 to Perkins et al., both incorporated herein by reference in their entireties, and fluorocarbon compound treatments are available commercially.
To impart repellency to low surface tension liquids, treatment station 30 may desirably be a dip and squeeze station as is known in the art and which contains a bath of an aqueous emulsion of fluorocarbon compound. The fibrous web material 20 travels a path which immerses the web in the bath to saturate it with the treatment emulsion. Web material 20 continues through nip rollers 32 and 34 which squeeze off the excess treatment bath emulsion. Despite having the excess bath removed by nip rollers 32 and 34 , the web material 20 will typically have about a 100 percent “wet pick up” upon exiting treatment station 30 . That is, a web material of approximately 70 gsm when dry will weigh approximately 140 gsm after exiting treatment station 30 and nip rollers 32 and 34 , and must be dried prior to storage of the material. The web material should contain as little residual moisture as is practicable, desirably less than about 5 percent moisture by weight, more desirably less than about 2 percent by weight, and still more desirably less than about 1 percent or even 0.5 percent by weight residual moisture.
A conventional method well known in the art for drying treated webs is the use of steam canisters, such as the steam canisters 40 , 50 and 60 which are incorporated as part of the treatment process shown in FIG. 1 . Fibrous web 20 travels between and in tensioned contact with canisters 40 , 50 and 60 which are heated with steam to heat the web material and drive off moisture via evaporation. Typically, the number and/or temperature of the steam canisters will be adjusted to match the amount of drying needed in order to fully or nearly fully dry the fibrous web material. However, this has several drawbacks. Because the planar surfaces of the web material are in direct contact with the heated canisters, the outer surfaces of web material will tend to become fully dry well before the center of the material, which will result in the surfaces of the material being exposed to overheating. Further, certain areas of a moving web material, often the edges and the transverse middle portion of the web, will be under more tension than other areas of the web and be pressed against the heated canisters with more force than the other areas of the web material, resulting in these higher tension areas becoming dry before the other areas and therefore being exposed to overheating. Because the web materials are made with thermoplastic resins, overheating of the web material surfaces and overheating of other high tension areas results in undesirable heat-glazing (that is, a slight to moderate melting) of the material surfaces, making the material stiff and making the material surfaces harsh and unappealing to the touch. Also, overheating of the web material generally causes heat shrinkage of the material, often resulting in web width losses of 5 percent or even greater.
In order to alleviate the overheating problems caused by attempting to fully dry the fibrous web material 20 with external heat, FIG. 1 and process line 10 further include a radio frequency station 70 which generates a radio frequency energy field through which fibrous web 20 passes. In the practice of the invention, rather than fully drying the fibrous web material with the externally applied heat of the steam canisters, the web material is only partially dried until it retains about 40 percent by weight or less of residual moisture. Depending on equipment available and the particular web to be dried, it may be advantageous to partially dry the web until it has only about 20 percent or only about 10 percent by weight of residual moisture. As explained below, to avoid overheating the web material it is important that the web still retain some moisture after the partial drying step. Further drying is accomplished by the radio frequency energy at radio frequency drying station 70 .
As known in the art, radio frequency energy or dielectric is an alternating electromagnetic field which causes susceptible molecules to attempt to orient the molecular poles alternatingly to follow the alternating electromagnetic field. Molecules susceptible to the dielectric field include polar molecules such as the water molecule and other polar liquid solvents in which treatment chemicals are typically dissolved, suspended or emulsified. As the molecules in the liquid continue to alternatingly reorient themselves they “vibrate” and thereby gain frictional heat energy and cause evaporation of the liquid. However, because conventional thermoplastic resins useful for fibrous nonwoven web materials are generally non-polar molecules they are not susceptible to the radio frequency energy field, and are therefore not heated by the radio frequency energy. In this manner the fibrous web material may be further dried until it has less than about 5 percent by weight moisture, and desirably until is has less than about 2 percent moisture, without any dried portions of the web being contacted by external heat sources in excess of 100 degrees Celsius and thereby avoiding the deleterious effects of overheating. Radio frequency “ovens” are commercially available which produce radio frequency energy fields at frequencies of from about 1 megahertz (MHz) to about 80 megahertz, typically from about 10 to about 50 megahertz, and commonly available radio frequency units are available at 13, 27 and 40 MHz. Although not shown in FIG. 1 , radio frequency drying station 70 may desirably also include a vent or vacuum system suitably attached to evacuate the water vapor produced by drying the web.
As shown in FIG. 1 , as the fibrous web material 20 exits the radio frequency drying station 70 it may be wound up as a roll of dried web material on winding roll 80 . As an alternative to taking the dried fibrous web material up on winding roll 80 , the material may be directed to various finishing steps such as web slitting, stretching or further treating, or may be directed immediately to various converting or integrated product forming operations.
As another example, the fibrous web material 20 may be a lofty nonwoven material such as a bonded carded staple fiber web, or as a spunbond web material made with crimped multicomponent or bicomponent fibers in side-by-side or eccentric sheath-core arrangement. Such crimped multicomponent fibers and lofty webs are described in U.S. Pat. No. 5,382,400 to Pike et al., incorporated herein by reference in its entirety. Lofty nonwoven web materials find extensive use in personal care absorbent products, and for many such uses it is desirable for the nonwoven web materials to be wettable. Wettability may be imparted by topically treating the web with, for example, surfactant treatments as are known in the art by saturation dipping at treatment station 30 , or alternatively by such well known methods as brush treating, spraying or foaming. The partial drying step may be accomplished by the steam canisters as shown in FIG. 1 . Alternatively, because lofty nonwoven webs typically have much higher air permeability than the barrier laminate materials previously discussed, it would also be useful to employ means such as a vacuum or through air drying using heated air to partially dry the web until it retains less than about 40 percent by weight residual moisture as stated above. Then, the remainder of the moisture may be evaporated by radio frequency heating of the water without overly heating the web.
Where steam canisters are the means used for partial drying of the lofty nonwoven web, the use of a radio frequency energy field to remove the residual moisture in the web can be particularly advantageous for helping to retain the loft of the web. For example, in order to hold the lofty nonwoven web against the steam canister as the web travels over the canister there must be tension on the web, which can result in some compression forces pushing the web against the canister, decreasing the loft of the web. Where these compression forces are still being applied at the point in the process when the web is completely dry and beginning to be overheated, overheating can “set” the web structure, resulting in permanent loss of loft. Also, as mentioned above with regard to barrier laminate materials, continued contact with the hot surface of the steam canisters after the surface of the lofty web is fully dried can result in heat glazing of the surface, making it stiff and harsh to the touch.
Other webs may suitably be treated and dried by use of the invention. For example, nonwoven webs made by the spunbonding method are frequently used for liners and coverstock material for personal care absorbent garments, and are therefore often treated to impart hydrophilicity to assist the absorbent garment in accepting and absorbing bodily fluid exudates from the wearer. Where topical liquid surfactant application is desired, as by spray treater, a vacuum source is generally applied to the liner materials to remove the excess liquid treatment. Still, after vacuum removal of excess treatment the webs contain substantial moisture, which can lead to undesirable microorganism growth on the webs if the webs are stored in this moist condition. However, liner and coverstock materials are meant to be used in close contact with intimate portions of the user's anatomy, and prior to treatment these materials will already have undergone at least one heat-intensive processing step such as thermal point bonding. Therefore the method described herein, utilizing vacuum to partially dry the web materials and utilizing radio frequency energy to further dry the web to a fully or nearly fully dry state is an advantageous way to avoid unnecessary additional heating of the webs. The vacuum extraction may additionally be used in combination with the external heat partial drying as described above.
Polymers suitable for the fibrous web materials include the known polymers suitable for production of nonwoven webs and materials such as for example polyolefins, polyesters, polyamides, polycarbonates and copolymers and blends thereof. However it should be noted that certain commercially available polymers and staple-length fibers which have abundant dipoles or which have had other radio frequency susceptible added to the polymer are susceptible to radio frequency heating, such as for example the CoPET-A “Kodel 410” binder fibers available from the Eastman Chemical Company. These types of polymers and fibers should not be use unless it is specifically desired to heat bond or partially heat bond the fibrous web material while performing the further drying step in the radio frequency drying station.
Numerous other patents have been referred to in the specification and to the extent there is any conflict or discrepancy between the teachings incorporated by reference and that of the present specification, the present specification shall control. Additionally, while the invention has been described in detail with respect to specific embodiments thereof, it will be apparent to those skilled in the art that various alterations, modifications and/or other changes may be made without departing from the spirit and scope of the present invention. It is therefore intended that all such modifications, alterations and other changes be encompassed by the claims. | The present invention provides an efficient method for topically treating and drying fibrous web materials such as nonwoven web materials and nonwoven laminate materials without unduly damaging the materials due to excessive heating during drying. | 3 |
PRIORITY
This application claims the benefit of U.S. Provisional Application Ser. No. 61/511,502, filed on Jul. 25, 2011, which is hereby incorporated by reference in its entirety herein.
FIELD
The present invention generally relates to a PEEK spacer for use in the spine. More particularly, the present invention relates to a PEEK spacer configured to fit through Kambin's Triangle and expand upon insertion.
SUMMARY
It is desirable to spare the facet joint when placing spacers for intervertebral stabilization, support and fusion. There is a need for a PEEK spacer that is small enough to fit through Kambin's Triangle, yet able to expand upon insertion to fully support and/or stabilize the intervertebral space. According to one embodiment of the present invention, the PEEK spacer may be placed via a facet sparing, transforaminal approach. In an embodiment, the PEEK spacer of the present invention may be placed through a minimally invasive operative access. In another embodiment, the PEEK spacer of the present invention may be placed through a percutaneous operative access.
According to one embodiment of the present invention, the PEEK spacer may be sized to be placed through a 15 mm×6 mm area at the L4-L5 vertebra. According to another aspect, the PEEK spacer of the present invention may be placed at any other desired vertebral level. In another embodiment of the present invention, the PEEK spacer may contain bone graft. According to one aspect, the PEEK spacer of the present invention may include an opening for bone graft insertion. In yet another embodiment of the present invention, the PEEK spacer may be configured to allow bony ingrowth through the spacer. According to one aspect of the present invention, the PEEK spacer may include an anti-backout feature.
In yet another embodiment, the PEEK spacer of the present invention may be configured to rotate from a first insertion position to a second implanted position. In an embodiment of the present invention, the PEEK spacer may be inserted in a first collapsed geometry and expanded to a second geometry after placement. In one embodiment of the present invention, the PEEK spacer may include arms, wings or other expandable members. In an embodiment of the present invention, expandable members may be solid such that fill material cannot escape back out of the entrance hole. In another embodiment expandable members may include slots or slits to allow bone ingrowth.
According to one embodiment of the present invention, the PEEK spacer may include a PEEK film configured to maintain the spacer in a collapsed geometry. In one aspect of the present invention, an expansion tool may be configured to pierce the PEEK film allowing the arms, wings or other expandable members to expand.
In yet another embodiment, the PEEK spacer of the present invention may be expanded using a screw or other suitable mechanism. According to another aspect of the present invention, the PEEK spacer may employ a ramp mechanism for expansion.
In an embodiment of the present invention, the PEEK spacer may include a central strut having a diversion configured to split a stream of bone or other fill material directing the fill material to both sides of the strut.
In yet another embodiment of the present invention, the arms, wings or other expandable members may be pivotally or otherwise movably attached to the spacer body. According to one aspect of the present invention, the PEEK spacer may include an asymmetrical taper along the implant width. In another embodiment, the PEEK spacer of the present invention may include lateral support features to help the implant stay upright when the disc space is subjected to shear forces.
According to one embodiment, a mesh container may be used with the PEEK spacer to contain fill material.
The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of an embodiment of the present invention.
FIG. 2 depicts a perspective view of an embodiment of the present invention.
FIG. 3 depicts a perspective view of an embodiment of the present invention in an expanded configuration.
FIG. 4 depicts a side perspective view of an embodiment of the present invention in an expanded configuration.
FIG. 5 depicts a perspective view of an embodiment of the present invention.
FIG. 6 depicts a perspective view of an embodiment of the present invention.
FIG. 7 depicts a perspective view of an embodiment of the present invention.
FIG. 8 depicts a perspective view of an embodiment of the present invention.
FIG. 9 depicts a perspective view of an embodiment of the present invention.
FIG. 10 depicts a perspective view of an embodiment of the present invention.
FIG. 11 depicts a perspective view of an embodiment of the present invention.
FIG. 12 depicts a perspective view of an embodiment of the present invention.
FIG. 13 depicts a perspective view of an embodiment of the present invention.
FIG. 14 depicts a perspective view of an embodiment of the present invention.
FIG. 15 depicts a perspective view of an embodiment of the present invention.
FIG. 16 depicts a perspective view of an embodiment of the present invention.
FIG. 17 depicts a perspective view of an embodiment of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, cross-hatching, dashing or shading in the figures is provided to demonstrate sealed portions and/or integrated regions or devices for the package.
DETAILED DESCRIPTION
In the following descriptions, the present invention will be explained with reference to example embodiments thereof. However, these embodiments are not intended to limit the present invention to any specific example, embodiment, environment, applications or particular implementations described in these embodiments. Therefore, description of these embodiments is only for purpose of illustration rather than to limit the present invention. It should be appreciated that, in the following embodiments and the attached drawings, elements unrelated to the present invention are omitted from depiction; and dimensional relationships among individual elements in the attached drawings are illustrated only for ease of understanding, but not to limit the actual scale.
As shown in FIGS. 1-5 , an embodiment of the present invention may include spacer body 12 and expandable members 14 a and 14 b . According to an embodiment of the present invention, the spacer of the present invention may be inserted into an intervertebral disc space while sparing the facet joint. The spacer of the present invention is sized to fit through Kambin's triangle via a far lateral surgical approach thus sparing the facet joint.
Expandable members 14 a and 14 b may be movably attached to spacer body 12 . Peek or other suitable film 16 may be wrapped around spacer 10 such that spacer 10 remains in a collapsed geometry during insertion. In another embodiment, any thin thread, woven tape or other suitable material may be wrapped around spacer 10 such that spacer 10 remains in a collapsed geometry during insertion.
After placement of spacer 10 is complete, expansion tool 18 may be inserted through channels 20 a and 20 b such that tool 18 pierces film 16 allowing spacer 10 to be expanded into its expanded configuration. In an embodiment, film 16 may be pulled to expand spacer 10 . Spacer 10 may be rotated once placed. Bone graft or other desired bone substitute or fill material, may be inserted through an opening in spacer 10 .
FIG. 6 depicts another embodiment of spacer 30 having spacer body 32 and expandable member 34 . Opening 36 may accept the introduction of fill material.
FIG. 7 depicts an alternate embodiment of spacer 40 having spacer body 42 and expandable members 44 a and 44 b.
FIG. 8 depicts another embodiment of spacer 50 having spacer body 52 and expandable members 54 a and 54 b.
FIG. 9 depicts an embodiment of spacer 60 having spacer body 62 and expandable members 64 a and 64 b.
FIG. 10 depicts an embodiment of spacer 70 having spacer body 72 , wherein only one expandable member 74 a is shown to illustrate ramp 76 .
FIG. 11 depicts spacer 80 having spacer body 82 and expandable members 84 a and 84 b . Spacer 80 is shown in the expanded position illustrating expansion tool 86 .
FIG. 12 depicts an alternate embodiment of spacer 90 having spacer body 92 and expandable members 94 a and 94 b . Opening 96 may accept the introduction of fill material.
FIG. 13 depicts another embodiment of spacer 100 having spacer body 102 and an expandable member 104 . Opening 106 may accept the introduction of fill material.
FIG. 14 depicts an alternate embodiment of spacer 110 having expandable members 112 , 114 , 116 , and 118 . Expandable members 112 , 114 , 116 , and 118 are movably connected to one another such that spacer 110 may be inserted in a collapsed geometry and opened to an expanded geometry after placement.
FIG. 15 depicts spacer 120 having spacer body 122 and expandable members 124 a and 124 b . Spacer 120 may be opened to an expanded configuration by drawing back distal ramp 128 back with a screw or other suitable mechanism.
FIG. 16 depicts an embodiment of spacer 130 having spacer body 132 and expandable member 134 .
FIG. 17 depicts an embodiment of spacer 140 having spacer body 142 and expandable members 144 a and 144 b . Any of the embodiments of the present invention may include expandable members which may be expanded from a first closed position to a second open position, or any position therebetween, in a variety of ways. According to one aspect of the present invention, expandable members may be expanded by a mechanical expansion tool such as for example, a paddle or rod. In such an example embodiment, a mechanical expansion tool may be inserted through an opening in spacer body 142 and in between expandable members 144 a and 144 b . A mechanical expansion tool may then be actuated to move expandable members from a first closed position to a second open position. Expandable members 144 a and 144 b may be partially opened, fully opened or opened to any position therebetween.
In another embodiment, expandable members may be expanded by the introduction of a balloon. In such an example embodiment, a deflated balloon may be inserted through an opening in spacer body 142 and in between expandable members 144 a and 144 b . The balloon may then be inflated, moving expandable members 144 a and 144 b from a first closed position to a second open position. Expandable members 144 a and 144 b may be partially opened, fully opened or opened to any position therebetween.
In yet another embodiment, expandable members may be expanded by the introduction of fill material, such as for example bone graft, bone substitute or any biocompatible fill material or any combination thereof. Expandable members may be partially opened, fully opened or any opened to any position therebetween.
Although the description of the invention generally contemplates placing the PEEK spacer of the present invention in the intervertebral space, the PEEK spacer of the present invention may also be placed within a vertebral body.
Although the description of the invention generally contemplates using spacer comprised of PEEK, any biocompatible material or combination thereof may be used in the composition of the spacer.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | A PEEK spacer for use in the spine is disclosed. The PEEK spacer may be configured to fit through Kambin's Triangle and expand upon insertion. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for operating an internal combustion engine, in whose exhaust gas system an exhaust gas treatment device is positioned, and in which a reagent is introduced into the exhaust gas system upstream from the exhaust gas treatment device, possibly mixed with compressed air, and a device for executing the method.
BACKGROUND INFORMATION
[0002] An exhaust gas treatment device of an internal combustion engine, in which an SCR catalytic converter (selective catalytic reduction), which reduces the nitrogen oxides contained in the exhaust gas to nitrogen using the reducing agent ammonia, is used to reduce the NOx emissions, is described in German Patent Application No. DE 101 39 142. The ammonia is obtained from a urea-water solution in a hydrolysis catalytic converter positioned upstream from the SCR catalytic converter. The hydrolysis catalytic converter converts the urea contained in the urea-water solution with water into ammonia and carbon dioxide. To ensure exact dosing, the concentration of the urea-water solution is ascertained. The urea-water solution is brought to a predefined pressure using a pump. A dosing valve-fixes a predefined flow rate. Compressed air is mixed with the urea-water solution in a mixing chamber. The urea-water solution is sprayed together with the added air into the exhaust gas of the internal combustion engine in such a way that a largely uniform flow against the SCR catalytic converter is achieved.
[0003] A method and a device, in which a pressurized reagent is also sprayed into the exhaust gas of an internal combustion engine upstream from an SCR catalytic converter, are described in German Patent Application No. DE 10 2004 018 221 (not previously published). The reagent pressure is fixed at a predefined reagent setpoint pressure as a function of a characteristic quantity. An operating variable of the internal combustion engine and/or a characteristic quantity of the exhaust gas of the internal combustion engine may be used as the characteristic quantity. The predefined reagent pressure setpoint value is regulated during a regulation in which the reagent actual pressure is detected by a reagent pressure sensor. Compressed air may be added to the reagent. The compressed air pressure may also be regulated to a predefined compressed air pressure setpoint value as a function of a characteristic quantity during a regulation, the compressed air actual pressure being detected by a compressed air pressure sensor. A defect of at least one of the pressure sensors may result in reduced performance capability of the SCR catalytic converter, with the consequence that unpurified exhaust gas may reach the environment.
[0004] A method and a device, in which a pressurized reagent is sprayed into the exhaust gas of an internal combustion engine upstream from an SCR catalytic converter, are described in German Patent Application No. DE 10 2004 044 506 (not previously published). The compressed air is guided via a check valve which has an opening pressure. It provides for diagnostics of the compressed air pressure beginning at a starting instant with the closing of a compressed air regulating valve. A check is performed at at least a second instant to determine whether the compressed air pressure corresponds at least to a lower threshold value, which at least approximately corresponds to the opening pressure of the check valve added to the ambient air pressure. An error signal is provided when the condition is not fulfilled.
[0005] A further method and a device, in which a pressurized reagent is sprayed into the exhaust gas of an internal combustion engine upstream from an SCR catalytic converter, are described in German Patent Application No. DE 101 59 849. Fuel which acts as a reducing agent for the NO 2 component in the exhaust gas in particular is provided as the reagent.
[0006] The present invention is based on the object of providing a method for operating an exhaust gas treatment device of an internal combustion engine, in whose exhaust gas system an exhaust gas treatment device is positioned, and in which a reagent, which is possibly admixed with compressed air, is introduced into the exhaust gas system upstream from the exhaust gas treatment device, and a device for executing the method, which ensure high reliability.
SUMMARY OF THE INVENTION
[0007] The method according to the present invention for operating an internal combustion engine first provides that a reagent is introduced into the exhaust gas system upstream from an exhaust gas treatment device. A reagent pump brings the reagent to a predefined reagent setpoint pressure. The reagent is dosed using a reagent dosing valve. The reagent pressure is detected upstream from the reagent dosing valve. During diagnostics, in which the reagent setpoint pressure has a predefined time curve, the detected reagent pressure is compared to at least one threshold value in at least one predefined state of the reagent dosing valve. If the threshold is exceeded, an error signal is provided.
[0008] The method according to the present invention is alternatively or additionally suitable for diagnosing a compressed air path. The compressed air path contains a compressed air pump and a compressed air valve and provides for the detection of the compressed air pressure.
[0009] The method according to the present invention significantly increases the reliability during operation of the internal combustion engine through the evaluation of the reagent and/or compressed air pressure, in particular if the reagent, such as fuel, is easily flammable. A leak in the reagent and/or compressed air path may be discovered using the method according to the present invention. Furthermore, it is possible to check at least one valve positioned in the reagent and/or compressed air path, which may stick in the closed or at least partially open state in case of fault. The method according to the present invention ensures that the exhaust gas treatment device is ready for use on the basis of the diagnostics and that a required exhaust gas purification is maintained.
[0010] According to one embodiment, a periodic time curve of the reagent setpoint pressure and/or of the compressed air setpoint pressure is predefined. This measure makes it possible to fix the at least one threshold value and/or threshold value curve easily. In normal dosing operation, in which the reagent dosing valve and/or the compressed air valve is at least partially open, it may be checked whether the predefined time curve is reflected in the reagent pressure and/or compressed air pressure. For example, predefining a sinusoidal time curve of the reagent setpoint pressure and/or the compressed air setpoint pressure is suitable. Furthermore, predefining a pulsed time curve of the reagent setpoint pressure and/or the compressed air setpoint pressure is suitable.
[0011] According to one embodiment, an operating state of the reagent dosing valve, in which the valve is closed, is predefined, and the threshold value is adjusted to the maximum predefined reagent setpoint pressure. Using this measure, it may be checked whether there is a leak in the reagent path or whether the reagent dosing valve sticks in the at least partially open state. A possibly occurring pressure drop may be established by ascertaining the pressure gradient or at least one pressure differential quotient and a subsequent comparison to at least one threshold value.
[0012] According to one embodiment, an operating state of the reagent dosing valve, in which the valve is at least partially open, is predefined, and the threshold value is adjusted to the expected time curve. Using this measure, it may be checked whether the reagent dosing valve sticks in the closed state.
[0013] Corresponding embodiments are possible in the compressed air path if the compressed air valve is electrically controllable. Otherwise, the threshold value is adjusted to the maximum compressed air setpoint pressure. Therefore, it may at least be determined whether the compressed air valve sticks in the closed state. Furthermore, according to one embodiment, the threshold value may be adjusted to the expected time curve of the predefined compressed air setpoint pressure. Therefore, it may also be determined whether the compressed air valve sticks in the closed state.
[0014] One embodiment provides for the checking of a reagent pump and/or a compressed air pump.
[0015] The device according to the present invention for operating an internal combustion engine primarily relates to a control unit which is implemented to perform the method.
[0016] In particular, the control unit contains a diagnostic controller, a threshold value default for predefining the time curve of the setpoint pressure, and a comparator, which compares the at least one threshold value to the detected pressure.
[0017] The control unit preferably contains at least one electrical memory, in which the method steps are stored as a computer program.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a technical environment in which a method according to the present invention is executed.
[0019] FIGS. 2 a , 2 b and 2 c show signal curves as a function of time.
DETAILED DESCRIPTION
[0020] FIG. 1 shows an internal combustion engine 10 , in whose intake area 11 an intake air detector 12 is positioned and in whose exhaust gas system 13 a reagent introduction device 14 and an exhaust gas treatment device 15 are positioned.
[0021] Intake air detector 12 outputs an air signal msL to a control unit 20 and internal combustion engine 10 outputs a speed n to control unit 20 .
[0022] Control unit 20 provides a fuel signal mK to a fuel metering device 30 .
[0023] In a reagent path 31 , a reagent stored in a reagent tank 32 is brought to a predefined reagent setpoint pressure pReaSW by a reagent pump 33 . Reagent pump 33 is activated by a reagent pump activation signal 34 , which is provided by a reagent pump activator 35 positioned in control unit 20 .
[0024] The reagent reaches a reagent dosing valve 36 , which is connected to a mixing chamber 37 . Furthermore, mixing chamber 37 is connected to a compressed air path 40 . After mixing chamber 37 , the reagent reaches reagent introduction device 14 .
[0025] A reagent pressure sensor 41 , which provides reagent pressure pRea to both reagent pump activator 35 and also a comparator 42 , is positioned between reagent pump 33 and reagent dosing valve 36 . Comparator 42 provides an error signal F.
[0026] A setpoint default 43 provides a reagent setpoint pressure pReaSw to both reagent pump activator 35 and also comparator 42 .
[0027] A dosing valve activation signal msRea, provided by a reagent dosing controller 44 , to which a dosing signal 45 is supplied, is applied to reagent dosing valve 36 .
[0028] A diagnostic controller 46 outputs a setpoint default signal 47 to setpoint default 43 , a comparison signal 48 to comparator 42 , and a diagnostic signal 49 to reagent dosing controller 44 .
[0029] Compressed air path 40 contains a compressed air pump 50 to which a compressed air pump activation signal 51 is applied, a compressed air pressure sensor 52 , which provides a compressed air pressure pDI, and a compressed air valve 53 , which is positioned on mixing chamber 37 .
[0030] FIG. 2 a shows a predefined reagent setpoint pressure pReaSW as a function of time t. Between first and second instants t 1 , t 2 , a reagent nominal pressure pReaN is predefined as reagent setpoint pressure pReaSW. A time curve 60 of reagent setpoint pressure pReaSW is predefined at second instant t 2 . Time curve 60 has a maximum pReaMax at a third instant t 3 , a relative zero crossing 61 at a fourth instant t 4 , and a minimum pReaMin at a fifth instant t 5 . Minimum pReaMin is above an exhaust gas pressure pabg.
[0031] FIG. 2 b shows reagent pressure pRea as a function of time t. Between first and second instants t 1 , t 2 , reagent pressure pRea is predefined reagent nominal pressure pReaN. Between second and third instants t 2 , t 3 , reagent pressure pRea rises to maximum pReaMax of predefined reagent setpoint pressure pReaSW.
[0032] FIG. 2 c also shows reagent pressure pRea as a function of time t. Reagent pressure pRea is predefined reagent nominal pressure pReaN between first and second instants t 1 , t 2 . Between second and third instants t 2 , t 3 , reagent pressure pRea rises to just below predefined maximum pReaMax of reagent setpoint pressure pReaSW.
[0033] Reagent pressure pRea has a pressure drop 62 between third and sixth instants t 3 , t 6 .
[0034] The method according to the present invention functions as follows:
[0035] The exhaust gas of internal combustion engine 10 contains undesired components such as nitrogen oxides. Exhaust gas treatment device 15 is responsible for reducing the undesired components as much as possible. Exhaust gas treatment device 15 is implemented as a catalytic converter, preferably as an SCR catalytic converter according to the related art cited at the beginning, for example. An SCR catalytic converter requires the reagent such as ammonia. Hydrocarbons may be provided as a reagent as a function of the design of the SCR catalytic converter. The ammonia may be obtained from a urea-water solution through hydrolysis. Possibly necessary hydrocarbons may be provided by fuel.
[0036] In the exemplary embodiment shown, the reagent may be mixed in mixing chamber 37 with compressed air which is provided by compressed air path 40 . Compressed air path 40 and mixing chamber 37 may be dispensed with as a function of the concrete design. According to another embodiment, reagent introduction device 14 , which is simply a spray pipe, for example, may be identical to reagent dosing valve 36 . Reagent dosing valve 36 is then dispensed with. In this design, reagent dosing valve 36 is positioned directly in exhaust gas system 13 .
[0037] Reagent pressure sensor 41 detects reagent pressure pRea in reagent path 31 between reagent pump 33 and reagent dosing valve 36 .
[0038] Compressed air pump 50 , whose pressure is fixed at a predefined compressed air setpoint pressure pDISW using compressed air pump activation signal 51 , is provided in compressed air path 40 . The compressed air reaches mixing chamber 37 via compressed air valve 53 . Compressed air valve 53 is a check valve, for example, which has a flow-dependent opening pressure. According to an embodiment which is not shown in greater detail, compressed air valve 53 may be electrically actuated. Compressed air pressure sensor 52 , which detects compressed air pressure pDI in compressed air path 40 , is positioned between compressed air pump 50 and compressed air valve 53 .
[0039] The following description is directed to a diagnosis of reagent path 31 . The diagnosis of compressed air path 40 is performed analogously. Reagent pump 33 contained in reagent path 31 corresponds to compressed air pump 50 positioned in compressed air path 40 . Reagent dosing valve 36 positioned in reagent path 31 corresponds to compressed air valve 53 positioned in compressed air path 40 , and reagent pressure sensor 41 positioned in reagent path 31 corresponds to compressed air pressure sensor 52 positioned in compressed air path 40 . Reagent setpoint pressure pReaSW predefined in reagent path 31 corresponds to compressed air setpoint value pDISW predefined in compressed air path 40 .
[0040] A diagnosis through an evaluation of reagent pressure pRea provided by reagent pressure sensor 41 in regard to the absolute value and/or the changes first allows a check of whether there is a leak in reagent path 31 . A leak, in particular a leak which occurs in exhaust gas system 13 , may entail increased operating danger, in particular if the reagent is an easily flammable material such as fuel.
[0041] Reagent pressure pRea is evaluated in comparator 42 by comparison to at least one predefined threshold value, which may be an absolute pressure and/or a pressure change and/or a pressure gradient. A targeted diagnosis, which extends to the proper functioning of reagent dosing valve 36 or another valve provided, may be performed via suitable fixing of diagnostic signal 49 by diagnostic controller 46 . Furthermore, reagent pump 33 may be checked for proper functioning.
[0042] During normal operation of exhaust gas treatment device 15 , the dosing is performed using dosing signal 45 , which is supplied to reagent dosing controller 44 . The normal dosing operation may be interrupted by diagnostic signal 49 , which is provided by diagnostic controller 46 .
[0043] It is first assumed that the normal dosing operation of the reagent is provided between first and second instants t 1 , t 2 . Setpoint default 43 outputs reagent pressure nominal value pReaN, which reagent pump activator 35 attempts to set via corresponding fixing of reagent pump activation signal 34 .
[0044] A first diagnostic possibility is checking whether reagent pressure pRea at least approximately corresponds to predefined reagent nominal pressure pReaN. Comparator 42 compares reagent pressure pRea to a threshold value or multiple threshold values, which are related to predefined reagent nominal pressure pReaN. If a deviation is determined, error signal F is provided.
[0045] Time curve 60 of reagent setpoint pressure pReaSW, which is preferably superimposed on predefined reagent nominal pressure pReaN, is predefined starting from second instant t 2 . A periodic, sinusoidal curve 60 , which may generally be provided without increased demands on reagent pump 33 , is provided in the exemplary embodiment shown. Reagent pump 33 must merely be capable of providing a reagent pressure pRea which exceeds reagent nominal pressure pReaN. Furthermore, a pulsed curve 60 , which places higher demands on reagent pump 33 , is suitable. Purely in principle, any curve 60 which has a chronological change may be provided.
[0046] It is first assumed that reagent dosing valve 36 is at least partially open during normal dosing operation. Reagent pressure pRea is evaluated in that comparator 42 compares measured reagent pressure pRea to at least one threshold value, preferably to a time curve of the threshold value corresponding to curve 60 , the threshold value or the threshold value curve being adapted to predefined curve 60 and possibly to reagent nominal pressure pReaN. If the signal curve of reagent pressure pRea shown in FIG. 2 b occurs, in which predefined time curve 60 may no longer be found again at least from third instant t 3 , a reagent dosing valve 36 which sticks in the closed state must be assumed.
[0047] Another diagnosis provides that reagent dosing valve 36 is closed at second instant t 2 or at the latest at third instant t 3 . If reagent path 31 is in working order, reagent pressure pRea rises to predefined maximum pReaMax of reagent setpoint pressure pReaSW, as shown in FIG. 2 b , and subsequently remains there. For the diagnosis, it is sufficient if comparator 42 checks whether a pressure drop of reagent pressure pRea has occurred at at least one predefined instant, for example, at fourth instant t 4 , at which relative zero crossing 61 lies, and/or at fifth instant t 5 , at which minimum pReaMin lies. Comparator 42 may relate the threshold value to maximum pReaMax, for example. If no pressure drop or only a small permissible pressure drop is determined, reagent path 31 is in working order. If predefined time curve 60 , possibly having significantly reduced amplitudes, may be found again, reagent dosing valve 36 sticks in the at least partially open state. If there is a leak in reagent path 31 , a reagent pressure pRea will occur as shown as an example in FIG. 2 c.
[0048] The situation may first occur in which reagent pressure pRea does not rise to expected maximum pReaMax at third instant t 3 . If this is the case, a larger leak must be assumed, in which reagent pump 33 is no longer capable of maintaining predefined reagent setpoint pressure pReaSW.
[0049] After third instant t 3 , i.e., after reaching maximum pReaMax, pressure drop 62 exists, which is ended in the exemplary embodiment shown from sixth instant t 6 of predefined time curve 60 by the pressure increase. In addition to a comparison with a threshold value, for example, at fourth and/or fifth instant t 4 , t 5 , a pressure gradient which may preferably be implemented as at least one differential quotient may be provided as a threshold value.
[0050] If comparator 42 determines the threshold has been exceeded at least once, error signal F is provided and may be stored in a fault memory (not shown in greater detail) or displayed, for example. | A method for operating an internal combustion engine, in whose exhaust gas system an exhaust gas treatment device is positioned, a reagent, which is possibly mixed with compressed air, being introduced into the exhaust gas system upstream from the exhaust gas treatment device, and a device for performing the method. The reagent is brought to a predefined reagent setpoint pressure using a reagent pump and subsequently metered using a reagent dosing valve. The reagent pressure existing upstream from the reagent dosing valve is detected. In the framework of a diagnosis, a time curve of the reagent setpoint pressure is predefined. The reagent pressure detected during the diagnosis is compared to at least one predefined threshold value. If the threshold value is exceeded, an error signal is provided. The corresponding diagnosis of a compressed air path may be provided alternatively or additionally to the diagnosis of the reagent path. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to methods for producing phospholipids, and in particular relates to methods for producing phospholipids by phospholipase A2.
BACKGROUND ART
[0002] Recent studies on lipids have revealed that highly unsaturated fatty acids such as docosahexaenoic acid (DHA) and eicosapentaenoic acid (EPA) have various functions such as the improvement of learning function, the prevention of arteriosclerosis, and the improvement function of lipid metabolism. In particular, it has been revealed that the intake of DHA in a form bonded to a phospholipid such as phosphatidylcholine provides higher antioxidant activity and higher stability than those of the triglyceride form as well as it leads to good absorption to readily provide physiological activities of the DHA. Functional fatty acids other than DHA, such as EPA, conjugated linoleic acid, and arachidonic acid are also expected to achieve higher physiological activities by the bonding to a phospholipid.
[0003] Methods for producing a phospholipid bonded with a functional fatty acid such as DHA are classified into a method of extraction of a natural product and a method of synthesis from a material such as soybean phospholipids. Specific examples of the former method include a method of extraction of a DHA-bonded phospholipid from aquatic animal roes as a material (Patent Document 1) and a method of extraction from marine products such as a squid with an organic solvent (Patent Document 2). However, these methods cannot produce phospholipids bonded with functional fatty acids other than DHA because the materials are expensive and cannot stably be supplied and the composition of phospholipid depends on materials.
[0004] Examples of methods capable of introducing a desired fatty acid not depending on a material composition include a method by adding any fatty acid to a culture solution of a microorganism to produce a phospholipid bonded with the fatty acid by the microorganism (Patent Document 3). However, the method produces the phospholipid in a small amount from a large amount of the culture solution and thus the production efficiency is poor.
[0005] Among the latter methods, examples of the method of bonding DHA to soybean phospholipids and the like include a method of adding a high-permittivity substance capable of forming hydrogen bonds to a reaction system of lipase and phospholipase (Patent Document 4). However, the method can achieve a high reaction rate in the reaction of a lysophospholipid and a fatty acid by the lipase but cannot achieve a high reaction rate by phospholipase A2. Furthermore, it is important for the expression of physiological activities of the DHA-bonded phospholipid that DHA is bonded to the 2-position, but a target fatty acid is mainly bonded to the 1-position in a phospholipid through a reaction by the lipase, and therefore such a method is not highly practical.
[0006] Meanwhile, as a method for efficiently bonding a desired fatty acid to the 2-position in a phospholipid, there have been reported some bonding methods using phospholipase A2 in glycerin (Patent Document 5 and Non-patent Document 1). However in these reports, toxic chloroform-methanol is used for extraction after the reaction. Thus, the solvent cannot be used depending on an intended use of the phospholipid, or an apparatus for removing the solvent is required. Moreover, the phospholipase A2 is expensive, and hence such a method is required to reduce costs.
[0007] In a common enzyme reaction, enzyme immobilization is widely performed for the efficient use of the enzyme. However, there have been reports that when an immobilized phospholipase A2 is used in esterification by the phospholipase A2, the esterification is unlikely to efficiently proceed even when a fatty acid is used in a large amount with respect to a lysophospholipid (Non-patent Document 2 and Non-patent Document 3).
CITATION LIST
Patent Literature
[0008] Patent Document 1: JP-A No. 8-59678
[0009] Patent Document 2: JP-A No. 8-325192
[0010] Patent Document 3: JP-A No. 2007-129973
[0011] Patent Document 4: JP-A No. 8-56683
[0012] Patent Document 5: JP-A No. 5-236974
Non-Patent Literature
[0013] Non-patent Document 1: Fisheries Science, Vol. 72, pages 909-911 (2006)
[0014] Non-patent Document 2: Journal of the American Oil Chemists' Society, Vol. 72, pages 641-646 (1995)
[0015] Non-patent Document 3: Biochimica et Biophysica Acta, Vol. 1343, pages 76-84 (1997)
SUMMARY OF INVENTION
Technical Problem
[0016] As described above, it is demanded to develop a method of recovering a phospholipid after efficient esterification by phospholipase A2 and of reusing the phospholipase A2. Hence, it is an object of the present invention to provide a method for producing a phospholipid at low cost by reusing phospholipase A2 in the method of producing the phospholipid bonded with any fatty acid to the 2-position in the phospholipid through esterification by the phospholipase A2 in glycerin.
Solution to Problem
[0017] The present inventors have carried out intensive studies in order to solve the problems, as a result, have found that, by esterifying a lysophospholipid by phospholipase A2 in glycerin, then extracting a phospholipid with a solvent immiscible with glycerin, then removing the solvent by evaporation, and adding the lysophospholipid and an acyl donor, re-esterification of the lysophospholipid with the acyl donor can be performed by reusing the phospholipase A2 remaining in glycerin, and the invention has been accomplished.
[0018] Namely, the present invention relates to a method for producing a phospholipid characterized by including producing a phospholipid through esterification of a lysophospholipid with an acyl donor by phospholipase A2 in glycerin, then adding a solvent immiscible with glycerin to form a glycerin layer and a solvent layer, extracting the phospholipid into the solvent layer, transferring the phospholipase A2 into the glycerin layer, then collecting the glycerin layer, removing a remaining solvent by evaporation from the glycerin layer to give a glycerin solution, adding the lysophospholipid and the acyl donor to the glycerin solution, and esterifying using the phospholipase A2 remaining in the glycerin solution.
[0019] In the present invention, a ketone solvent may be added as the solvent immiscible with glycerin, or an alcohol having 4 or less carbon atoms may be added after the esterification and then at least one solvent selected from the group consisting of hydrocarbon solvents, ketone solvents, and ester solvents may be added as the solvent immiscible with glycerin.
[0020] In the present invention, in the esterification, an amino acid and/or a peptide having three or less amino acid residues may be added to the reaction system.
[0021] The amino acid is preferably at least one selected from the group consisting of glycine, alanine, asparagine, glutamine, isoleucine, leucine, serine, threonine, valine, phenylalanine, and tyrosine.
[0022] The peptide is preferably a combination including glycine, alanine, and/or serine.
ADVANTAGEOUS EFFECTS OF INVENTION
[0023] According to the present invention, a method of producing a phospholipid at low cost by reusing phospholipase A2 in the method of producing the phospholipid bonded with any fatty acid to the 2-position in the phospholipid through esterification by the phospholipase A2 in glycerin can be provided.
DESCRIPTION OF EMBODIMENTS
[0024] Hereinafter, the present invention will be described in further detail. The method for producing a phospholipid of the present invention is characterized by including producing a phospholipid through esterification of a lysophospholipid with an acyl donor by phospholipase A2 in glycerin, then adding a solvent immiscible with glycerin to form a glycerin layer and a solvent layer, extracting the phospholipid into the solvent layer, transferring the phospholipase A2 into the glycerin layer, then collecting the glycerin layer, removing a remaining solvent by evaporation from the glycerin layer to give a glycerin solution, adding the lysophospholipid and the acyl donor to the glycerin solution, and re-esterifying using the phospholipase A2 remaining in the glycerin solution.
[0025] The lysophospholipid in the present invention is a compound of removing a fatty acid from the 2-position in a phospholipid and means a lipid different from phospholipids. The lysophospholipid used in the present invention may be a modified phospholipid and is preferably derived from soybeans, rapeseeds, and egg yolk due to easy availability. The lysophospholipid derived from soybeans is more preferred due to low cost, but lysophospholipids derived from other plants may be used.
[0026] Examples of the method for modifying a phospholipid to remove a fatty acid residue from the 2-position include, but are not necessarily limited to, a method of using phospholipase A2 or the like to hydrolyze the fatty acid residue at the 2-position in the phospholipid. The phospholipid usable in this case is a molecule having a glycerin skeleton, a phosphate group, and two fatty acid esters, is capable of being a substrate of the phospholipase A2, and does not include a molecule having a sphingosine skeleton. Specific examples include phosphatidylcholine, phosphatidylethanolamine, and phosphatidylserine. The method using the phospholipase A2 can be carried out without using any toxic substance, and therefore can be employed for the production of a phospholipid used, for example, for foods.
[0027] In the invention, the fatty acid as the acyl donor that is introduced to the 2-position of a lysophospholipid in the esterification of the lysophospholipid by phospholipase A2 in glycerin is not specifically limited. A free fatty acid may be used or an ethyl ester or a triglyceride is hydrolyzed by an enzyme such as lipase in a reaction system to be used, but from the viewpoint of reactivity, a free fatty acid is preferably used. Specific examples include, considering functionality, highly unsaturated fatty acids such as DHA, EPA, arachidonic acid, and conjugated linoleic acid. Examples of the usable DHA and EPA include free fatty acids that are obtained by hydrolysis of mainly marine animal oils or oils and fats derived from algae. The acyl donor used in the present invention is preferably used in an amount of 30 to 1000 parts by weight with respect to 100 parts by weight of a lysophospholipid from the viewpoints of reaction efficiency and costs.
[0028] When a fatty acid is difficult to be obtained as a single compound from natural resources, for example, DHA, a fatty acid mixture containing a desired fatty acid may be used. In such a case, the fatty acid mixture desirably includes a desired fatty acid in an amount of about 20% by weight or more. For example, in the case of DHA, a DHA-containing fatty acid mixture preferably has a DHA concentration of 20% by weight or more, and a mixture having a DHA concentration of 45% by weight or more is more preferably used. After the esterification according to the invention, solvent separation or the like may be carried out to increase the concentration of a phospholipid as the reaction product.
[0029] The phospholipase A2 used in the present invention may be derived from any source, and is preferably phospholipase A2 that can be commonly used for foods. Examples include those derived from porcine pancreas and microorganisms. The phospholipase A2 used in the present invention is preferably used in an amount of 1000 to 100000 U with respect to 1 g of a lysophospholipid from the viewpoints of reaction efficiency and costs.
[0030] In the present invention, the esterification is carried out in glycerin. This is because glycerin has high polarity to be effective for esterification and can be used for foods. It also has an advantage because it can dissolve amino acids described later as optional components. The glycerin is preferably used in an amount of 500 to 10000 parts by weight with respect to 100 parts by weight of a lysophospholipid, considering reactivity and the like.
[0031] In the present invention, the esterification is carried out in the glycerin as mentioned above, and hence, for the extraction of a resulted phospholipid, a solvent immiscible with the glycerin is used to extract the phospholipid. As the solvent immiscible with glycerin used in the present invention, at least one solvent selected from the group consisting of hydrocarbon solvents, ketone solvents, and ester solvents may be used, and the use of such a solvent leads to efficient extraction of a target phospholipid. Where, except for the extraction with the ketone solvent alone, it is preferable that an alcohol having 4 or less carbon atoms is added and then the solvent is added in order to reduce the viscosity of a reaction solution containing glycerin for easy extraction. The reason why the addition of the alcohol is not required when the ketone solvent is used alone is because it has higher solubility to glycerin than those of the hydrocarbon solvents and the ester solvents. The solvent is preferably added in an amount of 20 to 300 parts by weight with respect to 100 parts by weight of glycerin, considering recovery efficiency of a phospholipid and the like.
[0032] The hydrocarbon solvent means a compound capable of being used as a solvent among compounds composed of carbons and hydrogens alone. Specific examples include pentane, hexane, and heptane, and hexane is more preferred because it is readily removed by evaporation due to its low boiling point and can be used as a food additive.
[0033] The ketone solvent means a compound capable of being used as a solvent among compounds having a keto group in the molecule. Specific examples include acetone and butanone, and acetone is preferred because it is readily removed by evaporation due to its low boiling point and can be used as a food additive.
[0034] The ester solvent means a compound capable of being used. as a solvent among compounds having an ester linkage in the molecule. Specific examples include methyl acetate and ethyl acetate, and ethyl acetate is preferred because it is used for foods.
[0035] In the present invention, in the esterification of a lysophospholipid by the phospholipase A2, an antioxidant may be used in order to suppress the oxidation of an acyl donor, and a calcium source such as calcium chloride, an amino acid, and a peptide having 3 or less amino acid residues may be used in order to activate the phospholipase A2. Other additives may also be used as necessary.
[0036] As the antioxidant, any antioxidant may be used as far as the antioxidative effect on fatty acids such as DHA can be expected, and examples include poly-phenols such as catechin, tocopherol, ascorbic acid, derivatives of them, and dibutylhydroxytoluene (BHT) from the viewpoint of food applications.
[0037] In order to suppress the oxidation of a fatty acid, the esterification of a lysophospholipid may be carried out under a nitrogen atmosphere without oxygen.
[0038] The amino acid means a compound mainly constituting a protein and having a carboxyl group and an amino group in the molecule, and is preferably a compound capable of being used for foods. Among them, neutral amino acids are preferred because such an amino acid can activate the phospholipase A2 while causing relatively little effect on a charge state of the phospholipase A2, and examples include glycine, alanine, asparagine, glutamine, isoleucine, leucine, serine, threonine, valine, phenylalanine, and tyrosine. For the method for producing a phospholipid of the present invention, at least one. selected from them may be used.
[0039] The peptide having three or less amino acid residues means mainly a dimer or a trimer of amino acids through amide linkages. It may be synthesized from amino acids or may be a degradation product of a protein by an enzyme or the like. It is preferably a peptide including glycine, alanine, and/or serine because such a peptide has a comparatively high solubility to glycerin, and examples include glycylglycine. The use of such a peptide having a few amino acid residues leads to a high molarity when it is dissolved in glycerin and may efficiently activate the phospholipase A2.
[0040] The calcium source is used in order to activate the phospholipase A2 as described above and is preferably a compound capable of being present as a calcium ion in the reaction system. Thus, preferred calcium sources are compounds having a comparatively high solubility and also usable as food materials. Suitable examples of the calcium source include calcium chloride as mentioned above.
[0041] Each amount of the antioxidant, the calcium source, the amino acid, and the peptide having three or less amino acid residues may be an amount suitable for the achievement of each purpose. However, each of the amino acid and the peptide having three or less amino acid residues is preferably added in an amount of 10 to 2000 parts by weight with respect to 100 parts by weight of a lysophospholipid, and more preferably 50 to 500 parts by weight. The addition of such a compound in an amount of less than 10 parts by weight may reduce the reaction efficiency, and the addition of such a compound in an amount of more than 2000 parts by weight increases the cost and may reduce the reaction efficiency. Two or more of the amino acids and the peptides having three or less amino acid residues may be added in combination of them in order to increase the total dissolution amount in the esterification system.
[0042] A preferred example of the method for producing a phospholipid of the present invention will be described below.
[0043] First, a lysophospholipid and an acyl donor are dissolved in glycerin; phospholipase A2 and, as necessary, an antioxidant and an amino acid, a peptide having three or less amino acid residues, and calcium chloride for activating the phospholipase A2 are added to give a glycerin reaction solution; and the glycerin reaction solution is stirred to esterify the lysophospholipid with the acyl donor. As necessary, the esterification may be carried out under a nitrogen atmosphere without oxygen in order to suppress the oxidation of the fatty acid.
[0044] At this time, the esterification is preferably carried out at a temperature ranging from 35° C. to 80° C. and more preferably at a temperature ranging from 45° C. to 70° C. from the viewpoints of the optimum temperature of the phospholipase A2 and the suppression of the oxidation of the fatty acid as the acyl donor.
[0045] Depressurization may be carried out during the reaction in order to remove water that is formed through the esterification by the phospholipase A2 to accelerate the esterification. The depressurization for removing water may be carried out, for example, lat a temperature of 35 to 80° C. at 150 torr (20 kPa) or less for 12 to 24 hours.
[0046] As described above, the esterification of the lysophospholipid with the fatty acid as the acyl donor forms a phospholipid introduced with the desired fatty acid to the 2-position of the lysophospholipid. The progress of the esterification may be checked by thin layer chromatography (TLC) and the like.
[0047] To the glycerin reaction solution containing the phospholipid formed through the esterification as above, a ketone solvent is added, or an alcohol having 4 or less carbon atoms is added to reduce the glycerin viscosity for easy extraction and then at least one solvent selected from the group consisting of hydrocarbon solvents, ketone solvents, and ester solvents is added to the reaction solution to form a glycerin layer and a solvent layer. Then, the phospholipid formed through the esterification is extracted into the solvent layer, the phospholipase A2 is transferred into the glycerin layer, and consequently the target phospholipid can be extracted. At this time, the solvent layer (upper layer) includes the target phospholipid/lysophospholipid, the solvent, and the acyl donor, and the glycerin layer (lower layer) mainly includes the glycerin, the solvent, the phospholipase A2, the phospholipid/lysophospholipid that cannot completely be extracted, other additives, and the like. Next, the solvent layer (upper layer) and the glycerin layer (lower layer) are separated (collected). At this time, the addition of a predetermined solvent and the separation may be properly repeated, considering the improvement of the phospholipid purity and the operating efficiency. In this manner, the target phospholipid can be efficiently extracted from the glycerin reaction solution.
[0048] The phospholipid and the phospholipase A2 can he separated as above, but the phospholipase A2 may be included in the solvent layer in a trace amount accompanying the target phospholipid. In this case, the target phospholipid may be mixed with the phospholipase A2 even after the treatment as exemplified below. Such a mixture including the phospholipase A2 may be used for foods, but, if necessary, the phospholipase A2 may be properly degraded and inactivated by, for example, using a degradative enzyme such as protease.
[0049] The alcohol having 4 or less carbon atoms means methanol, ethanol, propanol, and butanol, and ethanol is more preferred because it has low toxicity and can be used as a food additive. The alcohol is preferably added in an amount of 10 to 150 parts by weight with respect to 100 parts by weight of glycerin.
[0050] In the present invention, the fatty acid as the acyl donor may be removed from the separated solvent layer (upper layer) containing the target phospholipid as above. The method for removing the fatty acid as the acyl donor from the separated upper layer is not specifically limited, and examples of the method include a defatting method with a ketone solvent, an ethanol-hexane mixed solvent, or the like and a method of removing the fatty acid using silica gel.
[0051] For example, in the method using a ketone solvent or the like, the solvent in the separated (collected) upper layer is removed by evaporation; then a ketone solvent or the like is newly added; the mixture is cooled at 5° C. or less to precipitate the phospholipid; and the ketone solvent dissolving the fatty acid is separated and removed to give the phospholipid introduced with a desired fatty acid to the 2-position in the lysophospholipid. In the method, the ketone solvent or the like for adding after the solvent removal by evaporation is preferably acetone because it has a low boiling point to be readily removed by evaporation and can be used as a food additive.
[0052] In the method of removing the fatty acid using silica gel, the upper layer is separated (collected); then, the upper layer is passed through a column packed with silica gel to adsorb the phospholipid and to flow out the fatty acid for removal; then an eluent solvent such as methanol is passed through the column to desorb the phospholipid that is adsorbed to the silica gel and to collect a desired phospholipid fraction alone; then the phospholipid is recrystallized to give the phospholipid introduced with a desired fatty acid to the 2-position in the lysophospholipid.
[0053] Meanwhile, a solvent such as ethanol may inhibit the phospholipase A2 activity. Thus, the upper layer and the lower layer are separated (collected), and the glycerin layer as the lower layer may be decompressed to remove the remaining solvent. Such a treatment provides the glycerin solution containing the phospholipase A2, the remaining phospholipid/lysophospholipid, other optional additives, and the like.
[0054] Then, to the glycerin solution, the lysophospholipid as the reaction substrate and the fatty acid as the acyl donor are further added to achieve re-esterification using the phospholipase A2 remaining in the glycerin solution, and consequently the phospholipase A2 can be reused.
[0055] At this time, the manner of adding the lysophospholipid and the acyl donor is not specifically limited. To the glycerin solution, the lysophospholipid and the acyl donor may be simultaneously added, the lysophospholipid may be added followed by the addition of the acyl donor, or the acyl donor may be added followed by the addition of the lysophospholipid. Each amount may be properly adjusted so as to be substantially the same as that in the former esterification depending on the progress of the reaction or the extraction degree while considering that the unreacted lysophospholipid is present in the glycerin solution. Furthermore, the materials other than the lysophospholipid and the acyl donor, such as the calcium source, the amino acid and/or the peptide having three or less amino acid residues, and the glycerin may be properly added in an amount reduced by the extraction of the phospholipid when the lysophospholipid and the acyl donor are added. The re-esterification may be carried out in the same conditions as those in the former esterification, and the extraction of the phospholipid may be carried out in the same manner as the above.
[0056] In this manner, as far as the phospholipase A2 maintains the activity, such an operation is repeated to reuse the phospholipase A2 many times, and consequently a desired phospholipid can be produced at lower cost. At this time, when the productivity of the phospholipid is lowered, the amount of the phospholipase A2, optional additives such as the amino acid, the peptide having three or less amino acid residues, and the calcium chloride, the glycerin, or the like may be partly reduced due to the extraction, or the activity of the phospholipase A2 or the like may be reduced. Hence, such a material may be added as necessary. Furthermore, in the same manner as in the former esterification, in order to suppress the oxidation of the fatty acid, the esterification may be carried out with an antioxidant or in a nitrogen atmosphere without oxygen, as necessary.
[0057] The method for producing a phospholipid of the present invention may be suitably employed as a method for producing a phospholipid introduced with a desired fatty acid to the 2-position. The method can be carried out without using materials and solvents such as chloroform unsuited for foods in the production process, and therefore is suitably employed especially for the production of edible phospholipids. Furthermore, the phospholipid obtained in this manner, in particular, the phospholipid introduced with a highly unsaturated fatty acid to the 2-position can be suitably used as a high-function edible phospholipid.
EXAMPLES
[0058] Hereinafter, the present invention will be described in further detail with reference to examples, but the present invention is not intended to be limited to the examples. In the examples, “part” and “%” are based on weight.
<Determination of Fatty Acid Composition in Phospholipid>
[0059] In Examples, Comparative Examples, and the like, after the completion of the reaction, to 50 μl of the reaction solution, 200 μl of a solvent of chloroform:methanol=2:1 (volume ratio) and 500 μl of a saturated sodium chloride solution were added, then the whole was stirred and centrifuged at 13000 rpm for 1 minute, and the lower layer was extracted. The centrifugation was carried out again using 200 μl of a solvent of chloroform:methanol=2:1 (volume ratio) in a similar manner, and the lower layer was extracted. The treated lower layer containing a phospholipid and a fatty acid was developed by TLC (thin layer chromatography) with the solvent to collect a fraction of the phospholipid and lysophospholipid. The fraction was esterified with sodium methylate to form methyl esters, and the fatty acid composition of the fatty acids bonded to the phospholipid and the lysophospholipid was analyzed with a gas chromatograph (“GC-14B” manufactured by Shimadzu Corporation). The area ratio % of each fatty acid in the gas chromatogram was regarded as the weight ratio % of the corresponding fatty acid.
Example 1
[0060] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 105 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of DHA-50G (manufactured by Nippon Chemical Feed Co., Ltd., DHA content: 51.8% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 37.5 mg of glycine (manufactured by Showa Denko K. K.) and. 37.5 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD., 53 U/mg) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution and 30 μl of water were added, and the whole was reacted at 50° C. for 24 hours. The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 13.4% by weight.
[0061] To the reaction solution, 1 ml of ethanol was added. The whole was stirred and then extracted with 1 ml of hexane twice to separate (collect) the hexane layer (upper layer) and the glycerin layer (lower layer) in a common procedure. As for the fatty acid composition of the phospholipid and lysophospholipid fraction included in each of the separated (collected) hexane layer (upper layer) and the glycerin layer (lower layer), the hexane layer had a DHA content of 20.7% by weight, and the glycerin layer had a DHA content of 6.3% by weight.
[0062] The separated (collected) glycerin layer (lower layer) was decompressed at 0.6 torr (80 Pa) for 15 minutes to remove the solvent. To the decompressed glycerin layer (glycerin solution), 18 mg of the lysophosphatidylcholine (SLP-LPC70) and 105 mg of the DHA-containing fatty acid mixture were added, then 40 μl of water was further added, and the whole was reacted at 50° C. for 24 hours. The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 13.6% by weight.
Example 2
[0063] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 30 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of Incromega DHA-J46 (manufactured by Croda Japan KK., DHA content: 49.7% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 25 mg of glycine (manufactured by Showa Denko K. K.) and 25 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD., 53 U/mg) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 16.9% by weight.
[0064] The reaction solution was extracted with 1 ml of acetone twice to separate (collect) the acetone layer (upper layer) and the glycerin layer (lower layer) in a common procedure. As for the fatty acid composition of the phospholipid and lysophospholipid fraction included in each of the separated (collected) acetone layer (upper layer) and the glycerin layer (lower layer), the acetone layer had a DHA content of 17.6% by weight, and the glycerin layer had a DHA content of 14.1% by weight.
[0065] The separated (collected) glycerin layer was decompressed at 0.6 torr (80 Pa) for 15 minutes to remove acetone. To the decompressed glycerin layer (glycerin solution), 30 mg of the lysophosphatidylcholine (SLP-LPC70) was added and stirred at 50° C. for 30 minutes to be dissolved. The DHA content in the phospholipid and lysophospholipid fraction included in the reaction solution was determined to be 4.8% by weight. To the mixture, 30 mg of the DHA-containing fatty acid mixture was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 11.2% by weight after the reaction of 24 hours.
Example 3
[0066] To 50 mg of lysophosphatidylcholine (manufactured by Tsuji Oil Mills Co., Ltd. “SLP-WhiteLyso”), 30 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of Incromega DHA-J46 (manufactured by Croda Japan KK., DHA content: 49.7% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 25 mg of glycine (manufactured by Showa Denko K. K.) and 25 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD., 53 U/mg) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 15.3% by weight.
[0067] To the reaction solution, 0.5 ml of ethanol was added. The whole was stirred and then extracted with a mixed solvent of 0.5 ml of hexane and 0.2 ml of acetone twice to separate (collect) the hexane/acetone layer (upper layer) and the glycerin layer (lower layer) in a common procedure. As for the fatty acid composition of the phospholipid and lysophospholipid fraction included in each of the separated (collected) hexane/acetone layer (upper layer) and the glycerin layer (lower layer), the hexane/acetone layer had a DHA content of 18.0% by weight, and the glycerin layer had a DHA content of 11.6% by weight.
[0068] The separated (collected) glycerin layer was decompressed at 0.6 torr (80 Pa) for 15 minutes to remove the solvent. To the decompressed glycerin layer (glycerin solution), 30 mg of the lysophosphatidylcholine (SLP-WhiteLyso) was added and stirred at 50° C. for 30 minutes to be dissolved. The DHA content in the phospholipid and lysophospholipid fraction included in the reaction solution was determined to be 6.6% by weight. To the mixture, 30 mg of the DHA-containing fatty acid mixture was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 12.3% by weight after the reaction of 24 hours.
Example 4
[0069] To 50 mg of lysophosphatidylcholine (manufactured by Tsuji Oil Mills Co., Ltd. “SLP-WhiteLyso”), 30 mg of an EPA-containing fatty acid mixture that was prepared by common hydrolysis of EPA-45G (manufactured by Nippon Chemical Feed Co., Ltd., EPA content: 45.7% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 25 mg of glycine (manufactured by Showa Denko K. K.) and 25 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD., 53 U/mg) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had an EPA content of 19.5% by weight.
[0070] To the reaction solution, 0.25 ml of ethanol was added. The whole was stirred and then extracted with 0.75 ml of ethyl acetate twice to separate (collect) the ethyl acetate layer (upper layer) and the glycerin layer (lower layer) in a common procedure. As for the fatty acid composition of the phospholipid and lysophospholipid fraction included in each of the separated (collected) ethyl acetate layer and the glycerin layer, the ethyl acetate layer had an EPA content of 22.1% by weight, and the glycerin layer had an EPA content of 17.8% by weight.
[0071] The separated (collected) glycerin layer was decompressed at 0.6 torr (80 Pa) for 15 minutes to remove the solvent. To the decompressed glycerin layer (glycerin solution), 36 mg of the lysophosphatidylcholine (SLP-WhiteLyso) was added and stirred at 50° C. for 30 minutes to be dissolved. The EPA content in the phospholipid and lysophospholipid fraction included in the reaction solution was determined to be 11.2% by weight. To the mixture, 30 mg of the EPA-containing fatty acid mixture was added, and the whole was reacted at 50° C. for 24 hours while decompressing at 50 torr (6.7 kPa). The phospholipid and lysophospholipid fraction included in the reaction solution had an EPA content of 16.3% by weight after the reaction of 24 hours.
Example 5
[0072] To 7.5 g of lysophosphatidylcholine (manufactured by Tsuji Oil Mills Co., Ltd. “SLP-WhiteLyso”), 3 g of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of Incromega DHA-J46 (manufactured by Croda Japan KK., DHA content: 49.7% by weight) and 100 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 3 g of glycine (manufactured by Showa Denko K. K.) and 3 g of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 3 g of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD., 53 U/mg) was further added, and 0.5 ml of a 2 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added. The whole was reacted at 50° C. for 24 hours under a reduced pressure of 3 torr (0.40 kPa).
[0073] To the reaction solution, 50 ml of ethanol was added. The whole was stirred and then extracted with 50 ml of hexane twice to separate (collect) the hexane layer (upper layer) and the glycerin layer (lower layer) in a common procedure. The solvent in the separated hexane layer (upper layer) was removed by evaporation, and 50 ml of acetone was added. The whole was cooled at 0° C. for 1 hour to give 6.3 g of the target phospholipid as a precipitate. As for the fatty acid composition, the phospholipid had a DHA content of 17.0% by weight. As for the fatty acid composition of the phospholipid and lysophospholipid fraction, the separated glycerin layer (lower layer) had a DHA content of 8.3% by weight.
[0074] To the separated glycerin layer, 5.5 g of the lysophosphatidylcholine (SLP-WhiteLyso) and 3 g of the DHA-containing fatty acid mixture (prepared from Incromega DHA-J46) were added. The glycerin layer was stirred at 100 torr (13 kPa) for 30 minutes to remove the solvent by evaporation, and reacted at 50° C. for 24 hours while decompressing at 3 torr (0.40 kPa). After the completion of the reaction, the reaction mixture was extracted with ethanol and hexane, and purified with acetone in a similar manner to the above to give 6.0 g of the target phospholipid. As for the fatty acid composition, the phospholipid had a DHA content of 15.8% by weight.
[0075] As described above, it was revealed that the reuse of phospholipase A2 can lead to the production of a phospholipid bonded with an arbitrary fatty acid to the 2-position of the phospholipid. Hereinafter, the results of the first esterification that used various amino acids, peptides having three or less amino acid residues, and the like will be described as Reference Examples.
[0076] As mentioned below, it is clear that the use of various amino acids, peptides having three or less amino acid residues, and the like can achieve an efficient production of a desired phospholipid. Therefore, the reuse of the phospholipase A2 with such a compound is also expected to achieve the efficient production of a desired phospholipid.
Reference Example 1
[0077] To 35 mg of lysophosphatidylcholine (manufactured by Tsuji Oil Mills Co., Ltd. “SLP-LPC70H”), 97 mg of oleic acid (manufactured by TOKYO CHEMICAL INDUSTRY CO., LTD.) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 50 mg of glycine (manufactured by Wako Pure Chemical Industries, Ltd.) was further added. Next, 10 mg of phospholipase A2 (“Lecitase 100S” manufactured by Novozymes Japan, 130 U/mg) and 2.5 μl of a 1.0 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution were further added, and the whole was reacted at 60° C. for 24 hours to give a phospholipid (phosphatidylcholine) bonded with oleic acid to the 2-position. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an oleic acid content of 39.2% by weight.
Reference Example 2
[0078] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 113 mg of DHA (manufactured by TOKYO CHEMICAL INDUSTRY CO., LTD.) and 1 g of glycerin (manufactured by Wako Pure Chemical Industries, Ltd.) were added, and 50 mg of glycine (manufactured by Wako Pure Chemical Industries, Ltd.) was further added. Next, 10 mg of phospholipase A2 (“Lecitase 100S” manufactured by Novozymes Japan, 130 U/mg) and 2.5 μl of a 1.0 mold calcium chloride (manufactured by Wako Pure Chemical Industries, Ltd.) solution were added, and 3 mg of dibutylhydroxytoluene (manufactured by Wako Pure Chemical Industries, Ltd.) was further added as an antioxidant. The whole was reacted at 60° C. for 48 hours to give a phospholipid (phosphatidylcholine) bonded with a highly unsaturated fatty acid (DHA) to the 2-position. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 34.2% by weight.
Reference Example 3
[0079] To 35 mg of lysophosphatidylcholine (SLP-LPC70 manufactured by Tsuji Oil Mills Co., Ltd.), 113 mg of DHA (manufactured by TOKYO CHEMICAL INDUSTRY CO., LTD.) and 1 g of glycerin (manufactured by Wako Pure Chemical Industries, Ltd.) were added, and 60 mg of glycylglycine (manufactured by Wako Pure Chemical Industries, Ltd.) was further added. Next, 20 mg of phospholipase A2 (manufactured by SANYO FINE CO., LTD., powdered Lysonase, 53 U/mg) and 2.5 μl of a 1.2 mol/l calcium chloride (manufactured by Wako Pure Chemical Industries, Ltd.) solution were added, and 3 mg of Sankatol NO1 (manufactured by Taiyo Kagaku Co., Ltd.) containing catechin and 3 mg of ascorbic acid (manufactured by Wako Pure Chemical Industries, Ltd.) were further added as antioxidants. The whole was reacted at 60° C. for 48 hours to give a phospholipid (phosphatidylcholine) bonded with a highly unsaturated fatty acid (DHA) to the 2-position. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 30.7% by weight.
Reference Example 4
[0080] A phospholipid bonded with a highly unsaturated fatty acid (EPA) to the 2-position was obtained in a similar manner to that in Reference Example 3 except that 104 mg of EPA (manufactured by NACALAI TESQUE, INC.) was used in place of 113 mg of DHA and 60 mg of glycine was used in place of 60 mg of glycylglycine. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an EPA content of 28.5% by weight.
Reference Example 5
[0081] A phospholipid (phosphatidylcholine) bonded with a highly unsaturated fatty acid (arachidonic acid) to the 2-position was obtained in a similar manner to that in Reference Example 3 except that 103 mg of arachidonic acid (manufactured by Sigma-Aldrich Japan) was used in place of 113 mg of DHA and 40 mg of glycine was used in place of 60 mg of glycylglycine. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an arachidonic acid .content of 32.3% by weight.
Reference Example 6
[0082] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 105 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of DHA-50G (manufactured by Nippon Chemical Feed Co., Ltd., a DHA content of 51.8% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 75 mg of glycine (manufactured by Showa Denko K. K.) was further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD.) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added, and the whole was reacted at 60° C. for 48 hours to give a phospholipid (phosphatidylcholine) bonded with a highly unsaturated fatty acid (DHA) to the 2-position. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 15.5% by weight.
Reference Example 7
[0083] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 105 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of DHA-50G (manufactured by Nippon Chemical Feed Co., Ltd., a DHA content of 51.8% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 37.5 mg of glycine (manufactured by Showa Denko K. K.) and 37.5 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD.) was further added, and the whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water. Then, 10 μl of a 0.3 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was added, and the whole was reacted at 60° C. for 48 hours to give a phospholipid (phosphatidylcholine) bonded with a highly unsaturated fatty acid (DHA) to the 2-position. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 17.2% by weight.
Reference Example 8
Preparation of Phospholipid-Containing Esterification Solution for Improving Purity of Phosphatidylcholine
[0084] To 35 mg of lysophosphatidylcholine (“SLP-LPC70” manufactured by Tsuji Oil Mills Co., Ltd.), 30 mg of a DHA-containing fatty acid mixture that was prepared by common hydrolysis of DHA-50G (manufactured by Nippon Chemical Feed Co., Ltd., a DHA content of 51.8% by weight) and 1 g of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) were added, and 37.5 mg of glycine (manufactured by Showa Denko K. K.) and 37.5 mg of alanine (manufactured by Musashino Chemical Laboratory, Ltd.) were further added. Next, 20 mg of phospholipase A2 (“powdered Lysonase” manufactured by SANYO FINE CO., LTD.) was added, and 6 μl of a 0.5 mol/l calcium chloride (manufactured by Tomita Pharmaceutical Co., Ltd.) solution was further added. The whole was decompressed at 0.6 torr (80 Pa) for 10 minutes to remove water, and reacted at 50° C. for 24 hours to give a phospholipid-containing esterification solution for improving the purity of a phosphatidylcholine. The phospholipid and lysophospholipid fraction included in the reaction solution had a DHA content of 15.3% by weight.
Comparative Example 1
[0085] A phospholipid bonded with oleic acid to the 2-position was obtained in a similar manner to that in Reference Example 1 except that glycine was not used. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an oleic acid content of 19.4% by weight.
Comparative Example 2
[0086] A phospholipid bonded with a highly unsaturated fatty acid (DHA) to the 2-position was obtained in a similar manner to that in Reference Example 3 except that glycylglycine was not used. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 12.9% by weight.
Comparative Example 3
[0087] A phospholipid bonded with a highly unsaturated fatty acid (EPA) to the 2-position was obtained in a similar manner to that in Reference Example 4 except that glycine was not used and 60 μl of water was added. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an EPA content of 8.9% by weight.
Comparative Example 4
[0088] A phospholipid bonded with a highly unsaturated fatty acid (arachidonic acid) to the 2-position was obtained in a similar manner to that in Reference Example 5 except that glycine was not used. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had an arachidonic acid content of 5.5% by weight.
Comparative Example 5
[0089] A phospholipid bonded with a highly unsaturated fatty acid (DHA) to the 2-position was obtained in a similar manner to that in Reference Example 6 except that glycine was not used. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 4.4% by weight.
Comparative Example 6
[0090] A phospholipid bonded with a highly unsaturated fatty acid (DHA) to the 2-position was obtained in a similar manner to that in Reference Example 8 except that glycine and alanine were not used. As for the fatty acid composition, the obtained phospholipid and lysophospholipid fraction had a DHA content of 7.6% by weight. | Provided is a method for producing a phospholipid at low cost by reusing phospholipase A2 in a method for producing the phospholipid whereby an arbitrary fatty acid is bonded to the 2-position of a phospholipid using an esterification reaction catalyzed by phospholipase A2 in glycerol. The method for producing a phospholipid is characterized by comprising conducting an esterification reaction catalyzed by phospholipase A2 between a lysophospholipid and an acyl donor in glycerol to from a phospholipid, adding a solvent immiscible with glycerol to form a glycerol layer and a solvent layer, extracting said phospholipid into said solvent layer, allowing phospholipase A2 to migrate into said glycerol layer, and, after separating the glycerol layer and distilling off the solvent remaining therein, further adding to the residual glycerol solution the lysophospholipid and the acyl donor to thereby conduct the esterification reaction again with use of phospholipase A2 remaining in said glycerol solution. | 2 |
This application claims the benefit of Provisional appl. No. 60/408,083, filed Sep. 4, 2002.
FIELD OF THE INVENTION
This invention relates to the field of lighting and particularly to color-image-creating devices known as gobos comprising one or more thin substrates and more particularly to an integrally bonded gobo and a method of making same.
BACKGROUND OF THE INVENTION
Tannemyer et al. in U.S. Pat. No. 6,081,383 teaches a multi-color, pattern-projecting gobo in which a multi-color pattern that is color-separated into single-color components that are disposed to parallel planes in the gobo and at least two of these planes are mutually separated by means of a transparent substrate. Such a gobo may include a plurality of mutually superimposed disc-shaped and transparent substrates each of which may include a dichroic surface coating so as to form a color filter. Thus combinations of the filters are able to reproduce the colors of the multi-color pattern and respective color-emitting surface coatings present a pattern that coincides with the pattern of corresponding color components in the multi-color pattern. The technical advance in the art contributed by this teaching, although not stated per se therein, allows the use of extremely thin substrates thereby vastly improving the focus of the entirety. In the prior art, in which the substrates are thicker, only one image-creating surface is in true focus.
Nevertheless, the gobo made according to Tannemyer et al. has certain deficiencies, which derive from the technique used in bonding the substrates together. The patent discloses a stepped profile assembly in which each successive layer of disc-shaped transparent pattern-bearing substrates is of smaller diameter than the preceding substrate. The patent teaches gluing the discs together by placing glue on the steps. In actual practice, as a person of skill in the art knows, the stepped profile is eliminated except after the initial substrate, the one carrying a blocking pattern. The color separation substrates are all of the same smaller diameter and the glue binding them together while applied around the circumference of the interface is applied in spaced dots of glue. Dots of the adhesive are placed around the edges of unbonded layers and then the next layer is aligned and placed on top to be adhered. Ordinarily the glue used is Dow Silicone # 732 or equivalent (available from Dow). This is a very viscous silicone product. The dotting of glue is important with these bonding techniques. This adhesive polymerizes under the action of the moisture contained in the ambient air. The reaction produces acetic acid, which must be removed by migration. The dots have a large surface area in relation to volume, which facilitates this process. In addition, the dots need to be close to the edge of the layers. The dots also present a minimized area of viscous adhesive, which permits the layers to be moved prior to polymerization to obtain perfect alignment. When a typical gobo is finished (such as those obtainable from Beacon AB of Sweden or their licensees) it contains four layers, adhered with three layers of edge dots of silicone.
There is, however, a negative aspect to this technique: The center of the gobo has air spaces and the layers can flex under load and cause breakage because of this weakness. Moreover, the structure is highly sensitive to impacts. Further, dust, dirt and other unwanted contaminants can work into these air spaces and render the gobo unusable or at least require that compressed air be blasted into the spaces to remove the contaminants. Sometimes even this type of cleaning does not solve the problem and the gobo is rendered useless. In the course of ordinary service, the life of a gobo so made is limited.
It is the object of the invention to improve the service life of gobos of the type taught by Tannemyer et al. by eliminating entrapment of air between facing substrates of the gobo and preventing the incursion of contaminants into the interfaces between layers.
SUMMARY OF THE INVENTION
This object is attained by bonding the substrates of a gobo generally fabricated according to the teaching of Tannemyer et al. gobo not along the periphery of the disc-like substrates but over the entirety of the surfaces between adjoining substrates to form an integrally bonded structure.
To do so, however, requires solution of problems hitherto unresolved. Inasmuch as the temperature at the critical interfaces during extended operation, may rise to the neighborhood of 700 degrees Fahrenheit (371 degrees Celsius), any glue used must have extraordinary physical properties. The bonding means must not be degraded in service. It must not lose adherence. It must not lose clarity. It must not emit liquid or gas or char in place. It must not interfere with or interact with any image formed on any surface. Further it must be amenable to application by a method providing a uniform layer of sufficient thinness not to interfere with the optical properties of the assembly. Finally, the adhesive must permit adjustment of the successive layer during assembly to obtain perfect alignment.
We have found that an adhesive having the above listed properties and a viscosity of about 30,000 cps (centipoise) or less as applied solves the problems of the prior art. Lower viscosity works better. Preferably used is a glue which is a two-part silicone curing by chemical reaction (oxime) of the two parts without emitting a by-product needing removal. Such an adhesive is Product Code SS-5060 made by Silicone Solutions of Twinsburg Ohio which has all the characteristics needed. The as-applied viscosity is in the order of 1000 cps. This glue is a room temperature curing silicone capable of self-leveling application by applying a measured dose at the center of the layer. It can also be applied by using a fine-tipped brush with straight edge leveling at room temperature. In either modality the glue forms a uniform, continuous layer only 0.001-0.002 inches thick (0.025-0.050 mm). The layer so formed is bubble-free and it meets the harsh, alternating temperature conditions of service. Further, this preferred adhesive is non-thixotropic which gives it uniform viscosity after mixing which does not change as a function of shear rate. Prior art adhesives, which are thixotropic, rapidly increase viscosity after mixing and change viscosity under applied pressure interfering with both leveling and adjustment of the layers.
We have also found that a single-part silicone (Silicone Solutions #SS-6001) with an as-applied viscosity of about 30,000 cps or less can be used to form a continuous layer as described above. This product is less preferred because we have found that a maximum diameter surface of 1.5 inches is the largest we can bond with this product compared to up to 2.6 inches diameter with the two-part silicone. In addition this more viscous glue requires the application of a greater volume of materials and yields thicker inter-layers of the order of 0.003-0.007 inches (0.076-0.178 mm) which tend to contribute to breakage when force is applied to the assembly in fabrication.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a gobo according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Projection lighting has been used in theatrical performance for a long time. In recent times applications have been developed for advertising and sales. The earliest form of projection lighting employed “dias”, films of colored plastic and the like held in front of a powerful light.
Instead of dias, thin stainless steel or chrome foils were used but proved limited due to mechanical problems. Heat-resistant glass has had considerable success and is amenable to gray scale (“bende”) and rastering to project better images. The greatest advance has been the provision of full color images through the use of color separated images on stacked glass substrates which together form what is termed a “gobo”. Roman et al. in U.S. Pat. No. 5,806,951 presents a gobo produced by acid etching. A multi-colored light pattern is formed by first and second substrates having abutting planar surfaces. Each surface includes a complimentary portion of the pattern acid etched in a coating deposited on the surface. At least one coating is dichroic. The substrates are secured in abutting relationship by mechanical means such as by a pair of rings attached with screws. Bulk is one disadvantage of such a structure; lack of permanence is another.
Hutton in U.S. Pat. No. 5,959,768 teaches a reflective layer absorptive to infra-red radiation from which a desired pattern has been removed by laser ablation of a portion of the layer to form an image which can be colored using a filter layer. The problem of assemblage of layers into a compact and permanent form is not addressed.
Tannemyer et al. achieves such a compact and lasting structure as described in the aforementioned U.S. Pat. No. 6,081,383 the teachings of which are incorporated herein by reference.
The improvement of this invention over the prior art is the addition of bonding over the entirety of each interface between substrates.
Refer now to FIG. 1 in which 10 indicates the improved gobo of the invention. Substrate 12 carries the blocking layer, as is known, and is in abutting, facing-relationship with superimposed substrate layer 14 which abuts layer 16 which in turn abuts layer 18 . All interfaces between mutually superimposed layers have polymerized continuous and uniform adhesive interlayers 20 to form an integrally bonded structure. Each of layers 14 , 16 , 18 carries one color separation as is known. Each adhesive (glued) interlayer 20 preferably is about 0.001-0.002 inches (0.254-0.508 mm) thick.
We have found that an adhesive having the above listed properties and a viscosity of about 30,000 cps or less as applied solves the problems of the prior art. Glue which is a two-part silicone, which cures without emitting a by-product needing removal and meets all performance requirements as well is preferred. A two-part silicone glue Product Code SS-5060 made by Silicone Solutions of Twinsburg Ohio has the characteristics needed, particularly an initial; viscosity of 1,000 cps, and is preferred for the interfacing adhesive layers 14 , 16 , 18 . This glue is a room temperature curing, self-leveling and non-thixotropic, silicone. It cures by an oxime reaction, which does not emit by-products that must be removed from the interface. Substrate 12 is held in a fixture. A measured dose is applied at the center of this layer at room temperature, as it will be for successive layers. By measured dose, it is meant that the exact amount or slightly more than enough glue is applied than required to form the desired thin, uniform interlayer of glue. Any slight excess that exudes from the sides is wiped away or cleaned off using mineral spirits or the like. The preferred glue is self leveling and non-thixotropic. The layer being added may be moved to obtain alignment. Glue may also be applied using a fine-tipped brush with straight edge leveling at room temperature. With either technique, a uniform, continuous interlayer is formed. In either case, the interlayer of adhesive is only 0.001-0.002 inches (0.025-0.050 mm) thick and is bubble-free. It meets the harsh, alternating and extreme temperature conditions of service. Relatively large area gobos up to 2.6 inches (66.0 mm) in diameter have been fabricated using this technique. Development of full strength takes up to 72 hours at room temperature but can be significantly accelerated by heating to 150 degrees Fahrenheit (65.6 degrees Celsius) for as little as ten minutes.
The proper amount of as-applied glue can readily be determined by one of skill in the art and will depend upon the characteristics of the particular glue used and the area of the gobo. For example, we have found that for a 2.6 inch (66 mm) diameter gobo using the SS-5060 glue a dose of about 0.2-0.3 ml is adequate for a self-leveling application for a single interfacial layer. This dosage provides some excess, which we wipe away as explained before. We prefer to work with a slight excess rather than risking leaving an uncovered area, an air space, in an interlayer that might contribute to premature failure of the gobo. For a 1.5 inch (38 mm) diameter gobo we have found that a dose of 0.2-0.3 ml serves well.
We have also found that a single-part silicone (Silicone Solutions #SS-6001) with an as-applied viscosity of 30,000 cps can be used to form a continuous interlayer as described above. This product is less preferred because we have found that a maximum diameter surface of 1.5 inches is the largest we can bond with this product compared to up to 2.6 inches with the two-part silicone. As mentioned above, another negative for this glue is that this more viscous glue requires the application of a greater volume of materials and yields thicker interlayers of the order of 0.003-0.007 inches (0.076-0.178 mm). This tends to contribute to breakage when force is applied to the assembly in fabrication.
The single-part process is probably limited by the rate of moisture migration to drive the reaction and by the rate of migration of the reaction products both relative to the rate at which the viscosity of the glue increases with polymerization.
To those skilled in the art, it can be appreciated that the present invention provides a gobo that will survive and serve better than prior art gobos.
It should be understood, of course, that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A gobo is described wherein the superimposed layers are integrally bonded with a continuous and uniform layer of polymerized gluing material. Preferred bonding glues, their required characteristics, and a method for fabricating the integrally bonded gobo are disclosed. | 6 |
BACKGROUND OF INVENTION
1. Cross Reference to Other Applications
This invention is a continuation-in-part of application Ser. No. 08/275,724 filed Jul. 19, 1994, now U.S. Pat. No. 5,478,020, which in turn is a continuation of application Ser. No. 08/77,106, filed Jun. 16, 1993, now U.S. Pat. No. 5,354,004.
2. Prior Art
This invention relates to a solid waste communiting apparatus. Such devices have been established in the art and are now widely used in a variety of industrial applications, such as municipal waste treatment and industrial applications. Reference is made to U.S. Pat. No. 4,046,324, which discloses such a basic system that has achieved commercial success.
By definition, comminution is the reduction of particle size of solid waste material to minute particles. It is generally performed by shearing, shredding and crushing of the waste material. As set forth in the '324 patent, comminution occurs by utilizing a pair of counter-rotating intermeshed cutting members.
The solid waste material is fed into the interface between cutting elements, typically utilizing a fluid carrier medium and shearing action occurs because the two cutters overlap each other such that opposing forces of counter-rotation of the cutting elements on the different stacks act on the solid material as it passes through the device.
In practice, such devices are generally used in an influent/effluent path. That is, the solid material is generally entrained in a liquid and the device is placed directly in the liquid stream. By having the solid material entrained in a liquid stream transportation of the material to and from the unit occurs. Further, by softening the solid particles, a greater degree of comminution is achieved. Devices of the type disclosed in the '324 patent have found commercial success and are widely used in waste treatment facilities, shipboard use and the like. As can be appreciated, the environment of use is very harsh for the equipment and as such, routine maintenance is required in both a preventative sense and also to immediately repair breakdowns when they occur thus minimizing system down-time.
An important aspect of such maintenance and repair is the integrity of the seals which provide the cutter stacks to rotate while minimizing friction. Given the mass of the cutter stacks together with high motor torque, loads on the seals are large and thus seal integrity is a primary consideration. In the past, two-shafted machines such as the '324 device required that the seal assembly be an integral part of the device. Such is illustrated in FIG. 1 of the '324 patent. As a result, if there was a seal failure other critical components of the device were likely to be effected. This failure of a seal could thus mean that bearings could fail and seize up the cutter stack.
Importantly, to repair the seal assembly, in the prior art, there was a requirement that the device be disassembled and completely reassembled. In the context of a unit which is used in fluid waste treatment that down-time, in some cases as long as a day could have detrimental effects in the ability of a plant to process waste. Such would require rerouting solid waste, shutting down a portion of the facility and otherwise result in an inefficient operation.
Moreover, in prior art two-shafted machines, the cutter stack and the various seal components were integral and in-line with a fixed geometry. Consequently, tightening of the cutter stack, by compression, resulted in compression of the seals. Again, such is illustrated in FIG. 1 of the '324 patent. It has been recognized however, that under normal operating conditions the cutter thickness experiences wear and thus the overall thickness of the stack tends to reduce over time. The result is an effective reduction in the overall stack height and the stack therefore tends to become loose. As a consequence, initial compression of various seal components is lost and the seal faces tend to separate. The result is leakage across the seal with the subsequent result of bearing failure.
Another deficiency in the prior art was the use of a labyrinth between the main fluid chamber and the seal faces. The labyrinth was generally incorporated into the seal components as sacrificial component. Because such devices are used in applications which include a high grit content, the labyrinth tended to be a relatively high wear component. As a consequence, seal components had to be removed to replace the labyrinth with the potential for seal damage upon reassembly.
SUMMARY OF THE INVENTION
Given these deficiencies in the prior art, it is an object of this invention to provide an improved solid waste comminutor that overcomes the operational and assembly problems of prior devices in terms of access to components.
It is a further object of this invention to provide a solid waste comminutor which employs a cartridge with a balanced seal-bearing design to produce a constant seal face pressure.
A further object of this invention is to provide a solid waste comminutor of improved seal and bearing life by improved seal effectiveness which is independent of stack tightness.
Yet another object of this invention is to provide a seal cartridge for a solid waste comminutor which has an independent labyrinth that can be replaced without disassembly of the seal-bearing structure.
Another object of this invention is to provide an improved solid waste comminutor that utilizes an improved side rail assembly to direct flow through the comminutor.
A still further object of this invention is to provide an improved solid waste comminutor that employs an access port at the top of the cutter stack to permit stack tightening and a reduction in the size of the lower compartment to reduce head drop.
These and other objects of this invention are achieved by a dual stack solid waste comminutor having preassembled bearing-sealing elements that are replaceable individually. That modular assembly improves system life while minimizing down-time. In accordance with this invention a cartridge type seal is employed utilizing two modular assemblies, one on each end of the cutter stack. Each of the modular bearing-seal assemblies comprises a pair of identical bearing-seal cartridges. Two identical bearing-seal cartridges are assembled into the end housing to thus form top and bottom modular pairs.
Further, in accordance with this invention the bearing-seal cartridges float within the housing to provide movement with shaft movement thereby reducing the stress on the shafts and bearings.
A quick exchange of the mechanical subassembly, which includes bearings, O-ring seals and cartridge housing itself can be effectuated. As a result of this modular assembly, an individual seal cartridge can be installed quickly without the need to disassemble the entire subassembly.
Another advantage of this technique is that the bearing-seal cartridge is identical for the top and bottom of the cutter stack. As a consequence, a deficiency in the prior art which used two different assemblies has been eliminated. The bearing-seal cartridge is an item which is preassembled and installed as received. Thus, there is no requirement that the individual items, the various races, bearings and the like be assembled at the job site. Rather, the cartridge is interchangeable as a unit and is inserted into the end housing.
Further, in accordance with this invention re-torquoring of the cutter stack can be accomplished while the unit is still in-channel and installed. This is accomplished by an access port located at the top of the cutter stack assembly. It has been demonstrated that in practice, the most common preventative maintenance function is re-torquing the cutter stack to maintain stack compression for maximum cutting efficiency.
Prior to this invention a loss of stack compressibility leads directly to premature seal and bearing failure, primarily of the bottom seal assembly. In accordance with this invention, the tightness of the seal assembly is independent of total stack height, since it is designed as a self contained unit no disassembly is required.
Another advantage of this invention is an early warning seal failure detection system which can be used to prevent premature bearing failure. The invention provides for a drain port and/or weep holes in the shafts that allow fluid permeating from the seal to escape to the exterior. This can thus be viewed by maintenance personnel during routine checks of the system.
Additionally, this invention uses an improved side rail system to both strengthen the device as well as direct flow around and toward the cutter elements. The side rails have a greater strength compared to normal unit side plates and thus provide additional stiffness for the device. The two side rails function to channel the flow at the input side of the device into the cutters. At the periphery of the cutter and on the downstream side, the side rails accelerate the flow to promote cleaning of the cutter elements.
These and other objects of this invention will become apparent by a review of the attached drawing and the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cut-away side view of the overall comminution system of this invention in accordance with a first preferred embodiment;
FIG. 2 is a schematic view illustrating the seal cartridges and their assembly to form a dual seal cartridge in the first preferred embodiment;
FIGS. 3, 4 and 5 illustrate a second preferred embodiment in which, FIG. 3 is a schematic side view, FIG. 4 is a cut-away view illustrating the internal components and FIG. 5 is a perspective view of the side rail; and
FIG. 6 is an embodiment of an alternative seal-bearing assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a cut-away side view of the overall system according to a first preferred embodiment is depicted. In FIG. 1 the housing 1 has an inlet and outlet, not illustrated. At the bottom of the housing, a pair of access cut-outs 4 are provided to permit stack tightening, to be described herein, without disassembly of the device. The unit employs, three essential subsystems, which comprise a complete comminution apparatus 10 . These are a drive subsystem 11 with a motor 24 and speed reducer 12 , a gearing subsystem 14 , and a cutting subsystem 16 . The housing 26 for the speed reducer 12 is mounted to the gear and cutter system 14 , 16 by a pair of conforming flange elements 18 , 20 , which are clamped together by means of bolts 22 . The motor is typically an electric drive motor 24 , the details of which need not be discussed in detail. It will be recognized by those skilled that a suitable motor and drive system can be employed consistent with the scope of intended use. The speed reducer is contained in a housing 26 and employs an input shaft 30 and an output shaft 28 . The input shaft 30 is journaled for rotation using a coupling 32 to the motor 24 . This provides axial and radial alignment of the motor unit 24 with the speed reducer 12 .
The output shaft 28 of the sped reducer 12 passes through a transition piece 34 in which the output shaft 28 is keyed to a drive shaft 36 of one cutter stack by means of a coupling 35 . The drive shaft 36 carries a gear 38 . The drive shaft 37 of the other cutter stack carries a gear 40 . Both gears 38 and 40 are housed in housing 42 of the gear unit 14 . The two gears provide counter-rotation to a pair of cutter stacks 44 , 46 . That is, shaft 36 is the drive shaft and shaft 37 is the driven shaft which counter-rotates due to gears 38 , 40 . Each of the cutter stacks 44 , 46 comprises an alternating sequence of cutting elements 48 and spacers 50 . As illustrated in FIG. 1, the interface is such that by beginning the stack 44 with a cutter element and stack 46 with a spacer element the cutter elements interleave with each other in the area between the two cutter stacks, which has been denoted by numeral 52 . It is this interactive pair of stacks in zone 52 which provides the shredding of material as it passes through the cutter elements.
The cutter elements themselves may be either the same on each stack or differ from stack to stack. For example, it has been found that having eleven teeth on one cutter element and five on the opposing element improves the clean-out efficiency of the unit. Moreover, the geometry of the cutter elements may also be different in addition to the variations in the number of teeth.
As illustrated in FIG. 1, the cutter stack 16 is supported top and bottom by means of a pair of bearing seal assemblies 54 , 56 . FIG. 2 illustrates in greater detail those two subassemblies, although only one is illustrated.
Referring now to FIG. 2, the assembly 56 is explained in greater detail. It will be understood from reference to FIG. 1 that the assembly on top 54 is the same as the assembly on the bottom 56 , the unit simply being inverted. FIG. 2 illustrates the seal bearing assembly 56 . The units are assembled into respective end housings, 58 and 60 . FIG. 2 illustrates the end housing 60 . As illustrated two identical bearing-seal cartridges are employed in the end housing. FIG. 2 illustrates one seal assembly 62 in place with a second seal assembly 64 inserted into the end housing 60 .
Illustrated in phantom line in FIG. 2 are the ends 66 , 68 of the shafts 36 and 37 for the respective cutter assemblies 44 and 46 . It will be understood that the shaft ends 66 and 68 protrude through the respective seal cartridges but are held in place by end nuts 69 . Stack tightness is achieved by tightening the end nuts 69 . Access is via the cut-outs 4 so that an individual stack may be tightened. O-rings 70 , and 72 are employed to provide a fluid tight seal for each shaft.
As illustrated in FIG. 2, the bearing-seal cartridge comprises a cartridge housing 74 with an outer flange 76 and an inner tubular portion 78 . A spring 80 is inserted between the flange portion 76 and the cylindrical portion 78 . A dynamic race 82 sealed by means of an O-ring 84 . The dynamic race 82 is placed between the spring 80 and the cylindrical portion 78 . This spring provides a means by which the race 82 is provided with float.
A static race 86 with an O-ring forms the race structure. The race is held in place by means of the bearing cartridge 88 having a flange element 91 to cage the static race into position and to also limit axial travel of the dynamic race. The dynamic race 82 has a face in contact with a confronting face of static race 86 . A bearing structure 90 is housed inside the bearing cartridge and is held in place by means of a retaining ring, such as a snap ring illustrated as element 92 . A second spring 87 may optionally be used to allow the races 82 and 86 to axially float. The advantage is prevention of potential skew of the faces of the races relative to each other.
As illustrated in FIG. 2, the second seal cartridge 54 has an identical construction of its elements. The units are held in place and are biased by means of springs 94 , 96 . Those springs provide float for the bearing-seal cartridges 62 , 64 .
Sealing occurs by means of O-rings 98 , 100 . It will be appreciated that with respect to the seal cartridge illustrated in its installed position on the right hand side of FIG. 2 the same elements are present. They have been denoted with prime numbers to connote the same numbering sequence. While not illustrated, it is apparent from FIG. 1 that the upper end housing, inverted having a pair of identical seal cartridges is employed. The upper end seal-bearing module may be provided with an upper spacer 103 . This spacer rests on the outer race to preload the top bearing stack as the housing 42 is mounted on the housing 58 via bolts 104 .
Importantly, in accordance with the first preferred embodiment of this invention the labyrinth illustrated by dotted lines with numeral 102 is not a part of the seal assembly. Rather, the labyrinth is considered to be a part of the stack assembly and is separated from the seal cartridge assembly itself. The labyrinth 102 protrudes to the influent/stream where it is subjected to particles and the like while the device is in operation. Hence, it is a component that wears and must, from time to time be replaced. In accordance with this invention, the labyrinth 102 can be replaced as a single component since it is merely placed into the annular groove 108 of the housing 60 . It is compressed into position by a force applied through annular raised surface 110 that loads the labyrinth on surface 111 , causes it to slightly deflect. This deflection serves to compensate for wear in the cutter stack.
As is apparent from FIGS. 1 and 2, this first preferred embodiment offers a number of important advantages. First, given the fact that the bearing-seal assemblies are a modular cartridge assembly, repair of a seal assembly requires only that a preassembled cartridge 64 be installed in place of the defective unit. Thus, the seal components and the bearing elements are combined into a single cartridge assembly 64 . This allows for important advantages over the prior art in that the individual components do not have to be disassembled at a job site.
Secondly, by this invention stack tightening occurs independent of compression forces on the seal components. This occurs because, in accordance with this invention, the cartridges themselves are positioned and loaded independent of the cutter stack. That is the housing 58 is attached to gear housing 42 by means of the bolts 104 . Tightening the cutter stacks by means of the nuts 69 does not increase the forces on the bearings or seals. Rather, the force is a function of the spring force of the spring 80 .
In the case of the upper assembly axial positioning is obtained by the spacer 103 which opposed by spring 94 as the unit is bolted by means of bolts 104 . The bottom assembly is allowed to float. The bottom assembly is mounted by means the mounting bolts 106 , without the use of a spacer. It is understood that the cover plates and mounting structure of the housing 1 have been eliminated.
This invention also includes a provision of leak detection by means of a leak detection plug 108 . Thus, an upper seal failure can be ascertained by fluid in the upper housing via the leak detection plug 108 . If there is any water in the area, it will alert personnel that there is a potential failure in the upper bearing seal. Additionally, a leakage path can be provided in each of the shafts 36 , 37 . To the extent that fluid permeates the seal it will thus escape to the exterior where it can be viewed during routine maintenance checks.
As set forth herein, in accordance with this invention a cartridge type bearing-seal 64 allows for replacement of units on an individual basis as opposed to replacement of the entire seal pair at the top or bottom of the cutter stack. Additionally, the entire assembly with the bearings intact can be removed from the housing for servicing. Given the construction of those cartridge elements tightening of the cutter stack can be accomplished without impairing the effectiveness of the seal. That is, compression of the seal components themselves occurs during the assembly of each of the seal cartridge units illustrated in FIG. 2 . Thus, the integrity of those units is accomplished independent of the tightness of the cutter stack.
Moreover, as illustrated in FIGS. 1 and 2 the labyrinth 102 is placed between the main fluid chamber and either of the seal faces. In this invention the labyrinth 102 is distinct and separate from each of the seal cartridges. To the extent that the labyrinth requires replacement, it can be done by removing the cartridge, inserting a new labyrinth and then reinstallation of the cartridge 56 without any disassembly of the seal components.
Referring now to FIGS. 3, 4 and 5 , a second preferred embodiment of this invention is illustrated. This second preferred embodiment differs from the first in that the stack access port is located at the top of the cutter stack and additionally, a side rail system is employed to promote flow around the cutter stacks. To the extent that elements common to the first preferred embodiment are employed, such use common numerals and the description thereof will not be repeated.
As illustrated in FIG. 3, this preferred embodiment employs an access port 150 positioned at the top of the head stack assembly. This port is used to gain access to the nut and bolt for tightening the stack. An advantage of moving the head tightening access to the top of the unit is that the lower housing may be reduced in profile allowing more of the cutting chamber to be submerged and active, thus reducing upstream head drop. It will be appreciated that a reduction in upstream head is significant because it reduces the possibility of flooding or backup in the channel. Another advantage is that the device can be directly serviced from the top, if necessary by removal of the top cover 152 .
As illustrated in FIGS. 3 and 4, when the access port 150 is opened, direct exposure of the stack tightening bolt 154 and nut 156 occurs. Stack screw 154 bears on the stack having gear 40 and is tightened directly into that gear by internal threads. It will be understood that the tightening action of this screw compresses the head stack by a compressive force applied to the cutter stack 48 , 50 via the housing 54 for the upper bearing assembly assembly. Tightening of the other stack assembly, which is in line with the motor drive shaft 36 is by nut 156 which tightens on threads 158 cut into shaft 36 .
As illustrated in FIGS. 4 and 5, the device employs a pair of side rails 160 and 162 . The side rails extend from the top of the unit where they are joined to top housing members 54 and 58 respectively and at the bottom where they are joined to the bottom housing members 56 and 60 respectively. As can be a appreciated from these figures, the side rails have an appreciable gauge and rigidity from the rails and thus serve to strengthen the device by stiffening it. This provides the advantage of allowing the seal bearing assemblies to float.
Each of the side rails has a portion with projections 164 with recesses or slots 166 formed herebetween. As illustrated in FIG. 4 these projections and recesses are offset with respect to the elements of the cutter stack assemblies. They may be slightly offset, as illustrated. As a result flow channels are created at the upstream, input side of the device to direct solids into the cutter elements. This occurs due to the angular orientation of the front of the side rails which initially directs flow toward the cutters. The slots however permit water flow through the rails and accelerate the flow rate due to the decrease in sectional area around the cutters.
Referring now to FIG. 5 the details of the side rail are illustrated. Such devices are known per se, for example as described in commonly assigned U.S. Pat. No. 4,702,422. The configuration here departs from that in the use of a significant open area 168 on the downstream side of the device. It has been found that this configuration allows for greater acceleration of fluid around the outside of the cutter elements, thus cleaning them while at the same time carrying out the primary function of diverting solids at the input side toward the cutter stack.
While FIG. 5 illustrated the left hand side rail, it will be appreciated the the right hand one 162 will be of the same configuration. FIG. 6 illustrates in sectional view an alternative seal assembly. In this embodiment a single assembly is described, it being understood that this assembly will be employed in a manner identical to that of the first preferred embodiment. The units are assembled into respective end housings. As illustrated in FIG. 6, the bearing-seal cartridge comprises a cartridge housing 174 with an outer flange 176 and an inner tubular portion 178 . A dynamic race 182 sealed by means of an O-ring 184 which is placed between the flange 176 and a recess in the dynamic race 182 .
A static race 186 has a contact surface with the dynamic race and is biased into contact by the wave spring 187 . The static race is held in place by means of the bearing cartridge 188 having a flange element 191 to cage the static race into position. The dynamic race 182 has a face in contact with a confronting face of static race 186 . The dynamic race is positioned by means of lugs 193 . The static race is positioned by lugs 189 and pins 183 .
A bearing structure 190 is housed inside the bearing cartridge and is held in place by means of a retaining ring, such as a snap ring illustrated as element 192 . In this embodiment the wave spring on the back side is eliminated. As a result, the rotating seal face is fixed in the axial direction. The anti-rotation lugs on the inner diameter prevent rotation with respect to the seal cartridge 178 / 174 / 176 . The position of the wave spring 187 together with the elongated axial extension 191 of the bearing cartridge 188 support axial movement thereof and properly load the static seal face. The O-ring 184 for the static race in this embodiment is positioned in a recess in the housing as opposed to one in the race as in the first embodiment.
In the embodiment of FIG. 6 the anti-rotation mechanism for the static race 186 is achieved by radial slots located adjacent to the wave spring. The pins 183 are then pressed through the bearing cartridge 188 and engage the radial slots of the static race 186 . Also, as illustrated in FIG. 6, the seal face geometry is modified from that of FIG. 1 to allow flexibility in seal balance ratios.
It will be apparent to those of skill in this technology that modifications of this invention can be made without departing from the essential scope thereof. | A solid waste material comminuting system having a electric motor for providing rotary motion, a pair of cutter stacks with cutter elements of one stack interleaved with cutter elements of the other, and gear means to transmit the rotary motion of the electric motor to counter-rotate cutter elements of one stack with cutter elements of the other. Each of the cutter stacks comprise a central shaft journaled for rotation and a bearing module at each end of the central shafts. Each bearing module comprises an end housing, and a pair of insertable preassembled bearing assemblies mountable in each of said end housings. One bearing assembly has a thru-hole for journaling a first shaft for rotation and a second bearing assembly has a thru-hole for journaling a second shaft for rotation. The housing has an inspection port at the top to allow for tightening of the cutter stack. The device employs side rails having interleaved and smooth portions to guide solids to the cutter stack and to accelerate the flow of fluid around the outside of the cutters. | 1 |
CROSS-REFERENCE TO EARLIER FILED APPLICATIONS
This is a continuation, of application Ser. No. 08/315,660 filed Sep. 29, 1994 now abandoned which is a continuation-in-part of U.S. patent application Ser. No. 08/297,274 filed, Aug. 26, 1994, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 08/134,209, filed Oct. 12, 1993 now abandoned. The disclosures of these earlier filed applications are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel compounds, compounds and pharmaceutical compositions thereof, and to methods of using same in the treatment of psychiatric disorders and neurological diseases including major depression, anxiety-related disorders, post-traumatic stress disorder, supranuclear palsy eating feeding disorders, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems.
2. Description of the Related Art
Corticotropin releasing factor (herein referred to as CRF), a 41 amino acid peptide, is the primary physiological regulator of proopiomelanocortin (POMC)-derived peptide secretion from the anterior pituitary gland (J. Rivier et al., Proc. Nat. Acad. Sci . ( USA ) 80:4851 (1983); W. Vale et al., Science 213:1394 (1981)). In addition to its endocrine role at the pituitary gland, immunohistochemical localization of CRF has demonstrated that the hormone has a broad extrahypothalamic distribution in the central nervous system and produces a wide spectrum of autonomic, electrophysiological and behavioral effects consistent with a neurotransmitter or neuromodulator role in brain (W. Vale et al., Rec. Prog. Horm. Res. 39:245 (1983); G. F. Koob, Persp. Behav. Med. 2:39 (1985); E. B. De Souza et al., J. Neurosci. 5:3189 (1985)). There is also evidence demonstrating that CRF may also play a significant role in integrating the response of the immune system to physiological, psychological, and immunological stressors (J. E. Blalock, Physiological Reviews 69:1 (1989); J. E. Morley, Life Sci. 41:527 (1987)).
Clinical data have demonstrated that CRF may have implications in psychiatric disorders and neurological diseases including depression, anxiety-related disorders and eating disorders. A role for CRF has also been postulated in the etiology and pathophysiology of Alzheimer's disease, Parkinson's disease, Huntington's disease, progressive supranuclear palsy and amyotrophic lateral sclerosis as they relate to the dysfunction of CRF neurons in the central nervous system (for review see E. B. De Souza, Hosp. Practice 23:59 (1988)).
In affective disorder, or major depression, the concentration of CRF is significantly increased in the cerebral spinal fluid (CSF) of drug-free individuals (C. B. Nemeroff et al., Science 226:1342 (1984); C. M. Banki et al. Am. J. Psychiatry 144:873 (1987); R. D. France et al., Biol. Psychiatry 28:86 (1988); M. Arato et al., Biol. Psychiatry 25:355 (1989)). Furthermore, the density of CRF receptors is significantly decreased in the frontal cortex of suicide victims, consistent with a hypersecretion of CRF (C. B. Nemeroff et al., Arch. Gen. Psychiatry 45:577 (1988)). In addition, there is a blunted adrenocorticotropin (ACTH) response to CRF (i.v. administered) observed in depressed patients (P. W. Gold et al., Am J. Psychiatry 141:619 (1984); F. Holsboer et al., Psychoneuroendocrinology 9:147 (1984); P. W. Gold et al., New Eng. J. Med. 314:1129 (1986)). Preclinical studies in rats and non-human primates provide additional support for the hypothesis that hypersecretion of CRF may be involved in the symptoms seen in human depression (R. M. Sapolsky, Arch. Gen. Psychiatry 46:1047 (1989)). There is preliminary evidence that tricyclic antidepressants can alter CRF levels and thus modulate the number of CRF receptors in brain (Grigoriadis et al., Neuropsychopharmacology 2:53 (1989)).
There has also been a role postulated for CRF in the etiology of anxiety-related disorders. CRF produces anxiogenic effects in animals and interactions between benzodiazepine/non-benzodiazepine anxiolytics and CRF have been demonstrated in a variety of behavioral anxiety models (D. R. Britton et al., Life Sci. 31:363 (1982); C. W. Berridge and A. J. Dunn Regul. Peptides 16:83 (1986)). Preliminary studies using the putative CRF receptor antagonist α-helical ovine CRF (9-41) in a variety of behavioral paradigms demonstrate that the antagonist produces “anxiolytic-like” effects that are qualitatively similar to the benzodiazepines (C. W. Berridge and A. J. Dunn Horm. Behav. 21:393 (1987), Brain Research Reviews 15:71 (1990)). Neurochemical, endocrine and receptor binding studies have all demonstrated interactions between CRF and benzodiazepine anxiolytics providing further evidence for the involvement of CRF in these disorders. Chlordiazepoxide attenuates the “anxiogenic” effects of CRF in both the conflict test (K. T. Britton et al., Psychopharmacology 86:170 (1985); K. T. Britton et al., Psychopharmacology 94:306 (1988)) and in the acoustic startle test (N. R. Swerdlow et al., Psychopharmacology 88:147 (1986)) in rats. The benzodiazepine receptor antagonist (Ro15-1788), which was without behavioral activity alone in the operant conflict test, reversed the effects of CRF in a dose-dependent manner while the benzodiazepine inverse agonist (FG7142) enhanced the actions of CRF (K. T. Britton et al., Psychopharmacology 94:306 (1988)).
The mechanisms and sites of action through which the standard anxiolytics and antidepressants produce their therapeutic effects remain to be elucidated. It has been hypothesized, however, that they are involved in the suppression of the CRF hypersecretion that is observed in these disorders. Of particular interest is that preliminary studies examining the effects of a CRF receptor antagonist (α-helical CRF 9-41 ) in a variety of behavioral paradigms have demonstrated that the CRF antagonist produces “anxiolytic-like” effects qualitatively similar to the benzodiazepines (for review, see G. F. Koob and K. T. Britton, In: Corticotropin - Releasing Factor: Basic and Clinical Studies of a Neuropeptide , E. B. De Souza and C. B. Nemeroff eds., CRC Press p.221 (1990)).
In order to study these specific cell-surface receptor proteins, compounds must be identified that can interact with the CRF receptor in a specific manner dictated by the pharmacological profile of the characterized receptor. Toward that end, there is evidence that the direct CRF antagonist compounds and compositions of this invention, which can attenuate the physiological responses to stress-related disorders, will have potential therapeutic utility for the treatment of depression and anxiety-related disorders. All of the aforementioned references are hereby incorporated by reference.
U.S. Pat. Nos. 4,788,195 and 4,876,252 teach the synthesis of compounds with the general formula (A):
The utility of these compounds is described as treatment of asthma, allergic diseases, inflammation, and diabetes in mammals.
PCT application WO 89/01938 describes the synthesis and utility of compounds with the formula (B):
These compounds can be utilized in the treatment of neurologic diseases, having an effect of regenerating and repairing nerve cells and improving and restoring learning and memory.
U.S. Pat. No. 4,783,459 describes the utility and synthesis of compounds with the following general formula (C):
The compounds have activity as fungicides, especially against fungal diseases of plants.
U.S. Pat. No. 4,992,438 discloses the utility and synthesis of compounds with the following general formula:
The utility of these compounds is described as fungicides with a broad spectrum activity against plant pathogenic fungi.
European Patent Application 0 013 143 A2 discloses the utility and synthesis of compounds with the following general formula:
These compounds are described as pre- and post-emergence herbicides.
U.S. Pat. No. 5,063,245 discloses a method of producing CRF antagonism with compounds with the general formulae:
PCT application WO 91/18887 discloses compounds of the general formula:
wherein R 2 may be C 1 -C 4 alkyl and R 3 may be substituted phenyl, said compounds being useful for the inhibition of gastric acid secretion.
European patent application EP 0588762 A1 discloses compounds of the general formula:
wherein R 4 may be C 1 -C 3 alkyl, said compounds being useful as protein kinase C inhibitors and antitumor agents. The application also generally discloses the use of these compounds for the treatment of AIDS, atherosclerosis, and cardiovascular and central nervous system disorders.
European patent application EP 336494 A2 discloses compounds of the general formula:
wherein X may be N—R 4 and R 4 may be (un)substituted alkyl, said compounds being useful as herbicides.
U.S. Pat. No. 3,988,338 discloses compounds of the general formula:
wherein R″″ may be an optionally substituted phenyl, said compounds having anticytokinin activity.
European patent application EP 0563001 A1 discloses compounds of the general formula:
said compounds having claimed utility for the treatment of psychosis, depression, and convulsive disorders.
European patent application EP 0155911 A1 discloses compounds of the general formula:
wherein R 3 may be substituted phenyl, said compounds being useful as herbicides.
Australian patent AU 8425873 A discloses compounds of the general formula:
wherein R 2 may be a substituted phenyl group, said compounds being useful as antiulcer agents.
Eswaran et al, Org. Prep. Proced. Int. 24(1):71-3, (1992), discloses the use of related 5,7-diazaindoles as synthetic intermediates. El-Bayouki et al, J. Heterocycl. Chem. 22(3):853-6, (1985) discloses the use of related 5,7-diazaisoindazoles as synthetic intermediates.
The compounds and methods of the present invention provide the methodology for the production of specific high-affinity compounds capable of inhibiting the action of CRF at its receptor protein in the brain. These compounds should be useful in the treatment of a variety of neurodegenerative, neuropsychiatric and stress-related disorders such as irritable bowel syndrome, immune suppression. Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems. It is further asserted that this invention may provide compounds and pharmaceutical compositions suitable for use in such a method. Further advantages of this invention will be clear to one skilled in the art from the reading of the description that follows.
SUMMARY OF THE INVENTION
The present invention relates to compositions and methods of use and preparation of N-alkyl-N-aryl-pyrimidinamines and derivatives thereof. These compounds interact with and have antagonist activity at the CRF receptor and would thus have some therapeutic effect on psychiatric disorders and neurological diseases including major depression, anxiety-related disorders, post-traumatic stress and eating disorders, supranuclear palsy, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems.
Novel compounds of this invention include compounds of formula:
or a pharmaceutically acceptable salt or prodrug thereof, wherein Y is CR 3a , N, or CR 29 ;
when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, halogen, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , and S(O) n R 8 ;
R 3 is C 1 -C 4 alkyl, aryl, C 3 -C 6 cycloalkyl, C 1 -C 2 haloalkyl, halogen, nitro, NR 6 R 7 , OR 8 , S(O) n R 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , —(CHR 16 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , —C(OH)(R 25 )(R 25a ), —(CH 2 ) p S(O) n -alkyl, —(CHR 16 )R 25 , —C(CN)(R 25 )(R 16 ) provided that R 25 is not —NH-containing rings, —C(═O)R 25 , —CH(CO 2 R 16 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 , NR 10 CH(R 11 )CO 2 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, phenyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group of N, CH, and CX′;
M is CR 5 or N;
V is CR 1a or N;
Z is CR 2 or N;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, halomethyl, C 1 -C 3 alkyl, and cyano;
R 4 is (CH 2 ) m OR 16 , C 1 -C 4 alkyl, allyl, propargyl, (CH 2 ) m R 13 , or —(CH 2 ) m OC(O)R 16 ;
X is halogen, S(O) 2 R 8 , SR 8 , halomethyl, —(CH 2 ) p OR 8 , —OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , —C(═O)R 8 , C 1 -C 6 alkyl, C 4 -C 10 cycloalkylalkyl, C 1 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 2 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, or —C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X′ is independently selected at each occurrence from the group consisting of hydrogen, halogen, S(O) n R 8 , halomethyl, —(CHR 16 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, and —C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, —C(═NOR 16 )—C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, —(CHR 16 ) p OR 8 , —(CHR 16 ) p S(O) n R 8 , —(CHR 16 ) p NR 14 R 15 , C 3 14 C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 1 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , —C(═NOR 16 )H, or —C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, C 1 -C 6 alkoxy, (C 4 -C 12 )-cycloalkylalkyl, —(CH 2 ) k R 13 , (CHR 16 ) p OR 8 , —(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, —S(O) 2 -aryl or —(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z —(C 1 -C 6 -alkyl); or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
A is CH 2 , O, NR 25 , C(═O), S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(NR 14 R 15 ), C(H)(OR 20 ), C(H)(C(═O)R 21 ), or N(S(O) n R 21 );
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; —(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; —NR 6 R 7 ; aryl; —NR 16 (CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z (C 1 -C 6 -alkyl);
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, aryl substituted with 0-3 R 18 , and —(C 1 -C 6 alkyl)-aryl substituted with 0-3 R 18 ;
R 10 , R 16 , R 23 , and R 24 are independently selected at each occurrence from hydrogen or C 1 -C 4 alkyl;
R 11 is C 1 -C 4 alkyl substituted with 0-3 groups chosen from the following: keto, amino, sulfhydryl, hydroxyl, guanidinyl, p-hydroxyphenyl, imidazolyl, phenyl, indolyl, indolinyl,
or, when taken together with an adjacent R 10 , are (CH 2 ) t ;
R 12 is hydrogen or an appropriate amine protecting group for nitrogen or an appropriate carboxylic acid protecting group for carboxyl;
R 13 is independently selected at each occurrence from the group consisting of CN, OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 4 -C 10 cycloalkyl-alkyl, and R 19 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , NR 23 R 24 , and (C 1 -C 6 ) alkyl (C 1 -C 4 ) alkoxy;
R 18 is independently selected at each occurrence from the group consisting of R 10 , hydroxy, halogen, C 1 -C 2 haloalkyl, C 1 -C 4 alkoxy, C(═O)R 24 , and cyano;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) w R 22 , and aryl substituted with 0-3 R 18 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 , C(═O)R 31 , and C 2 -C 4 alkenyl;
R 21 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, NR 23 R 24 , and hydroxyl;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, —S(O) n R 31 , and —C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H and R 25 ;
R 27 is independently selected at each occurrence from the group consisting of C 1 -C 3 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, aryl, nitro, cyano, halogen, aryloxy, and heterocycle optionally linked through O;
R 31 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl, and aryl-(C 1 -C 4 ) alkyl;
k, m, and r are independently selected at each occurrence from 1-4;
n is independently selected at each occurrence from 0-2;
p, q, and z are independently selected at each occurrence from 0-3;
t and w are independently selected at each occurrence from 1-6,
provided that when J is CX′ and K and L are both CH, and M is CR 5 , then
(A) when V and Y are N and Z is CH and R 1 and R 3 are methyl,
(1) and R 4 is methyl, then
(a) R 5 can not be methyl when X is OH and X′ is H;
(b) R 5 can not be —NHCH 3 or —N(CH 3 ) 2 when X and X′ are —OCH 3 ; and
(c) R 5 can not be —N(CH 3 ) 2 when X and X′ are —OCH 2 CH 3 ;
(2) and R 4 is ethyl, then
(a) then R 5 can not be methylamine when X and X′are —OCH 3 ;
(b) R 5 can not be OH when X is Br and X′ is OH; and
(c) R 5 can not be —CH 2 OH or —CH 2 N(CH 3 ) 2 when X is —SCH3 and X′ is H;
(B) when V and Y are N, Z is CH, R 4 is ethyl, R 5 is iso-propyl, X is Br, X′ is H, and
(1) R 1 is CH 3 , then
(a) R 3 can not be OH, piperazin-1-yl, —CH 2 -piperidin-1-yl, —CH 2 —(N-4-methylpiperazin-1-yl), —C(O)NH-phenyl, —CO 2 H, —CH 2 O-(4-pyridyl), —C(O)NH 2 , 2-indolyl, —CH 2 O-(4-carboxyphenyl), —N(CH 2 CH 3 )(2-bromo-4-isopropylphenyl);
(2) R 1 is —CH 2 CH 2 CH 3 then R 3 can not be —CH 2 CH 2 CH 3 ;
(C) when V, Y and Z are N, R 4 is ethyl, and
(1) R 5 is iso-propyl, X is bromo, and X′ is H, then
(a) R 3 can not be OH or —OCH 2 CN when R 1 is CH 3 ; and
(b) R 3 can not be —N(CH 3 ) 2 when R 1 is —N(CH 3 ) 2 ;
(2) R 5 is —OCH—, X is —OCH 3 , and X′ is H, then R 3 and R 1 can not both be chloro;
further provided that when J, K, and L are all CH and M is CR 5 , then
(D) at least one of V, Y, and Z must be N;
(E) when V is CR 1a , Z and Y can not both be N;
(F) when Y is CR 3a , Z and V can not both be N;
(G) when Z is CR 2 , V and Y must both be N;
(H) Z can be N only when both V and Y are N or when V is CR 1a and Y is CR 3a ;
(I) when V and Y are N, Z is CR 2 , and R 2 is H or C 1 -C 3 alkyl, and R 4 is C 1 -C 3 alkyl, R 3 can not be 2-pyridinyl, indolyl, indolinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-phenothiazinyl, or 4-pyrazinyl;
(J) when V and Y are N; Z is CR 2 ; R 2 is H or C 1 -C 3 alkyl; R 4 is C 1 -C 4 alkyl; R 5 , X, and/or X′ are OH, halo, CF 3 , C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, cyano, amino, carbamoyl, or C 1 -C 4 alkanoyl; and R 1 is C 1 -C 4 alkyl, then R 3 can not be —NH(substituted phenyl) or —N(C 1 -C 4 alkyl)(substituted phenyl);
and wherein, when Y is CR 29 :
J, K, L, M, Z, A, k, m, n, p, q, r, t, w, R 3 , R 10 , R 11 , R 12 , R 13 , R 16 , R 18 , R 19 , R 21 , R 23 , R 24 , R 25 , and R 27 are as defined above and R 25a , in addition to being as defined above, can also be C 1 -C 4 alkyl, but
V is N;
R 1 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, halogen, amino, methylamino, dimethylamino, aminomethyl, or N-methylaminomethyl;
R 2 is independently selected at each occurrence from the group consisting of hydrogen, halo, C 1 -C 3 alkyl, nitro, amino, and —CO 2 R 10 ;
R 4 is taken together with R 29 to form a 5-membered ring and is —C(R 28 )═ or —N═ when R 29 is —C(R 30 )═ or —N═, or —CH(R 28 )— when R 29 is —CH(R 30 )—;
X is Cl, Br, I, S(O) n R 8 , OR 8 , halomethyl, —(CHR 16 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X′ is hydrogen, Cl, Br, I, S(O) n R 8 , —(CHR 16 ) p OR 8 , halomethyl, cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 , alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 2 -C 10 )-alkoxy, nitro, thio-(C 2 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, —C(═NOR 16 )—C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C1-C3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 1 -C 10 )-alkyl, thio-(C 1 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , —C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, —(CH 2 ) k R 13 , (C 4 -C 12 )-cycloalkylalkyl, C 1 -C 6 alkoxy, —(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, —S(O) z -aryl or —(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano; or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, —(C 4 -C 12 ) cycloalkylalkyl, (CH 2 ) t R 22 , C 3 -C 10 cycloalkyl, —(C 1 -C 6 alkyl)-aryl, heteroaryl, —NR 16 , —N(CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 , —(C 1 -C 6 alkyl)-heteroaryl or aryl optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano;
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, and aryl substituted with 0-3 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) t R 22 , and aryl substituted with 0-3 R 18 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , and NR 23 R 24 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 and C(═O)R 31 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, —S(O) n R 31 , and —C(═O)R 25 ;
R 26 is hydrogen or halogen:
R 28 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, hydrogen, C 1 -C 2 alkoxy, halogen, or C 2 -C 4 alkylamino;
R 29 is taken together with R 4 to form a five membered ring and is: —CH(R 30 )— when R 4 is —CH(R 28 )—, —C(R 30 )═ or —N═ when R 4 is —C(R 28 )═ or —N═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halogen, C 1 -C 2 alkenyl, nitro, amido, carboxy, or amino;
R 31 is C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, or aryl-(C 1 -C 4 ) alkyl;
provided that when J, K, and L are all CH, M is CR 5 , Z is CH, R 3 is CH 3 , R 28 is H, R 5 is iso-propyl, X is Br, X′ is H, and R 1 is CH 3 , then R 30 can not be H, —CO 2 H, or —CH 2 NH 2 ;
and further provided that when J, K and L are all CH; M is CR 5 ; Z is N; and
(A) R 29 is —C(R 1 )═; then one of R 28 or R 30 is hydrogen;
(B) R 29 is N; then R 3 is not halo, NH 2 , NO 2 , CF 3 , CO 2 H, CO 2 -alkyl, alkyl, acyl, alkoxy, OH, or —(CH 2 ) m Oalkyl;
(C) R 29 is N; then R 28 is not methyl if X or X′ are bromo or methyl and R 5 is nitro; or
(D) R 29 is N, and R 1 is CH 3 and R 3 is amino; then R 5 is not halogen or methyl.
Preferred compounds of this invention are those compounds of Formula I wherein,
Y is CR 3a or N:
R 3 is C 1 -C 4 alkyl, aryl, halogen, C 1 -C 2 haloalkyl, nitro, NR 6 R 7 , OR 8 , SR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , —(CHR 16 ) p OR 8 , —C(OH)(R 25 )(R 25a ), —(CH 2 ) p S(O) n -alkyl, —C(CN)(R 25 )(R 16 ) provided that R 25 is not an —NH— containing ring, —C(═O)R 25 , —CH(CO 2 R 16 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 )alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, indolinyl, indolyl, pyrazoyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, or 5-methyl-2-thienyl, azetidinyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thiazolyl, triazinyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group consisting of CH and CX′;
M is CR 5 ;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, methyl, or cyano;
X is halogen, S(O) 2 R 8 , SR 8 halomethyl, (CH 2 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, -C(═NOR 16 )H, or —C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X′ is hydrogen, halogen, S(O) n R 8 , halomethyl, (CH 2 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 -alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 ) —C 1 -C 4 -alkyl, —C(═NOR 16 )H, or —C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, —C(═NOR 16 )—C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-akyl, aryl-(C 2 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 2 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , —C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, cycloalkylalkyl, —(CH 2 ) k R 13 , C 1 -C 6 alkoxy, —(CHR 16 ) p OR 8 , —(C 1 -C 6 alkyl)-aryl, aryl, heteroaryl, —(C 1 -C 6 alkyl)-heteroaryl or aryl, wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , carboxy, CO 2 (C 1 -C 6 alkyl), cyano, or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-3 R 17 , or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, (C 1 -C 6 )alkyl(C 1 -C 4 )alkoxy, and C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; —(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; —NR 6 R 7 ; aryl; —NR 16 (CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 ; and CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , carboxy, and CO 2 (C 1 -C 6 alkyl);
R 10 is hydrogen;
R 13 is independently selected at each occurrence from the group consisting of OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, and C 4 -C 10 cycloalkyl-alkyl;
R 17 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, and (C 1 -C 6 )alkyl(C 1 -C 4 )alkoxy;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, and aryl substituted with 0-3 R 18 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, —S(O) n R 31 , and —C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H, phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, thiophenyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
t is independently selected at each occurrence from 1-3; and
w is 1-3.
Other preferred compounds of this invention are those compounds of Formula I wherein,
Y is CR 29 ;
Z is CR 2 ;
R 1 is methyl, amino, chloro, or methylamino;
R 2 is hydrogen;
R 3 is C 1 -C 4 alkyl, aryl, halogen, nitro, NR 6 R 7 , OR 8 , SR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 ) k OR 8 , —C(OH)(R 25 )(R 25a ), —(CH 2 ) p S(O) n -alkyl, —C(═O)R 25 , —CH(CO 2 R 16 ) 2 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, or is N-linked piperidinyl, piperazinyl, morpholino, thiomorpholino, imidazolyl, 2-pyridinyl, 3-pyridinyl, 4-pyridinyl, where substitution by R 27 can occur on any carbon containing substituent;
J, K, and L are independently selected at each occurrence from the group consisting of CH and CX′;
M is CR 5 ;
R 4 is taken together with R 29 to form a five membered ring and is —CH═;
X is Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , R 18 substituted alkyl, or amino-(C 1 -C 2 ) alkyl;
X′ is hydrogen, Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , R 18 substituted alkyl, or amino-(C 1 -C 2 ) alkyl;
R 5 is independently selected at each occurrence from the group consisting of halogen, -C(═NOR 16 )—C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , —NR 14 R 15 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C(═O)R 8 , and C(═O)NR 8 R 15 ; R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, —(CH 2 ) k R 13 , (C 3 -C 6 )cycloalkyl-(C 1 -C 6 )alkyl, —(C 1 -C 6 alkyl)-aryl, heteroaryl, —(C 1 -C 6 alkyl)-heteroaryl or aryl, wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, amino, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), and N(C 1 -C 2 alkyl) 2 , or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-2 R 17 , or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-2 groups consisting of hydrogen, C 1 -C 3 alkyl, hydroxy, or C 1 -C 3 alkoxy;
A is CH 2 , O, NR 25 , C(═O), or S(O) n ;
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; —(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; —NR 6 R 7 ; aryl; —NR 16 (CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, amino, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), N(C 1 -C 2 alkyl),, R 9 is hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, and C 3 -C 6 cycloalkyl substituted with 0-2 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, (CH 2 ) t R 22 , and aryl substituted with 0-2 R 18 ;
R 16 is independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl;
R 17 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halo, and NR 23 R 24 ;
R 18 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halo, and NR 23 R 24 ;
R 22 is independently selected at each occurrence from the group consisting of OR 24 , SR 24 , R 23 R 24 , and —C(═O)R 25 ;
R 23 and R 24 are independently selected at each occurrence from hydrogen and C 1 -C 2 alkyl;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl, benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a is independently selected at each occurrence from the group consisting of H and C 1 -C 4 alkyl;
R 29 is taken together with R 4 to form a five membered ring and is —C(R 30 )═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, or halogen;
k is 1-3;
p is 0-2;
q and r are 2; and
t and w are independently selected at each occurrence from 1-2.
More preferred compounds of this invention are those compounds of Formula I wherein, when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 2 alkyl, C 1 -C 2 haloalkyl, NR 6 R 7 , and OR 8 ;
R 3 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 ) k OR 8 , —C(CN)(R 25 )(R 16 ) provided that R 25 is not an —NH— containing ring, —C(OH)(R 25 )(R 25a ), —(CH 2 ) p S(O) n -alkyl, —C(═O)R 25 , —CH(CO 2 R 16 ) 2 , 2-pyridinyl, indolinyl, indolyl, pyrazoyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 1H-indazolyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4H-quinolizinyl, benzofuranyl, carbazolyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, methyl, and cyano;
X is Cl, Br, I, OR 8 , NR 14 R 15 , (CH 2 ) m OR 16 , or (CHR 16 )NR 14 R 15 ;
X′ is hydrogen, Cl, Br, I, OR 8 , NR 14 R 15 , (CH 2 ) m OR 16 , or (CHR 16 )NR 14 R 15 ;
R 5 is halo, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p NR 14 R 15 , or C 3 -C 6 cycloalkyl;
R 6 and R 7 are independently selected at each occurrence from the group consisting of
C 1 -C 6 alkyl, (CHR 16 ) p OR 8 , C 1 -C 6 alkoxy, and —(CH 2 ) k R 13 , or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with —CH 2 OCH 3 ;
A is CH 2 , O, S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(OR 20 ), NR 25 , or C(═O);
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) t R 22 , —NR 6 R 7 , —NR 16 (CH 2 ) n NR 6 R 7 , and —(CH 2 ) k R 25 ,
R 9 is C 1 -C 4 alkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 3 -C 6 cycloalkyl, and C 4 -C 6 cycloalkyl-alkyl;
R 16 is hydrogen;
R 1a is C 1 -C 3 alkyl;
R 20 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, and C 2 -C 3 alkenyl;
R 22 is independently selected at each occurrence from the group consisting of OR 24 , —S(O) n R 19 , and —C(═O)R 25 ;
R 23 and R 24 are independently selected at each occurrence from hydrogen and C 1 -C 2 alkyl;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl. quinuclidinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H, phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4H-quinolizinyl, azocinyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isoindolinyl, isoindolyl, isoquinolinyl, benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
k is 1-3;
p and q are 0-2; and
r is 1-2.
Other more preferred compounds of this invention are those compounds of Formula I wherein, when Y is CR 29 :
R 1 is methyl;
R 3 is C 1 -C 2 alkyl, NR 6 R 7 , OR 8 , SR 8 , C 1 -C 2 alkyl or aryl substituted with R 27 , halogen, or is N-linked piperidinyl, piperazinyl, morpholino, thiomorpholino, imidazolyl, or is 2-pyridinyl, 3-pyridinyl, 4-pyridinyl, where substitution by R 27 can occur on any carbon containing substituent;
X is Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , or alkyl substituted with R 5 ;
X′ is hydrogen, Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , or alkyl substituted with R 5 ;
R 5 is halogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, or —NR 14 R 15 ;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl, or, when considered with the commonly attached nitrogen, can be taken together to form piperidine, piperazine, morpholine or thiomorpholine;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, and aryl optionally substituted with 1-2 groups selected from hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), and N(C 1 -C 2 alkyl) 2 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl; and
R 30 is hydrogen or cyano.
The following compounds are specifically preferred:
N-(2,4-dimethoxyphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromophenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-methylphenyl)-N-methyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2,4-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-dibromophenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-ethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-tert-butylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-tert-butylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-trifluoromethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-trifluoromethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4,6-trimethoxyphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4,6-trimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-allyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-propyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-cyclohexylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-diethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-ethyl-4,6-diethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-formyl-piperazino)-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-trifluoromethyl-2-pyrimidinamine;
N-(2-bromo-4-methoxyethyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(2-thiopheno)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-cyanomethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-cyclopropylmethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-propargyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4-thiomorpholino-6-methyl-2-pyrimidinamine;
N-(2-iodo-4-methoxyethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-methoxyethylphenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrmidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-methylthio-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-dimethylamino-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl -2-pyrimidinamine;
N-(2-methylthio-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-dimethylamino-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-dimethylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-methylthiomethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(1-methylethyl)phenyl)-N-ethyl -4-methyl-6-thiomorpholino-2-pyrimidinamine;
N-(2,4-diiodophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-diiodophenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(N-methyl-2-hydroxyethylamino)-2-pyrimidinamine;
N-(2,6-dimethoxy-4-methylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-iodophenyl)-N-methyl-4,6-diethyl-2-pyrmidinamine;
N-(2-iodophenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-trifluoromethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
4,6-dimethyl-2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-methylamino)pyridine;
4,6-dimethyl-2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)pyridine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-2,4-dimethoxy-6-pyrimidinamine;
2,6-dimethyl-4-(N-(2-bromo-4-(1-methylethyl)phenyl)amino)pyridine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(4-morpholinylcarbonyl)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(morpholinylmethyl)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(1-piperidinylcarbonyl)-2-pyrimidinamine;
Methyl-2-((2-bromo-4-(1-methylethyl)phenyl)ethylamino)-6-methyl-4-pyrimidinecarboxylate;
2-((2-bromo-4-(1-methylethyl)phenyl)ethylamino)-N-cyclohexyl-6-methyl-4-pyrimidinecarboxamide;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(4-methyl-1-piperazinylcarbonyl)-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-1,3,5-triazin-2-amine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5-triazin-2-amine;
N-ethyl)-N-{2-iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(4-thiomorpholinyl)-1,3,5-triazin-2-amine;
N-ethyl-N-{2-iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(4-morpholinyl)-1,3,5-triazin-2-amine;
N-ethyl-N-{2 -iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(1-piperidinyl)-1,3,5-triazin-2-amine;
1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4-phenyl-6-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-phenyl-6-methyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-1)-3-cyano-4,6-dimethyl-7-azaindole:
1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-N,N-diethylamino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4,6-dimethoxy-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-imidazolino-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-N,N-dimethylamino-6-methyl-1,3,5 triazin-2-amine;
N-(2,4,6-trimethoxyphenyl)-N-ethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine,
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-N,N-dimethylamino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-thiozolidino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-benzyloxy-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-phenyloxy-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-{4-(ethylpiperizinoate)}-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-{4-(piperizinic acid)}-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-{3-(malon-2-yldiethyl ester)}-6-methyl-1,3,5-triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-(1-cyano-1-phenylmethyl)-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-1-methylethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine;
N-(2-iodo-4-dimethylhydroxymethylphenyl)-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, S-dioxide;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, S-oxide;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-benzyloxy-1,3,5 triazin-2-amine;
N-(2-iodo-4-dimethylhydroxymethyl)-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-allyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-ethyl-4-chloro-6-methyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4(S)-(N-methyl-2-pyrrolidinomethoxy)-6-methyl-2-pyrimidinamine;
N-{2,6-dibromo-4-(1-methylethyl)phenyl}-4-thiomorpholino-6-methyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylsulfinyl-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-ethyl-4-thiazolidino-6-methyl-2-pyrimidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4,6-dimethyl-2-pyrimidinamino)-2,3,4,5-tetrahydro-4-(1-methylethyl)-1,5-benzothiazepine;
N-{2-methylsulfonyl-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-ethylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-ethylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylsulfonyl-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-bromo-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-ethyl-2-methylthiophenyl)-N-(1-methylethyl)-4,6-dimethyl-2-pyrimidinamine;
N-(4-ethyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylthio-4-(N-acetyl-N-methylamino)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-carboethoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyirmidinamine;
N-(4-methoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-cyano-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-acetyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-propionyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(1-methoxyethyl)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(N-methylamino)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(N,N-dimethylamino)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-formyl-6-methyl-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-hydroxyethoxymethyl-6-methyl-2-pyrimidinamine;
N-(2-bromo-6-hydroxy-4-methoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(3-bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,3-dibromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(ethoxy)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-chloro-3-cyano4-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-chloro-4-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-chloro-34yano-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole;
N-(2-bromo-6-methoxy-pyridin-3-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(3-bromo-5-methyl-pyridin-2-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(6-methoxy-pyridin-3-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-6-methoxy-pyridin-3-yl)-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5 triazin-2-amine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{N-(2-furylmethyl)-N-methylamino}carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{(4,4-ethylenedioxypiperidino)carbonyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-oxopiperidino)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-oxopiperidino)methyl-6-methylpyrimidinamine, hydrochloride salt;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(imidazol-1-yl)methyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{3-(methoxyphenyl)methoxymethyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(2-thiazolyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(2-imidazolyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(5-indolylcarbonyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-fluorophenyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-carboxy-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-acetyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(hydroxy-3-pyridyl-methyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{4-(methoxyphenyl)-3-pyridyl-hydroxymethyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(3-pyrazolyl)-6-methylpyrimidinamine, hydrochloride salt;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(1-aminoethyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{2-(4-tetrazolyl)-1-methylethyl}-6-methylpyrimidinamine;
2-(N-{2-bromo-4-(2-propyl)phenyl}amino)-4-carbomethoxy-6-methylpyrimidine;
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-4-carbomethoxy-6-methylpyrimidine;
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-6-methylpyrimidine-4-morpholinocarbonyl;
9{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino purine;
9{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino-8-azapurine;
1{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino-5,7-diaza-indazole; and
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-4-(morpholinomethyl)-6-methylpyrimidine.
The above-described compounds and their corresponding salts possess antagonistic activity for the corticotropin releasing factor receptor and can be used for treating affective disorders, anxiety, depression, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, or fertility problems in mammals.
Further included in this invention is a method of treating affective disorders, anxiety, depression, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, or fertility problems in mammals in need of such treatment comprising administering to the mammal a therapeutically effective amount of a compound of formula (I):
or a pharmaceutically acceptable salt or prodrug thereof, wherein Y is CR 3a ,
N, or CR 29 ;
when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, halogen, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , and S(O) n R 8 ;
R 3 is C 1 -C 4 alkyl, aryl, C 3 -C 6 cycloalkyl, C 1 -C 2 haloalkyl, halogen, nitro, NR 6 R 7 , OR 8 , S(O) n R 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , —(CHR 16 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , —C(OH)(R 25 )(R 25a ), —(CH 2 ) p S(O) n -alkyl, —(CHR 16 )R 25 , —C(CN)(R 25 )(R 16 ) provided that R 25 is not —NH— containing rings, —C(═O)R 25 , —CH(CO 2 R 16 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 , NR 10 CH(R 11 )CO 2 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, phenyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group of
N, CH, and CX′;
M is CR 5 or N;
V is CR 1a or N;
Z is CR 2 or N;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, halomethyl, C 1 -C 3 alkyl, and cyano;
R 4 is (CH 2 ) m OR 16 , C 1 -C 4 alkyl, allyl, propargyl, (CH 2 ) m R 13 , or —(CH 2 ) m OC(O)R 16 ;
X is halogen, S(O) 2 R 8 , SR 8 , halomethyl, —(CH 2 ) p OR 8 , —OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , —C(═O)R 8 , C 1 -C 6 alkyl, C 4 -C 10 cycloalkylalkyl, C 1 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 2 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, or —C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X′ is independently selected at each occurrence from the group consisting of hydrogen, halogen, S(O) n R 8 , halomethyl, —(CHR 16 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, —C(═NOR 16 )H, and —C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, —C(═NOR 16 )—C 1 - 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, —(CHR 16 ) p OR 8 , —(CHR 16 ) p S(O) n R 8 , —(CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 1 -C 10 alkynyl, aryl-(C 2 -C 10 )-akyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 2 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , —C(═NOR 16 )H, or —C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, C 1 -C 6 alkoxy, (C 4 -C 12 )-cycloalkylalkyl, —(CH 2 ) k R 13 , (CHR 16 ) p OR 8 , —(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, —S(O) n -aryl or —(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z —(C 1 -C 6 -alkyl); or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
A is CH 2 , O, NR 25 , C(═O), S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(NR 14 R 15 ), C(H)(OR 20 ), C(H)(C(═O)R 21 ), or N(S(O) n R 21 );
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; —(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) n R 22 ; C 3 -C 10 cycloalkyl; —NR 6 R 7 ; aryl; —NR 16 (CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z (C 1 -C 6 -alkyl);
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 1 -C 4 alkenyl, aryl substituted with 0-3 R 18 , and —(C 1 -C 6 alkyl)-aryl substituted with 0-3 R 18 ;
R 10 , R 16 , R 23 , and R 24 are independently selected at each occurrence from hydrogen or C 1 -C 4 alkyl;
R 11 is C 1 -C 4 alkyl substituted with 0-3 groups chosen from the following: keto, amino, sulfhydryl, hydroxyl, guanidinyl, p-hydroxyphenyl, imidazolyl, phenyl, indolyl, indolinyl, or, when taken together with an adjacent R 10 , are (CH 2 ) t ;
R 12 is hydrogen or an appropriate amine protecting group for nitrogen or an appropriate carboxylic acid protecting group for carboxyl;
R 13 is independently selected at each occurrence from the group consisting of CN, OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 4 -C 10 cycloalkyl-alkyl, and R 19 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , NR 23 R 24 , and (C 1 -C 6 ) alkyl (C 1 -C 4 ) alkoxy;
R 18 is independently selected at each occurrence from the group consisting of R 10 , hydroxy, halogen, C 1 -C 2 haloalkyl, C 1 -C 4 alkoxy, C(═O)R 24 , and cyano;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) w R 22 , and aryl substituted with 0-3 R 18 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 , C(═O)R 31 , and C 2 -C 4 alkenyl;
R 21 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 − alkoxy, NR 23 R 24 , and hydroxyl;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, —S(O) n R 31 , and —C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H and R 25 ;
R 27 is independently selected at each occurrence from the group consisting of C 1 -C 3 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, aryl, nitro, cyano, halogen, aryloxy, and heterocycle optionally linked through O;
R 31 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl, and aryl-(C 1 -C 4 ) alkyl;
k, m, and r are independently selected at each occurrence from 1-4;
n is independently selected at each occurrence from 0-2;
p, q, and z are independently selected at each occurrence from 0-3;
t and w are independently selected at each occurrence from 1-6,
provided that when J is CX′ and K and L are both CH, and M is CR 5 , then
(A) when V and Y are N and Z is CH and R 1 and R 3 are methyl,
(1) and R 4 is methyl, then
(a) R 5 can not be methyl when X is OH and X′ is H;
(b) R 5 can not be —NHCH 3 or —N(CH 3 ) 2 when X and X′ are —OCH 3 ; and
(c) R 5 can not be -N(CH 3 ) 2 when X and X′ are —OCH 2 CH 3 ;
(2) and R 4 is ethyl, then
(a) then R 5 can not be methylamine when X and X′ are —OCH 3 ;
(b) R 5 can not be OH when X is Br and X′ is OH; and
(c) R 5 can not be —CH 2 OH or —CH 2 N(CH 3 ) 2 when X is —SCH3 and X′ is H;
(B) when V and Y are N, Z is CH, R 4 is ethyl, R 5 is iso-propyl, X is Br, X′ is H, and
(1) R 1 is CH 3 , then
(a) R 3 can not be OH, piperazin-1-yl, —CH 2 -piperidin-1-yl, —CH 2 -(N-4-methylpiperazin- 1-yl), —C(O)NH-phenyl, —CO 2 H, —CH 2 O-(4-pyridyl), —C(O)NH 2 , 2-indolyl, —CH 2 O-(4-carboxyphenyl), —N(CH 2 CH 3 )(2-bromo-4-isopropylphenyl);
(2) R 1 is —CH 2 CH 2 CH 3 then R 3 can not be —CH 2 CH 2 CH 3 ;
(C) when V, Y and Z are N, R 4 is ethyl, and
(1) R 5 is iso-propyl, X is bromo, and X′ is H, then
(a) R 3 can not be OH or —OCH 2 CN when R 1 is CH 3 ; and
(b) R 3 can not be —N(CH 3 ) 2 when R 1 is —N(CH 3 ) 2 ;
(2) R 5 is —OCH—, X is —OCH 3 , and X′ is H, then R 3 and R 1 can not both be chloro;
further provided that when J, K, and L are all CH and M is CR 5 , then
(D) at least one of V, Y, and Z must be N;
(E) when V is CR 1a , Z and Y can not both be N;
(F) when Y is CR 3a , Z and V can not both be N;
(G) when Z is CR 2 , V and Y must both be N;
(H) Z can be N only when both V and Y are N or when V is CR 1a and Y is CR 3a ;
(I) when V and Y are N, Z is CR 2 , and R 2 is H or C 1 -C 3 alkyl, and R 4 is C 1 -C 3 alkyl, R 3 can not be 2-pyridinyl, indolyl, indolinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-phenothiazinyl, or 4-pyrazinyl;
(J) when V and Y are N; Z is CR 2 ; R 2 is H or C 1 -C 3 alkyl; R 4 is C 1 -C 4 alkyl; R 5 , X, and/or X′ are OH, halo, CF 3 , C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, cyano, amino, carbamoyl, or C 1 -C 4 alkanoyl; and R 1 is C 1 -C 4 alkyl, then R 3 can not be —NH(substituted phenyl) or —N(C 1 -C 4 alkyl)(substituted phenyl);
and wherein, when Y is CR 29 :
J, K, L, M, Z, A, k, m, n, p, q, r, t, w, R 3 , R 10 , R 11 , R 12 , R 13 , R 16 , R 18 , R 19 , R 21 , R 23 , R 24 , R 25 , and R 27 are as defined above and R 25a , in addition to being as defined above, can also be C 1 -C 4 alkyl, but
V is N;
R 1 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, halogen, amino, methylamino, dimethylamino, aminomethyl, or N-methylaminomethyl;
R 2 is independently selected at each occurrence from the group consisting of hydrogen, halo, C 1 -C 3 alkyl, nitro, amino, and —CO 2 R 10 ;
R 4 is taken together with R 29 to form a 5-membered ring and is —C(R 28 )═ or —N═ when R 29 is —C(R 30 )═ or —N═, or —CH(R 28 )— when R 29 is
X is Cl, Br, I, S(O) n R 8 , OR 8 , halomethyl, —(CHR 16 ) p OR 8 , cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, —C(═NOR 16 )—C 1 -C 4 -alkyl, -C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X′ is hydrogen, Cl, Br, I, S(O) n R 8 , —(CHR 16 ) p OR 8 , halomethyl, cyano, —(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 , alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 2 -C 10 )-alkoxy, nitro, thio-(C 2 -C 10 )-alkyl, —C(═NOR 16 )-C 1 -C 4 -alkyl, —C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, —C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C1-C3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 1 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 1 -C 10 )-alkyl, thio-(C 1 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , —C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, —(CH 2 ) k R 13 , (C 4 -C 12 )-cycloalkylalkyl, C 1 -C 6 alkoxy, —(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, —S(O) z -aryl or —(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl), nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano; or can be taken together to form —(CH 2 ) q A(CH 2 ) r —, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, —(C 4 -C 12 ) cycloalkylalkyl, (CH 2 ) t R 22 , C 3 -C 10 cycloalkyl, —(C 1 -C 6 alkyl)-aryl, heteroaryl, —NR 16 , —N(CH 2 ) n NR 6 R 7 ; —(CH 2 ) k R 25 , —(C 1 -C 6 alkyl)-heteroaryl or aryl optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano;
R 9 is independently selected at each occurrence from R 2 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, and aryl substituted with 0-3 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) t R 22 , and aryl substituted with 0-3 R 18 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , and NR 23 R 24 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 and C(═O)R 31 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, R 24 , SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, —S(O) n R 31 , and —C(═O)R 25 ;
R 26 is hydrogen or halogen:
R 28 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, hydrogen, C 1 -C 2 alkoxy, halogen, or C 2 -C 4 alkylamino; R 29 is taken together with R 4 to form a five membered ring and is: —CH(R 30 )— when R 4 is —CH(R 28 )—, —C(R 30 )═ or —N═ when R 4 is —C(R 28 )═ or —N═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halogen, C 1 -C 2 alkenyl, nitro, amido, carboxy, or amino;
R 31 is C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, or aryl-(C 1 -C 4 ) alkyl;
provided that when J, K, and L are all CH, M is CR 5 , Z is CH, R 3 is CH 3 ,
R 28 is H, R 5 is iso-propyl, X is Br, X′ is H, and R 1 is CH 3 , then R 30 can not be H, —CO 2 H, or —CH 2 NH 2 ;
and further provided that when J, K and L are all CH; M is CR 5 ; Z is N; and
(A) R 29 is —C(R 1 )═; then one of R 28 or R 30 is hydrogen;
(B) R 29 is N; then R 3 is not halo, NH 2 , NO 2 , CF 3 , CO 2 H, CO 2 -alkyl, alkyl, acyl, alkoxy, OH, or —(CH 2 ) m Oalkyl;
(C) R 29 is N; then R 28 is not methyl if X or X′ are bromo or methyl and R 5 is nitro; or
(D) R 29 is N, and R 1 is CH 3 and R 3 is amino; then R 5 is not halogen or methyl.
Further included in this invention are pharmaceutical compositions comprising a pharmaceutically acceptable carrier and therapeutically effective amount of any one of the above-described compounds.
The compounds provided by this invention (and especially labelled compounds of this invention) are also useful as standards and reagents in determining the ability of a potential pharmaceutical to bind to the CRF receptor. These would be provided in commercial kits comprising a compound provided by this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention it has been discovered that the provided compounds useful as antagonists of Cortocotropin Releasing Factor and for the treatment of effective disorders, anxiety, or depression.
The present invention also provides methods for the treatment of effective disorder, anxiety or depression by administering to a host a therapeutically effective amount of a compound of formula (I) as described above. By therapeutically effective amount is meant an amount of a compound of the present invention effective to antagonize abnormal levels of CRF or treat the symptoms of affective disorder, anxiety or depression in a host.
The compounds herein described may have asymmetric centers. All chiral, diastereomeric, and racemic forms are included in the present invention. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compound described herein, and all such stable isomers are comtemplated in the present invention. It will be appreciated that certain compounds of the present invention contain an asymmetrically substituted carbon atom, and may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis, from optically active starting materials. Also, it is realized that cis and trans geometric isomers of the compounds of the present invention are described and may be isolated as a mixture of isomers or as separated isomers forms. All chiral, diastereomeric, and racemic forms and all geometric isomers forms of a structure are intended, unless the specific stereochemistry or isomer form is specifically indicated.
When any variable (for example, R 1 through R 10 , m, n, A, w, Z, etc.) occurs more than one time in any constituent or in formula (I) or any other formula herein, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, in —NR 8 R 9 , each of the substituents may be independently selected from the list of possible R 8 and R 9 groups defined. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. “Alkenyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur at any stable point along the chain, such as ethenyl, propenyl, and the like. “Alkynyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur at any stable point along the chain, such as ethynyl, propynyl and the like. “Haloalkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms, substituted with 1 or more halogens; “alkoxy” represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge; “cycloalkyl” is intended to include saturated ring groups, including mono-, bi- or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and so forth. “Halo” or “halogen” as used herein refers to fluoro, chloro, bromo, and iodo.
As used herein, “aryl” or “aromatic residue” is intended to mean phenyl, biphenyl or naphthyl.
The term “heteroaryl” is meant to include unsubstituted, monosubstituted or disubstituted 5-, 6- or 10-membered mono- or bicyclic aromatic rings, which can optionally contain from 1 to 3 heteroatoms selected from the group consisting of O, N, and S and are expected to be active. Included in the definition of the group heteroaryl, but not limited thereto, are the following: 2-, or 3-, or 4-pyridyl; 2- or 3-furyl; 2- or 3-benzofuranyl; 2-, or 3-thiophenyl; 2- or 3-benzo[b]thiophenyl; 2-, or 3-, or 4-quinolinyl; 1-, or 3-, or 4-isoquinolinyl; 2- or 3-pyrrolyl; 1- or 2- or 3-indolyl; 2-, or 4-, or 5-oxazolyl; 2-benzoxazolyl; 2- or 4- or 5-imidazolyl; 1- or 2- benzimidazolyl; 2- or 4- or 5-thiazolyl; 2-benzothiazolyl; 3- or 4- or 5-isoxazolyl; 3- or 4- or 5-pyrazolyl; 3- or 4- or 5-isothiazolyl; 3- or 4-pyridazinyl; 2- or 4- or 5-pyrimidinyl; 2-pyrazinyl; 2-triazinyl; 3- or 4- cinnolinyl; 1-phthalazinyl; 2- or 4-quinazolinyl; or 2-quinoxalinyl ring. Particularly preferred are 2-, 3-, or 4-pyridyl; 2-, or 3-furyl; 2-, or 3-thiophenyl; 2-, 3-, or 4-quinolinyl; or 1-, 3-, or 4-isoquinolinyl.
As used herein, “carbocycle” or “carbocyclic residue” is intended to mean any stable 3- to 7-membered monocyclic or bicyclic or 7- to 14-membered bicyclic or tricyclic or an up to 26-membered polycyclic carbon ring, any of which may be saturated, partially unsaturated, or aromatic. Examples of such carbocyles include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, phenyl, biphenyl, naphthyl, indanyl, adamantyl, or tetrahydronaphthyl (tetralin).
As used herein, the term “heterocycle” is intended to mean a stable 5- to 7-membered monocyclic or bicyclic or 7- to 10-membered bicyclic heterocyclic ring which is either saturated or unsaturated, and which consists of carbon atoms and from 1 to 4 heteroatoms independently selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl, pyrimidinyl, furanyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, quinolinyl, isoquinolinyl or benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl or octahydroisoquinolinyl, azocinyl, triazinyl, 6H- 1,2,5-thiadiazinyl, 2H,6H-1,5,2-dithiazinyl, thiophenyl, thianthrenyl, furanyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxathiinyl, 2H-pyrrolyl, pyrrole, imidazolyl, pyrazolyl, isothiazolyl, isoxazole, pyridinyl, pyrazinyl, pyrimidinyl, pyridazinyl, indolizinyl, isoindole, 3H-indolyl, indolyl, 1H-indazolyl, purinyl, 4H-quinolizinyl, isoquinolinyl, quinolinyl, phthalazinyl, naphthyridinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, 4aH-carbazolyl, carbazolyl, β-carbolinyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, pyrrolidinyl, pyrrolinyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperidinyl, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl or oxazolidinyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles.
The term “substituted”, as used herein, means that one or more hydrogens of the designated moiety is replaced with a selection from the indicated group, provided that no atom's normal valency is exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O), then 2 hydrogens attached to an atom of the moiety are replaced.
By “stable compound” or “stable structure” is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture and formulation into an efficacious therapeutic agent.
As used herein, the term “appropriate amino acid protecting group” means any group known in the art of organic synthesis for the protection of amine or carboxylic acid groups. Such amine protecting groups include those listed in Greene and Wuts, “Protective Groups in Organic Synthesis” John Wiley & Sons, New York (1991) and “The Peptides: Analysis, Synthesis, Biology, Vol. 3, Academic Press, New York (1981), the disclosure of which is hereby incorporated by reference. Any amine protecting group known in the art can be used. Examples of amine protecting groups include, but are not limited to, the following: 1) acyl types such as formyl, trifluoroacetyl, phthalyl, and p-toluenesulfonyl; 2) aromatic carbamate types such as benzyloxycarbonyl (Cbz) and substituted benzyloxycarbonyls, 1-(p-biphenyl)-1-methylethoxycarbonyl, and 9-fluorenylmethyloxycarbonyl (Fmoc); 3) aliphatic carbamate types such as tert-butyloxycarbonyl (Boc), ethoxycarbonyl, diisopropylmethoxycarbonyl, and allyloxycarbonyl; 4) cyclic alkyl carbamate types such as cyclopentyloxycarbonyl and adamantyloxycarbonyl; 5) alkyl types such as triphenylmethyl and benzyl; 6) trialkylsilane such as trimethylsilane; and 7) thiol containing types such as phenylthiocarbonyl and dithiasuccinoyl.
The term “amino acid” as used herein means an organic compound containing both a basic amino group and an acidic carboxyl group. Included within this term are natural amino acids, modified and unusual amino acids, as well as amino acids that are known to occur biologically in free or combined form but usually do not occur in proteins. Included within this term are modified and unusual amino acids, such as, those disclosed in, for example, Roberts and Vellaccio (1983) The Peptides, 5: 342-429, the teaching of which is hereby incorporated by reference. Modified or unusual amino acids that can be used in the practice of the invention include, but are not limited to, D-amino acids, hydroxylysine, 4-hydroxyproline, an N-Cbz-protected amino acid, ornithine, 2,4-diaminobutyric acid, homoarginine, norleucine, N-methylaminobutyric acid, naphthylalanine, phenylglycine, β-phenylproline, tert-leucine, 4-aminocyclohexylalanine, N-methyl-norleucine, 3,4-dehydroproline, N,N-dimethylaminoglycine, N-methylaminoglycine, 4-aminopiperidine-4-carboxylic acid, 6-aminocaproic acid, trans-4-(aminomethyl)-cyclohexanecarboxylic acid, 2-, 3-, and 4-(aminomethyl)-benzoic acid, 1-aminocyclopentanecarboxylic acid, 1-aminocyclopropanecarboxylic acid, and 2-benzyl-5-aminopentanoic acid.
The term “amino acid residue” as used herein means that portion of an amino acid (as defined herein) that is present in a peptide.
The term “peptide” as used herein means a compound that consists of two or more amino acids (as defined herein) that are linked by means of a peptide bond. The term “peptide” also includes compounds containing both peptide and non-peptide components, such as pseudopeptide or peptide mimetic residues or other non-amino acid components. Such a compound containing both peptide and non-peptide components may also be referred to as a “peptide analog”.
The term “peptide bond” means a covalent amide linkage formed by loss of a molecule of water between the carboxyl group of one amino acid and the amino group of a second amino acid.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound of formula (I) is modified by making acid or base salts of the compound of formula (I). Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like.
“Prodrugs” are considered to be any covalently bonded carriers that release the active parent drug according to formula (I) in vivo when such prodrug is administered to a mammalian subject. Prodrugs of the compounds of formula (I) are prepared by modifying functional groups present in the compounds in such a way that the modifications are cleaved, either in routine manipulation or in vivo, to the parent compounds. Prodrugs include compounds of formula (I) wherein hydroxy, amine, or sulfhydryl groups are bonded to any group that, when administered to a mammalian subject, cleaves to form a free hydroxyl, amino, or sulfhydryl group, respectively. Examples of prodrugs include, but are not limited to, acetate, formate and benzoate derivatives of alcohol and amine functional groups in the compounds of formula (I); and the like.
Pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa. (1985), p. 1418, the disclosure of which is hereby incorporated by reference.
SYNTHESIS
The novel substituted-2-pyridinamines, substituted triazines, substituted pyridines and substituted anilines of the present invention can be prepared by one of the general schemes outlined below (Scheme 1-23).
Compounds of the Formula (I), wherein Z is CR 2 and J is CX′ and K and L are both CH, can be prepared as shown in Scheme 1. 2-Hydroxy-4,6-dialkylpyrimidine (II) was converted to the corresponding derivative (III) with an appropriate leaving group in the 2-position such as, but not limited to, Cl, Br, SO 2 CH 3 , OSO 2 CH 3 , or OSO 2 C 6 H 4 —CH 3 , or SCH 3 by treatment with phosphorous oxychloride (POCl 3 ), phosphorous oxybromide (POBr 3 ), methanesulfonyl chloride (MsCl), p-toluenesulfonyl chloride (TsCl), or sodium thiomethoxide optionally followed by oxidation with hydrogen peroxide, chlorine gas, or an organic peracid, such as, m-chloroperbenzoic
acid, respectively. This derivative was reacted with the appropriate 2,4-substituted aniline (IV) in a high boiling solvent, such as, but not limited to, ethylene glycol, methoxyethoxyethanol etc., or in an aprotic solvent such as tetrahydrofuran, dioxane, toluene, xylene, or N,N-dimethyformamide, facilitated by the optional use of a base such as sodium hydride (NaH), lithium diisopropylamide (LDA), which are preferred. The coupled product (V) was treated with a base such as NaH or LDA in an aprotic solvent such as tetrahydrofuran (THF) or N,N-dimethylformamide (DMF) or in a combination of potassium tert-butoxide in t-butanol (tBuOK/tBuOH) followed by an alkylating agent R 4 L′, such as an alkyl iodide, mesylate or tosylate to afford the corresponding alkylated product of Formula (I).
The compounds of Formula (I), wherein V and Y are N and Z, J, K, and L are all CH, can be prepared as shown in Scheme 2. The substituted aniline (VI) was converted to the corresponding guanidinium salt (VII) by treatment with the appropriate reagent such as cyanamide.
The guanidinium salt (VII) was reacted with a β-diketone (VIII) in the presence of a base such as potassium carbonate (K 2 CO 3 ) in N,N-dimethylformamide (DMF) or in an alcoholic solvent in the presence of the corresponding alkoxide to afford the corresponding pyrimidine (IX). This was subsequently alkylated to provide (X), a compound of Formula (I) wherein X′ is hydrogen, by conditions identical to those described in Scheme 1.
Compounds of the Formula (I), wherein V and Y are N and Z, J, K, and L are all CH and R 3 is NR 6 R 7 , can be prepared as shown in Scheme 3. Treatment of 2,4-dichloro-6-alkylpyrimidine (XI) with a primary or secondary amine in the presence of a non-nucleophilic base such as a trialkylamine afforded selectively the corresponding 4-substituted amino adduct (XII).
This in turn, was reacted with the substituted aniline (IV) under conditions identical to those described in Scheme 1 to afford the corresponding secondary pyrimidinamine (XIII). This was alkylated under conditions described in Schemes 1 and 2.
Compounds of Formula (I) wherein J, K, and L are CH and Z is CR 2 and V and Y are N can also be prepared by the route outlined in Scheme 4. The guanidinium salt (XII) was reacted with a β-ketoester (XV) in the presence of a base such as an alkoxide in the corresponding alcoholic solvent to give the adduct (XVI). Treatment of the hydroxy group in (XVI) with either phosphorous oxychloride, phosphorous oxybromide, methanesulfonyl chloride, p-toluenesulfonyl chloride, or trifluoromethanesulfonic anhydride provided (XVII), wherein the L is a leaving group and is, respectively, Cl, Br, I, OMs, OTs, or OTf. The L group of (XVII) was displaced with a nucleophile such as NR 6 R 7 , OR 6 , SR 6 , CN, an organolithium, organomagnesium, organosodium, organopotassium, an alkyl cuprate, or in general an organometallic reagent to the corresponding adduct (IX), which was further alkylated under the standard conditions to produce (XVIII).
Compounds of the Formula (I) that are substituted at the 2-position of the phenyl ring could be prepared as outlined in Scheme 5.
Compounds of the Formula (I) wherein X is other than bromine can be prepared by the intermediates shown in Scheme 5. Reaction of the 2-halo compound (V) wherein X is bromine or hydrogen with a metalating agent such as, but not limited to, n-BuLi or t-BuLi in an aprotic solvent, preferably ether or tetrahydrofuran, provided the corresponding 2-lithio intermediate (X=Li, not isolated) which was further reacted with an electrophile such as iodine or trimethyltin chloride ((CH 3 ) 3 SnCl) to give the corresponding 2-substituted product (XIX). These intermediates can also be further reacted using palladium-catalyzed coupling reactions well known to one of skill in the art to prepare the compounds of the invention.
Compounds of the Formula (I) wherein Z, K and L are all CHI, J is N or CH, and R′ is ethyl can be prepared as illustrated in Scheme 6. Sequential addition/re-oxidation of an alkyllithium to 2-chloropyrimidine can provide intermediate (XXII) wherein the R 1 and R 3 can be independent of one another. Displacement of the chlorine by a suitable nitrogen nucleophile such as an aniline under similar conditions of Scheme 1, followed by attachment of the R 4 group by alkylation in an analogous method of Schemes 1 or 2 can provide the compounds of the invention.
Compounds of the Formula (I) wherein Z is N can be prepared according to the method outlined in Scheme 7. Known triazine (XXIII), synthesis of which is reported in J. Amer. Chem. Soc. 77:2447 (1956), can be reacted with a substituted aniline (IV) in a analogous manner to Scheme 1. Similarly, the 2,4 dichloro 6-methyltriazine, which can be prepared via the method reported in U.S. Pat. No. 3,947,374 can be coupled to the substituted aniline (IV) to provide (XXIV) where R 3 is chlorine. Nucleophilic addition in protic or aprotic solvents allows for a variety of substituents at this position (XXV). Alkylation of the secondary amine as previously described provide triazine compounds of formula (I).
Compounds wherein R 3 is carboxy-derived are synthesized according to Scheme 8. A pyrimidine ester of formula (XXVI), which is prepared by the literature method reported in Budesinsky and Roubinek, Collection. Czech. Chem. Comm. 26:2871-2885 (1961) is reacted with an amine of formula (IV) in the presence of an inert solvent to afford an intermediate of formula (XXVII). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane), dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons of 6 to carbons. Compounds of formula (XXVII) are treated with a base and a compound of Formula R 4 X, where X is halogen (preferably Cl, Br or I) in an inert solvent. Such bases include a tertiary amine, an alkali metal hydride
(preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. The choice of inert solvent must be compatible with the choice of base (see J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 364-366, 412; H. O. House, Modern Synthetic Reactions (New York: W. A. Benjamin Inc., 1972, pp. 510-536)). Solvents include lower alkyl alcohols of 1 to 6 carbons, lower alkanenitriles (preferably acetonitrile), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably tetrahydrofuran or dioxane), dialkylformamides (preferably N,N-dimethylformamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons. Esters of formula (XXVIII) may be converted to acids of formula (XXIX) by acidic or basic hydrolysis (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 334-338) or by treatment with an alkali metal salt (preferably LiI or NaCN) in the presence of an inert solvent at temperatures ranging from 50 to 200° C. (preferably 100 to 180° C.) (cf. McMurray, J. E. Organic Reactions , Dauben, W. G. et al., eds., J. Wiley and Sons, New York (1976), Vol. 24, pp. 187-224). Inert solvents include dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), and dialkyl sulfoxides (preferably dimethyl sulfoxide), or aromatic amines (preferably pyridine). Acids of formula (XXIX) may be treated with a halogenating agent to give an acid halide, which may or may not be isolated, then reacted with an amine of formula HNR 6 R 7 , with or without an inert solvent, with or without a base, as taught by the literature (J. March, Advanced Organic Chemistry , J. Wiley and Sons, New York (1985), pp. 370-373, 389), to provide amides of formula (XXX). Halogenating agents include thionyl chloride (SOCl 2 ), oxalyl chloride ((COCl) 2 ), phosphorous trichloride (PCl 3 ), phosphorous pentachloride (PCl 5 ), or phosphorous oxychloride (POCl 3 ). Inert solvents include lower halocarbons of 1 to 6 carbons and 2 to 6 halogens (preferably dichloromethane or dichloroethane), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane) or aromatic hydrocarbons to 6 to 10 carbons. Bases include trialkyl amines or aromatic amines (preferably pyridine). Alternatively, esters of formula (XXVIII) may be reacted with an amine of formula HNR 6 R 7 , with or without an inert solvent, with or without a base, as taught by the literature (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 370-373, 389) to generate amides of formula (XXX). Solvents include lower alkyl alcohols of 1 to 6 carbons, lower alkanenitriles (preferably acetonitrile), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably tetrahydrofuran or dioxane), dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons. Such bases include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Amides of formula (XXX) may be treated with a reducing agent in an inert solvent to provide amines of formula (XXXI). Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably lithium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such as lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocarbons of 6 to 10 carbons. Reaction temperatures for the reduction range from about −78° to 200° C., preferably about 50° to 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (pp. 1093-1110).
Scheme 9 depicts the synthesis and chemical modifications to form compounds of formula (XXXIII). Esters of formula (XXVIII) or acids of formula (XXIX) may be treated with a reducing agent in an inert solvent to provide alcohols of formula (XXXII). Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably lithium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such as lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocarbons of 6 to 10 carbons. Reaction temperatures for the reduction range from about −78° to 200° C., preferably about 50° to 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (pp. 1093-1110). Alcohols of Formula (XXXII) may be converted to ethers of formula (XXXIII) by treatment with a base and a compound of Formula R 8 X, where X is halogen. Bases which may be used for this reaction include, but are not limited to, alkali metal hydrides, preferably sodium hydride, alkali metal carbonates, preferably potassium carbonate, alkali metal dialkylamides, preferably lithium di-isopropylamide, alkali metal bis-(trialkylsilyl)amides, preferably sodium bis-(trimethylsilyl)amide, alkyl alkali metal compounds (such as butyl lithium), alkali metal alkoxides (such as sodium ethoxide), alkyl alkaline earth metal halides (such as methyl magnesium bromide), trialkylamines (such as triethylamine or di-isopropylethylamine), polycyclic di-amines (such as 1,4 diazabicyclo[2.2.2]octane or 1,8-diazabicyclo-[5.4.0]undecene) or quaternary ammonium salts (such as Triton B). The choice of inert solvent must be compatible with the choice of base (J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 255-446; H. O. House, Modern Synthetic Reactions (New York:
W. A. Benjamin Inc., 1972, pp. 546-553)). Solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons, preferably tetrahydrofuran or dioxane, dialkylformamides, preferably N,N-dimethylformamide, dialkylacetamides, preferably N,N-dimethylacetamide, cyclic amides, preferably N-methylpyrrolidinone, hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons.
Alternatively, compounds of formula (XXXII) may be converted to compounds of formula (XXXIV), where Y is halide, arylsulfonyloxy (preferably p-toluenesulfonyloxy), alkylsulfonyloxy (such as methanesulfonyloxy), haloalkylsulfonyloxy (preferably trifluoromethyl-sulfonyloxy), by reaction with a halogenating agent or a sulfonylating agent. Examples of halogenating agents include, but are not limited to, SOCl 2 , PCl 3 , PCl 3 , POCl 3 , Ph 3 P—CCl 4 , Ph 3 P—CBr 4 , Ph 3 P—Br 2 , Ph 3 P—I 2 , PBr 3 , PBr 5 . The choice of halogenating agents and reaction conditions are known to those skilled in the prior art (March reference, pp. 382-384). Sulfonylating agents include, but are not limited to, (lower alkyl)sulfonyl chlorides (preferably methanesulfonyl chloride), (lower haloalkyl) sulfonic anhydrides (preferably trifluoromethylsulfonic anhydride, phenyl or alkyl substituted-phenyl sulfonyl chlorides (preferably p-toluenesulfonyl chloride). The sulfonylation or halogenations may require a base as taught by the literature (March reference, pp. 1172, 382-384). Such bases include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Solvents for the halogenation or sulfonylation should be inert under the reaction conditions as taught by the literature. Such solvents include lower halocarbons (preferably dichloromethane or dichloroethane), or ethereal solvents (preferably tetrahydrofuran or dioxane). Intermediates of formula (XXXIV) may then be converted to compounds of formula (XXXIII) by treatment with a compound of formula R 8 OH with or without a base, in an inert solvent (March reference, pp. 342-343). Such bases include alkali metal hydrides, preferably sodium hydride, alkali metal carbonates, preferably potassium carbonate, alkali metal dialkylamides, preferably lithium diiisopropylamide, alkali metal bis-(trialkylsilyl)amides, preferably sodium bis-(trimethylsilyl)amide, alkyl alkali metal compounds (such as n-butyllithium), alkali metal alkoxides (such as sodium ethoxide), alkyl alkaline earth metal halides (such as methyl magnesium bromide), trialkylamines (such as triethylamine or di-isopropylethylamine), polycyclic diamines (such as 1,4 diazabicyclo[2.2.2]octane or 1,8-diazabicyclo[5.4.0]undecene) or quaternary ammonium salts (such as Triton B). Solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons, preferably tetrahydrofuran or dioxane, dialkylformamides, preferably N,N-dimethylformamide, dialkylacetamides, preferably N,N-dimethylacetamide, cyclic amides, preferably N-methylpyrrolidinone, hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons.
Intermediates of formula (XXXIII) may be prepared from intermediates of formula (XXXII) by reaction with a triarylphosphine (preferably triphenylphosphine), a di-(lower alkyl) azodicarboxylate) and a compound of formula R 8 OH in the presence of an inert solvent as described in the general literature (Mitsunobu, O., Synthesis 1:1-28 (1981)).
Compounds of formula (XXXI) may be prepared by treatment of a compound of formula (XXXIV) with a compound of Formula HNR 6 R 7 , with or without a base, in an inert solvent (Scheme 9). Such bases and inert solvents may be the same ones used for the transformation of compounds (XXVIII) to compounds (XXX) in Scheme 8.
Compounds of Formula (I) which are substituted at the 4-position of the pyrimidine ring can be prepared as outlined in Scheme 10.
Known pyrimidine (XXXV), synthesis of which is reported in Eur. J. Med. Chem. 23:60 (1988), can be reacted with a substituted aniline (IV) in an analogous manner to Scheme 1. Treatment of the hydroxy group in (XXXVI) with either phosphorous oxychloride, phosphorous oxybromide, p-toluenesulfonyl chloride, or trifluoromethanesulfonic anhydride provided (XXXVII), wherein the L is a leaving group. Alkylation under the standard conditions gives (XXXVIII). The L group of (XXXVIII) was displaced with a nucleophile such as NR 6 R 7 , OR 6 , SR 6 , CN, or an organometallic reagent to the corresponding adduct (XXXIX).
Compounds of the Formula (I), wherein X or X′ is alkylmercapto, or functionalized alkylmercapto can be synthesized under the conditions described in Scheme 11.
Treatment of the appropriately ortho-functionalized aniline XXXIX with a substituted 2-mercaptopyrimidine XL in the presence of a base such as potassium carbonate, sodium carbonate, alkali metal alkoxide, potassium sodium or lithium hydride, a lithium, sodium or potassium dialkylamide, or an alkali metal in the presence of copper powder or copper salts gives the corresponding aryl sulfide XLI which is subjected to a Smiles rearrangement by treatment with an strong acid such as hydrochloric, hydrobromic, hydriodic, sulfuric, phosphoric or perchloric, to give the corresponding disulfide XLIII. This is reduced to the sulfide XLIV with a reducing agent such as sodium borohydride and alkylated on the sulfur with the appropriate alkylating agent such as an alkyl halide, tosylate or mesylate. The rearrangement of XLI may be carried out with a strong base such as lithium, sodium, or potassium hydride; lithium, sodium, or potassium dialkylamide; or lithium sodium or potassium metal, in an appropriate solvent such as decahydronaphthalene, xylenes, high boiling alcohols, dimethylformamide, dimethylsulfoxide, dimethylacetamide, and N-methylpyrrolidinone. The rearrangement product can be selectively alkylated on the sulfur with the use of a base such as potassium, sodium or lithium carbonate, potassium, sodium or lithium alkoxide, or trialkylamine and the appropriate alkylating agent as described above. The alkylsulfide can be further alkylated on the nitrogen by using identical conditions as described above to yield compound XLV.
Compounds of formula (I), wherein R 3 is (CH 2 ) k OR 8 and R 8 is (CH 2 ) t C(═O)OR 24 , (CH 2 ),C(═O)NR 6 R 7 , or (CH 2 ) t NR 6 R 7 can be made according to Scheme 12.
Compounds XLVII, XLVIII, and XLIX are made using the product of Example 24 as starting material by procedures analogous to those used to make the products of Examples 25, 16, and 17 respectively.
The novel 7-azaindoles of the present invention are prepared by Scheme 13 outlined below. The potassium salt of formylsuccinonitrile is treated with the appropriate substituted aniline L to give LI. This undergoes base catalyzed cyclization to a 1-aryl-2-amino-4-cyanopyrrole LII. Reaction with an appropriate 1,3-dicarbonyl compound gives the desired 7-azaindole LIII.
The nitrile substituent at position 3 of structure LIII is readily removed by refluxing the 3-cyano compound with 65% sulfuric acid. Position 3 then can be resubstituted by halogenation or nitration. Reduction of the nitro group can provide the 3-amino substituent.
Alternatively, the nitrile group can be converted to desired L groups by methods described in “Comprehensive Organic Transformations”, by Richard C. Larock, VCH Publishers, Inc., New York, N.Y., 1989. For instance, the nitrile group can be reduced with diisobutylaluminum hydride to give the 3-aldehyde. The 3-aldehyde can be reduced via the hydrazone under Wolff-Kishner conditions (KOH in hot diethylene glycol) to give L=methyl. Furthermore, the aldehyde can be converted to L═CH═CH 2 by adding it to a mixture of methyltriphenylphosphonium bromide and potassium tertiary-butoxide in tetrahydrofuran (Wittig reaction). Reduction of the ethenyl group to give L═CH 2 CH 3 can be effected by hydroboration-protonolysis ( J. Am. Chem. Soc. 81:4108(1959)).
Scheme 13 generally provides a mixture isomeric in substituents R 1 and R 3 , which then can be separated, Sometimes the preferred isomer is the one obtained in lower yield. In that event Scheme 14 can be used to prepare the preferred isomer. Intermediate LII is treated with the appropriate acyl- or aroyl-acetic ester under either thermal or acid-catalyzed conditions to give the 6-hydroxy compound LV. Compound LV is converted to the 6-chloro compound LVI and de-cyanylated to compound LVII. When R 1 substituents other than chloro are desired, the chloro group can be converted to other substituents. For instance, treatment of compound LVII with an alkyl Grignard reagent can provide compound LVIII where R 1 =alkyl. Heating with a primary or secondary amine can provide compound LVIII where R 1 =amino.
Scheme 15 affords another route to compounds of this invention. Intermediate LII can be treated with the appropriate acylacetaldehyde dialkyl acetal under acid catalyzed conditions to give compounds LXa and LXb, 7-azaindoles unsubstituted at positions 4 and 6 respectively. Compound LXa can be oxidized with m-chloroperoxybenzoic acid to give the N-oxide compound LXI. Heating compound LXI with phosphorus oxychloride can give compound XIIa, which can be decyanylated to compound LXIII.
Compound LXIV where R 3 is an amino substituent can be prepared by heating LXIII with the appropriate amine; where R 3 =alkoxide, the metal alkoxide can be heated with LXIII; where R 3 =aryl, compound LXIII can treated with the arylboronic acid in the presence of tetrakis(triphenylphosphine)p alladium (TTPP) and sodium carbonate; and where R 3 =alkyl, alkenyl, aralkyl, and cycloalkyl, compound LXIII can be coupled with the appropriate organotin reagent, also in the presence of 7TPP.
Compound LXIV where R 3 is a nitro group can be prepared by nitration of LXI, decyanylation, and reduction of the N-oxide with a trivalent phosphorus compound such as triethyl phosphite.
Compound LXb can be substituted in the 6 position using methods described for the substitution of LXa.
The novel 7-azabenzimidazoles of this invention can be prepared as outlined in Scheme 16 where R 29 is nitrogen. Compounds L and LXV can react upon heating in the presence of a base, e.g. sodium hydride, to give the diarylamine LXVI. Reduction of the nitro group with stannous chloride can give LXVII, which can be closed to the 7-azabenzimidazole LXVIII.
The purines of this invention can be prepared as shown in Schemes 17 and 18.
Compounds L and LXIX ( J. Heterocyclic Chem. 28:465 (1991)) can be heated in the presence of a base, e.g. sodium hydride, to give compound LXX. Heating LXX with the appropriate carboxylic acid in the presence of a mineral acid catalyst can give LXXI where R 28 is hydrogen, alkyl, alkenyl, or alkynyl. The chloro substituent can then be converted to R 3 to give compounds LXXII by using one of the methods described above for the introduction of R 3 to obtain compounds LXIV.
Scheme 18 can be used to prepare purines where R 28 is halogen or alkoxide. Compounds LXX can be heated with a dialkyl carbonate, such as diethyl carbonate, to give the carbonyl compound LXXIII; if the conversion is undesirably slow, more reactive species such as trichloromethyl chlorocarbonate or carbonyl diumidazole can be used in place of diethyl carbonate. The chloro substituent can then be converted to R 3 to give LXXIV by using one of the methods described above for the introduction of R 3 to obtain LXIV. Heating LXXIV with phosphorus oxychloride can give the 2-chloropurine, LXXV. To prepare the 2-alkoxypurines, LXXVI, LXXV can be heated with a metal salt of the alcohol R 31 OH, e.g. the sodium or potassium salt, wherein in R 31 is C 1 -C 4 alkyl.
The method of synthesis of the 7-azaindolines of this invention is shown in Scheme 19.
A number of compounds of the general structure LXXVIII with desired R 1 and R 2 groups have been described by W. Paudler and T.-K. Chen, J. Heterocyclic Chem. 7:767 (1970). These can be oxidized with a peracid, e.g. m-chloroperoxybenzoic acid, to the sulfone LXXIX. Sulfone LXXIX can be heated in the presence of the desired aniline and a base, e.g. sodium hydride to give the diaryl amine LXXX. Alkylation of LXXX with the desired unsubstituted or 4-substituted 3-butynyl iodide (or 3-butynol mesylate) can give LXXXI. LXXXI can undergo an intramolecular Diels-Alder reaction to give LXXXII.
In a number of cases, the desired 4-substituted 3-butynyl iodide is not readily available or is unstable. In that event unsubstituted 3-butynyl iodide is used to give compound LXXXII where R 3 =H.
The synthesis of the 5,7-diazaindoles of this invention is outlined in Scheme 20.
The desired formamidine LXXXIII can be treated with LXXXIV in the presence of sodium ethoxide in ethanol to give the pyrimidine LXXXV. Refluxing LXXXV in phosphorus oxychloride gives the dichloropyrimidine LXXXVI. Compound LXXXVI can be converted to the carbonyl compound LXXXVII by treatment with one equivalent of ozone at −78° to give an ozonide, which on treatment with sodium iodide and acetic acid gives the desired carbonyl compound. The preparation of LXXXVII (R 1 =H, R 28 =CH 3 and R 1 =R 28 =CH 3 ) by a different route has been described by E. Basagni et al., Bull. Soc. Chim. Fr., 4338 (1969).
Before the coupling reaction, the carbonyl of compound LXXXVII is protected by treatment with 2,2-dimethoxypropane in the presence of a catalytic amount of acid to give compound LXXXVIII. Compound LXXXVIII is then coupled with the appropriate aniline L by heating in the presence of a base, e.g. sodium hydride, to give compound LXXXIX. Compound LXXXIX can be cyclized to give the 5,7-diazaindole XC, the target compound wherein R 3 =Cl. Compound XC is also a useful intermediate for the preparation of Compounds XCI with other R 3 groups. For example, heating the chloro compound with the appropriate amine gives the desired amino compound. Heating with a metal alkoxide gives the desired alkoxy compound. Treating compound XC (R 3 =Cl) with R 3 MgBr (R 3 =alkyl, aryl, or aralkyl) converts the chloro compound to the desired alkyl, aryl, or aralkyl compound XCI.
Compounds wherein R 5 is dimethylhydroxymethyl, X′ is iodine and R 1 and R 3 are chlorine can be prepared according to scheme 21. Ethyl 4-aminobenzoate is iodinated in a methylene chloride/water (50:50) mixture in the presence of sodium bicarbonate to provide compound (XCII). This material is coupled to cyanuric chloride, then the secondary amine is alkylated in an analogous manner to that in Scheme 1 to yield XCIII. Compound XCIII is treated with 5 equivalents of MeMgBr to provide the desired material of formula (XCIV).
Scheme 22 depicts the synthesis of compounds of Formula (I), where Y=N, Z=CR 2 and R 3 is COR 25 , CH(OH)R 25 or C(OH)R 25 R 25a . An ester of Formula (XCVI) may be converted to an amide of Formula (C) by treatment with an amine of Formula HN(OR a )R b , where R a and R b are lower alkyl (preferably Me), in the presence of a trialkylaluminum reagent (preferably Me 3 Al) in an inert solvent preferably an aromatic hydrocarbon (e.g., benzene) or an ethereal solvent (e.g., tetrahydrofuran) as taught by the prior art (cf. J. I. Levin, E. Turos, S. M. Weinreb, Synthetic Communications 12:989-993 (1982)). Amides of Formula (C) may be converted to ketones of Formula (CI) by treatment with an organolithium reagent R 25 Li or an organomagnesium halide R 25 MgX, where X=Cl, Br or I, in an inert solvent, preferably an ethereal solvent (e.g., diethyl ether or tetrahydrofuran), as taught by the prior art (cf. S. Nahm and S. M. Weinreb, Tetrahedron Letters 22:3815-3818 (1981)). Alternatively, ketones of Formula (CI) can be prepared from acids of Formula (XCV) by treatment with an organolithium reagent R 25 Li in the presence of an inorganic salt (preferably a transition metal halide (e.g., CeCl 3 )) in an inert solvent (preferably an ethereal solvent (e.g., tetrahydrofuran)) as taught by the prior art (cf. Y. Ahn and T. Cohen, Tetrahedron Letters 35:203-206 (1994)). Alternatively, esters of Formula (XCVI) can be converted directly to ketones of Formula (XCVIII) by reaction with an organolithium reagent R 25 Li or an organomagnesium halide R 25 MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent e.g., diethyl ether or tetrahydrofuran) at temperatures ranging from −100 to 150° C. (preferably −78 to 80° C.) (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985, pp.433-434). Ketones of Formula (XCVIII) can be converted to alcohols of Formula (XCIX) by reaction with an organolithium reagent R 25 Li or an organomagnesium halide R 25 MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent (e.g. diethyl ether or tetrahydrofuran) at temperatures ranging from −100 to 150° C. (preferably −78 to 80° C.) (cf. the above March reference, pp. 434-435). Alternatively, esters of Formula (XCVI) can be converted to alcohols of Formula (XCIX) by reaction with an organolithium reagent R 25a Li or an organomagnesium halide R 25a MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent e.g., diethyl ether or tetrahydrofuran) at temperatures ranging from −100 to 150° C. (preferably −78 to 100° C.), preferably using an excess amount of organometallic reagent (cf. the above March reference, pp. 434-435). In this last instance, R 25 =R 25 . Ketones of Formula (XCVIII) can be converted to alcohols of Formula (C) by treatment with a reducing agent in an inert solvent. Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably sodium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such as lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocarbons of 6 to 10 carbons. Reaction temperatures for the reduction range from about −78° to about 200° C., preferably about 0° to about 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (Advanced Organic Chemistry, pp. 1093-1110).
Compounds of Formula (I) can also be prepared by the procedures outlined in Scheme 23. A compound of Formula (CI) (Formula I, where Z=CR 2 , Y=N, R 3 =(CHR 11 ) p CN) can be reacted with sodium azide and ammonium chloride in a polar solvent at high temperatures (preferably 70 to 150° C.) to give a tetrazole of Formula (CII) as taught by the prior art (cf. R. N. Butler, Tetrazoles, in Comprehensive Heterocyclic Chemistry; A. R. Katritzky, C. W. Rees, Eds.; (New York: Pergamon Press, 1984), pp. 828-832). Such polar solvents may be dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide) or dioxane. A compound of Formula (CIII) (Formula I, where Y=N, Z=CR 2 and R 3 =COCH 3 ) may be treated with a halogenating agent in an inert solvent to give a haloketone of Formula (CIV). Such halogenating agents include bromine, chlorine, iodine, N-halosuccinimides (e.g. N-bromosuccinimide), N-halophthalimides (e.g., N-bromophthalimide) or N-tetrasubstituted ammonium perbromides (e.g., tetraethylammonium perbromide) (cf. the above March reference, Advanced Organic Chemistry, pp. 539-531; S. Kajigaeshi, T. Kakinami, T. Okamoto, S. Fujisaki, Bull. Chem. Soc. Japan 60:1159-1160 (1987) and references cited therein). Inert solvents include lower halocarbons of 1 to 6 carbons and 2 to 6 halogens (preferably dichloromethane or dichloroethane), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane) or aromatic hydrocarbons to 6 to 10 carbons. Haloketones of Formula (CIV) may be converted to imidazoles of Formula (CVII) by treatment with formamide with or without an inert solvent as taught by the prior art (H. Brederick and G. Theilig, Chem. Ber. 86:88-108 (1953)). Alternatively, ketones of Formula (CIII) may be converted to vinylogous amides (CV) by reaction with N,N-di(lower alkyl)formamide di(lower alkyl)acetals (e.g., N,N-dimethylformamide dimethyl acetal) or Gold's reagent ((dimethylaminomethyleneaminomethylene)-dimethylammonium chloride) in an inert solvent with or without base as taught by the prior art (cf. J. T. Gupton, S. S. Andrew, C. Colon, Synthetic Communications 12:35-41 (1982); R. F. Abdulla, K. H. Fuhr, J. Organic Chem. 43:4248-4250 (1978)). Such inert solvents include aromatic hydrocarbons of 6 to 10 carbons, lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, or cyclic ethers of 4 to 10 carbons (preferably dioxane). Such bases may include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Vinylogous amides (CV) can be condensed with hydrazine in an inert solvent to form pyrazoles of Formula (CVI) as taught by the prior art (cf. G. Sarodnick, Chemische Zeitung 115:217-218 (1991); Y. Lin, S. A. Lang, J. Heterocyclic Chem. 14:345 (1977); E. Stark et al., Chemische Zeitung 101:161 (1977); J. V. Greenhill, Chem. Soc. Reviews 6:277 (1977)). Such inert solvents include aromatic hydrocarbons of 6 to 10 carbons, lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, or cyclic ethers of 4 to 10 carbons (preferably dioxane).
The purines and 8-aza-purines of the present invention are readily synthesized following the methods shown in Schemes 24 and 25. The purine (CXI) is derived from an appropriately substituted pyrimidine (CVIII). The trisubstituted hydroxypyrimidine is nitrated under standard conditions with fuming nitric acid. Following conversion of the hydroxy compound to the chloro derivative via treatment with phosphorus oxychloride, reduction of the nitro group with iron powder in acetic acid and methanol yielded the aminopyrimidine (CIIX). Compound CIIX is reacted with the appropriately substituted aniline in the presence of base catalyst to yield an anilinopyrimidine (CX), which was then converted to the desired purine (CXI) via reaction with triethylorthoformate in acetic anhydride. Starting from compound CX, the desired 8-aza-purine can be prepared via reaction with sodium nitrite in acetic acid.
If R 3 of the purine is a chloro group, that substituent can be further elaborated to other R 3 substituents as shown in Scheme 25. Compound (CXII), wherein R 3 is chlorine, is reacted with a nucleophile with or without an inert solvent at temperatures ranging from 20° C. to 200° C., to effect the formation of the 8-azapurine (CXIII). In a similar fashion, the R 3 of an appropriately substituted purine (CXI) may be converted to other functional groups to yield the purine (CXIV) having the desired substitution pattern. Similarly, if R 1 is a chloro group, it may be converted to another functional group via reaction with an appropriate nucleophile. Nucleophiles include amine, hydroxy, or mercapto compounds or their salts.
Compounds of the Formula (I) wherein J, K, and/or L are N, such as (CXXVII), (CXXVIII), (CXXIX), or (CXXX), were prepared according to Schemes 26 and 27. The preparation of the lower ring heterocycle of the compound of the Formula (I) is shown in Scheme 26. 2,4-Dihydroxy-5-nitropyrimidine (CXV) was first converted to the dichloro compound (CXVI) via treatment with phosphorus oxychloride. Compound (CXVI) was then converted to the symmetrically bis-substituted pyrimidines, (CXVII) and (CXVIII), via reaction with the appropriate R 5 or X group radicals, MR 5 and MX, respectively, where M is a metal atom. It is understood that compounds of the Formula (I) wherein R 5 and X have the same definition fall within the scope of this invention. A method of forming the unsymmetrically bis-substituted compounds (CXIX) and (CXX) is treatment of (CXVI) with equimolar amounts of MR 5 and X to form a statistical distribution of products, (CXVII), (CXVIII), (CXIX) and (CXX), which can be purified by standard techniques, such as, recrystallization or chromatography,
The desired (N-pyrimidino-N-alkyl)aminopyrimidines of the present invention were prepared according to Scheme 27. An appropriately substituted 2-hydroxypyrimidine (CXXI) was converted to the 2-chloropyrimidine (CXXII) via treatment with phosphorus oxychloride. The intermediate (N-pyrimidino)aminopyrimidines, (CXXIII), (CXXIV), (CXXV), and (CXXVI), were prepared via treatment of (CXXII) with the appropriate 5-aminopyrimidine, (CXVII), (CXVIII), (CXIX) and (CXX) respectively, in the presence of a base, such as, NaH. Simple alkylation of the amino groups in (CXXIII), (CXXIV), (CXXV), and (CXXVI) via treatment with R 4 I and sodium hydride gave the desired (N-pyrimidino-N-alkyl)aminopyrimidines, (CXXVII), (CXXVIII), (CXXIX), and (CXXX).
The (N-heterocycle-N-alkyl)aminopyrimidines or N-heterocycle-N- alkyl)aminotriazines of the present invention may also be prepared according to Scheme 28. Commercially available amino substituted heterocycles (CXXXI) may be brominated using a tetrasubstituted ammonium tribromide, preferably benzyltrimethylammonium tribromide (BTMA Br 3 ) to yield the appropriately substituted o-bromo-aminoheterocycle (CXXXII). Such reactions are carried out in an inert solvent, such as, lower alcohols or halocarbons of 1 to 4 carbons and 1 to 4 halogens in the presence of a base, such as, alkali metal or alkaline earth metal carbonates. Compound (CXXXII) is then coupled to a substituted pyrimidine or triazine (CXXXIII) to form an (N-heterocycle)aminopyrimidine (CXXXIVa) or (N-heterocycle)aminotriazine (CXXXIVb). (CXXXIVa or b) is then further alkylated in the presence of a base to the target (N-heterocycle-N-alkyl)aminopyrimidine (CXXXVa) or (N-heterocycle-N-alkyl)aminotriazine (CXXXVb), respectively.
The compounds of the invention and their syntheses are further illustrated by the following examples and preparations. All temperatures are in degrees Celsius.
EXAMPLE 1
N-(2-bromo-4-methylphenyl)-N-methyl-4,6-dimethyl-2-pymidinamine
Part A: To 4,6-dimethyl-2-hydroxypyrimidine (37.1 g), cooled in an ice bath was slowly added phosphorous oxychloride (60 mL) and the mixture was stirred at 0° C. for 15 minutes and heated to reflux for 23 hours. The mixture was allowed to cool to room temperature, poured slowly over ice and extracted with diethyl ether (20×100 mL). The combined ether layers were dried over magnesium sulfate and concentrated in vacuo to yield an off-white crystalline solid (19.77 g). The remaining material was subjected to lighter-than-water liquid/liquid extraction using diethyl ether for 19.5 hours to yield additional off-white crystalline solid (3.53 g) after concentration. A total of 23.31 g of 2-chloro-4,6-dimethylpyrimidine was obtained (55% yield).
Part B: To a solution of the product from Part A (2.0 g) in ethylene glycol (80 mL) was added 2-bromo-4-methylaniline (2.6 g, 1 eq) and the mixture was heated to reflux for 4.5 hours. After cooling to room temperature, the mixture was partitioned between water (200 mL) with ethyl acetate (3×100 mL). The ethyl acetate layers were combined, washed with brine, dried over magnesium sulfate, and concentrated under vacuum to yield a brown solid (4.92 g). This product was purified on a silica gel-60 column using 25% ethyl acetate in hexanes as eluent. The intermediate, N-(2-bromo-4-methylphenyl)-4,6-dimethyl-2-pyrimidinamine (3.29 g) was obtained as light tan fine crystals (80% yield).
Part C: To the product from Part B (1.0 g) in dry tetrahydrofuran (40 mL) was added potassium tert-butoxide in 2-methyl-2-propanol (1.0 M, 6.8 mL) and iodomethane (1.0 mL, 5 eq). The mixture was stirred for 72 hours at room temperature. After partitioning between water (50 ml) using ethyl acetate (2×100 ml), the ethyl acetate layers were combined, washed with brine, dried over magnesium sulfate, and concentrated in vacuo to yield a yellow liquid (1.06 g). The crude product was purified on a silica gel-60 column using 15% ethyl acetate in hexanes as eluent. The title compound, as the free base, was obtained as a thick yellow liquid (0.89 g; 85% yield). Anal. Calcd C 14 H 16 BrN 3 : % C, 54.92; % H, 5.27; % N, 13.72; ; % Br: 26.09. Found: % C, 54.61; % H, 5.25; % N, 13.55; % Br; 26.32.
The hydrochloride salt was made using anhydrous hydrogen chloride in diethyl ether; mp 120-121° C.
EXAMPLE 2
N-(2-bromo-4-(1-methylethyl)phenyl)-N-methyl-4,6-dimethyl-2-pymidinamine
Part A: A mixture of the product from Example 1, Part A (2.01 g, 14.01 mmoles), 2-bromo-4-(1-methylethyl)aniline (3 g, 14.10 mmoles) in ethylene glycol (20 mL) was heated to reflux for 1.5 hours. Following cooling to room temperature and partitioning between ethyl acetate (200 mL) and aqueous sodium hydroxide (1 M, 50 mL), the organic layer was washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 5% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4,6-dimethylpyrimidinamine(3.28 g).
Part B: The product from Part A (1.64 g, 5.12 mmoles) was treated with sodium hydride (60% in oil, 0.41 g, 10.25 mmoles) in tetrahydrofuran (10 mL) at 25° C. for 15 minutes and iodomethane (0.82 mL, 13 mmoles) was added. The mixture was stirred at 25° C. for 90 hours and partitioned between ethyl acetate (100 mL) and water (30 mL). The water was extracted with additional ethyl acetate (60 mL) and the combined organic extracts were washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 8% ethyl acetate in hexanes to give the title compound (1.4 g) as the free-base.
The free-base was dissolved in ether (10 mL) and treated with a solution of anhydrous hydrogen chloride in ether (1 M, 6 mL). The precipitated solid was collected and dried under vacuum (mp 163-164° C.).
EXAMPLE 3
N-(2-bromo-4-ethylphenyl)-N-methyl-4,6-dimethyl-2-pypimidinamine
Part A: 2-Bromo-4-acetylacetanilide (2 g, 7.81 mmoles) was dissolved in trifluoroacetic acid (20 mL) and triethylsilane (2.8 mL, 17.5 mmoles) was added. The mixture became warm and was stirred without cooling for 4 h. Then it was basified with conc. NH 4 OH and NaHCO 3 and extracted with EtOAc (2×100 mL). The organic extracts were combined, washed with brine, dried and stripped in vacuo. The residue was >90% clean and directly used in the next step.
Part B: Using the product from Part A and the procedure outlined for Example 1, the desired compound was obtained in good yield.
EXAMPLE 4
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pymidinamine
Part A: A mixture of 2,4-dichloro-6-methylpyrimidine (4 g, 24.54 mmoles), morpholine (2.14 mL, 24.54 mmoles) and N,N-diisopropylethylamine (4.52 mL) in ethanol (60 mL) was stirred at 0° C. for 3 hours, 25° C. for 24 hours, followed by reflux for 1 hour. The solvent was removed under vacuum and the residue was partitioned between ethyl acetate (200 mL) and aq. sodium hydroxide (1 M, 50 mL). The organic layer was washed with water and brine and dried and concentrated in vacuo. The residue was recrystallized from ethyl acetate/hexanes to give 2-chloro-4-morpholino-6-methylpyrimidine (3.8 g).
Part B: The product from Part A (1 g, 4.67 mmoles) and 2-bromo-4-(1-methylethyl)aniline (1 g, 4.67 mmoles) were heated to reflux in ethylene glycol (6 mL) for 1.5 hours. After cooling, the mixture was partitioned between ethyl acetate (100 mL) and aq. sodium hydroxide (1 M, 20 mL). The organic layer was washed with water and brine, dried and concentrated on a rotary evaporator. The residue was chromatographed on silica gel using 25% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4-morpholino-6-methylpyrimidinamine (1.5 g).
Part C: The product from Part B (1.0 g, 2.56 mmoles) was treated with sodium hydride (60% in oil, 0.15 g, 3.75 mmoles) in tetrahydrofuran (10 mL) at 25° C. for 20 minutes, followed by addition of iodoethane (0.32 mL, 4 mmoles). The mixture was stirred at 25° C. for 24 hours and heated to reflux for 5 hours. After partitioning between ethyl acetate (100 mL) and water (20 mL), the organic extract was washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 12% ethyl acetate in hexanes to give the title compound (0.94 g) as the free-base.
The hydrochloride salt of the above title compound was prepared by dissolving the isolate in ether (10 mL) and treating with anhydrous hydrogen chloride in ether (1 M, 4 mL). The precipitated solid was collected and dried under vacuum (mp 219-222° C.).
EXAMPLE 5
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6dimethyl-2-pyrimidinamine
Part A: To a solution of 2-bromo-4-(1-methylethyl)aniline (6 g, 28.2 mmoles) and cyanamide (4.7 g, 112.08 mmoles) dissolved in ethyl acetate (100 mL) and ethanol (13 mL) was added hydrogen chloride in ether (1 M, 38 mL, 38 mmoles) and the mixture was stirred at 25° C. for 1 hour. The volume of the reaction was reduced by 75 mL by distillation. The residue was heated to reflux for 3 hours and after cooling, ether (120 mL) was added. The precipitated solid, 2-bromo-4-(1-methylethyl)phenylguanidinium hydrochloride, was collected and dried (10.4 g), and was used in the next reaction without purification.
Part B: A mixture of the product from Part A (5.0 g, 13.47 mmoles), potassium carbonate (1.86 g, 13.47 mmoles) and 2,4-pentanedione (2.8 mL, 27.28 mmoles) in N,N-dimethylformamide (35 mL) was heated to reflux for 24 hours. After cooling, the reaction was partitioned between ethyl acetate (120 mL) and aq. sodium hydroxide (0.5 M, 100 mL). The aqueous layer was extracted with additional ethyl acetate (120 mL) and the combined organic extracts were washed with water, brine, dried and concentrated in vacuo. The residue was chromatographed on silica gel eluting with 8% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4,6-dimethylpyrimidinamine (3.37 g).
Part C: The product isolated from Part B (3.0 g, 9.37 mmoles) was alkylated with sodium hydride and iodoethane in tetrahydrofuran in an analogous manner to that described for Example 4, Part C. The title compound was isolated as the free-base (2.88 g).
The hydrochloride salt was prepared in a manner analogous to that of Example 4 using hydrogen chloride in ether, to give a solid, mp 151-153° C.
EXAMPLE 6
N-ethyl-N-(2-bromo-4-(2-methoxyethyl)phenyl)4-morpholino-6-methyl-2-pyrimidinamine
Part A: To 4-Hydroxyethylaniline, 16.55 g (0.12 moles) in a mixture of pyridine (23 mL, 0.29 moles) and CH 2 Cl 2 (100 mL) cooled to 0° C. was added acetyl chloride (18.8 mL, 0.26 moles) dropwise. The mixture was stirred at 0° C. for 2 h and at 25° C. for 48 h and then added to saturated NaHCO 3 solution (100 mL). The CH 2 Cl 2 was separated, washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 25% and 1:1 EtOAc/hexanes to give the product (24 g, 90% yield).
Part B: 4-Acetoxyethylacetanilide was brominated according to the method described in Org. Synth. Coll . Vol I, 111, wherein the anilide (14 g, 63 mmoles) was dissolved in glacial acetic acid (70 mL) and bromine (4 mL, 77.4 mmoles) was added dropwise. The resulting solution was stirred at 25° C. for 60 hours. A solution of sodium sulfite (20 mL) was then added, followed by H 2 O (200 mL) and the precipitated bromide was isolated by filtration. The filtrate was further diluted with H 2 O (300 mL) and cooled to give an additional amount of bromide. The isolated bromide was heated to reflux in HCl solution (6M, 100 mL) for 2 h and the resulting mixture was neutralized with solid NaHCO 3 and extracted with EtOAc (2×160 mL each). The combined EtOAc extracts were washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the product (2.8 g) in 20% yield for the two steps.
Part C: 2-Bromo-4-hydroxyethylaniline (1.6 g, 7.3 mmoles) and 2-chloro-4,6-dimethylpyrimidine (1.1 g, 7.3 mmoles) were reacted in ethylene glycol (6 mL) at reflux for 1.5 h. After cooling the mixture was partitioned between EtOAc (100 mL) and NaOH solution (0.5M, 25 mL). The aqueous layer was extracted with additional EtOAc (50 mL) and the combined organic extracts were washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the product (1.3 g) in 64% yield.
Part D: The product from Part C (1.39 g, 4.77 mmoles) was dissolved in dry CH 2 Cl 2 (30 mL) and 3,4-dihydro-2H-pyran (1.65 mL, 11.98 mmoles) was added, followed by conc. sulfuric acid (Conc. H 2 SO 4 , 0.2 mL). The mixture was stirred at 25° C. for 60 h and solid KpCp, (1 g) was added, followed by saturated NaHCO (50 mL), The mixture was partitioned be tween EtOAc (120 mL) and NaHCO 3 solution (20 mL). The EtOAc was washed with brine, dried, and stripped in vacuo. The dried crude product, dissolved in dry THF (15 mL) was treated with sodium hydride (60% in oil, 380 mg) at 25° C. for 15 min and then iodoethane (1 mL, 9.45 mmoles) was added.
The mixture was stirred at 25° C. for 12 h and heated to reflux for 4 h. Then it was partitioned between EtOAc (120 mL) and H 2 O (20 mL). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 15% EtOAc/hexanes to give the product (1.6 g) in 78% yield for the two steps.
Part E: The product from Part D was dissolved in MeOH (20 mL) and conc. H 2 SO 4 (0.4 mL) was added, followed by HCl in ether (1M, 1.5 mL). The mixture was stirred at 25° C. for 2 h, quenched with solid K 2 CO 3 (1 g), and partitioned between EtOAc (100 mL) and NaHCO 3 solution (30 mL) and NaOH solution (2 mL, 2 M). The H 2 O layer was extracted with additional EtOAc (60 mL) and the combined EtOAc extracts were washed with brine, dried, and stripped in vacuo. The residue was chromatographed on silica gel using 40% EtOAc/hexanes to give the product (1.23 g) in 95% yield.
Part F.: The product from Part E (720 mg, 2.06 mmoles) was treated with NaH (60% in oil, 120 mg, 3 mmoles) in THF (10 mL) at 0° C. for 5 min and at 25° C. for 15 min. lodomethane (0.25 mL, 4 mmoles) was added and the resulting mixture was stirred at 25° C. for 20 h. The reaction was partitioned between EtOAc (100 mL) and H 2 O (25 mL). The EtOAc was washed with brine, dried, and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (680 mg) (91% yield), which was converted into the hydrochloride salt by treatment with 1 M HCl/ether, mp 117-118.5° C.
EXAMPLE 7
N-Ethyl-N-(2-iodo4-(1-methylethyl)phenyl)4-morpholinyl-6-methyl-2-pyrimidinamine
A solution of the free-based Example 4 (1.4 g, 3.34 mmoles) dissolved in tetrahydrofuran (15 mL) at −78° C. was treated with n-butyllithium (1.6 M in hexanes, 3.3 mL, 3.7 mmoles). After stirring 15 minutes, a solution of iodine (1.0 g, 4 mmoles) in tetrahydrofuran (5 mL) was added dropwise and the mixture was stirred at −78° C. for an additional 30 minutes before warming to 25° C. The reaction was partitioned between ethyl acetate (100 mL) and sodium bisulfite solution (satd., 20 mL). The ethyl acetate layer was washed with water, brine, dried and concentrated in vacuo. The residue was chromatographed on silica gel using 15% ethyl acetate in hexanes as eluent to give the title compound (0.9 g) as a solid, mp 96-98° C.
EXAMPLE 8
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(2-thienyl)-2-pyrimidinamine
Part A: 2-Chloropyrimidine (2.0 g) was dissolved in diethyl ether (50 mL) and chilled to −30° C. A solution of methyllithum in ether (1.4 molar, 15 mL) was slowly added and the reaction was stirred at −30° C. for 30 minutes, then at 0° C. for an additional 30 minutes. A mixture of acetic acid (glacial, 1.2 mL), water (0.5 mL) and tetrahydrofuran (5 mL) was added to quench the reaction. 2,3-Dichloro-5,6-dicyano-1,4-benzoquinone (4.79 g) in tetrahydrofuran (20 mL) was then added and the reaction was allowed to stir for 5 minutes at room temperature. The mixture was chilled to 0° C. and aqueous sodium hydroxide solution (3 M, 50 mL) was added and the reaction mixture allowed to stir for 10 minutes. The organic layer was separated and washed with water and dried with magnesium sulfate. The solvent was removed in vacuo and the resulting residue chromatographed on silica gel (solvent 30% ethyl acetate in hexanes; R f 0.4) to yield 2-chloro-4-methylpyrimidine (1.4 g), m.p. 48-50° C.
Part B: To thiophene (0.66 g) in dry ether (25 mL) at 0° C. was added n-butyl lithium in hexanes (1.6 M, 2.7 mL) and the reaction was stirred at 0° C. for 15 minutes. After cooling to −30° C., a solution of 2-chloro-4-methylpyrimidine (1.0 g) in ether (10 mL) was slowly added and the reaction was stirred at −30° C. for 30 minutes and at 0° C. an additional 30 minutes before quenching with a mixture of acetic acid (glacial, 0.45 mL), water (0.5 mL) and tetrahydrofuran (1.0 mL). 2,3-Dichloro-5,6-dicyano-1,4-benzoquinone (1.77 g) in tetrahydrofuran (5 mL) was added and the reaction mixture was stirred at room temperature for 5 minutes, then cooled to 0° C. before aq. sodium hydroxide solution (3 M, 50 mL) was added. The organic layer was separated, washed with water, and dried with magnesium sulfate. The solvent was evaporated and the resultant crude oil was chromatographed on silica gel (30% ethyl acetate in hexanes; R f 0.55) to yield 2-chloro-4-methyl-6-(2-thienyl)pyrimidine (0.21 g). Anal. Calcd: % C, 51.46; % H, 3.33; % N, 13.33. Found: % C, 51.77; % H, 3.35; % N, 12.97.
Part C; 2-Bromo-4-(1-methylethyl)aniline (0.26 g) and 2-chloro-4-methyl-6-(2-thienyl)pyrimidine (0.21 g) in ethylene glycol were heated at reflux for 24 hours. The reaction mixture was diluted with ethyl acetate, washed with aq. sodium hydroxide solution (10% , 3×100 mL) and the organic phase was dried. Solvent removal gave a crude brown oil, which was purified on silica gel using 20% ethyl acetate in hexanes (R f 0.5) as eluent to provide N-(2-bromo-4-isopropylphenyl)-4-methyl-6-(2-thienyl)-2-pyrimidinamine (0.1 g) as a solid, mp 98-101° C. Mass spec (NH 3 -CI/DDIP): 390 (M+H) 30 .
Part D: The product from Part C (0.1 g) was slowly added to a solution of sodium hydride (50 mg) in dry tetrahydrofuran, after which iodoethane (0.1 g) was added and the mixture was refluxed for 24 hours. The reaction mixture was cooled and water (0.5 mL) was added. The solvent was evaporated and the crude material was taken up in ethyl acetate, washed with water (3×50 mL) and dried. The solvent was evaporated and the crude product chromatographed on silica gel using 10% ethyl acetate in hexanes (R f 0.5) to give the title compound (70 mg) as the free-base.
The HCl salt of this material was prepared using the procedure reported above; mp 95-97° C.; Mass spec. (NH 3 -CI/DDIP): 417 (M+H) + . Anal. Calcd for C 20 ,H 22 N 3 BrS.HCl: % C, 53.10; % H, 5.09; % N, 9.51. Found: % C, 53.78; % H, 5.22; % N, 9.10.
EXAMPLE 9
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-cyclopropylmethyl-4,6-dimethyl-2-pyrimidinamine)
By analogy to Example 2 the title compound was prepared by substituting 2-bromo-4-(1-methylethyl)aniline (4.0 g) and 2-chloro-4,6-dimethylpyrimidine in Part A, to give the desired pyrimidinamine intermediate, Mass spec. (NH 3 -CI/DDIP): 321 (M+H) + . By substituting (bromomethyl)cyclopropane in Part B of this same Example, the desired material was obtained, Mass spec. (NH 3 -CI/DDIP): 374 (M+H) + .
The hydrochloride salt of this free base was prepared, mp 146-148° C.
EXAMPLE 10
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-propargyl4,6-dimethyl-2-pyrimidinamine
By using 2-(2-bromo-4-(1-methylethyl)anilino)-4,6-dimethylpyrimidine and substituting propargyl chloride in Example 9, the title compound was isolated as the free-base, Mass spec. (NH 3 -CI/DDIP): 358 (M+H) + .
The hydrochloride salt of the free base was prepared.
EXAMPLE 11
N-Ethyl-N-(2-iodo4-(2-methoxyethyl)phenyl)4,6-dimethyl-2-pyrimidinamine, hydrochloride
Part A: 4-Hydroxyethylaniline was iodinated in a manner analogous to that described in Example 6 in conjunction with that reported in Tet. Lett. 33:373-376 (1992). The aniline (2 g, 14.58 mmoles) was dissolved in CH 3 CN (25 mL) and H 2 O (15 mL) containing NaHCO 3 (1.68 g, 20 mmoles) was added. The mixture was cooled to 12-15° C. by addition of ice and iodine (3.9 g, 15.35 mmoles) was added. The mixture was stirred at 25° C. for 16 h and then it was partitioned between EtOAc (100 mL) and NaOH solution (20 mL, 1M). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give 1.8 g product, a 47% yield.
Part B: The product from Part A (6.3 g, 23.94 mmoles) was dissolved in a mixture of EtOAc (100 mL) and EtOH (10 mL) and cyanamide (4.7 g, 112.5 mmoles) was added, followed by HCl in ether (31 mL, 1 M). The flask was fitted with a distillation head and 50 mL solvent was distilled off. The residual mixture was diluted with EtOH (15 mL) and heated to reflux for 5 h. After cooling, Et 2 O (100 mL) was added and the precipitated salt was washed with EtOAc and dried to give the product (4.5 g) in 55% yield.
Part C: The guanidinium salt from Part B (8.53 g, 24.95 mmoles), potassium carbonate (3.84 g, 27.72 mmoles) and 2,4-pentanedione (9 mL, 42.65 mmoles) were heated to reflux in DMF (70 mL) for 16 h. The reaction mixture was partitioned between EtOAc (150 mL) and H 2 O (50 mL) and the organic layer was washed with H 2 O (2×80 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the product (2.8 g) in 30% yield.
Part D: To the product from Part C (3.3 g (8.93 mmoles) in CH 2 Cl 2 (60 mL) and 3,4-dihydro-2H-pyran (3.1 mL, 22.7 mmoles) was added Conc. H 2 SO 4 (0.5 mL) and the mixture was stirred at 25° C. for 16 h. An additional portion of H 2 SO 4 (0.2 mL) was added and stirring was continued for 3 h. EtOAc (100 mL) and saturated NaHCO 3 (100 mL) was added and the layers separated. The aqueous layer was extracted with additional EtOAc (100 mL) and the combined organic extracts were washed with NaHCO 3 , brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (1.2 g) in 31% yield.
Part E: The product from Part D was dissolved in dry THF (15 mL) and NaH (60% in oil, 220 mg, 5.5 mmoles) was added. The mixture was stirred at 25° C. for 15 min and iodoethane (0.5 mL, 5.7 mmoles) was added. The mixture was stirred at 25° C. for 16 h and then heated to reflux for 2 h. The reaction product was then partitioned between EtOAc (100 mL) and H 2 O (30 mL). The organic layer was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 10% EtOAc/hexanes to give the product (1.1 g). This material was dissolved in MeOH (20 mL). HCl in ether (3 mL, 1M) was added and the mixture was stirred at 25° C. for 2 h. Then it was partitioned between EtOAc (100 mL) and NaOH (30 mL, 1 M). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was used in the next step without purification.
Part F: The product from Part E (950 mg, 2.4 mmoles) in dry THF (10 mL) was treated with NaH (60% in oil, 140 mg, 3.5 mmoles), stirred at 25° C. for 15 min and 0.25 mL lodoethane (4 mmoles) was added. The resulting mixture was stirred at 25° C. for 16 h and then partitioned between EtOAc (100 mL) and H 2 O (20 mL). The organic layer was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (500 mg), which was converted into the hydrochloride salt in the usual manner, mp 129-131° C.
EXAMPLE 12
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pymidinamine
Part A: The product from Example 8, Part A (0.2 g) and 2-bromo-4-(1-methylethyl)aniline were coupled using the same method described in Example 8, Part C to provide N-(2-bromo-4-(1-methylethyl)phenyl)-4-methyl-2-pyrimidinamine (0.7 g) as a viscous oil; Mass spec. (NH 3 -CI/DDIP): 307 (M+H).
Part B: The product from Part A was alkylated with iodoethane using the same method described in Example 8, Part D to give the desired N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pyrimidinamine (0.3 g) as the free base.
The hydrochloride salt of this material was prepared in the usual manner; mp 145-147° C. Mass spec. (NH 3 -CI/DDIP). 334 (M+H) + .
EXAMPLE 13
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(N-methyl-2-hydroxyethlamino)-2-pyrimidinamine
Part A: A solution of 2,4-dichloro-6-methylpyrimidine (1.0 g) and 2-(methylamino)ethanol (0.4 g) in ethanol (50 mL) was refluxed for 24 hours. The solvent was evaporated to give a crude residue, which was chromatographed on silica gel using 5% methanol in chloroform to yield 2-chloro-4-methyl-6-(N-methyl-2-hydroxyethylamino)pyrimidine (370 mg).
Mass spec. (NH 3 -CII/DDIP): 202 (M+H) + .
Part B: The hydroxyl group in the product from Part A was protected as the methoxymethyl ether (MOM-ether) using N,N-di(1-methylethyl)ethylamine and bromomethyl methyl ether (0.35 g) in dry tetrahydrofuran to provide the protected adduct (310 mg, Mass spec. 246 (M+H) + ), which was carried on without purification.
Part C: The protected MOM-ether was coupled with 2-bromo-4-(1-methylethyl)aniline using the procedure of Example 8, Part C. Under these conditions, the methoxymethyl protecting group was also removed providing N-(2-bromo-4-(1-methylethyl)phenyl)-4-methyl-6-(N-methyl-2-hydroxyethylamine)-2-pyrimidinamine (mass spec. NH 3 -CI/DDIP 379 (M+H) + ). This hydroxyl group was reprotected for subsequent reactions as described in Part B, (Mass spec. for MOM-ether (NH 3 -CI/DDIP): 453 (M+H) + ). Alkylation with iodoethane was carried out using the method of Example 8, Part D. The MOM-ether was deprotected by stirring at room temperature in a solution of methanol (5 mL) and hydrochloric acid (1 M, 5 mL) for 24 hours. Upon workup and isolation, the title compound was obtained as the free-base.
The hydrochloride salt was prepared using the described procedure. High Res. Mass Spec; 407.144640 (M+H) + ; Expected 407.144648 (M+H) + .
EXAMPLE 14
N-ethyl-N-(2-iodo4-(1-methylethyl)phenyl)4-thiomorpholino-6-methyl-2-pyrimidinamine, S-oxide
The desired product was obtained by sodium periodate oxidation of the product of Example 22, according to the method of J. H. Bushweller et. al. J. Org. Chem. 54:2404, (1989).
EXAMPLE 15
N-(2-Bromo-4-(isopropoxy)phenyl)-N-ethyl-4,6dimethyl-2-pymidinamine
Part A: The synthesis of 2-bromo-4-isopropoxy-aniline was accomplished using the bromination procedure for 4-isopropoxy-aniline reported by Kajigaeshi et al. in Bull. Chem. Soc. Jpn. 61:597-599 (1988). The aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of MeOH:CH 2 Cl 2 (2:5) for one hour. The solids were removed by filtration and the filtrate was evaporated under vacuum. The residue was taken up in H 2 O and this mixture was then extracted three times with CH 2 Cl 2 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 15% EtOAc in hexanes. (R f =0.43)
Part B: Using the procedure for Example 1, Parts B-C and substituting the aniline from Part A, the title compound was obtained.
EXAMPLE 16
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(4-morpholinylcarbonyl)-2-pyrimidinamine
To sodium hydride (60% in oil, 0.24 g, 6.0 mmol) suspended in anhydrous THF (10 mL) was added morpholine (0.52 g, 6.0 mmol) with stirring; the reaction mixture was warmed to reflux temperature and stirred for 1 hour. The reaction mixture was then cooled to ambient temperature and 2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-carbomethoxy-6-methyl-pyrimidine (2.0 g, 5.1 mmol) was added. Stirring was continued for 26 hours. The reaction mixture was then poured onto a 1N NaOH solution, stirred and extracted three time with EtOAc. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo. Column chromatography (Et 2 O) afforded the title compound as a solid (900 mg, 39% yield): mp 145° C.; NMR (CDCl 3 , 300 MHz):d 7.5 (d, 1H, J=1), 7.2 (dd, 1H, J=7,1), 7.1 (d, 1H, J=7), 6.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.3 (m, 11H), 3.1-3.0 ( m, 1H), 2.9 (septet, 1H, J=7), 1.3 (d, 6H, J=7), 1.15 (t, 3H, J=7); Anal. (C 21 H 27 BrN 4 O 2 ) Calcd: C, 56.38; H, 6.08; N, 12.52; Br, 17.86; Found: C, 56.07; H, 6.05; N, 12.29; Br, 18.08.
EXAMPLE 17
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(4-morpholinylmethyl)-2-pyrmidinamine
A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(4-morpholinylcarbonyl)-2-pyrimidinamine (750 mg, 1.72 mmol) in anhydrous THF (1.4 mL) was stirred at ambient temperature under a nitrogen atmosphere. A solution of borane in THF (1 M, 3.6 mL, 3.6 mmol) was added dropaise. The reaction mixture was then warmed to reflux temperature and stirred for 20 hours. After cooling to room temperature, acetic acid (3.5 mL) was added slowly and the mixture was heated to reflux temperature and stirred for 30 min. After being cooled to ambient temperature, the reaction mixture was poured onto a 3N NaOH solution, mixed and extracted three times with EtOAc. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo. Column chromatography (EtOAc) of the residue afforded the title compound as an oil (300 mg, 39% yield, R f 0.3): NMR (CDCl 3 , 300 MHz): d 7.5 (s, 1H), 7.2 (d, 1H, J=7), 7.15 (d, 1H, J=7), 6.5 ( s, 1H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 7H), 3.5-3.3 (m, 2H),2.9 (septet, 1H, J=7), 2.55-2.35 (br m, 3H), 2.35-2.25 ( m, 2H), 1.3 (d, 6H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: calcd: 433.1603 (M+H), found: 433.1586.
EXAMPLE 18
Methyl 2-((2-bromo-4-(1-methylethyl)phenyl)ethylamino)-6-methyl-4-pyrimidinecarboxylate
To sodium hydride (60% in oil, 4.8 g, 120 mmol) in THF (150 mL) at ambient temperature under a nitrogen atmosphere was added methyl-2-((2-bromo-4-(1-methylethyl)phenyl)amino)-6-methyl-4-pyrimidinecarboxylate (42.8 g, 118 mmol) portionwise over 30 min. After the gas evolution subsided, iodoethane (31.2 g, 16 mL, 200 mmol) was added in one portion and the reaction mixture was heated to a gentle reflux for 24 h. After cooling to room temperature, the reaction mixture was quenched carefully with water and extracted three times with ethyl acetate. The combined organic extracts were washed with water twice, dried over magnesium sulfate and filtered. Solvent was removed in vacuo to afford a brown oil. Column chromatography of the oil (Et 2 O:hexanes::1:1) provided two fractions: (1) methyl-2-((2-bromo-4-(1-methylethyl)phenyl)amino)-6-methyl-4-pyrimidinecarboxylate (4.6 g, 11% yield, R f =0.8) and (2) the title product (20 g, R f =0.7) as a crude oil. The title product was recrystallized from hexanes and dried in vacuo to give a solid (18.0 g, 39% yield): mp 81-82° C.: NMR(CDCl 3 , 300 MHz):d 7.5 (br s, 1H), 7.25 (d, 1H, J=7), 7.15 (d, 1H, J=7), 7.1 (s, 1H), 4.3-4.1 (m, 1H), 4.05-3.75 (m, 4H), 2.95 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.25 (t, 3H, J=7); CI-HRMS: calcd: 392.0974 (M+H), found: 392.0960.
EXAMPLE 19
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(4-methylpiperazinylcarbonyl)-2-pyrimidinamine
Using a method analogous to that used for Example 16, but substituting 4-methylpiperazine, the desired product was obtained; mp 81-82° C.
EXAMPLE 20
N-(2-Bromo-4-(2-hydroxyethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The THP-hydroxyl protecting group was removed using HCl in ether product as described earlier to arrive at the title compound; mp 58-60° C.
EXAMPLE 21
N-ethyl-N-(2-methoxy4-(1-methylethyl)phenyl)4,6-dimethyl-2-pyimidinamine
Part A: Using the method of Example 1 and substituting 2-amino-5-methylphenol, the intermediate secondary amine was obtained.
Part B: By double methylating the amino and the phenol groups using excess sodium hydride and iodomethane in THF, the desired product was obtained.
EXAMPLE 22
N-ethyl-N-(2-iodo4-(1-methylethyl)phenyl)4-thiomorpholino-6-methyl-2-pyrimidinamine
Using the iodination method of Example 11 and the general synthesis described in Example 4 the desired compound was obtained; mp 51-53° C.
EXAMPLE 23
N-[2-bromo-4-(1-methylethyl)phenyl]-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5-triazin-2-amine
Part A: Methyl magnesium bromide (300 mmole, 3M in ether, Aldrich) was added dropwise over a 10 min period to a solution of cyanuric chloride (12.9 g, 69.9 mmole) in CH 2 Cl 2 (300 mL) under N 2 at −20° C. and stirring was continued at −20° C. for 4.5 hours. Water (36 mL) was added dropwise while keeping the reaction temperature below −15° C. The reaction mixture was allowed to reach room temperature and magnesium sulfate (40 g) was added. It was let stand for one hour. The reaction mixture was filtered and the solvent removed leaving a yellow solid (11.06 g). This material was purified using flash chromatography (CH 2 Cl 2 , silica) and gave 2,4-dichloro-6-methyl-s-triazine as a white solid (7.44 g) in 65% yield.
Part B: 2,4-dichloro-6-methyl-s-triazine (3 g, 18.29 mmol), 2-bromo-N-ethyl-4-isopropylaniline (6.07 g, 25.07 mmol) and diisopropylethylamine (3.2 g, 25.07 mmol) in dioxane (60 mL) under N 2 were heated at reflux for three hours. The solvent was removed and the residue was purified using flash chromatography (CH 2 Cl 2 , silica) to provide the product (4.58 g) as a clear oil in 68% yield.
Part C: The product from Part B (500 mg, 1.35 mmol) was dissolved in dioxane (20 mL) under N 2 at room temperature and morpholine (247 mg, 2.84 mmol) was added in one portion. Stirring was continued at room temperature for 17 hours. The reaction solvent was stripped away and the residue was triturated with ethyl acetate/hexane (1:3). The triturated material was purified using flash chromatography (EtOAc/hexane, 1:3 Silica). The product was collected as a clear oil (550 mg) in 97% yield. C 19 H 26 N 3 OBr
EXAMPLE 24
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-m ethyl-6-(hydroxymethyl)-2-pyrimidinamine
The product of Example 18 and lithium borohydride (1.5 eq.) were stirred in dry THF under nitrogen for fifty hours. The reaction was then poured into water and extracted three times with CHCl 3 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum to give a nearly quantitative yield of the product as a light yellow oil.
EXAMPLE 25
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(methoxymethyl)-2-pyrimidinamine
To the product of Example 24 and sodium hydride (1.1 eq.) in dry THF under nitrogen was added iodomethane (1.1 eq.) and after four hours the reaction was poured into H 2 O and extracted three times with CHCl 3 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum. The material was purified by chromatography on silica gel using 10% EtOAc in hexanes to give a light yellow oil. (R f =0.37)
Example 26
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine
Part A: 2-Bromo-4-isopropylaniline (8.9 g, 42 mmol) and 6-hydroxy-4-methyl-2-thiomethylpyrimidine (5 g, 32 mmol) were combined under N 2 and heated at 190° C. for 8 hours. The reaction mixture was cooled to room temperature. The residue was purified using flash chromatography (CH 2 Cl 2 /MeOH, 25:1, silica) to provide 9.16 g (89% yield) white solid.
Part B: The product from Part A (6 g, 18.6 mmol) and phosphorus oxychloride (20 mL, 214 mmol) were refluxed under N 2 for 15 minutes. The reaction mixture was cooled to room temperature, slowly poured onto ice (200 g), stirred about 30 minutes until the ice had melted, and the aqueous mixture was extracted with ethyl acetate (3×100 mL). The combined organic extracts were treated with water (100 mL) and brine (100 mL), dried over anhydrous sodium sulfate, filtered and stripped leaving 6.1 g tan oil. This material was purified using flash chromatography (CH 2 Cl 2 /hexane, 1:1, silica) to give 4.48 g (70% yield) of clear oil.
Part C: To the product of Part B (4.3 g, 12.65 mmol) in dimethylformamide (30 mL) under N 2 was added sodium hydride (658 mg, 16.45 mmol, 60% dispersion in oil) was added in small portions. After addition was complete, stirring was continued 4 hours at room temperature. Water (100 mL) was added to the reaction mixture and it was extracted with ethyl acetate (3×100 mL). The combined organic extracts were treated with water (100 mL) and brine (100 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 4.8 g tan oil. This material was purified using flash chromatography (EtOAc/hexane, 1:6, silica gel) to afford 4.4 g (95% yield) of oil.
Part D: The product of Part C (2 g, 5.4 mmol) and sodium thiomethoxide (558 mg, 7.6 mmol) in dioxane (50 mL) under N 2 were heated to reflux (20 hrs.). The solvent was stripped and the residue was purified using flash chromatography (CH 2 Cl 2 /hexane, 1:1, silica) to give 1.86 g (91% yield) of clear oil. Analysis: MS (NH3—CI/DDIP) : 380 (M+H) + .
EXAMPLE 27
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, dioxide
To the product of example 26 (1.8 g=4.8 mmol) in CH 2 Cl 2 (100 mL) under N 2 was added 3-chloroperbenzoic acid (3.16 g, 14.67 mmol, 80-85% purity) in small portions and after addition, stirring was continued for 30 minutes. Unreacted peroxide was consumed using 10% sodium sulfite (5 mL), and the reaction mixture was diluted with CH 2 Cl 2 (150 mL) followed by washing with 5% sodium bicarbonate (100 mL) and brine (100 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 2.19 g yellow oil. This material was purified using flash chromatography (CH 2 Cl 2 , silica) to provide 1.6 g of oil (79% yield). MS (NH3-CI/DDIP): 412 (M+H) + .
EXAMPLE 28
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, S-oxide
To Example 26 product (770 mg, 2 mmol) in methanol (200 mL) was added sodium periodate (648 mg, 3 mmol) in water (10 mL) in one portion and the reaction mixture was refluxed 28 hours. The reaction solvent was stripped away and the residue was partitioned between ethyl acetate (200 mL) and water (50 mL). The organic layer was separated and treated with brine (50 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 820 mg tan residue. This material was purified using flash chromatography (EtOAc/hexane, 1:1, silica) to afford 570 mg (71% yield) of oil. MS (NH3-CI/DDIP) : 396 (M+H) + .
EXAMPLE 29
N-[2-bromo-4(1-methylethyl)phenyl]-N-ethyl-4-methyl-6-benzyloxy-1,3,5 triazin-2-amine
Benzyl alcohol (197 mg, 1.82 mmol, 1.2 eq) was added slowly to a solution of NaH (73 mg 60% dispersion, 1.82 mmol) in dry DMF and stirred at room temperature for 15 minutes. The product from Part B (560 mg, 1.52 mmol) was then added and the resulting mixture stirred at room temperature for 2 hours, The reaction mixture was then poured into water and extracted three times with ethyl acetate. The organic layer was dried over magnesium sulfate, filtered and concentrated in vacuo. The crude oil was chromatographed on silica using 20% ethyl acetate in hexanes as solvent to afford the title compound. C 22 H 25 N 4 OBr Calcd: C, 55.46; H, 5.46; N, 11.76; Found: C, 55.30; H, 5.41; N, 12.02.
EXAMPLE 30
N-[2-iodo-4-dimethylhydroxymethylphenyl]-N-ethyl-4-6-dichloro-1,3,5 triazin-2-amine
Part A: Ethyl 4-aminobenzoate (5.0 gr, 30.27 mmol) and sodium bicarbonate (3.81 g, 45.40 mmol, 1.5 eq.) were added to a 50:50 mixture of methylene chloride and water. The mixture was chilled to 0 degrees and I 2 , (11.53 g, 45.40 mmol, 1.5 eq.) was added slowly. The reaction mixture was allowed to come to room temperature and was stirred for 72 hours. The layers were then separated and the aqueous layer washed with methylene chloride. All organics were combined and dried over magnesium sulfate, filtered and concentrated in vacuo. The resulting oil was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford ethyl 3-iodo-4-aminobenzoate. C 9 H 10 NO 2 I MS 292 (M+H) + 309 (M+NH 4 ) + .
Part B: The product from part A (1.0 g, 3.4 mmol) was added to a stirring solution of NaH (0.21 gr, 5.2 mmol) in 25 mL of dry DMF and allowed to stir at room temperature for 10 minutes. Ethyl iodide (0.8 g, 5.2 mmol) was then added and the mixture was allow to stir for 24 hours. The reaction was then poured into water and extracted with ethyl acetate. The organic layer was dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford ethyl 3-iodo-4-(N-ethyl)aminobenzoate. C 11 H 14 NO 2 I MS 320(M+H) + .
Part C: The product from part B (0.32 g, 1.0 mmol) was dissolved in dioxane and cyanuric chloride (0.18 g, 1.0 mmol) was added slowly. The reaction was heated to reflux for 4 hours, stirred at room temperature for 24 hours, then poured into water and extracted with ethyl acetate. The organic layer was dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 10% ethyl vacuo. The crude material was chromatographed on silica using 10% ethyl acetate in hexanes as solvent to afford N-[2-iodo-4-ethylcarboylate]-N-ethyl-4-6-dichloro-1,3,5triazin-2-amine. C 14 H 13 N 4 O 2 C 2 I MS 467 (M+H) + .
Part D: The product of part C (0.26 g, 0.6 mmol) was dissolved in 20 mL methylene chloride and chilled to −20 degrees. Methyl magnesium slowly. The reaction was allowed to come to room temperature and stirred for 4 hours, then poured into water and the layers were separated. The aqueous layer was extracted with methylene chloride and the organic layers combined, dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica gel using 30% ethyl acetate in hexanes as solvent to afford the title compound. C 15 H 18 N 4 OICl MS 453 (M +H) + .
EXAMPLE 31
N-(2-iodo4-(1-methylethyl)phenyl)-N-allyl4-morpholino-6-methyl-2-pyrimidinamine
mp 109-112° C. Elemental analysis for C 21 H 27 N 4 IO HCl: Theory C, 48.99; H, 5.48; N, 10.88; I, 24.65; Cl, 6.89. Found C, 48.81; H, 5.43; N, 10.59, I, 24.67; Cl, 6.86.
EXAMPLE 32
N-(2-iodo4-(1-methylethyl)phenyl)-N-ethyl-4-chloro-6-methyl-2-pyrimidinamine
Guanidine 39.5 mmoles crude, obtained by treatment of the corresponding guanidinium salt with K 2 CO 3 , 15 mL (118 mmoles) ethyl acetoacetate and 2.0 g (14.47 mmoles) K 2 CO 3 were heated to reflux in 120 mL absolute ethanol for 100 hr. Then the solvent was stripped in vacuo and the residue was chromatographed on silica gel using 40% EtOAc/hexanes as eluent to give 4 g product, a 27% yield for the three steps.
The 4-hydroxypyrimidine obtained from the above reaction (2.47 g, 6.69 mmoles) was dissolved into 20 mL POCl 3 and stirred at 25° C. for 4 hr. The reaction mixture was poured into ice, stirred for 30 min, and extracted with 100 mL EtOAc. The EtOAc extract was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 1.64 g of the corresponding 4-chloropyrimidine (63% yield).
1.6 g (4.13 mmoles) 4-chloropyrimidine obtained above, and 0.33 g (8.25 mmoles) of NaH (60% in oil) in 10 mL dry DMF at 25° C. were stirred together for 15 min. Then 0.7 mL (8.75 mmoles) of EtI was added and the reaction was stirred at 0° C. for 2 h and at 25° C. for 16 h. It was then partitioned between 100 mL EtOAc and 25 mL water and the EtOAc was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 8% EtOAc/hexanes to give 1.2 g product as a viscous liquid (70% yield); elemental analysis for C 16 H 19 N 3 ClI: Theory: C, 46.23; H, 4.61; N, 10.11; Cl, 8.53; I, 30.53. Found: C, 46.36; H, 4.57; N, 9.89; Cl, 8.79; I, 30.38.
EXAMPLE 33
N-(2-methylthio4-(1-methylethyl)phenyl)-N-ethyl-4(S)-(N-methyl-2′-pyrrolidinomethoxy)-6-methyl-2-pyrimidinamine
The chloropyrimidine described above, 0.66 g (1.59 mmoles), 70 mg (1.76 mmoles) of NaH (60% in oil) and 0.19 mL (1.6 mmoles) (S)-N-methylprolinol in 10 mL of dry THF under nitrogen were stirred at 25° C. for 36 h and then refluxed for 2h. The mixture was partitioned between 10 mL EtOAc and 20 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 0.5% NH 4 OH/5% CH 3 OH/CH 2 Cl 2 as eluent to give 340 mg product, which was converted into the dihydrochloride salt by treatment with 1 M HCl in ether, mp 101-103° C. (dec). Elemental analysis for C 22 H 31 N 4 IO. 2HCl: Theory C, 46.57; H, 5.86; N, 9.88; Cl, 12.50. Found C, 46.69; H, 6.02; N, 9.45; Cl, 12.69.
EXAMPLE 34
N-(2,6-dibromo-4-(1-methylethyl)phenyl)4-thiomorpholino-6-methyl-2-pyrimidinamine
580 mg (2.46 mmoles) of 2-chloro-4-thiomorpholino-6-methylpyrimidine, 793 mg (2.7 mmoles) of2,6-dibromo-4-isopropylaniline and 216 mg (5.4 mmoles) of NaH (60% in oil) were refluxed in toluene for 6 hr and purified by silica gel chromatography using 25% EtOAc/hexanes (79% yield); mp 194-195° C. Elemental analysis for C 18 H 22 N 4 Br 2 S: Theory C, 44.46; H, 4.56; N, 11.52; Br: 32.87; S,6.59. Found: C, 44.67; H, 4.54; N, 11.24; Br: 32.8; S, 6.62.
EXAMPLE 35
N-(2-methylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The product was synthesized by lithium-bromine exchange of the appropriately substituted 2-bromo-4-isopropylanilinopyrimidine with nBuLi in THF at 0° C. followed by reaction with dimethyldisulfide. It was purified by silica gel chromatography using 8% EtOAc/hexanes as eluent, (37% yield); mp 64-66° C. Elemental analysis for C 18 H25N 3 S: C, 68.53; H, 7.99; N, 13.32; S, 10.16. Found: C, 68.43; H, 7.94; N, 13.16; S, 10.02.
EXAMPLE 36
N-(2-methylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6dimethyl-2-pyrimidinamine
The hydrochloride salt of Example 35, was formed in the usual manner; mp 141-142° C. Elemental analysis for C 18 H 25 N 3 S HCl: Theory C, 61.43; H, 7.45; N, 11.94; S, 9.11; Cl, 10.07. Found: C, 61.07; H, 7.40; N, 11.80; S, 9.37; Cl, 9.77.
EXAMPLE 37
N-(2-methylsulfinyl-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The sulfide of Example 35, (300 mg, 0.95 mmoles), was reacted with 300 mg (1.41 mmoles) NaIO 4 in 6 mL MeOH and 3 mL water at 25° C. for 24 h. The reaction mixture was partitioned between 100 mL EtOAc and 25 mL water and the EtOAc extract was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 1:1 EtOAc/hexanes as eluent to give 220 mg product, (70% yield); mp 144-146° C. Elemental analysis for C 18 H 25 N 3 O 5 : Theory C, 65.22; H, 7.60; N, 12.68; S, 9.67. Found: C, 65.12; H, 7.63; N, 12.48; S, 9.71.
EXAMPLE 38
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4-thiazolidino-6-methyl-2-pyrimidinamine
The title compound was obtained as a viscous liquid. Elemental analysis for C 19 H 25 N 4 IS: Theory C, 48.72; H, 5.38; N, 11.96; S, 6.84; I, 27.09. Found: C, 48.80; H, 5.36; N, 11.84; S, 6.95; I, 27.05.
EXAMPLE 39
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was obtained as a viscous liquid. Elemental analysis for C 16 H 20 N 3 IO: Theory C, 48.37; H, 5.08; N, 10,58. Found C, 48.27; H, 5.00; N, 10.07.
EXAMPLE 40
N-(4,6-dimethyl-2-pyrimidinamino)-2,3,4,5-tetrahydro-4-(1-methylethyl)-1,5-benzothiazepine
To 4 grams, (15.32 mmoles) of 2-iodo-4-isopropylaniline, and 2.53 g (18.4 mmoles) of 4,6-dimethyl-2-mercaptopyrimidine in 30 mL DMF, were added 4.8 g (34.4 mmoles) of K 2 CO 3 and 600 mg (9.2 mmoles) of Cu powder and the resulting mixture was heated to reflux for 2 h. After cooling, 30 mL EtOAc was added and the solids were filtered off. The filtrate was partitioned between 200 mL EtOAc and 50 mL water and the EtOAc layer was washed with water (3×60 mL), brine, dried and stripped in vacuo to provide an oily residue that was used without further purification; MS(m/e) 275 (M+2, 20%); 274 (M+1, 100%).
To 0.6 g (2.2 mmoles) of the above crude product in 8 mL dry xylenes was added 132 mg (3.3 mmoles) NaH (60% in oil) and the mixture was heated to reflux for 5 h. Then 0.22 mL (2.2 mmoles) of 1,3-dibromopropane was added and the reaction was heated for another 2 h. Another 60 mg (1.2 mmoles) NaH (60% in oil) was added and heating was continued for another 3 h. After cooling the solids were filtered off, the solvent removed in vacuo, and the filtrate chromatographed on silica gel using 8% EtOAc/hexanes to give 220 mg product (32% yield for the two steps); High res MS: calc 314.169095; measured: 314.168333. This was converted into the hydrochloride salt by treatment with 1M HCl in ether, mp 157-159° C.
EXAMPLE 41
N-(2-methylsulfonyl-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The sulfoxide of Example 37, (100 mg, 0.3 mmoles) was stirred in 4 mL of CH 2 Cl 2 and 8 mL water with 20 mg (0.09 mmole) of benzyltriethylammonium chloride and 94.5 mg (0.6 mmole) KMnO 4 at 25° C. for 16 h. The mixture was partitioned between 60 mL EtOAc and 40 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 25% EtOAc/hexanes to give 85 mg product (81% yield); mp 174-175.3° C. Elemental analysis for C 18 H 25 N 3 O 2 S: Theory C, 62.22; H, 7.25; N, 12.09; S, 9.23. Found: C, 62.13; H, 7.28; N, 11.93; S, 9.12.
EXAMPLE 42
N-(2-ethylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6dimethyl-2-pyrimidinamine
The title compound was prepared in the same manner as the product of Example 36; mp 128-130° C. Elemental analysis for C 19 H 27 N 3 S HCl: Theory C, 62.36; H, 7.71; N, 11.48; S, 8.76; Cl, 9.69. Found: C, 62.64; H, 7.75; N, 11.43; S, 8.59; Cl, 9.58.
EXAMPLE 43
N-(2-ethylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in the same manner as the product of Example 44; mp 77-78° C. Elemental analysis for C 19 H 26 N 4 OS: Theory C, 63.66; H, 7.31; N, 15.63; S, 8.95. Found C, 63.70; H, 7.32; N, 15.64; S, 8.94.
EXAMPLE 44
N-(2-methylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 4 g (29.6 mmoles) of 4′-aminoacetophenone in 20 mL CH 2 Cl 2 and 50 mL water containing 3.6 g (42 mmoles) NaHCO 3 was added 9.0 g (35.4 mmoles) of I 2 . The mixture was stirred at 25° C. for 20 h. Then 20 mL of saturated aqueous Na 2 SO 3 was added and the mixture was stirred for 10 min and partitioned between 120 mL EtOAc and 10 mL water. The EtOAc extract was washed with brine, dried and stripped in vacuo and the residue chromatographed on silica gel using 25% EtOAc/hexanes as eluent to give 6.1 g product (79% yield).
To 3.05 g (11.69 mmoles) of 4′-amino-3′-iodoacetophenone in a mixture of 40 mL ethanol and 10 mL 3M NaOH was added 2.10 g (25.20 mmoles) methoxyamine hydrochloride and the mixture was heated to reflux for 2 h. The ethanol was stripped off in vacuo, the residue was partitioned between 100 mL EtOAc and 30 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 2.8 g product (83% yield).
The above product 1.5 g (5.18 mmoles) was coupled with 4,6-dimethyl-2-mercaptopyrimidine as described above, to give the corresponding adduct in 70% yield, after chromatographic purification.
The above product, 1.1 g (3.64 mmoles) was treated with 190 mg (4.73 mmoles) NaH (60% in oil) in 7 mL dry xylenes at reflux for 5.5 hours. The reaction mixture was then partitioned between 100 mL EtOAc and 20 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 25% EtOAc/hexanes to give 900 mg product (82% yield).
The above product, 900 mg (2.98 mmoles) was treated with 470 mg (3.4 mmoles) K 2 CO 3 and 0.22 mL (3.54 mmoles) CH 3 I at 25° C. for 4 h. Then it was partitioned between 100 mL EtOAc and 20 mL water, the EtOAc was washed with brine, dried and stripped in vacuo. The residue was used for the next reaction without further purification.
The above product, 940 mg (2.97 mmoles) was treated with 160 mg (4.0 mmoles) NaH (60% in oil) in 7 mL dry DMF for 20 min at 25° C. and then 0.32 mL (4.0 mmoles) EtI was added. The mixture was stirred at 25° C. for 16 h and partitioned between 100 mL EtOAc and 20 mL water, the EtOAc was washed with brine, dried, stripped in vacuo and the residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 600 mg product (58% yield); mp 106-108° C. Elemental analysis for C 18 H 24 N 4 OS: Theory C, 62.76; H, 7.02; N, 16.27; S, 9.31. Found C, 62.75; H, 7.03; N, 16.12; S, 9.45.
EXAMPLE 45
N-(2-methylsulfonyl-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The sulfide obtained from the sequence described above (0.3 g, 0.87 mmoles) was dissolved in 10 mL CH 2 Cl 2 and 0.53 g (2.61 mmoles) of m-chloroperbenzoic acid (mCPBA 85%) was added and the mixture was stirred at 25° C. for 16 min. The reaction mixture was quenched with Na 2 SO 3 and partitioned between 40 mL CH 2 Cl 2 and 30 mL 5% NaHCO 3 . The organic layer was dried, stripped in vacuo and the residue was chromatographed on silica gel using 40% EtOAc/hexanes to give 430 mg product, a 40% yield, mp 151-154° C. Elemental analysis for C 18 H 24 N 4 O 3 S: Theory C, 57.43; H, 6.43; N, 14.88; S, 8.52. Found: C, 57.24; H, 6.40; N, 14.18; S, 8.60.
EXAMPLE 46
N-(4-bromo-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
2-Iodo-4-bromoaniline was coupled with 4,6-dimethyl-2-mercaptopyrimidine in 93% yield. One gram of the adduct (3.22 mmoles) was dissolved in 10 mL methanol and 4 mL (4 mmoles) 1 M HCl in ether was added. The mixture was stirred at 25° C. for 2 h, the solvent was stripped in vacuo and the residue was partitioned between 150 mL of an 1:1 mixture EtOAc and CH 2 Cl 2 and 80 mL satd. NaHCO 3 . The organic layer was dried and stripped in vacuo to give 900 mg of the disulfide product, which was dissolved in 10 mL absolute ethanol and cooled to 0° C. To that solution 110 mg (2.92 mmoles) of NaBH 4 was added and the mixture was allowed to warm to 25° C. and stirred for 20 min before 0.36 mL (5.76 mmoles) CH 3 I was added and the mixture was stirred at 25° C. for 2 h. The solvent was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL satd. NaHCO 3 . The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 840 mg product, 80% yield for the two steps. MS(m/e): 326 (M+3, 100%); 324 (M+1, 93%).
This was ethylated under the conditions described above in 90% yield, mp91-93° C. Elemental analysis for C 15 H 18 BrN 3 S: Theory C,51.15; H, 5.15; N, 11.93; Br, 22.68; S, 9.10. Found C, 51.25; H, 5.15; N, 11.89; Br, 22.42; S, 9.22.
EXAMPLE 47
N-(4-ethyl-2-methylthiophenyl)-N-(1-methylethyl)4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 85-87° C. Elemental analysis for C 18 H 25 N 3 S: Theory C, 68.53; H, 7.99; N, 13.32; S, 10.16. Found: C, 68.56; H, 8.08; N, 13.24; S, 10.27.
EXAMPLE 48
N-(4-ethyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 140-141° C. Elemental analysis for C 17 H 23 N 3 S.HCl: Theory C, 60.43; H, 7.16; N, 12.44; S, 9.49; Cl, 10.49. Found C, 60.42; H, 6.89; N, 12.36; S, 9.61; Cl, 10.63.
EXAMPLE 49
N-(2-methylthio-4-(N-acetyl-N-methylamino)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 158-160° C. Elemental analysis for C 18 H 24 N 4 OS: Theory C, 62.76; H, 7.02; N, 16.26; S, 9.31. Found C, 62.67; H, 7.07; N, 16.24; S, 9.56.
EXAMPLE 50
N-(4-carboethoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 99-100° C. Elemental analysis for C 18 H 23 N 3 O 2 S: Theory C, 62.58; H, 6.71; N, 12.16; S, 9.28. Found C, 62.83; H, 6.78; N, 12.08; S, 9.44.
EXAMPLE 51
N-(4-methoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
A mixture of 352 mg (1 mmole) 4-bromo-2-methylmercaptoanilinopyrimidine, 14.3 mg (0.1 mmole) CuBr and 0.5 mL (2.5 mmoles) 25% w/w MeONa in MeOH was heated to reflux in 5 mL dry DMF for 1.5 h. The reaction mixture was partitioned between 100 mL EtOAc and 30 mL water and the EtOAc layer was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 210 mg product (69% yield); mp 128-130° C. Elemental analysis for C 16 H 21 N 3 OS.¼H 2 O: Theory C, 62.41; H, 7.07; N, 13.64; S, 10.41. Found C, 62.06; H, 6.97; N, 13.26; S, 10.47.
EXAMPLE 52
N-(4-cyano-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 51; mp 112-113° C. Elemental analysis for C 16 H 18 N 4 S: Theory C, 64.40; H, 6.08; N, 18.78; S, 10.74. Found: C, 64.28; H, 6.16 N, 18.58; S, 11.08.
EXAMPLE 53
N-(4-acetyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 0.5 g (1.68 mmoles) of the nitrile of Example 52 in 10 mL dry C 6 H 6 was added 1.1 mL (3.3 mmoles) of a 3 M solution CH 3 MgI in ether and the mixture was stirred at 25° C. for 2 h and at reflux for 1 h. The reaction was quenched with water and 10% HCl and stirred for 20 min before 1 M NaOH was added until the solution was alkaline and the mixture was extracted with 100 mL EtOAc. The organic layer was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 370 mg product (70% yield); mp 125-126° C. Elemental analysis for C 17 H 21 N 3 OS: Theory C, 64.73; H, 6.71; N, 13.32; S, 10.16. Found C, 64.53; H, 6.73; N, 13.08; S, 10.19.
EXAMPLE 54
N-(4-propionyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 53; mp 139-141° C. Elemental analysis for C 18 H 23 N 3 OS: Theory C, 65.62; H, 7.04; N, 12.75; S, 9.73. Found C, 65.33; H, 7.19; N, 12.51; S, 9.62.
EXAMPLE 55
N-(4-(1-methoxyethyl)-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 1.05 g (3.33 mmoles) of the ketone of Example 53 in 20 mL absolute ethanol cooled to 0° C. was added 127 mg (3.32 mmoles) NaBH 4 and the mixture was allowed to warm to 25° C. and stirred for 16 h. Then the solvent was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL 0.3 M NaOH. The EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 2:1 EtOAc/hexanes to give 1 g product; mp 46-49° C. The above alcohol, 0.72 g (2.27 mmoles), was reacted with 108.09 mg (2.7 mmoles) of NaH (60% in oil) in 5 mL dry DMF at 25° C. for 20 min and then 0.3 mL (4.8 mmoles) of CH 3 I was added. The mixture was stirred for 20 h and an additional 60 mg (1.5 mmoles) of NaH (60%) was added, as well as 0.1 mL CH 3 I and the mixture was stirred for an additional 16 h. It was then partitioned between 100 mL EtOAc and 30 mL water and the EtOAc was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 600 mg product as a viscous liquid. This was converted into the hydrochloride salt by treatment with 1 M HCl in ether, mp 120-122° C.
EXAMPLE 56
N-(4-(N-methylamino)-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
A solution of 0.2 g (0.58 mmole) 4-N-acetyl-N-methyl-2-methylmercaptoanilinopyrimidine, in 10 mL ethanol and 2 mL water containing 272 mg (5 mmoles) KOH was refluxed for 4 h. An additional 200 mg of KOH was added and the heating was continued for 3 h. The ethanol was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL water. The EtOAc extract was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give 140 mg product, an 80% yield, mp 141-142° C. Elemental analysis for C 16 H 22 N 4 S: Theory C, 63.54; H, 7.33; N, 18.52; S, 10.60. Found C, 63.63; H, 7.41; N, 18.55; S, 10.80.
EXAMPLE 57
N-(4-(N,N-dimethylamino)-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 0.36 g (1.2 mmoles) 4-N-methyl-2-methylmercaptoanilinopyrimidine in 4 mL dry DMF was added 60 mg (1.5 mmoles) NaH (60% in oil) and the mixture was stirred for 20 min before 0.1 mL (1.67 mmoles) CH 3 I was added and the reaction was continued at 25° C. for 16 h. It was then partitioned between 100 mL EtOAc and 20 mL water. The EtOAc extract was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 150 mg product (40% yield); mp 119-120° C. Elemental analysis for C 17 H 24 N 4 S: Theory C, 64.52; H, 7.64; N, 17.70; S, 10.13. Found C, 64.55; H, 7.65; N, 17.50; S, 10.31.
EXAMPLE 58
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-formyl-6-methyl-2-pyrimidinamine
Example 23 product (453 mg, 1.2 mmol) and manganese dioxide (1.7g, 20 mmol) were heated to reflux in 25 mL dichloromethane for three days. The reaction was filtered through a pad of Celite, and the filtrate was concentrated in vacuo to give a light yellow oil. The oil was purified by silica gel chromatography using 10% ethyl acetate in hexanes to yield 112 mg of a white solid. CI-HRMS: calcd: 362.0868 (M+H), found: 362.0864.
EXAMPLE 59
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxyethoxymethyl-6-methyl-2-pyrimidinamine
Compound XLVII from Scheme 12 above (0.41 g, 0.92 mmol) and sodium borohydride (76 mg, 2 mmol) in 10 mL ethanol were stirred for 21 hours at room temperature. The reaction was acidified with 1.0 N hydrochloric acid, stirred for ten minutes, basified with 1.0 N sodium hydroxide and extracted with dichloromethane. The combined extracts were dried with magnesium sulfate and stripped in vacuo to yield a clear oil which was chromatographed on silica gel using 30% ethyl acetate in hexanes to give 345 mg product (92% yield). CI-HRMS: calcd: 408.1287 (M+H), found: 408.1284.
EXAMPLE 60
N-(2-Bromo-6-hydroxy-4-methoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
N-(2-Bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine (214 mg, 0.58 mmol) in 15 mL dichloromethane under nitrogen was cooled in a dry ice/acetone bath, and boron tribromide (1.0 M in dichloromethane, 0.58 mL) was slowly added. The reaction was allowed gradually to warm to room temperature whereupon it was stirred overnight. After quenching with water, the aqueous portion was basified with saturated sodium bicarbonate and extracted with dichloromethane. The combined extracts were dried with magnesium sulfate and concentrated in vacuo to give a tan solid. The solid was recrystallized from ethyl acetate/hexanes to yield 58 mg product; mp 157-160° C. Anal. Calcd: %C, 51.15; %H, 5.15; %N, 11.93; %Br, 22.69. Found: %C, 51.02; %H, 5.10; %N, 11.83; %Br, 22.52.
EXAMPLE 61
N-(3-Bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A (Synthesis of 3-bromo-4,6-dimethoxy aniline): To a mixture of 2,4-dimethoxy aniline (5.0 g, 33 mmol) and potassium carbonate (10.4 g, 75 mmol) in 30 mL chloroform was slowly added bromine (5.27 g, 33 mmol) in 20 mL chloroform. After stirring two hours the reaction was washed three times with water, dried with magnesium sulfate, and concentrated in vacuo to give a dark solid. The material was purified by chromatography on silica gel using 20% ethyl acetate in hexanes to yield 1.77 g product as a tan solid (23% yield).
Part B: Using the procedure for Example 1; Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 62
N-(2,3-Dibromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A (Synthesis of 2,3dibromo-4,6-dimethoxy aniline): 2,4-dimethoxy aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of methanol:dichloromethane (2:5) for one hour. The solution was filtered, the filtrate was evaporated under vacuum, and the residue taken up in water and extracted three times with dichloromethane. The combined extracts were dried over magnesium sulfate, filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 20% ethyl acetate in hexanes. (Rf=0.2)
Part B: Using the procedure for Example 1; Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 63
N-(2,6-Dibromo-4-(ethoxy)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A: The synthesis of 2,6-dibromo-4-ethoxy-aniline was accomplished using the bromination procedure for 4-ethoxy-aniline reported by Kajigaeshi et. al. in Bull. Chem. Soc. Jpn. 61:597-599 (1988). The aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of MeOH:CH 2 Cl 2 (2:5) for one hour. The solids were collected, the filtrate was evaporated under vacuum, and the residue taken up in H 2 O and extracted three times with CH 2 Cl 2 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 10% EtOAc in hexanes.
Part B: Using the procedure for Example 1; Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 64
1-(2-Bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole
Part A: A solution of 42.80 g (0.200 mole) of the potassium salt of formyl-succinonitrile (K. Gewald, Z. Chem., 1:349 (1961)) and 29.20 g (0.200 mole) of 2-bromo-4-isopropylaniline in a mixture of 50 mL of glacial acetic acid and 120 mL of ethanol was refluxed (nitrogen atmosphere) for two hours. The mixture was stripped of most of the acetic acid and ethanol and the residue was taken up in ethyl acetate. This solution was washed with 10% sodium bicarbonate solution, dried with anhydrous sodium sulfate, and evaporated to give a dark, oily residue, which was chromatographed on silica gel with 80:20 hexane-ethyl acetate to give 24.23 g (40%) of N-(2-bromo-4-isopropylphenyl)-aminomethylene-succinonitrile. Mass spec: (m+NH 4 ) + =321.0; calculated, 321.0.
Part B: To a solution of 10 mL of 1M potassium tert-butoxide in tetrahydrofuran and 10 mL of ethanol was added 1.11 g (3.65 mmole) of N-(2-bromo-4-isopropyl-phenyl)-aminomethylene-succinonitrile (Part A). The mixture was stirred for 16 hrs under a nitrogen atmosphere. The solvents were removed by evaporation. The residue was taken up in ethyl acetate and washed successively with 1 N hydrochloric acid, 10% sodium bicarbonate solution, and brine. The solution was dried with anhydrous sodium sulfate and evaporated to give a dark residue. The residue was dissolved in dichloromethane, 20 g of silica gel was added, and the mixture was evaporated to dryness. This mixture was placed on top of a chromatographic column of 150 g of silica gel in hexane. The column was eluted successively with 10, 15, 20, 25; and 30% ethyl acetate in hexane to give 0.65 g (59% yield) of 1-(2-bromo-4-isopropylphenyl)-2-amino-4-cyano-pyrrole. Mass spec: (m+H) + =304.0; calculated, 304.0. The R f =0.22 on silica gel thin layer chromatography by elution with 70:30 hexane-ethyl acetate. The preparation was scaled up for Part C.
Part C: A mixture of 18.51 g (0.0609 mole) of 1-(2-bromo-4-isopropylphenyl)-2-amino-4-cyano-pyrrole, 300 mL of ethanol, 0.6 mL of conc. hydrochloric acid, and 10 mL (9.75 g, 0.0974 mole) of 2,4-pentanedione was refluxed with stirring under a nitrogen atmosphere for 4 hrs. The mixture was allowed to cool and the solvent was removed under reduced pressure. The residue was dissolved in ethyl acetate. The solution was washed with 10% sodium bicarbonate solution, then with brine. The solution was dried with anhydrous sodium sulfate and evaporated to give 21.76 g of dark, tarry residue. The residue was chromatographed on silica gel by eluting in step gradients of 0, 10, 15, 20, 25; and 30% ethyl acetate in hexane. The initial fraction is 17.6 g (78%) 1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole; m.p. 105.8°. Mass spec: (m+H) + =368.0749; calculated, 368.0762 ( 79 Br). R f =0.45 on silica gel thin layer chromatography with 70:30 hexane-ethyl acetate.
EXAMPLE 65
1-(2-Bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole
A mixture of 4.00 g of 1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole and 40 mL of 65% sulfuric acid was refluxed for one hour. The solution was cooled and poured onto ice. Conc. ammonium hydroxide was added until the mixture was alkaline to pH paper. The mixture was extracted with ethyl acetate. The solution was dissolved in 60:40 hexane-ethyl acetate and passed through a short column of silica gel. The eluate was evaporated, and the residue was crystallized from 20 mL of hexane to give 2.45 g (66% yield) of 1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole. Mass spec: (m+H) + =343.0818; calculated, 343.0810. R f =0.57 on silica gel with 70:30 hexane-ethyl acetate.
EXAMPLE 66
1-(2-Bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl-7-azaindole
A mixture of 737 mg (2.00 mmole) of the product from Example 64 (Part B), 324 mg (2.00 mmole) of benzoylacetone and 25 mL of xylene was heated in a flask equipped with a water separator for 2 hours. The solvent was removed by evaporation, and the residue chromatographed on silica gel, eluting in step gradients with 0, 5, 10; and 15% ethyl acetate in hexane. Both 1-(2-bromo-4-isopropylphenyl)-3-cyano-4-methyl-6-phenyl-7-azaindole and 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-methyl-7-azaindole were obtained. The R f values were respectively 0.38 and 0.28 (silica gel with 80:20 hexane-ethyl acetate). The assignment of the structures was based on the nmr data of the de-cyanylated compounds in Example 67.
EXAMPLE 67
1-(2-Bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole
A mixture 130 mg (0.302 mmole) of 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl-7-azaindole (Example 66) and 10 mL of 65% sulfuric acid were refluxed for one hour. The mixture was poured onto ice, Conc. ammonium hydroxide was added until the mixture was basic to pH paper. The mixture was extracted with ethyl acetate. The extract was evaporated and chromatographed on silica gel with 70:30 hexane-ethyl acetate. There was obtained 112 mg (92% yield) of 1-(2-bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole. Mass spec: (m+H) + =405.10; calculated, 405.10.
In the same way, 1-(2-bromo-4-isopropylphenyl)-4-methyl-6-phenyl-7-azaindole was obtained, mp 95.8°.
EXAMPLE 68
1-(2-Bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole
Part A: N-(2-bromo-4,6-dimethoxyphenyl)-aminomethylene-succinonitrile was prepared from 2-bromo-4,6-dimethoxyaniline by the method described in Example 64, Part A. Mass spec: (m+H) + =322.0; calculated, 322.16. R f =0.19 (silica gel with 60:40 hexane-ethyl acetate).
Part B: The product from Part A was cyclized by the method described in Example 64, Part B to give 1-(2-bromo-4,6-dimethoxy-phenyl)-2-amino-4-cyano-pyrrole (79% yield). R f =0.19 (silica gel with 60:40 hexane-ethyl acetate).
Part C: The product from Part B was treated with 2,4-pentanedione as described in Example 64, Part C to give 1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole (92% yield). Mass spec: (m+H) + =388.0; calculated, 388.0. R f =0.44 (silica gel with 60:40 hexane-ethyl acetate).
EXAMPLE 69
1-(2-bromo-4,6-dimethoxyphenyl,)-4,6-dimethyl-7-azaindole
A mixture of 200 mg of 1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole and 10 ml of 65% sulfuric acid was refluxed for one hour. The mixture was worked up as described in Example 65 to give 185 mg of crude product. A 40 mg portion was purified by preparative liquid chromatography on a nitrile column using 95:5 1-chlorobutane-acetonitrile to give 11 mg of 1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole. Mass spec: (m+H) + =360.9; calculated, 361.1.
EXAMPLE 70
1-(2-Bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole
Part A: A solution of 3.04 g of the product of Example 64 (Part B), 1.9 mL (1.94 g; 14.9 mmole) of ethyl acetoacetate, and 0.1 mL of conc. hydrochloric acid in 30 mL of ethanol was refluxed for 16 hours. A precipitate formed upon cooling. The precipitate was removed by filtration to give 1.68 g of crystals; mp 202.4° C., of 1-(2-bromo-4-isopropylphenyl)-4-methyl-7-azaindole-6-one. TLC on silica gel with 70:30 hexane-ethyl acetate showed a single spot, R f =0.29. Mass spec. (m+H) + =370.5; calcd., 370.05 ( 79 Br).
Part B: A mixture of 185 mg of the 7-azaindole-6-one (Part A) and 50 ml of phosphorus oxychloride was heated in an autoclave at 180° C. for 10 hrs. The excess phosphorus oxychloride was removed by distillation at reduced pressure. The residue was distributed between ethyl acetate and water. The ethyl acetate layer was separated and washed with 10% sodium bicarbonate solution, then with brine. The solution was dried (Na 2 SO 4 ) and evaporated. TLC of the residue on silica gel with 70:30 hexane-ethyl acetate showed a major new product, R f =0.52 with minor spots at R f 0.45 and 0.29. Chromatography on silica gel with step gradients of 5, 10, 15, and 20% ethyl acetate in hexane gave 109 mg of the R f 0.52 product; mp 123.8° C. This is 1-(2-bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole.
EXAMPLE 71
1-(2-Bromo-4-isopropylphenyl)-6-chloro-4-methyl-7-aziandole
A mixture of 52 mg of 1-(2-bromo-4-isopropyphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole and 10 mL of 65% sulfuric acid was refluxed for one hour. The cooled solution was poured onto ice, and 17 mL of conc. ammonium hydroxide was added. The alkaline mixture was extracted with ethyl acetate. The extract was washed (brine), dried (Na 2 SO 4 ), and evaporated. TLC of the residue on silica gel with 70:30 hexane-ethyl acetate showed a major new spot, R f =0.58; with a trace of unchanged starting material (R f 0.52). The crude product was purified by preparative TLC to give 39 mg of non-crystaline product, which slowly crystallized on standing. Mass spec. (m+H) + =363.0247; calcd., 363.0264 ( 79 Br, 35 Cl).
EXAMPLE 72
1-(2-Bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole
To a solution of 1.085 g (5.07 mmole) of the product from Example 64 (part B) and 0.80 mL (0.797 g; 6.03 mmole) of acetoacetaldehyde dimethyl acetal in 20 mL of ethanol was added 0.10 mL of conc. hydrochloric acid. The mixture was refluxed for 16 hours, then cooled and evaporated to give a dark, thick oil. TLC on silica gel with 70:30 hexane-ethyl acetate showed two major spots at R f 0.47 and 0.41. The oil was dissolved in ethyl acetate, 20 mL silica gel powder was added, and the mixture was evaporated to dryness. The powdery residue was loaded on top of a column of 60 mL of silica gel in hexane. The column was eluted in step gradients of 0, 5, 10, 15, 20, and 25% ethyl acetate in hexane. The first fraction to elute was 0.32 g of the desired 1-(2-bromo-4-isopropyl-phenyl)-3-cyano-6-methyl-7-azaindole, Rf 0.47. The material can be crystallized from hexane to give 176 mg of crystals; mp 176.0° C. Mass spec. (m+H) + =354.0595; calcd., 354.0606.
EXAMPLE 73
1-(2-Bromo-4-isopropylphenyl)-6-methyl-7-azaindole
Material from Example 72 was treated with 65% sulfuric acid as described in Example 65 to give the desired product as a viscous oil. TLC on silica gel with 70:30 hexane-ethyl acetate showed Rf =0.57. Mass spec. (m+H) + =329.0641; calcd., 329.0653 ( 79 Br).
EXAMPLE 74
1-(2-Bromo-4-isopropylphenyl)-4-chloro-3-cyano-6-methyl-7-azaindole
Part A: A solution of 1.24 g of 1-(2-bromo-4-isopropyl-phenyl)-3-cyano-6-methyl-7-azaindole (Example 72) and 1.42 g of 85% 3-chloro-peroxybenzoic acid in 20 mL of chloroform was refluxed for 6 hrs. The mixture was cooled and washed first with 10% sodium bicarbonate solution, then with brine. The solution was dried (Na 2 SO 4 ) and evaporated to give a residue. TLC on silica gel with 95:5 dichloromethane-methanol showed a trace spot at R f 0.88 and a major spot at R f 0.34. The material was purified by chromatography on silica gel with dichoromethane, followed by 1% methanol in dichloromethane, to give a trace of unchanged 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole (R f 0.88) and 0.92 g of 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole 7-oxide (R f 0.34); mp 179.2°. Mass spec. (m+H) + =370.0559; calcd., 370.0555 ( 79 Br).
Part B: A mixture of 370 mg of the 7-oxide (Part A) and 5 mL of phosphorus oxychloride was refluxed for two hours. The solution was cooled, poured on ice, and stirred until most of the phosphorus oxychloride was hydrolysed. The mixture was made alkaline with conc. ammonium hydroxide and extracted with ethyl acetate. The extract was dried (Na 2 SO 4 ) and evaporated to give a viscous residue. TLC on silica gel with 95:5 dichloromethane-methanol showed a major spot at R f =0.79. The material was purified by preparative TLC on silica gel with 70:30 hexane-ethyl acetate to give crystals. Recrystallization from hexane gave 158 mg of 1-(2-bromo-4-isopropylphenyl)-4-chloro-3-cyano-6-methyl-7-azaindole; mp 123.3° C. Mass spec. (m+H) + =388.0197; calcd., 388.0216 ( 79 Br, 35 Cl).
EXAMPLE 75
1-(2-Bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole
A mixture of 190 mg of the 3-cyano-7-azaindole (Example 71) and 5 mL of 65% sulfuric acid was refluxed for 30 minutes. The solution was poured onto ice and extracted with ethyl acetate. The extract was washed with brine, dried (Na 2 SO 4 ), and evaporated to give a residue. TLC of the residue on silica gel with 60:40 hexane-ethyl acetate showed a major spot at R f =0.67. The residue was purified by preparative TLC to give 130 mg of a viscous oil, which is 1-(2-Bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole. Mass spec. (m+H) + =363.0246; calcd., 363.0264 ( 79 Br, 35 Cl).
EXAMPLE 76
N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
Part A: To 3.18 grams (25.6 mmol) of commercially available 5-amino-2-methoxypyridine in a solution of methylene chloride (50 ml) and methanol (20 ml) was added benzyltrimethylammonium tribromide (10 g, 25.6 mmol) and the mixture was stirred at room temperature for 24 hours. The solvent was then stripped and the resulting residue was taken up in water and extracted (3×100 mL) with ethyl acetate. The organic extracts were dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford 5-amino-2-bromo-6-methoxypyridine. C 6 H 7 N 2 OBr MS 203 (M+H) + .
Part B: The product of part A above was coupled to 2-chloro-4,6-dimethylpyrimidine (Example 1; part A) using NaH (1.2 eq) in DMF to give N-[2-bromo-6-methoxy-pyridin-3-yl]-4,6-dimethyl-2-pyrimidinamine. C 12 H 13 N 4 OBr MS 309 (M+H) + .
Part C: The product of part B above was alkylated in the same manner as used in Example 4; part C to provide the title compound. C 14 H 17 N 4 OBr MS 337 (M+H) + .
EXAMPLE 77
N-[3-bromo-5-methyl-pyridin-2-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
Part A: A 1.0 gram (5.35 mmol) portion of commercially available 2-amino-3-bromo-5-methylpyridine was coupled to 2-chloro-4,6-dimethylpyrimidine (Example 1; part A) using NaH (1.2 eq) in DMF to give N-[3-bromo-5-methyl-pyridin-2-yl]-4,6-dimethyl-2-pyrimidinamine. C 12 H 13 N 4 Br MS 293 (M+H) + .
Part B: The product of part A was alkylated in the same manner as used in Example 4; part C to provide the title compound. C 14 H 17 N 4 Br MS 321 (M+H) + .
EXAMPLE 78
N-[6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
To 200 mg of N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine in 25 ml dry DMF was added 500 mg K 2 CO 3 , 100 mg of CuI, and 0.4 mL of morpholine and the reaction was heated to reflux for 6 hour. The reaction mixture was then filtered and poured into water and then extracted with ethyl acetate (3×50 mL). The extracts were dried and the solvent removed and the resulting residue was chromatographed on silica gel with 20% ethyl acetate in hexane as the solvent (rf 0.4) to provide the title compound. C 14 H 18 N 4 O MS 259 (M+H) + .
EXAMPLE 79
N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5 triazin-2-amine
Part A: To 2,4-dichloro-6-methyl-s-triazine (Part A, Example 23, 2.0 grams, 12.3 mmol) in 50 mL of CH 2 Cl 2 chilled to 0 degrees was added morpholine (1.1 mL, 12.3 mmol) and the reaction was allowed to come to room temperature and stirred for 2 hours. The reaction was then poured into water and the layers separated. The aqueous layer was washed with CH 2 Cl 2 , (3×50 mL) and the organic layers were combined and dried. The solvent was stripped and the crude material was chromatographed on silica with 30% ethyl acetate in hexane as the solvent to give 2-chloro-4-(N-morpholino)-6-methyl-s-triazine. C 8 H 11 N 4 OCl (M+H) + .
Part B: The product of Example 76; Part A (0.6 gram, 3.0 mmol) and the product of Example 79; Part A (0.63 gram, 3.0 mmol) in dioxane were stirred at room temperature for 24 hours. The reaction mixture poured into water then extracted with ethyl acetate (3×50 mL). The extracts were dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford the coupled material C 14 H 17 N 6 O 2 Br MS 381 (M+H) + .
Part C: The product of part B above was alkylated in the same manner as used in Example 5; part C to provide the title compound. C 16 H 21 N 6 O 2 Br MS 409 (M+H) + .
EXAMPLE 80
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(N-(2-furylmethyl)-N-methylamino)carbonyl-6-methylpyrimidinamine
Sodium hydride (60% in oil, 0.1 g, 2.4 mmol), washed with hexanes and decanted twice, was suspended in anhydrous N,N-dimethylformamide (DMF) (5 mL) and a solution of N-(2-bromo- 4 -(1-methylethyl)phenyl)-N-ethyl-4-((2-furylmethyl)-amino)carbonyl-6-methylpyrimidinamine (1.0 g, 2.2. mmol) in anhydrous DMF (5 mL) was added dropwise with stirring. After 30 min, iodomethane (0.37 g, 2.6 mmol) was added and the reaction mixture was stirred for 18 h. Water (50 mL) was added carefully and the aqueous mix was extracted three times with chloroform. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (ethyl acetate:hexanes::1:2) afforded the title product as a brown oil (850 mg, 82% yield, R f 0.35): NMR (CDCl 3 300 MHz): 7.5 (d, 1H, J=9), 7.3 (d, 1H, J=12), 7.25-7.2 (m, 1H), 7.12 (dd, 1H, J=8, 1), 6.8 (s, 1H), 6.3 (d, 1H, J=12), 6.0 (br s, 0.5H), 5.9 (br s, 0.5H), 4.65 (br s, 2H), 4.2 (br s, 1H), 3.75-3.6 (m, 1H), 3.0-2.8 (m, 4H), 2.4 (br s, 3H), 1.40 (d, 6H, J=7), 1.2 (t, 3H, J=8);
CI-HRMS: Calcd (C 23 H 27 BrN 4 O 2 ): 471.1396 (M+H); Found: 471.1387.
EXAMPLE 81
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-((4,4-ethylenedioxypiperidino)carbonyl)-6-methylpyrimidinamine
Sodium hydride (60% in oil, 0.12 g, 3 mmol), washed with hexanes and decanted twice, was suspended in anhydrous THF (5 mL) and a solution of 4-piperidone ethylene glycol ketal (0.43 g, 3 mmol) in anhydrous THF (5 mL) was added dropwise with stirring. The reaction mixture was heated to reflux temperature, stirred for 30 min and then cooled to ambient temperature. A solution of methyl 2-((2-bromo-4-(1-methylethyl)-phenyl)ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (1.0 g, 2.54 mmol) in anhydrous THF (10 mL) was added and the reaction mixture was stirred at room temperature for 98 h. The reaction mixture was poured onto a 1N NaOH solution (100 mL), mixed and extracted three times with ethyl acetate and the combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (chloroform:methanol::9:1) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)carbonyl-6-methylpyrimidinamine as an orange-yellow oil (260 mg, 52% yield, R f 0.75):CI-HRMS: Calcd (C 24 H 31 BrN 4 O 3 ): 503.16578 (M+H); Found: 503.16571.
EXAMPLE 82
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-oxopiperidino)carbonyl-6-methylpyrimidinamine
A solution-of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-((4,4-ethylenedioxypiperidino)carbonyl)-6-methylpyrimidinamine (260 mg) in a mixture of a 1N HCl solution (2.5 mL) and THF (2.5 mL) was stirred at reflux temperature for 20 h. The reaction mixture was poured into a 1N NaOH solution, and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give the title product as a yellow oil (240 mg, 100% yield, R f 0.75): NMR (CDCl 3 , 300 MHz): 7.5 (s, 1H), 7.2 (d, 1H, J=8), 7.1 (d, 1H, J=8), 6.8 (br s, 1H), 4.3-4.1 (m, 1H), 3.95-3.85 (m, 1H), 3.75-3.6 (m, 1H), 3.55-3.4 (m, 1H), 2.95-2.85 (m, 1H), 2.6-2.3 (m, 4H), 2.0-1.6 (m, 2H), 1.4-1.15 (m, 12H); CI-HRMS: Calcd (C 22 H 27 BrN 4 O 2 ): 459.1396 (M+H); Found: 459.1386.
EXAMPLE 83
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-oxopiperidino)methyl-6-methylpyriimidinamine, hydrochloride salt
A solution of borane in tetrahydrofuran (1M, 29 mL, 29 mmol) was added dropwise to a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)carbonyl-6-methylpyrimidinamine (1.67 g, 3.3 mmol) in anhydrous THF (7 mL) with stirring under a nitrogen atmosphere. The reaction mixture was heated to reflux temperature and stirred for 20 h, then cooled to ambient temperature. A solution of glacial acetic acid was added dropwise; then the reaction mixture was heated to reflux temperature and stirred for 4 h, then cooled to ambient temperature. The reaction mixture was concentrated in vacuo; the residue was treated with excess 1N NaOH solution, and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate) afforded N-(2-bromo-4-( 1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)methyl-6-methylpyrimidinamine as a pale brown oil (860 mg): CI-MS, 489, 491 (M+H).
The ketal was dissolved in a mixture of a 33% HCl solution (10 mL) and THF (5 mL). The resulting solution was stirred at reflux for 65 h, then cooled to ambient temperature and basified with a 1N NaOH solution. The aqueous mix was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::4:1) afforded the title product as its free base and as an oil (600 mg, 41% overall yield): CI-HRMS: Calcd (C 22 H 29 BrN 4 O): 444.1603(M+H); Found: 444.1594.
The above oil (0.55 g, 1.24 mmol) was dissolved in ether (5 mL) and treated with a 1N HCl solution in ether. The resulting precipitate was collected and washed with copious amounts of ether. Drying in vacuo afforded a white powder (500 mg, 84% yield): mp 186-188° C.; Anal.(C 22 H 29 BrN 4 O-HCl): C, 54.92; H, 6.24; N, 11.65; Br, 16.64; Cl, 7.39; Found: C, 54.62; H, 6.37; N, 11.41; Br, 16.57; Cl, 7.35.
EXAMPLE 84
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(imidazol-1-yl)methyl-6-methylpyrimidinamine
To a mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxymethyl-6-methylpyrimidinamine (1.57 g, 4.3 mmol), triethylamine(2.5 mL, 17 mmol) and dichloromethane (15 mL) at 0° C. under a nitrogen atmosphere was added methanesulfonyl chloride (0.54 g, 4.7 mmol) dropwise and the reaction mixture was stirred at 0° C. for 1.5 h. It was then washed successively with an ice-cold 1N HCl solution, a saturated NaHCO 3 solution and a saturated NaCl solution. Drying the methylene chloride solution over MgSO 4 , filtration and removal of solvent in vacuo gave N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methanesulfonyloxymethyl-6-methylpyrimidinamine as a clear colorless oil (1.6 g): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.5 (s, 1H), 5.05-4.9 (br s, 2H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 1H), 3.0-2.85 (m, 1H), 2.8-2.6 (br s, 3H), 2.5-2.25 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-MS, 442, 444 (M+H).
To sodium hydride (60% in oil, 0.1 g, 2.4 mmol), washed with hexanes and decanted twice, suspended in anhydrous THF (10 mL) was added imidazole (146 mg, 2.14 mmol) in one portion and the reaction mixture was warmed to reflux temperature and stirred for 2 h. A solution of the crude mesylate in anhydrous THF (10 mL) was added dropwise to the reaction mixture, which had been cooled to ambient temperature. The reaction mixture was stirred for 68 h, then it was poured onto water and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate) afforded (1) N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxymethyl-6-methylpyrimidinamine (130 mg, 8% overall yield, R f 0.7) and (2) the title product (600 mg, 59% overall yield, R f 0.07): NMR (CDCl 3 , 300 MHz): 7.6-7.4 (m, 2H), 7.2 (dd, 1H, J=7, 1), 7.15 (d, 1H, J=8), 7.05 (s, 1H), 7.0-6.8 (m, 1H), 6.05 (s, 1H), 4.95-4.8 (m , 2H), 4.25-4.1 (m, 1H), 3.8-3.6 (m, 1H), 3.0-2.85 (m, 1H), 2.4-2.1 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-HRMS: Calcd (C 20 H 24 BrN5): 413.1293 (M+H), Found: 413.1275.
EXAMPLE 85
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-(methoxyphenyl)methoxymethyl)-6-methylpyrimidinamine
To a mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxymethyl-6-methylpyrimidinamine (1.0 g, 2.7 mmol), triethylamine (1.4 mL, 10 mmol) and dichloromethane (20 mL) at 0° C. under a nitrogen atmosphere was added methanesulfonyl chloride (0.34 g, 3.0 mmol) dropwise. The reaction was performed as for Example 84, except the reaction time was 15 min.
Sodium hydride (0.12 g, 3 mmol) and 3-methoxybenzyl alcohol (0.41 g, 3 mmol) were reacted in anhydrous THF (10 mL) as for Example 84. A solution of the crude mesylate in anhydrous THF (10 mL) was added dropwise. The reaction mixture was stirred at reflux temperature for 18 h, cooled to room temperature, poured into a 1N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::1:1) afforded the title product as a viscous yellow liquid (800 mg, 60% overall yield, R f 0.7): NMR (CDCl 3 , 300 MHz): 7.5 (s, 1H), 7.3-7.1 (m, 4H), 6.95-6.9 (m, 2H), 6.85 (br d, 1H, J=8), 6.75 (s, 1H), 5.6 (br s, 2H), 4.45-4.3 (m, 2H), 4.25-4.05 (m, 1H), 3.8 (s, 3H), 3.8-3.6 (m, 1H), 2.9 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: Calcd (C 25 H 30 BrN 3 O 2 ): 484.1599; Found: 484.1592.
EXAMPLE 86
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-thiazolyl)carbonyl-6-methylpyrimidinamine
To a solution of n-butyl lithium in hexanes (2.4 M, 1.34 mL, 3.24 mmol) in anhydrous THF (5 mL) at −78° C. under a nitrogen atmosphere was added 2-bromothiazole (0.49 g, 0.27 mL, 3.0 mmol) dropwise. After the addition was complete, the reaction mixture was stirred at −78° C. for 30 min. A solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)-phenyl)-N-ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (1.0 g, 2.5 mmol) in anhydrous THF (10 mL) was added dropwise. The reaction mixture was then warmed to −60° C. and stirred for 4 h. A saturated aqueous solution of NaHCO 3 was added and the reaction mixture was warmed to ambient temperature. Three extractions with ethyl acetate, followed by two washings of the combined organic layers with water, drying over MgSO 4 , filtration and concentration in vacuo gave a dark brown oil. Column chromatography (ethyl acetate: hexanes::1:1) afforded the title product, a brown solid (950 mg, 85% yield, R f 0.43): mp 97-98.5° C.; NMR (CDCl 3 , 300 MHz):8.0 (s, 1H), 7.60 (s, 1H), 7.4-7.2 (m, 4H, J=6), 3.05-2.9 (m, 1H), 2.8-2.7 (m, 1H), 2.6 (br s, 3H), 1.4-1.2 (m, 9H); CI-HRMS Calcd: 445.0698 (M+H), Found: 445.0699; Anal.(C 20 H 21 BrN 4 S): C, 54.05; H, 4.73; N, 12.61; Br, 18.02; S, 7.21; Found: C, 53.86; H, 4.66; N, 12.53; Br, 18.20; S, 7.46.
EXAMPLE 87
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-imidazolyl)carbonyl-6-methylpyrimidinamine
To a solution of 1-(dimethylaminomethyl)imidazole (0.63 g, 5 mmol) in anhydrous diethyl ether (50 mL) at −78° C. under a nitrogen atmosphere was added a solution of n-butyl lithium in hexanes (2.4 M, 2.1 mL, 5 mmol) dropwise and the pale yellow suspension was stirred at −78° C. for 1 h. Methyl 2-(N-(2-bromo-4-(1-methylethyl)-phenyl)-N-ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (1.47 g, 5 mmol) was added in one portion and the reaction mixture was warmed to room temperature over 23 h. A 1N HCl solution was added until pH=1 (test paper) and the reaction mixture was stirred for 4 h. A 3N NaOH solution was added until the solution became basic (pH=10; test paper). Three extractions with ethyl acetate, drying the combined organic layers over MgSO 4 , filtration and concentration in vacuo gave a brown oily solid. Column chromatography (chloroform:methanol::9:1) afforded the title product, a yellow glass (900 mg, 42% yield, R f 0.43): mp 75-76° C.; NMR (CDCl 3 , 300 MHz): 12.2-12.1 (m, 1H), 7.7 (d, 1H, J=1), 7.45-7.35 (m, 2H), 7.3-7.2 (m, 2H), 6.55 (br s, 1H), 4.3 (sextet, 1H, J=7), 3.8 (sextet, 1H, J=7), 3.05 (septet, 1H, J=7), 2.65 (br s, 3H), 1.4 (d, 6H, J=7), 1.3 (t, 3H, J=7); CI-HRMS: Calcd: 428.1086 (M+H), Found: 428.1089; Anal (C 20 H 24 BrN 5 O) C, 56.08; H, 5.18; N, 16.35; Br, 18.66; Found: C, 56.20; H, 5.10; N, 15.88; Br, 18.73.
EXAMPLE 88
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(5-indolylcarbonyl)-6-methylpyrimidinamine
To a suspension of potassium hydride (35% in oil, 0.16 g, 1.4 mmol), washed with hexanes and decanted twice, in anhydrous ether (5 mL), cooled to 0° C. under a nitrogen atmosphere was added a solution of 5-bromoindole (0.27 g, 1.4 mmol) in anhydrous ether. After being stirred for 30 min., the reaction mixture was cooled to −78° C. and transferred via cannula to a pre-cooled (−78° C.) mixture of t-butyl lithium (1.7 M in pentane, 1.6 mL, 2.7 mmol) in dry ether (5 mL). The resulting white suspension was stirred at −78° C. for 30 min and a solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)-phenyl)-N-ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (0.5 g, 1.25 mmol) in anhydrous ether (5 mL) was added dropwise. After quenching the reaction mixture as in Example 87; it was extracted three times with ethyl acetate, followed by two washings of the combined organic layers with a saturated NaHCO 3 solution, drying over MgSO 4 , filtration and concentration in vacuo to give a dark brown oil. Column chromatography (ethyl acetate: hexanes::1:4) afforded the title product, a light brown solid (140 mg, 24% yield, R f 0.2): mp 77-79° C.; NMR (DMSO-d 6 , 400 MHz, 90° C.): 11.6-11.35 (br s, 1H), 8.30 (s, 1H), 7.75 (dd, 1H, J=8, 1), 7.55 (d, 1H, J=1), 7.4-7.35 (m, 2H), 7.35-7.25 (m, 2H), 6.9 (s, 1H), 6.60-6.55 (m, 1H), 4.1-3.7 (m, 2H), 2.95-2.8 (m, 1H), 2.4 (br s, 3H), 1.25-1.1 (m, 9H); Anal (C 25 H 25 BrN 4 O): C, 62.90; H, 5.28; N, 11.74; Br, 16.74; Found: C, 63.13; H, 5.60; N, 11.37; Br, 16.80.
EXAMPLE 89
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-fluorophenyl)carbonyl-6-methylpyrimidinamine
To a suspension of N,O-dimethylhydroxylamine hydrochloride (1.46 g, 15 mmol) in benzene (20 mL) at 5-10° C. under a nitrogen atmosphere was added a solution of trimethyl aluminum in toluene (2 M, 7.5 mL, 15 mmol) dropwise and the reaction mixture was then warmed to ambient temperature over 1 h. The reaction mixture was transferred to an addition funnel and added dropwise to a solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (2.25 g, 5.73 mmol) in benzene (40 mL). The reaction mixture was heated at reflux and stirred for 16 h. After being cooled to room temperature, the mixture was poured into a 5% HCl solution (100 mL), mixed and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (ethyl acetate: hexanes::1:1) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(N-methyl-N-methoxycarboxamido)-6-methylpyrimidinamine (1.0 g, 41% yield, R f 0.4): CI-MS, 421, 423 (M+H).
The crude amide was dissolved in anhydrous THF (10 mL). A solution of 4-fluorophenylmagnesium bromide in ether (2 M, 1.25 mL, 2.5 mmol) was added dropwise and the reaction mixture was stirred for 22 h. The reaction was quenched by pouring onto a 1 N NaOH solution (50 mL). The aqueous solution was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an orange yellow oil. Column chromatography (ethyl acetate:hexanes::1:9) afforded the title product as a yellow solid (700 mg, 65% yield, R f 0.5): mp 70° C.; NMR (CDCl 3 , 300 MHz): 8.3-8.05 (m, 2H), 7.55 (d, 1H, J=1), 7.2-6.75 (m, 5H), 4.85-4.7 (m, 1H), 4.3-4.15 (m, 1H), 2.95 (septet, 1H, J=7), 2.5 (br s, 3H), 1.4-1.15 (m, 9H); CI-HRMS: Calcd(C 23 H 23 BrFN 3 O): 456.1087 (M+H), Found: 456.1084.
EXAMPLE 90
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-carboxy-6-methylpyriimidinamine
A mixture of methyl 2-(N-(2-bromo-4-(1-methylethyl)-phenyl)-N-ethylamino)-6-methyl-4-pyrimidinecarboxylate (Example 18) (10 g, 25 mmol), ethanol (100 mL) and a 1N NaOH solution (250 mL) was stirred at reflux temperature for 18 h. After being cooled to ambient temperature, the reaction mixture was concentrated twofold in vacuo and acidified with a concentrated HCl solution. Three extractions with chloroform, drying the combined organic layers over MgSO 4 , filtration and removal of solvent in vacuo gave a pale brown solid (9.0 g, 95% yield): mp 102-104° C.; NMR (CDCl 3 , 300 MHz): 7.55 (d, 1H, J=1), 7.25-7.20 (m, 2H), 7.15 (d, 1H, J=7), 4.30-4.10 (m, 1H), 3.88-3.7 (m, 1H), 3.00-2.85 (m, 1H), 2.55 (br s, 3H), 2.30 (br s, 1H), 1.30 (d, 6H, J=7), 1.20 (t, 3H, J=7); CI-HRMS: Calcd(C 17 H 20 BrN 3 O): 378.0817(M+H); Found: 378.0813.
EXAMPLE 91
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methylpyrimidinamine
Cerium trichloride (4.9 g, 19.6 mmol) was dried, with magnetic stirring, at 180° C. in vacuo for 4 h. After being cooled to room temperature and placed under a nitrogen atmosphere, the solid was stirred for 16 h in anhydrous THF (50 mL).
A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-carboxy-6-methylpyrimidinamine (3.7 g, 9.8 mmol) in anhydrous THF (25 mL) was cooled with stirring to −78° C. under a nitrogen atmosphere. A solution of methyl lithium in ether (1.4 M, 7 mL, 9.8 mmol) was added dropwise and the reaction mixture was stirred at −78° C. for 1 h. The CeCl 3 suspension was transferred via cannula into the reaction mixture and stirring at −78° C. was continued for 5 h. A solution of methyl lithium in ether (1.4 M, 7 mL, 9.8 mmol) was added dropwise and the reaction mixture was then warmed gradually to room temperature over 16 h. After cooling the reaction mixture to −78° C., the reaction was quenched with a 1 N HCl solution and warmed to room temperature. The resulting mixture was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an orange yellow oil. Column chromatography (ethyl acetate:hexanes::1:4) afforded the title product as an oil (2.5 g, 68% yield, R f 0.5): NMR (CDCl 3 , 300 MHz): 7.55 (d, 1H, J=1), 7.25-7.15 (m, 2H), 6.95 (s, 1H), 4.30-4.10 (m, 1H), 3.90-3.70 (m, 1H), 3.00-2.85 (m, 1H), 2.80-2.05 (m, 6H), 1.35-1.20 (m, 9H); CI-HRMS: Calcd (C 18 H 22 BrN3O): 376.1024 (M+H), Found: 376.1042.
EXAMPLE 92
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(hydroxy-3-pyridyl-methyl)-6-methylpyrimidinamine (XU472)
Sodium borohydride (0.11 g, 2.8 mmol) was added to a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyridylcarbonyl)-6-methylpyrimidinamine (0.6 g, 1.4 mmol) in ethanol (5 mL). After being stirred for 71 h, the reaction mixture was concentrated in vacuo, treated with a 1 N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were washed with brine, dried over MgSO 4 , filtered and concentrated in vacuo to give a colorless oil. Column chromatography (chloroform:methanol::9:1) afforded the title product as an oil (600 mg, 96% yield, R f 0.4): NMR (CDCl 3 , 300 MHz): 8.65-8.45 (m, 2H), 7.55 (br s, 2H), 7.3-7.1 (m, 2H), 6.25-6.15 (m, 1H), 5.7-5.5 (m, 0.5H), 5.45-5.3 (m, 0.5H), 5.15-4.95 (m, 1H), 4.3-4.1 (m, 1H), 3.9-3.7 (m, 1H), 3.0-2.85 (m, 1H), 2.45-2.2 (m, 3H), 2.3-2.2 (m, 1H), 1.35-1.2 (m, 9H); CI-HRMS: Calcd (C 22 H 25 BrN4O): 441.1290 (M+H), Found: 441.1274.
EXAMPLE 93
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-(methoxyphenyl)-3-pyridyl-hydroxymethyl)-6-methylpyrimidinamine
A solution of 4-bromoanisole (0.2 g, 1.1 mmol) in anhydrous THF (10 mL) was cooled with stirring to −78° C. under a nitrogen atmosphere. A solution of t-butyl lithium in pentane (1.7 M, 1.4 mL, 2.4 mmol) was added dropwise and the reaction mixture was stirred for 0.5 h. A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyridyl-carbonyl)-6-methylpyrimidinamine (0.45 g, 1 mmol) in anhydrous THF (10 mL) was added dropwise and the reaction mixture was warmed gradually to ambient temperature over 18 h. The reaction mixture was poured onto a saturated NH 4 Cl solution and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::4:1) afforded the title product as a pale brown glass (170 mg, 31% yield, R f 0.2): mp 68-70° C.; NMR (CDCl 3 , 300 MHz): 8.6-8.4 (m, 2H), 7.7-7.5 (m, 1H), 7.5 (s, 1H), 7.25-7.05 (m, 6H), 6.95-6.75 (m, 2H), 6.25-6.2 (m, 1H), 5.85-5.7 (m, 1H), 4.25-4.05 (m, 1H), 3.8 (br s, 3H), 3.95-3.75 (m, 1H), 3.00-2.8. (m, 1H), 2.45-2.1 (br s, 3H), 1.35-1.15 (m, 9H); CI-HRMS: Calcd(C 29 H31BrN 4 O 2 ): 547.1709 (M+H), Found: 547.1709.
EXAMPLE 94
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyrazolyl)-6-methylpyiimidinamine, Hydrochloride Salt
Sodium (0.08 g, 3.5 mmol) was added to methanol (20 mL) with stirring. After the sodium reacted, a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methyl-pyrimidinamine (1.0 g, 2.67 mmol) in methanol (5 mL) was added and the reaction mixture was stirred for 5 min. Gold's reagent ((dimethylaminomethyleneaminomethylene))dimethyl-ammonium chloride (0.66 g, 4 mmol) was added and stirring was continued for 19 h. The reaction mixture was concentrated in vacuo; the residue was dissolved in chloroform and the solution was washed with a saturated NaHCO 3 solution, dried over MgSO 4 and filtered solvent removal in vacuo gave a brown solid, which upon trituration with hexanes afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-dimethylaminopropenoyl)-6-methylpyrimidinamine as a yellow solid (700 mg): NMR (CDCl 3 , 300 MHz): 7.9-7.65 (br s, 1H), 7.5 (s, 1H), 7.25-7.2 (m, 2H), 7.15 (s, 1H), 6.1-5.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.75 (m, 1H), 3.2-3.0 (br s, 3H), 3.0-2.85 (m, 1H), 2.8-2.6 (br s, 3H), 2.5-2.3 (br s, 3H), 1.35-1.2 (m, 9H): CI-MS, 431, 433 (M+H).
A solution of the above vinylogous amide and anhydrous hydrazine (0.15 g, 4.7 mmol) in toluene (15 mL) was stirred at reflux temperature under a nitrogen atmosphere for 16 h. The reaction mixture was poured onto water and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ether) afforded the free base of the title product as a pale yellow glass (600 mg, 59% overall yield, R f 0.4): NMR (CDCl 3 , 300 MHz): 7.6 (s, 1H), 7.55 (s, 1H), 7.3-7.2 (m, 2H), 6.8 (s, 1H), 6.75-6.6 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.7 (m, 1H), 3.00-2.85 (m, 1H), 2.5-2.2 (br s, 3H), 1.3 (d, 6H, J=8), 1.25 (t, 3H, J=8); CI-HRMS: Calcd (C 19 H 22 BrN 5 ): 399.1137 (M+H), Found: 399.1140.
The free base was dissolved in ether and treated with an excess amount of a 1 N HCl solution in ether. The resulting precipitate was collected and washed with copious amounts of ether. Drying in vacuo at 60° C. afforded the title product as a powder (500 mg, 72% yield) mp 235-237° C.; NMR (DMSO-d 6 , 300 MHz): 7.9-7.7 (m, 1H), 7.6 (s, 1H), 7.4-7.3 (m, 2H), 7.2 (s, 1H), 7.05-6.85 (m, 1H), 4.3-4.1 (m, 1H), 3.85-3.65 (m, 1H), 3.05-2.9 (m, 1H), 2.45-2.1 (br m, 3H), 1.25 (d, 6H, J=8), 1.2 (t, 3H, J=8); Anal. (C 19 H 22 BrN 5 -HCl): C, 52.75; H, 5.31; N, 16.03; Br, 18.29; Cl, 8.12; Found: C, 52.53; H, 5.28; N, 15.93; Br, 18.44; Cl, 8.17.
EXAMPLE 95
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-aminoethyl)-6-methylpyrimidinamine
A mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methyl-pyrimidinamine (0.5 g, 1.33 mmol), ammonium acetate (1.1 g, 14 mmol), sodium cyanoborohydride (59 mg, 0.9 mmol) and methanol (5 mL) was stirred at ambient temperature for 90 h. A concentrated HCl solution was added until the solution became acidic (pH=2), then the reaction mixture was concentrated in vacuo. The residue was taken up in water, basified with a concentrated NaOH solution and extracted three times with ether. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes:: 1: then chloroform:methanol:NH 4 OH::95:5:0.5) gave (1) N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-aminothyl)-6-methyl-pyrimidinamine (80 mg, 16% yield, R f 0.34 (ethyl acetate:hexanes::1;1)) and (2) the title product as a brown oil (180 mg, 36% yield, R f 0.34 (chloroform:methanol:NH 4 OH::95:5:0.5)): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.2-7.1 (m, 2H), 6.4 (s, 1H), 4.25-4.05 (m, 1H), 3.9-3.65 (m, 2H), 3.0-2.85 (m, 1H), 2.4-2.2 (br m, 3H), 1.9-1.6 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-HRMS (C 18 H 25 BrN 4 ): 377.1341 (M+H), Found: 377.1330.
EXAMPLE 96
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-(4-tetrazolyl)-1-methylethyl)-6-methylpyrimidinamine
A mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-hydroxyethyl)-6-methylpyrimidinamine (1.1 g, 2.7 mmol), triethylamine (1.5 mL, 11 mmol) and dichloromethane (15 mL) was stirred at 0° C. under a nitrogen atmosphere. Methanesulfonylchloride (364 mg, 3.2 mmol) was added dropwise and the reaction mixture was then stirred for 1.5 h. The resulting turbid solution was washed successively with an ice-cold 1 N HCl solution, a saturated NaHCO 3 solution and a saturated NaCl solution. Drying over MgSO 4 , filtration and removal of solvent in vacuo gave N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-methanesulfonyloxyethyl)-6-methylpyrimidinamine as a clear colorless oil (1.0 g): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.55 (s, 1H), 4.3-4.05 (m, 1H), 3.85-3.6 (m, 1H), 3.0-2.5 (m, 4H), 2.5-2.05 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-MS, 456, 458 (M+H).
The crude mesylate was mixed with sodium cyanide (0.54 g, 11 mmol) in N,N-dimethylformamide (DMF) (20 mL) and stirred at reflux temperature for 67 h. After being cooled to room temperature, the reaction mix was poured onto water (200 mL), mixed and extracted with ethyl acetate three times. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::1:9) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-cyanoethyl)-6-methylpyrimidinamine as an oil (440 mg, R f 0.24): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.65-6.55 (m, 1H), 4.3-4.05 (m, 1H), 3.9-3.5 (m, 2H), 3.0-2.85 (m, 1H), 2.55-2.0 (br m, 3H), 1.8-1.4 (br m, 3H), 1.4-1.1 (m, 9H); CI-MS: 387, 389 (M+H).
A mixture of the crude cyanide, sodium azide (600 mg, 9 mmol), ammonium chloride (492 mg, 9 mmol) and DMF (20 mL) was stirred at 100-105° C. for 112 h. After being cooled to room temperature, the reaction mixture was poured onto water (200 mL), basified with a 1 N NaOH solution (pH>10) and extracted three times with chloroform. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (chloroform:methanol::9:1) afforded a brown solid (R f 0.22). Recrystallization from ether gave the title product as a white solid (35 mg, 3% overall yield): mp 127-129° C.; NMR (CDCl 3 , 400 MHz): 7.75 (s, 0.4H), 7.7(s, 0.6H), 7.45 (d, 0.6H, J=8), 7.4 (d, 0.4H, J=8), 7.3-7.2 (m, 2H), 6.5 (s, 0.4H), 6.48 (s, 0.6H), 4.28-4.0 (m, 1.4H), 4.28-4.18 (m, 0.6H), 3.94-3.82 (m, 0.6H), 3.8-3.7 (m, 0.4H), 3.1-3.0 (m, 1H), 2.45 (s, 3H), 1.5 (d, 3H, J=8), 1.4-1.3 (m. 5H), 1.3-1.2 (m, 4H); CI-HRMS: 430.1355 (M+H); 430.1347.
EXAMPLE 97
2-(N-(2-bromo-4-(2-propyl)phenyl)amino)-4-carbomethoxy-6-methylpyrimidine
A mixture of 2-chloro-4-carbomethoxy-6-methylpyrimidine (47.0 g, 252 mmol) and 2-bromo-4-(2-propyl)aniline (54.0 g, 252 mmol) in dioxane (400 mL) was stirred at reflux temperature for 20 h under a nitrogen atmosphere. The reaction mixture was cooled to ambient temperature and concentrated on a rotary evaporator. The residue was treated with a saturated sodium bicarbonate solution and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate and filtered. Solvent was removed in vacuo to provide a red oil. Column chromatography (ethyl acetate:hexanes::1:1) gave the title product as a crude oil. Recrystallization from ether-hexanes, collection by filtration and drying in vacuo afforded the title compound as a solid (42.8 g, 17% yield): mp 75-76° C.; NMR (CDCl 3 , 300 MHz): 8.4 (d, 1H, J=8); 7.65 (br s, 1H), 7.4 (d, 1H, J=1), 7.3 (s, 1H), 7.2 (dd, 1H, J=8,1), 4.0 (s, 3H), 2.85 (septet, 1H, J=7), 2.5 (br s, 3H), 1.25 (d, 6H, J=7); Anal. (C 16 H 18 BrN 3 O 2 ): C, 52.76, H, 4.98; N, 11.54; Br, 21.94; Found: C, 52.71; H, 4.99; N, 11.38; Br, 21.83.
EXAMPLE 98
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)4-carbomethoxy-6-methylpyrimidine
To sodium hydride (60% in oil, 4.8 g, 120 mmol), washed with hexanes (50 mL) twice and decanted in anhydrous tetrahydrofuran (150 mL) at ambient temperature under a nitrogen atmosphere was stirred 2-(N-(2-bromo-4-(2-propyl)phenylamino)-4-carbomethoxy-6-methylpyrimidine (42.8 g, 118 mmol) portionwise over 30 min. After gas evolution subsided, iodoethane (31.2 g, 16 mL, 200 mmol) was added in one portion and the reaction mixture was heated to a gentle reflux and stirred for 24 h. After being cooled to room temperature, the reaction mixture was quenched carefully with water and extracted three times with ethyl acetate. The combined organic layers were washed with water twice, dried over magnesium sulfate and filtered. Solvent was removed in vacuo to afford a brown oil. Column chromatography (ether:hexanes::1:1) provided two fractions: (1) 2-(N-(2-bromo-4-(2-propyl)phenylamino)-4-carbomethoxy-6-methylpyrimidine (4.6 g, 11% yield, R f =0.8) and (2) the title product (20 g, R f =0.7) as a crude oil.
The title product was recrystallized from hexanes and dried in vacuo to give a solid (18.0 g, 39% yield): mp 81-82° C., NMR(CDCl 3 , 300 MHz): 7.5 (br s, 1H), 7.25 (d, 1H, J=7), 7.15 (d, 1H, J=7), 7.1 (s, 1H), 4.3-4.1 (m, 1H), 4.05-3.75 (m, 4H), 2.95 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.25 (t, 3H, J=7); CI-HRMS: calcd: 392.0974 (M+H), found: 392.0960.
EXAMPLE 99
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-6-methylpyrimidine-4-carboxylic acid, morpholine amide
To sodium hydride (60% in oil, 0.24 g, 6.0 mmol), washed with hexanes twice and decanted, and suspended in anhydrous tetrahydrofuran (10 mL) was added morpholine (0.52 g, 6.0 mmol) and the reaction mixture was warmed to reflux temperature and stirred for 1 h. The reaction mixture was then cooled to ambient temperature and 2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-carbomethoxy-6-methyl-pyrimidine (2.0 g, 5.1 mmol) was added and stirring was continued for 26 h. The reaction mixture was then poured onto a 1 N NaOH solution, stirred and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Column chromatography (ether) afforded the title compound as a solid (900 mg, 39% yield): mp 145° C.; NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.2 (dd, 1H, J=7,1), 7.1 (d, 1H, J=7), 6.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.3 (m, 11H), 3.1-3.0 (m, 1H), 2.9 (septet, 1H, J=7), 1.3 (d, 6H, J=7), 1.15 (t, 3H, J=7); Anal. (C 21 H 27 BrN 4 O 2 ) Calcd: C, 56.38; H, 6.08; N, 12.52; Br, 17.86; Found: C, 56.07; H, 6.05; N, 12.29; Br, 18.08.
EXAMPLE 100
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-(morpholinomethyl)-6-methylpyrimidine
To a solution of 2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-6-methylpyrimidine-4-carboxylic acid, morpholine amide (750 mg, 1.72 mmol) in anhydrous tetrahydrofuran (1.4 mL) at ambient temperature under a nitrogen atmosphere was added a solution of borane in tetrahydrofuran (1 M, 3.6 mL, 3.6 mmol) dropwise and the reaction mixture was heated at reflux temperature for 20 h. After cooling to room, acetic acid (3.5 mL) was slowly added and the mixture was heated at reflux for 30 min. After being cooled to ambient temperature, the reaction mixture was poured into a 3 N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Column chromatography (ethyl acetate) afforded the title compound as an oil (300 mg, 39% yield, R f 0.3): NMR (CDCl 3 , 300 MHz) 7.5 (s, 1H), 7.2 (d, 1H, J=7), 7.15 (d, 1H, J=7), 6.5 (s, 1H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 7H), 3.5-3.3 (m, 2H), 2.9 (septet, 1H, J=7), 2.55-2.35 (br m, 3H), 2.35-2.25 (m, 2H), 1.3 (d, 6H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: calcd: 433.1603 (M+H), found: 433.1586.
EXAMPLE 101
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-chlropurine
Part A: Fuming nitric acid (40 mL) was added in portions to 4,6-dihydroxy-2-methylpyrimidine while cooling the reaction flask on ice. After completion of addition, the reaction was stirred an additional 60 min over ice followed by another 60 min at room temperature. The reaction mixture was then poured over ice (60 g) and the ice allowed to melt. A light pink solid was isolated by filtration and washed with cold water (50 mL). The solid was dried in a vacuum oven overnight to yield 22.6 g of product.
Part B: The product of Part A was added portionwise to phosphorus oxychloride (125 mL) under a nitrogen atmosphere. N,N-diethylaniline (25 mL) was added portionwise and the reaction mixture was refluxed for 150 min. then cooled to room temperature. The reaction mixture was poured over ice (750 g) and stirred for 1 hr. The aqueous layer was extracted with diethyl ether (4×400 mL) and the extracts combined. The extracts were washed with brine (300 mL) and the organic layer dried over Na 2 SO 4 . The dried organic layer was filtered and stripped down to a tan solid (21.51 g).
Part C: The product of Part B (3.0 g) was added to acetic acid (5.5 mL) and methanol (25 mL). This solution was added to iron powder (3.0 g) and the reaction was stirred for two hrs at 60-65° C. The reaction was cooled to room temperature and the product was filtered. The filtrate was stripped to a brown solid, which was extracted with ethyl acetate (3×100 mL). The combined organic extracts were washed with NaOH (1 N, 2×100 mL), water (100 mL), and brine (100 mL). The organic layer was dried over Na 2 SO 4 , filtered, and stripped to yield (2.13 g) an amber liquid that solidified upon cooling. MS (M+H) + 178.
Part D: The product of Part C (2.0 g), 2-bromo-4-isopropylaniline (2.4 g), and diisopropylethylamine (1.52 g) were mixed and the reaction mass was heated to 160° C. for 25 min. Purification of the reaction mass by flash chromatography (CH 2 Cl 2 :MeOH, 50:1; silica) followed by stripping of the product-containing fractions yielded (1.45 g) an off white solid. MS (M+H) + 356.
Part E: The product of Part D (1.32 g), triethylorthoformate (10 mL), and acetic anhydride (10 mL) were mixed under nitrogen and refluxed for 4.5 hrs. The reaction mixture was reduced to an oil and water (50 mL) was added. The aqueous mixture was basified (pH 8) with solid Na 2 CO 3 and extracted with CHCl 3 (3×80 mL). The combined organic extracts were dried over Na 2 SO 4 , filtered and stripped to yield an amber oil (1.63 g). Purification by flash chromatography (CH 2 Cl 2 :MeOH, 50:1; silica) yielded a light amber glass 9[2-bromo-4(2-propyl )phenyl]-2-methyl-6-chloropurine (0.94 g). Mp 49-52° C. MS (M+H) + 367.
EXAMPLE 102
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-morpholinopurine
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-chloropurine (1.3 g) and morpholine (10 mL) were combined under nitrogen and refluxed for 6 hrs. The reaction mixture was concentrated by rotovap and the residue was purified by flash chromatography (CH 2 C 2 :MeOH, 50:1; silica) to yield a yellow solid (0.54 g). MS (M+H) + 416, 418.
EXAMPLE 103
9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine
Part A: Fuming nitric acid (40 mL) was added in portions to 4,6-dihydroxy-2-methylpyrimidine while cooling the reaction flask on ice. After completion of addition, the reaction was stirred an additional 60 min over ice followed by another 60 min at room temperature. The reaction mass was then poured over ice (60 g) and the ice allowed to melt. A light pink solid was isolated by filtration and washed with cold water (50 mL). The solid was dried in a vacuum oven overnight to yield 22.6 g of product.
Part B: The product of Part A was added portionwise to phosphorus oxychloride (125 mL) under a nitrogen atmosphere and N,N-diethylaniline (25 mL) was added portionwise. The reaction mixture was refluxed for 150 min, cooled to room temperature, poured over ice (750 g) and stirred for 1 hr. The aqueous layer was extracted with diethyl ether (4×400 mL) and the extracts combined. The extracts were washed with brine (300 mL), dried over Na 2 SO 4 , filtered, and stripped down to a tan solid (21.51 g).
Part C: The product of Part B (6.5 g) was added to acetic acid (11 mL) and methanol (50 mL). This solution was added to iron powder (6.0 g), stirred for two hrs at 60-65° C., cooled to room temperature, and filtered. The filtrate was stripped to a brown solid, which was extracted with ethyl acetate (3×100 mL). The combined organic extracts were washed with NaOH (1 N, 2×100 mL), water (100 mL), and brine (100 mL). The organic layer was dried over Na 2 SO 4 , filtered, and stripped to yield (4.75 g) an amber liquid that solidified upon cooling. MS (M+H) + 178.
Part D: The product of Part C (4.75 g) and 2-bromo-4-isopropylaniline (5.71 g) were mixed and the reaction mass heated to 140° C. for 60 min. The reaction mass was suspended in CH 2 Cl 2 (300 mL) and the organic solution was washed with NaOH (1 N, 3×250 mL) and brine (250 mL). The organic phase was dried over Na 2 SO 4 , and stripped to a dark liquid (9.28 g). The liquid was purified by flash chromatography (CH 2 Cl 2 :MeOH, 50:1; silica) to yield (6.27 g) a light red solid. MS (M+H) + 356.
Part E: The product of Part D (2.0 g) was added to acetic acid (50%, 20 mL) and sodium nitrite (0.407 g) in water (2.0 mL) was added dropwise at room temperature. After 4.25 hrs, the reaction mixture was filtered and the collected solid was purified by flash chromatography (CH 2 Cl 2 :MeOH, 50:1; silica) to yield an orange oil 9 [2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine (0.75 g). MS (M+H) + 368.
EXAMPLE 104
9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-morpholinopurine
9 [2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine (1.34g) and morpholine (10 mL) were combined under nitrogen and refluxed for 2.5 hrs. CH 2 Cl 2 (200 mL) was added to the reaction mixture and the resulting solution washed with water (2×100 mL) and brine (100 mL). The organic phase was dried over Na 2 SO 4 , concentrated by rotovap and the residue purified by flash chromatography (CH 2 Cl 2 , silica) to yield a yellow solid (0.62 g). MP 145-148° C. MS (M+H) + 417, 419.
EXAMPLE 105
2-(N-(2,4-dimethyoxypyrimidin-5-yl)-N-ethylamino)-4,6dimethylpyrimidine
Part A: 5-Nitrouracil (25 g) was added to phosphorus oxychloride (130 mL) and N,N-diethylamine (32 mL) and the reaction was heated to reflux for 70 min. under nitrogen. After cooling to room temperature, the reaction mixture was poured over ice (600 g) and the mixture stirred until it reached room temperature (60 min). The aqueous layer was extracted with diethyl ether (4×300 mL). The extracts were combined, washed with brine (200 mL), and dried over Na 2 SO 4 . The organic layer was then stripped to yield an orange red liquid (17.69 g).
Part B: The product of Part A (17.69 g) in 60 mL methanol was added dropwise to a solution of sodium methoxide (30% wt, 38 mL) while cooling the flask in an ice bath. After addition was complete, the reaction mixture was stirred overnight at room temperature and then refluxed for 4 hrs. After cooling to room temperature, the reaction mixture was poured over ice (500 g) and the white precipitate that formed (10.38 g) was collected by filtration.
Part C: The product of Part B (4.1 g) and Pd/C (10% wt, 0.15 g) were added to ethanol (70 mL), methanol (10 mL) and water (1 mL) in a Parr reactor. The reaction mass was treated with hydrogen until TLC analysis showed no starting material. The reaction mass was filtered through celite and the filtrate stripped yielding a tan solid (3.32 g).
Part D: The product of Part C (1.086 g) and 2-chloro-4,6-dimethyl-pyrimidine (1.0 g) were dissolved in THF (50 mL) under nitrogen. Sodium hydride (0.336 g, 60% wt dispersion in oil) was added portionwise. After addition, the reaction was refluxed for 5.5 hrs, cooled to room temperature and the solid removed by filtration. The filtrate was concentrated and purified by flash chromatography (CH 2 C 2 :MeOH, 90:10, silica) to give a solid (0.52 g). MS (M+H) + 262.
Part E: The product of Part D (2.0 g) and iodoethane (1.49 g) were dissolved in dimethylformamide (20 mL) under nitrogen. Sodium hydride (0.383 g, 60% wt dispersion in oil) was added portionwise. After addition, stirring was continued at room temperature for 22 hrs. Water (200 mL) was added and the mixture was extracted with ethyl acetate (3×200 mL). The combined extracts were washed with water (100 mL) and brine (100 mL), dried over Na 2 SO 4 , filtered, and stripped to give an amber liquid 2-(N-(2,4-dimethyoxypyrimidin-5-yl)-N-ethylamino)-4,6-dimethylpyrimidine (2.68 g). MS (M+H)+290.
Many of the compounds described above may be converted to their salts by addition of the corresponding acid in a solution of the compound in an organic solvent. The choice of addition salt described above is not intended to limit the invention, and is intended to be illustrative of the generality of the described syntheses. Physical properties of representative compounds that can be synthesized utilizing the methods described above are provided in the tables below (Table 1 through Table 17). The column in the tables headed “Synth. Ex.” refers to the synthesis examples 1-105; supra. The designations “MS” and “HRMS” refer to low and high resolution mass spectral data, respectively.
TABLE 1
Synth.
Ex.
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
1*
1
CH 3
CH 3
CH 3
Br, H
CH 3
120-121
2*
CH 3
CH 3
CH 3
CH 3 O, H
CH 3 O
112-113
3*
CH 3
CH 3
allyl
Br, H
H
127-129
4*
2
CH 3
CH 3
CH 3
Br, H
iC 3 H 7
163-164
5
CH 3
CH 3
C 2 H 5
Br, H
H
94-95
6
CH 3
morpholino
CH 3
Br, H
CH 3
40-42
7
CH 3
CH 3
C 2 H 5
CH 3 O, H
CH 3 O
120-121
8
CH 3
CH 3
CH 3
Br, H
Br
101-103
9*
3
CH 3
CH 3
CH 3
Br, H
C 2 H 5
126-127
10*
CH 3
CH 3
C 2 H 5
Br, H
tC 4 H 9
191-193
11*
CH 3
CH 3
CH 3
Br, H
tC 4 H 9
193-195
12
CH 3
CH 3
CH 3
Br, H
CF 3
106-107
13*
CH 3
CH 3
C 2 H 5
Br, H
CF 3
125-130
14
CH 3
CH 3
CH 3
CH 3 O,
CH 3 O
145-146
CH 3 O
15
CH 3
CH 3
C 2 H 5
CH 3 O,
CH 3 O
115-116
CH 3 O
16*
4
CH 3
morpholino
C 2 H 5
Br, H
iC 3 H 7
219-222
17*
CH 3
morpholino
allyl
Br, H
iC 3 H 7
208-211
18*
CH 3
CH 3
allyl
Br, H
nC 4 H 9
116-118
19*
CH 3
CH 3
C 2 H 5
Br, H
nC 4 H 9
124-126
20
CH 3
CH 3
nC 3 H 7
Br, H
nC 4 H 9
49-50
21*
5
CH 3
CH 3
C 2 H 5
Br, H
iC 3 H 7
151-153
22*
CH 3
CH 3
C 2 H 5
Br, H
cC 6 H 11
170-172
23*
C 2 H 5
C 2 H 5
C 2 H 5
Br, H
iC 3 H 7
120-121
24*
C 2 H 5
C 2 H 5
C 2 H 5
Br, H
nC 4 H 9
116-118
25
CH 3
4-CHO-piperazino
C 2 H 5
Br, H
iC 3 H 7
61-63
26*
CH 3
CH 3
allyl
Br, H
iC 3 H 7
141-142
27*
CH 3
CH 3
C 2 H 5
I, H
iC 3 H 7
149-150
28
CH 3
CF 3
C 2 H 5
Br, H
iC 3 H 7
liquid
29*
6
CH 3
CH 3
C 2 H 5
Br, H
C 2 H 4 —OCH 3
117-119
30
7
CH 3
4-morpholino
C 2 H 5
I, H
iC 3 H 7
96-98
31*
8
CH 3
2-thiopheno
C 2 H 5
Br, H
iC 3 H 7
95-97
32
CH 3
CH 3
CH 2 CN
Br, H
iC 3 H 7
33*
9
CH 3
CH 3
CH 2 cyclopropyl
Br, H
iC 3 H 7
146-148
34
10
CH 3
CH 3
propargyl
Br, H
iC 3 H 7
MS
35
11
CH 3
CH 3
C 2 H 5
I, H
C 2 H 4 —OCH 3
36
CH 3
CH 3
C 2 H 5
I, H
CH 2 —OCH 3
37*
CH 3
4-allyloxy-piperidin-1-yl
C 2 H 5
Br, H
iC 3 H 7
38
CH 3
morpholino
C 2 H 5
I, H
CH 2 —OCH 3
39
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 2 —OCH 3
40
CH 3
CH 3
C 2 H 5
(CH 3 ) 2 N,
CH 2 —OCH 3
H
41
CH 3
CH 3
C 2 H 5
CH 3 S, H
iC 3 H 7
42
CH 3
CH 3
C 2 H 5
(CH 3 ) 2 N,
iC 3 H 7
H
43
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 3 S
44
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 2 —SCH 3
45
CH 3
CH 3
C 2 H 5
Br, Br
iC 3 H 7
46
CH 3
thiomorpholino
C 2 H 5
Br, Br
iC 3 H 7
47
CH 3
CH 3
C 2 H 5
I, H
I
48
CH 3
morpholino
C 2 H 5
I, H
I
49*
12
H
CH 3
C 2 H 5
Br, H
iC 3 H 7
145-147
50
13
CH 3
N(CH 3 )CH 2 —CH 2 OH
C 2 H 5
Br, H
iC 3 H 7
HRMS
51*
CH 3
CH 3
CH 2 CH 3
CH 3 O,
CH 3
CH 3 O
52*
CH 3
CH 3
CH 3
H, H
I
175-177
53*
CH 3
CH 3
CH 3
I, H
H
164-166
54*
CH 3
CH 3
CH 3
CF 3 , H
H
55*
CH 3
CH 3
CH 2 CH 3
Br, H
C 2 H 4 —OCH 2 CH 3
127-129
56
14
CH 3
thiomorpholino-S-oxide
C 2 H 5
I, H
iC 3 H 7
52-55
57*
15
CH 3
CH 3
C 2 H 5
Br, H
O—iC 3 H 7
MS
58
16
CH 3
C(═O)-4-morpholino
C 2 H 5
Br, H
iC 3 H 7
145
59
17
CH 3
CH 2 -4-morpholino
C 2 H 5
Br, H
iC 3 H 7
liquid
60
CH 3
C(═O)-1-piperidinyl
C 2 H 5
Br, H
iC 3 H 7
107-108
61
18
CH 3
C(═O)OCH 3
C 2 H 5
Br, H
iC 3 H 7
81-82
62
CH 3
C(═O)NH-cyclohexyl
C 2 H 5
Br, H
iC 3 H 7
115
63
19
CH 3
C(═O)-4-methyl)-1-piperazinyl
C 2 H 5
Br, H
iC 3 H 7
81-82
64
20
CH 3
CH 3
C 2 H 5
Br, H
CH 2 —CH 2 OH
58-60
65*
21
CH 3
CH 3
CH 3
OCH 3 , H
CH 3
66*
CH 3
CH 3
CH 3
H, H
iC 3 H 7
67
CF 3
CH 3
C 2 H 5
Br, H
iC 3 H 7
68*
CH 3
CH 3
CH 3
H, H
I
175-177
69*
CH 3
CH 3
CH 3
CF 3 , H
H
70*
CH 3
CH 3
CH 2 CN
Br, H
iC 3 H 7
71*
CH 3
CH 3
CH 3
Br, H
H
72*
CH 3
(2-methoxymethyl)-1-pyrrolyl
CH 3
Br, H
H
73
22
CH 3
4-thiomorpholino
C 2 H 5
I, H
iC 3 H 7
51-53
73*
22
CH 3
4-thiomorpholino
C 2 H 5
I, H
iC 3 H 7
234-236
74
CH 3
4-hydroxy-1-piperidinyl
C 2 H 5
Br, H
iC 3 H 7
61-63
138
24
CH 3
CH 2 OH
CH 3
Br, H
iC 3 H 7
oil, MS
139
25
CH 3
CH 2 OCH 3
CH 3
Br, H
iC 3 H 7
oil, MS
140
26
CH 3
SCH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
141
CH 3
CH 3
C 2 H 5
CH 3 O, Cl
CH 3 O
99-102
142
CH 3
C 2 H 5
Br, H
iC 3 H 7
78-81
143*
CH 3
C 2 H 5
Br, H
iC 3 H 7
131-135
144*
CH 3
C 2H 5
Br, H
iC 3 H 7
98-102
145
CH 3
CH 3
H
CH 3 O, Cl
CH 3 O
170-173
146*
CH 3
NHNH 2
C 2 H 5
Br, H
iC 3 H 7
117-121
147
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
148
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
149
CH 3
OCH 2 Ph
C 2 H 5
Br, H
iC 3 H 7
oil, MS
150
CH 3
O(CH 2 ) 3 SCH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
152
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
153
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
154
CH 3
Cl
C 2 H 5
Br, H
iC 3 H 7
oil, MS
155
CH 3
NH 2
C 2 H 5
Br, H
iC 3 H 7
oil, MS
156
CH 3
O(CH 2 ) 3 SO 2 CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
157
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
158
CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
159
27
CH 3
SO 2 CH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
160
28
CH 3
SOCH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
161*
CH 3
O(CH 2 ) 2 N(CH 3 ) 2
C 2 H 5
Br, H
iC 3 H 7
143-146
162
CH 3
O(CH 2 ) 3 SOCH 3
C 2 H 5
Br, H
iC 3 H 7
oil, MS
163
CH 3
NH(CH 2 ) 2 N(CH 3 ) 2
C 2 H 5
Br, H
iC 3 H 7
oil, MS
164
CH 3
NH(CH 2 ) 4 NH 2
C 2 H 5
Br, H
iC 3 H 7
oil, MS
165
31
CH 3
morpholino
allyl
I, H
iC 3 H 7
109-112
166
34
CH 3
thiomorpholino
H
Br, Br
iC 3 H 7
194-195
167
32
CH 3
Cl
C 2 H 5
I, H
iC 3 H 7
liquid
168
35
CH 3
CH 3
C 2 H 5
SCH 3 , H
iC 3 H 7
64-66
169
37
CH 3
CH 3
C 2 H 5
S(O)CH 3 ,
iC 3 H 7
144-146
H
170*
36
CH 3
CH 3
C 2 H 5
SCH 3 , H
iC 3 H 7
141-142
171
38
CH 3
thiazolidino
C 2 H 5
I, H
iC 3 H 7
liquid
172
39
CH 3
CH 3
C 2 H 5
I, H
CH 3 OCH 2
liquid
173*
40
CH 3
CH 3
C 3 H 6
S—, H
iC 3 H 7
157-159
174
41
CH 3
CH 3
C 2 H 5
S(O) 2 CH 3 ,
iC 3 H 7
174-176
H
175*
42
CH 3
CH 3
C 2 H 5
SC 2 H 5 , H
iC 3 H 7
128-130
176
43
CH 3
CH 3
C 2 H 5
SC 2 H 5 , H
CH 3 CNO—CH 3
77-78
177
33
CH 3
N-methyl prolinol
C 2 H 5
SCH 3 , H
iC 3 H 7
101-103
178
44
CH 3
CH 3
C 2 H 5
SCH 3 , H
CH 3 CNO—CH 3
106-108
179
45
CH 3
CH 3
C 2 H 5
S(O) 2 CH 3 ,
CH 3 CNO—CH 3
151-154
H
180
46
CH 3
CH 3
C 2 H 5
SCH 3 , H
Br
91-93
181
47
CH 3
CH 3
iC 3 H 7
SCH 3 , H
C 2 H 5
85-87
182*
48
CH 3
CH 3
C 2 H 5
SCH 3 , H
C 2 H 5
140-141
183
49
CH 3
CH 3
C 2 H 5
SCH 3 , H
CH 3 NCO—CH 3
158-160
184
50
CH 3
CH 3
C 2 H 5
SCH 3 , H
CO 2 C 2 H 5
99-100
185
51
CH 3
CH 3
C 2 H 5
SCH 3 , H
OCH 3
128-130
186
52
CH 3
CH 3
C 2 H 5
SCH 3 , H
CN
99-100
187
53
CH 3
CH 3
C 2 H 5
SCH 3 , H
COCH 3
125-126
188
54
CH 3
CH 3
C 2 H 5
SCH 3 , H
COC 2 H 5
139-141
189
55
CH 3
CH 3
C 2 H 5
SCH 3 , H
CH(OCH 3 )CH 3
liquid
190
56
CH 3
CH 3
C 2 H 5
SCH 3 , H
NHCH 3
141-142
191
57
CH 3
CH 3
C 2 H 5
SCH 3 , H
N(CH 3 ) 2
119-120
192
CH 3
pyrrolidino
C 2 H 5
Br, H
iC 3 H 7
106-107
193
CH 3
pyrrolidino
CH 3
Br, H
iC 3 H 7
119-120
194
C 2 H 5
piperidino
CH 3
Br, H
iC 3 H 7
211-212
195
CH 3
piperidino
CH 3
Br, H
iC 3 H 7
186-187
196
CH 3
CH 3
C 3 H 7
Br, H
iC 3 H 7
150-151
197
CH 3
CH 3
C 4 H 9
Br, H
iC 3 H 7
159-160
198
CH 3
CH 3
N,N-diethylacetamidino
Br, H
iC 3 H 7
101-102
199
CH 3
CH 3
N,N-diethylaminoethyl
Br, H
iC 3 H 7
65-66
200
CH 3
CH 3
N,N-dimethylaminoethyl
Br, H
iC 3 H 7
118-120
201
CH 3
CH 3
Et
Br, H
OEt
HRMS
202
CH 3
CH 3
Et
Br, OMe
OMe
113-115
203
CH 3
CH 3
H
Br, OMe
OMe
177-179
204
CH 3
CH 3
H
Br, H
OMe
118-119
205
CH 3
CH 3
Allyl
Br, OMe
OMe
88-90
206
CH 3
CH 3
Et
Br, H
OMe
HRMS
207
CH 3
CH 2 OCH 3
Et
I, H
iC 3 H 7
HRMS
208
CH 3
CH 2 O(4-methoxyphenyl)
Et
Br, H
iC 3 H 7
HRMS
209
CH 3
CH 2 OPh
Et
Br, H
iC 3 H 7
HRMS
210
CH 3
CH 2 O(2-pyridyl)
Et
Br, H
iC 3 H 7
HRMS
211
CH 3
CH 2 OCH 2 (4-methyl benzoate)
Et
Br, H
iC 3 H 7
HRMS
212
CH 3
CH 2 OCH 2 (3,4,5-trimethoxyphenyl)
Et
Br, H
iC 3 H 7
HRMS
213
CH 3
CH 2 O(2-pyrimidinyl)
Et
Br, H
iC 3 H 7
HRMS
214
CH 3
CH 2 O(3,4,5-trimethoxyphenyl)
Et
Br, H
iC 3 H 7
HRMS
215
CH 3
CH 2 O(3-(N,N-dimethyl)anilino)
Et
Br, H
iC 3 H 7
HRMS
216
CH 3
CH 2 OCH 2 (3-pyridyl)
Et
Br, H
iC 3 H 7
HRMS
217
CH 3
CH 2 O(4-methyl benzoate)
Et
Br, H
iC 3 H 7
136-139
218
CH 3
CH 2 O(4-(1-imidazole)phenyl)
Et
Br, H
iC 3 H 7
HRMS
219
CH 3
CH 2 OCH 2 (4-pyridyl)
Et
Br, H
iC 3 H 7
HRMS
220
CH 3
CH 2 OCH 3
Et
Br, H
iC 3 H 7
221
CH 3
CH 2 OCH 2 (2-furyl)
Et
Br, H
iC 3 H 7
HRMS
222
58
CH 3
CHO
Et
Br, H
iC 3 H 7
HRMS
223
CH 3
CH 3
H
Br, Br
OMe
175-177
224
63
CH 3
CH 3
Et
Br, Br
OEt
107-108
225
59
CH 3
CH 2 OCH 2 CH 2 OH
Et
Br, H
iC 3 H 7
HRMS
226
CH 3
CH 3
Et
Br, Br
OMe
101-103
227
CH 3
CH 2 OCH 2 CH 2 OCH 3
Et
Br, H
iC 3 H 7
HRMS
228
CH 3
CH 3
H
Br, Br
OEt
165-167
229
CH 3
CH 2 OCH 2 CO(4-morpholino)
Et
Br, H
iC 3 H 7
HRMS
230
60
CH 3
CH 3
Et
Br, OH
OMe
157-160
231
CH 3
CH 2 OCH 2 CH 2 (4-morpholino)
Et
Br, H
iC 3 H 7
HRMS
268
CH 3
(4-(2-methoxyphenyl)piperazinyl)carbonyl
Et
Br, H
iC 3 H 7
57-60
269
CH 3
(1,2,3,4-tetrahydroquinolinyl)carbonyl
Et
Br, H
iC 3 H 7
143-145
270
CH 3
(2-furylmethyl)aminocarbonyl
Et
Br, H
iC 3 H 7
87-88
271
CH 3
MeNHCO
Et
Br, H
iC 3 H 7
oil, MS
272
CH 3
(4-(pyrazinyl)piperazino)carbonyl
Et
Br, H
iC 3 H 7
51-53
273
CH 3
(4-(2-pyrimidyl)piperazino)carbonyl
Et
Br, H
iC 3 H 7
114-116
274
CH 3
(4-(2-pyridyl)piperazino)carbonyl
Et
Br, H
iC 3 H 7
oil, MS
275
CH 3
(4-(2-methoxyphenyl)piperazinyl)methyl, HCl salt
Et
Br, H
iC 3 H 7
102-104
276
CH 3
N-(2-furylmethyl)-N-methylaminomethyl
Et
Br, H
iC 3 H 7
oil, MS
277
CH 3
(1,2,3,4-tetrahydroquinolinyl)methyl, HCl salt
Et
Br, H
iC 3 H 7
88-90
278
CH 3
(4-pyrazinylpiperazino)methyl
Et
Br, H
iC 3 H 7
oil, MS
279
CH 3
dimethylaminomethyl
Et
Br, H
iC 3 H 7
oil, MS
280
CH 3
(4-(2-pyridyl)piperazino)methyl, HCl salt
Et
Br, H
iC 3 H 7
117-119
281
CH 3
(4-(2-pyrimidyl)piperazino)methyl, HCl salt
Et
Br, H
iC 3 H 7
125-127
282
CH 3
Me 2 NCO
Et
Br, H
iC 3 H 7
80-82
283
CH 3
3-indoylcarbonyl, HCL salt
Et
Br, H
iC 3 H 7
105-107
284
CH 3
3-pyridylcarbonyl
Et
Br, H
iC 3 H 7
165-167
285
CH 3
3-phenylcarbonyl
Et
Br, H
iC 3 H 7
oil, MS
286
CH 3
3-pyrazolylcarbonyl
Et
Br, H
iC 3 H 7
171-173
287
CH 3
4-methoxyphenylcarbonyl
Et
Br, H
iC 3 H 7
104-106
288
CH 3
2-furylcarbonyl
Et
Br, H
iC 3 H 7
136-138
289
CH 3
bis(4-methoxyphenyl)hydroxymethyl
Et
Br, H
iC 3 H 7
63-65
290
CH 3
bis(2-furyl)hydroxymethyl
Et
Br, H
iC 3 H 7
97-99
291
CH 3
(2-furyl)hydroxymethyl
Et
Br, H
iC 3 H 7
oil, MS
292
CH 3
(4-methoxyphenyl)hydroxymethyl
Et
Br, H
iC 3 H 7
oil, MS
293
CH 3
diphenylhydroxymethyl
Et
Br, H
iC 3 H 7
56-58
294
CH 3
bis(4-pyridyl)hydroxymethyl
Et
Br, H
iC 3 H 7
68-70
295
CH 3
(1-hydroxy-1-methyl)ethyl
Et
Br, H
iC 3 H 7
oil, MS
296
CH 3
1-hydroxyethyl
Et
Br, H
iC 3 H 7
oil, MS
*Hydrochloride salt
TABLE 2
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
75
CH 3
CH 3
CH 3
Br, H
CH 3
76
CH 3
CH 3
CH 3
CH 3 O, H
CH 3 O
77
CH 3
CH 3
allyl
Br, H
H
78*
CH 3
CH 3
CH 3
Br, H
iC 3 H 7
178-179
79
CH 3
CH 3
C 2 H 5
Br, H
H
80
CH 3
morpholino
CH 3
Br, H
CH 3
81
CH 3
CH 3
CH 2 H 5
CH 3 O, H
CH 3 O
82
CH 3
CH 3
CH 3
Br, H
Br
83
CH 3
CH 3
CH 3
Br, H
CH 2 H 5
84
CH 3
CH 3
C 2 H 5
Br, H
tC 4 H 9
85
CH 3
CH 3
CH 3
Br, H
tC 4 H 9
86
CH 3
CH 3
CH 3
Br, H
CF 3
87
CH 3
CH 3
CH 2 H 5
Br, H
CF 3
88
CH 3
CH 3
CH 3
CH 3 O, CH 3 O
CH 3 O
89
CH 3
CH 3
C 2 H 5
CH 3 O, CH 3 O
CH 3 O
90
CH 3
morpholino
C 2 H 5
Br, H
iC 3 H 7
91
CH 3
morpholino
allyl
Br, H
iC 3 H 7
92
CH 3
CH 3
allyl
Br, H
nC 4 H 9
93
CH 3
CH 3
C 2 H 5
Br, H
nC 4 H 9
94
CH 3
CH 3
nC 3 H 7
Br, H
nC 4 H 9
95*
CH 3
CH 3
C 2 H 5
Br, H
iC 3 H 7
194-196
96
CH 3
CH 3
C 2 H 5
Br, H
cC 6 H 11
97
C 2 H 5
C 2 H 5
C 2 H 5
Br, H
iC 3 H 7
98
C 2 H 5
C 2 H 5
C 2 H 5
Br, H
nC 4 H 9
99
CH 3
4-CHO-piperazino
C 2 H 5
Br, H
iC 3 H 7
100
CH 3
CH 3
allyl
Br, H
iC 3 H 7
101
CH 3
CH 3
C 2 H 5
I, H
iC 3 H 7
102
CH 3
CF 3
C 2 H 5
Br, H
iC 3 H 7
103
CH 3
CH 3
C 2 H 5
Br, H
C 2 H 4 —OCH 3
104
CH 3
morpholino
C 2 H 5
I, H
iC 3 H 7
105
CH 3
2-thiopheno
C 2 H 5
Br, H
iC 3 H 7
106
CH 3
CH 3
CH 2 CN
Br, H
iC 3 H 7
107
CH 3
CH 3
CH 2 cyclopropyl
Br, H
iC 3 H 7
108
CH 3
CH 3
propargyl
Br, H
iC 3 H 7
109
CH 3
CH 3
C 2 H 5
I, H
C 2 H 4 —OCH 3
110
CH 3
CH 3
C 2 H 5
I, H
CH 2 —OCH 3
111
CH 3
morpholino
C 2 H 5
I, H
C 2 H 4 —OCH 3
112
CH 3
morpholino
C 2 H 5
I, H
CH 2 —OCH 3
113
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 2 —OCH 3
114
CH 3
CH 3
C 2 H 5
(CH 3 ) 2 N, H
CH 2 —OCH 3
115
CH 3
CH 3
C 2 H 5
CH 3 S, H
iC 3 H 7
116
CH 3
CH 3
C 2 H 5
(CH 3 ) 2 N, H
iC 3 H 7
117
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 3 S
118
CH 3
CH 3
C 2 H 5
CH 3 S, H
CH 2 —SCH 3
119
CH 3
CH 3
C 2 H 5
Br, Br
iC 3 H 7
120
CH 3
thiomorpholino
C 2 H 5
Br, Br
iC 3 H 7
121
CH 3
CH 3
C 2 H 5
I, H
I
122
CH 3
morpholino
C 2 H 5
I, H
I
123
H
CH 3
C 2 H 5
Br, H
iC 3 H 7
124
CH 3
N(CH 3 )CH 2 —CH 2 OH
C 2 H 5
Br, H
iC 3 H 7
125
CH 3
CH 3
CH 2 CH 3
CH 3 O, CH 3 O
CH 3
126
CH 3
CH 3
CH 3
H, H
I
127
CH 3
CH 3
CH 3
I, H
H
128
CH 3
CH 3
CH 3
CF 3 , H
H
129*
H
H
CH 2 CH 3
Br, H
iC 3 H 7
*Hydrochloride salt
TABLE 3
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
130*
CH 3 O
CH 3 O
CH 2 CH 3
Br, H
iC 3 H 7
104-106
*Hydrochloride salt
TABLE 4
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
131*
CH 3
CH 3
H
Br, H
iC 3 H 7
124-125
*Hydrochloride salt
TABLE 5
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
132*
CH 3
CH 3
CH 2 CH 3
Br, H
iC 3 H 7
144-145
*Hydrochloride salt
TABLE 6
Synth.
Ex.
Ex.
R 1
R 3
R 4
X, X′
R 5
mp, ° C.
133
CH 3
CH 3
Et
Br, H
iC 3 H 7
oil, MS
134
23
CH 3
morpholino
Et
Br, H
iC 3 H 7
oil, MS
134*
CH 3
morpholino
Et
Br, H
iC 3 H 7
59-63
135
CH 3
thiomorpholino
Et
I, H
iC 3 H 7
oil, MS
136
CH 3
morpholino
Et
I, H
iC 3 H 7
oil, MS
137
CH 3
piperidinyl
Et
I, H
iC 3 H 7
oil, MS
232
CH 3
N′N-diethyl
Et
Br, H
iC 3 H 7
oil, MS
233
Cl
Cl
Et
Br, H
iC 3 H 7
oil, MS
234
OCH 3
OCH 3
Et
Br, H
iC 3 H 7
oil, MS
235
Cl
Cl
Et
I, H
iC 3 H 7
oil, MS
236
CH 3
imidazolino
Et
Br, H
iC 3 H 7
>200
237
CH 3
morpholino
Et
Br, CH 3 O
CH 3 O
90-95
238
CH 3
N(CH 3 ) 2
Et
Br, CH 3 O
CH 3 O
65-58
239
CH 3
morpholino
Et
CH 3 O, CH 3 O
CH 3 O
oil, MS
240
CH 3
N(CH 3 ) 2
Et
Br, H
iC 3 H 7
72-75
241
CH 3
thiazolidino
Et
Br, H
iC 3 H 7
70-72
242*
29
CH 3
benzyloxy
Et
Br, H
iC 3 H 7
89-90
243
CH 3
phenyloxy
Et
Br, H
iC 3 H 7
140-142
244
CH 3
4-ethylcarboxypiperizine
Et
Br, CH 3 O
CH 3 O
65-70
245
CH 3
4-carboxypiperizine
Et
Br, CH 3 O
CH 3 O
95-100
246
CH 3
HC(CO 2 Et) 2
Et
Br, H
iC 3 H 7
oil, MS
247
CH 3
PhCHCN
Et
Br, CH 3 O
CH 3 O
50-52
248
CH 3
morpholino
iC 3 H 7 O
Br, CH 3 , O
CH 3 O
oil, MS
249*
30
Cl
Cl
Et
I, H
CH(CH 3 ) 2 OH
oil, MS
250
CH 3
Cl
C 2 H 5
Br, H
iC 3 H 7
oil, MS
*Hydrochloride salt
TABLE 7
Synth.
X′,
Ex.
Ex.
R 1
R 2
R 4
X
R 5
R 6
mp, ° C.
251
62
CH 3
CH 3
Et
Br,
OMe
Br
133-138
OMe
252
CH 3
CH 3
H
H,
OMe
Br
179-181
OMe
253
61
CH 3
CH 3
Et
H,
OMe
Br
143-145
OMe
TABLE 8
Synth.
Ex.
Ex.
R 1
R 3
R 30
X
X′
R 5
mp, ° C.
254
64
CH 3
CH 3
CN
Br
H
i-Pr
105.8
313
CH 3
CH 3
CN
I
H
i-Pr
314
CH 3
CH 3
CN
Br
6-CH 3
i-Pr
315
CH 3
—morpholino
CN
I
6-CH 3
i-Pr
316
CH 3
Cl
CN
I
H
1-methoxy ethyl
317
CH 3
Ph
CN
I
H
1-methoxy ethyl
318
CH 3
CH 3
CN
Cl
H
1-methoxy ethyl
319
CH 3
CH 3
CN
I
H
1-methoxy ethyl
320
CH 3
CH 3
CN
Br
H
1-methoxy ethyl
321
CH 3
—morpholino
CN
I
CH 3
OCH 3
255
74
CH 3
Cl
CN
Br
H
i-Pr
179.2
256
66
CH 3
Ph
CN
Br
H
i-Pr
oil
322
CH 3
Ph
CN
—SCH 3
H
i-Pr
323
CH 3
CH 3
H
Cl
OCH 3
i-Pr
257
65
CH 3
CH 3
H
Br
H
i-Pr
MS 343.08
324
CH 3
CH 3
H
—SCH 3
H
i-Pr
258
68
CH 3
CH 3
CN
Br
OCH 3
OCH 3
MS 388.0
325
CH 3
—morpholino
H
I
6-OCH 3
i-Pr
259
75
CH 3
Cl
H
Br
H
i-Pr
MS 363.0
326
CH 3
Ph
H
I
H
1-methoxy ethyl
260
69
CH 3
CH 3
H
Br
OCH 3
OCH 3
MS 360.9
327
CH 3
CH 3
H
I
H
1-methoxy ethyl
328
CH 3
CH 3
H
Br
H
1-methoxy ethyl
329
CH 3
—morpholino
H
I
6-CH 3
OCH 3
330
CH 3
Cl
H
I
6-CH 3
i-Pr
261
67
CH 3
Ph
H
Br
H
i-Pr
MS 405.1
331
CH 3
—NHEt
H
Br
H
i-Pr
332
CH 3
—NHC(═O)CH 3
H
Br
H
i-Pr
333
CH 3
OCH 3
H
Br
H
i-Pr
334
CH 3
—OCH 2 Ph
H
Br
H
i-Pr
335
CH 3
CH 2 OPh
H
Br
H
i-Pr
336
CH 3
2-thiophenylmethoxy
H
Br
H
i-Pr
337
CH 3
—OCH(OH)Ph
H
Br
H
i-Pr
338
CH 3
—n-propoxy
H
Br
H
i-Pr
339
CH 3
—C(═O)N(Me) 2
H
Br
H
i-Pr
340
CH 3
—NHCH 2 Ph
H
Br
H
i-Pr
262
70
Cl
CH 3
CN
Br
H
i-Pr
123.8
341
N—Me 2
CH 3
H
Br
H
i-Pr
342
CH 3
—CH 2 OCH 3
H
Br
H
i-Pr
263
71
Cl
CH 3
H
Br
H
i-Pr
MS 363.0
343
CH 3
CH 3
Et
Br
H
i-Pr
344
CH 3
CH 3
—CCH
Br
H
i-Pr
TABLE 9
Ex.
R 1
R 3
X
X′
R 5
345
CH 3
CH 3
Br
H
i-Pr
346
CH 3
CH 3
I
H
i-Pr
347
CH 3
CH 3
Br
6-OCH 3
OCH 3
348
CH 3
—morpholino
I
6-CH 3
i-Pr
349
CH 3
Ph
Br
H
i-Pr
350
CH 3
CH 3
SMe
H
i-Pr
TABLE 10
Ex.
R 1
R 3
R 30
X
X′
R 5
351
CH 3
CH 3
H
Br
H
i-Pr
352
CH 3
CH 3
H
I
H
i-Pr
353
CH 3
—morpholino
CN
Br
H
i-Pr
354
CH 3
Ph
CN
Br
H
i-Pr
355
CH 3
CH 3
H
SMe
H
i-Pr
TABLE 11
Synth.
ms
Ex.
Ex.
R 5
R 4
R 3
X
Z
K
L
(m + H)
264*
CH 3
ethyl
CH 3
Br
CH
CH
CH
321
265*
OCH 3
ethyl
CH 3
Br
CH
CH
N
337
266*
OCH 3
ethyl
CH 3
H
CH
CH
N
259
267*
OCH 3
ethyl
CH 3
Br
N
CH
N
409
356
i-Pr
ethyl
CH 3
Br
N
N
N
357
i-Pr
allyl
CH 3
Br
N
N
N
358
i-Pr
allyl
CH 3
Br
CH
N
N
359
i-Pr
ethyl
CH 3
Br
CH
N
N
360
i-Pr
ethyl
morpholino
Br
N
N
N
361
i-Pr
allyl
morpholino
Br
N
N
N
362
i-Pr
allyl
morpholino
Br
CH
N
N
363
i-Pr
ethyl
morphoiino
Br
CH
N
N
364
OCH 3
ethyl
CH 3
Br
N
N
N
365
OCH 3
allyl
CH 3
Br
N
N
N
366
OCH 3
allyl
CH 3
Br
CH
N
N
367
OCH 3
ethyl
CH 3
Br
CH
N
N
368
OCH 3
ethyl
morpholino
Br
N
N
N
369
OCH 3
allyl
morpholino
Br
N
N
N
370
OCH 3
allyl
morpholino
Br
CH
N
N
371
OCH 3
ethyl
morpholino
Br
CH
N
N
372
OCH 3
ethyl
CH 3
OCH 3
N
N
N
373
OCH 3
allyl
CH 3
OCH 3
N
N
N
374
105
OCH 3
allyl
CH 3
OCH 3
CH
N
N
290
375
OCH 3
ethyl
CH 3
OCH 3
CH
N
N
376
OCH 3
ethyl
morpholino
OCH 3
N
N
N
377
OCH 3
allyl
morpholino
OCH 3
N
N
N
378
OCH 3
allyl
morpholino
OCH 3
CH
N
N
379
OCH 3
ethyl
morpholino
OCH 3
CH
N
N
380
OCH 3
ethyl
OCH 3
OCH 3
N
N
N
381
OCH 3
allyl
OCH 3
OCH 3
N
N
N
382
OCH 3
allyl
OCH 3
OCH 3
CH
N
N
383
OCH 3
ethyl
OCH 3
OCH 3
CH
N
N
384
OCH 3
ethyl
OCH 2 CH 3
OCH 3
N
N
N
385
OCH 3
allyl
OCH 2 CH 3
OCH 3
N
N
N
386
OCH 3
allyl
OCH 2 CH 3
OCH 3
CH
N
N
387
OCH 3
ethyl
OCH 2 CH 3
OCH 3
CH
N
N
*Hydrochloride salt
TABLE 12
Ex.
R 1
R 3
R 30
X
X′
R 5
388
CH 3
CH 3
CN
Br
H
i-Pr
389
CH 3
CH 3
CN
I
H
i-Pr
390
CH 3
CH 3
CN
Br
6-CH 3
i-Pr
391
CH 3
-morpholino
CN
I
6-CH 3
i-Pr
392
CH 3
Cl
CN
I
H
1-methoxy ethyl
393
CH 3
Ph
CN
I
H
1-methoxy ethyl
394
CH 3
CH 3
CN
Cl
H
1-methoxy ethyl
395
CH 3
CH 3
CN
I
H
1-methoxy ethyl
396
CH 3
CH 3
CN
Br
H
1-methoxy ethyl
397
CH 3
-morpholino
CN
I
CH 3
OCH 3
398
CH 3
Cl
CN
Br
H
i-Pr
399
CH 3
Ph
CN
Br
H
i-Pr
400
CH 3
Ph
CN
—SCH 3
H
i-Pr
401
CH 3
CH 3
H
Cl
OCH 3
i-Pr
402
CH 3
CH 3
H
Br
H
i-Pr
403
CH 3
CH 3
H
—SCH 3
H
i-Pr
404
CH 3
CH 3
CN
Br
OCH 3
OCH 3
405
CH 3
-morpholino
H
I
6-OCH 3
i-Pr
406
CH 3
Cl
H
Br
H
i-Pr
407
CH 3
Ph
H
I
H
1-methoxy ethyl
408
CH 3
CH 3
H
Br
OCH 3
OCH 3
409
CH 3
CH 3
H
I
H
1-methoxy ethyl
410
CH 3
CH 3
H
Br
H
1-methoxy ethyl
411
CH 3
-morpholino
H
I
6-CH 3
OCH 3
412
CH 3
Cl
H
I
6-CH 3
i-Pr
413
CH 3
Ph
H
Br
H
i-Pr
414
CH 3
—NHEt
H
Br
H
i-Pr
415
CH 3
—NHC(═O)CH 3
H
Br
H
i-Pr
416
CH 3
OCH 3
H
Br
H
i-Pr
417
CH 3
—OCH 2 Ph
H
Br
H
i-Pr
418
CH 3
CH 2 OPh
H
Br
H
i-Pr
419
CH 3
2-thiophenyl methoxy
H
Br
H
i-Pr
420
CH 3
OCH(OH)Ph
H
Br
H
i-Pr
421
CH 3
—n-propoxy
H
Br
H
i-Pr
422
CH 3
—C(═O)N(Me)
H
Br
H
i-Pr
423
CH 3
—NHCH 2 Ph
H
Br
H
i-Pr
424
CH 3
CH 3
CN
Br
H
i-Pr
425
N—Me 2
CH 3
H
Br
H
i-Pr
426
CH 3
—CH 2 OCH 3
H
Br
H
i-Pr
427
Cl
CH 3
H
Br
H
i-Pr
428
CH 3
CH 3
Et
Br
H
i-Pr
429
CH 3
CH 3
—CCH
Br
H
i-Pr
TABLE 13
Ex.
R 1
R 3
R 30
X
X′
R 5
430
CH 3
CH 3
CN
Br
H
i-Pr
431
CH 3
CH 3
CN
I
H
i-Pr
432
CH 3
CH 3
CN
Br
6-CH 3
i-Pr
433
CH 3
-morpholino
CN
I
6-CH 3
i-Pr
434
CH 3
Cl
CN
I
H
1-methoxy ethyl
435
CH 3
Ph
CN
I
H
1-methoxy ethyl
436
CH 3
CH 3
CN
Cl
H
1-methoxy ethyl
437
CH 3
CH 3
CN
I
H
1-methoxy ethyl
438
CH 3
CH 3
CN
Br
H
1-methoxy ethyl
439
CH 3
-morpholino
CN
I
CH 3
OCH 3
440
CH 3
Cl
CN
Br
H
i-Pr
441
CH 3
Ph
CN
Br
H
i-Pr
442
CH 3
Ph
CN
—SCH 3
H
i-Pr
443
CH 3
CH 3
H
Cl
OCH 3
i-Pr
444
CH 3
CH 3
H
Br
H
i-Pr
445
CH 3
CH 3
H
—SCH 3
H
i-Pr
446
CH 3
CH 3
CN
Br
OCH 3
OCH 3
447
CH 3
-morpholino
H
I
6-OCH 3
i-Pr
448
CH 3
Cl
H
Br
H
i-Pr
449
CH 3
Ph
H
I
H
1-methoxy ethyl
450
CH 3
CH 3
H
Br
OCH 3
OCH 3
451
CH 3
CH 3
H
I
H
1-methoxy ethyl
452
CH 3
CH 3
H
Br
H
1-methoxy ethyl
453
CH 3
-morpholino
H
I
6-CH 3
OCH 3
454
CH 3
Cl
H
I
6-CH 3
i-Pr
455
CH 3
Ph
H
Br
H
i-Pr
456
CH 3
—NHEt
H
Br
H
i-Pr
457
CH 3
—NHC(═O)CH 3
H
Br
H
i-Pr
458
CH 3
OCH 3
H
Br
H
i-Pr
459
CH 3
—OCH 2 Ph
H
Br
H
i-Pr
460
CH 3
CH 2 OPh
H
Br
H
i-Pr
461
CH 3
2-thiophenyl methoxy
H
Br
H
i-Pr
462
CH 3
OCH(OH)Ph
H
Br
H
i-Pr
463
CH 3
—n-propoxy
H
Br
H
i-Pr
464
CH 3
—C(═O)N(Me) 2
H
Br
H
i-Pr
465
CH 3
—NHCH 2 Ph
H
Br
H
i-Pr
466
Cl
CH 3
CN
Br
H
i-Pr
467
N—Me 2
CH 3
H
Br
H
i-Pr
468
CH 3
—CH 2 OCH 3
H
Br
H
i-Pr
469
Cl
CH 3
H
Br
H
i-Pr
470
CH 3
CH 3
Et
Br
H
i-Pr
471
CH 3
CH 3
—CCH
Br
H
i-Pr
TABLE 14
Ex.
R 1
R 3
R 30
X
X′
R 5
472
CH 3
CH 3
CN
Br
H
i-Pr
473
CH 3
CH 3
CN
I
H
i-Pr
474
CH 3
CH 3
CN
Br
6-CH 3
i-Pr
475
CH 3
-morpholino
CN
I
6-CH 3
i-Pr
476
CH 3
Cl
CN
I
H
1-methoxy ethyl
477
CH 3
Ph
CN
I
H
1-methoxy ethyl
478
CH 3
CH 3
CN
Cl
H
1-methoxy ethyl
479
CH 3
CH 3
CN
I
H
1-methoxy ethyl
480
CH 3
CH 3
CN
Br
H
1-methoxy ethyl
481
CH 3
-morpholino
CN
I
CH 3
OCH 3
482
CH 3
Cl
CN
Br
H
i-Pr
483
CH 3
Ph
CN
Br
H
i-Pr
484
CH 3
Ph
CN
—SCH 3
H
i-Pr
485
CH 3
CH 3
H
Cl
OCH 3
i-Pr
486
CH 3
CH 3
H
Br
H
i-Pr
487
CH 3
CH 3
H
—SCH 3
H
i-Pr
488
CH 3
CH 3
CN
Br
OCH 3
OCH 3
489
CH 3
-morpholino
H
I
6-OCH 3
i-Pr
490
CH 3
Cl
H
Br
H
i-Pr
491
CH 3
Ph
H
I
H
1-methoxy ethyl
492
CH 3
CH 3
H
Br
OCH 3
OCH 3
493
CH 3
CH 3
H
I
H
1-methoxy ethyl
494
CH 3
CH 3
H
Br
H
1-methoxy ethyl
495
CH 3
-morpholino
H
I
6-CH 3
OCH 3
496
CH 3
Cl
H
I
6-CH 3
i-Pr
497
CH 3
Ph
H
Br
H
i-Pr
498
CH 3
—NHEt
H
Br
H
i-Pr
499
CH 3
—NHC(═O)CH 3
H
Br
H
i-Pr
500
CH 3
OCH 3
H
Br
H
i-Pr
501
CH 3
—OCH 2 Ph
H
Br
H
i-Pr
502
CH 3
CH 2 OPh
H
Br
H
i-Pr
503
CH 3
2-thiophenyl methoxy
H
Br
H
i-Pr
504
CH 3
OCH(OH)Ph
H
Br
H
i-Pr
505
CH 3
-n-propoxy
H
Br
H
i-Pr
506
CH 3
C(═O)N(Me) 2
H
Br
H
i-Pr
507
CH 3
—NHCH 2 Ph
H
Br
H
i-Pr
508
Cl
CH 3
CN
Br
H
i-Pr
509
N—Me 2
CH 3
H
Br
H
i-Pr
510
CH 3
—CH 2 OCH 3
H
Br
H
i-Pr
511
Cl
CH 3
H
Br
H
i-Pr
512
CH 3
CH 3
Et
Br
H
i-Pr
513
CH 3
CH 3
—CCH
Br
H
i-Pr
TABLE 15
Synth.
Ex.
Ex.
R 1
R 3
X
X′
R 5
Mp (° C.)
514
CH 3
CH 3
Br
H
i-Pr
515
CH 3
CH 3
I
H
i-Pr
516
CH 3
CH 3
Br
6-OCH 3
OCH 3
517
CH 3
-morpholino
I
6-CH 3
i-Pr
518
CH 3
Ph
Br
H
i-Pr
519
CH 3
CH 3
SMe
H
i-Pr
520
101
CH 3
Cl
Br
H
i-Pr
49-52
521
CH 3
CH 3
Br
H
i-Pr
522
CH 3
CH 3
I
H
i-Pr
523
CH 3
CH 3
Br
6-OCH 3
OCH 3
524
CH 3
-morpholino
I
6-CH 3
i-Pr
525
CH 3
Ph
Br
H
i-Pr
526
CH 3
CH 3
SMe
H
i-Pr
527
102
CH 3
-morpholino
Br
H
i-Pr
132-135
528
CH 2 CH 3
CH 3
Br
H
i-Pr
529
CH 2 CH 3
CH 3
I
H
i-Pr
530
CH 2 CH 3
CH 3
Br
6-OCH 3
OCH 3
531
CH 2 CH 3
-morpholino
I
6-CH 3
i-Pr
532
CH 2 CH 3
Ph
Br
H
i-Pr
533
CH 2 CH 3
CH 3
SMe
H
i-Pr
534
CH 2 CH 3
Cl
Br
H
i-Pr
535
CH 2 CH 3
CH
Br
H
i-Pr
536
CH 2 CH 3
CH 3
I
H
i-Pr
537
CH 2 CH 3
CH 3
Br
6-OCH 3
OCH 3
538
CH 2 CH 3
-morpholino
I
6-CH 3
i-Pr
539
CH 2 CH 3
Ph
Br
H
i-Pr
540
CH 2 CH 3
CH 3
SMe
H
i-Pr
541
CH 2 CH 3
-morpholino
Br
H
i-Pr
TABLE 16
Synth.
Ex.
Ex.
R 1
R 3
X
X′
R 5
Mp (° C.)
542
CH 3
CH 3
Br
H
i-Pr
543
CH 3
CH 3
I
H
i-Pr
544
CH 3
CH 3
Br
6-OCH 3
OCH 3
545
CH 3
-morpholino
I
6-CH 3
i-Pr
546
CH 3
Ph
Br
H
i-Pr
547
CH 3
CH 3
SMe
H
i-Pr
548
103
CH 3
Cl
Br
H
i-Pr
MS 368
549
CH 3
CH 3
Br
H
i-Pr
550
CH 3
CH 3
I
H
i-Pr
551
CH 3
CH 3
Br
6-OCH 3
OCH 3
552
CH 3
-morpholino
I
6-CH 3
i-Pr
553
CH 3
Ph
Br
H
i-Pr
554
CH 3
CH 3
SMe
H
i-Pr
555
104
CH 3
-morpholino
Br
H
i-Pr
145-148
556
CH 2 CH 3
CH 3
Br
H
i-Pr
557
CH 2 CH 3
CH 3
I
H
i-Pr
558
CH 2 CH 3
CH 3
Br
6-OCH 3
OCH 3
559
CH 2 CH 3
-morpholino
I
6-CH 3
i-Pr
560
CH 2 CH 3
Ph
Br
H
i-Pr
561
CH 2 CH 3
CH 3
SMe
H
i-Pr
562
CH 2 CH 3
Cl
Br
H
i-Pr
563
CH 2 CH 3
CH 3
Br
H
i-Pr
564
CH 2 CH 3
CH 3
I
H
i-Pr
565
CH 2 CH 3
CH 3
Br
6-OCH 3
OCH 3
566
CH 2 CH 3
-morpholino
I
6-CH 3
i-Pr
567
CH 2 CH 3
Ph
Br
H
i-Pr
568
CH 2 CH 3
CH 3
SMe
H
i-Pr
569
CH 2 CH 3
-morpholino
Br
H
i-Pr
Utility
In vitro Receptor Binding Assay
Tissue Preparation: Male Sprague Dawley rats (180-200 g) were sacrificed by decapitation and the cortex was dissected on ice, frozen whole in liquid nitrogen and stored at −70° C. until use. On the day of assay, frozen tissue was weighed and homogenized in 20 volumes of ice cold buffer containing 50 mM Tris, 10 mM MgCl 2 , 2 mM EGTA, pH 7.0 at 22° C. using a Polytron (Brinkmann Instruments, Westbury, N.Y.; setting 6) for 20 s. The homogenate was centrifuged at 48,000× g for 10 min at 4° C. The supernatant was discarded, and the pellet was re-homogenized in the same volume of buffer and centrifuged at 48,000× g for 10 min at 4° C. The resulting pellet was resuspended in the above buffer to a final concentration of 20-40 mg original wet weight/mL and used in the assays described below. Protein determinations were performed according to the method of Lowry (Lowry et al., J. Biol. Chem. 193:265 (1951)) using bovine serum albumin as a standard.
CRF Receptor Binding: Receptor binding assays were carried out essentially as described by E. B. De Souza, J. Neurosci. 7:88 (1987).
Saturation Curve Analysis
In saturation studies, 100 μl 125 I-ovine CRF (50 pM-10 nM final concentration), 100 μl of assay buffer (with or without 1 mM r/hCRF final concentration, to define the non-specific binding) and 100 μl of membrane suspension (as described above) were added in sequence to 1.5 mL polypropylene microfuge tubes for a final volume of 300 μl. All assays were carried out at equilibrium for 2 h at 22° C. as described by E. B. De Souza, J. Neurosci. 7:88 (1987). The reaction was terminated by centrifugation of the tubes in a Beckman microfuge for 5 min at 12,000× g. Aliquots of the supernatant were collected to determine the “free” radioligand concentration. The remaining supernatant was aspirated and the pellets washed gently with ice-cold PBS plus 0.01% Triton X-100; centrifuged again and monitored for bound radioactivity as described above. Data from saturation curves were analyzed using the non-linear least-squares curve-fitting program LIGAND (P. J. Munson and D. Rodbard, Anal. Biochem. 107:220 (1980)). This program has the distinct advantage of fitting the raw experimental data on an untransformed coordinate system where errors are most likely to be normally distributed and uncorrelated with the independent variable. LIGAND does not expect the non-specific binding to be defined arbitrarily by the investigator, rather it estimates the value as an independent variable from the entire data set. The parameters for the affinity constants (K D ) and receptor densities (B max ) are also provided along with statistics on the general “fit” of the estimated parameters to the raw data. This program also offers the versatility of analyzing multiple curves simultaneously, thus improving the reliability of the data analysis and hence the validity of the final estimated parameters for any saturation experiment.
Competition Curve Analysis
In competition studies, 100 μl [ 125 I] ovine CRF ([ 125 I] CRF; final concentration 200-300 pM) was incubated along with 100 μl buffer (in the presence of varying concentrations of competing ligands, typically 1 pM to 10 mM) and 100 μl of membrane suspension as prepared above to give a total reaction volume of 300 μl. The reaction was initiated by the addition of membrane homogenates, allowed to proceed to equilibrium for 2 h at 22° C. and was terminated by centrifugation (12,000× g) in a Beckman microfuge to separate the bound radioligand from free radioligand. The resulting pellets were surface washed twice by centrifugation with 1 mL of ice-cold phosphate buffered saline and 0.01% Triton X-100; the supernatants discarded and the pellets monitored for radioactivity at approximately 80% efficiency. The level of non-specific binding was defined in the presence of 1 mM unlabeled rat/humanCRF (r/hCRF). Data from competition curves were analyzed by the program LIGAND. For each competition curve, estimates of the affinity of the radiolabeled ligand for the CRF receptor ([ 125 I]CRF) were obtained in independent saturation experiments and these estimates were constrained during the analysis of the apparent inhibitory constants (K i ) for the peptides tested. Routinely, the data were analyzed using a one- and two-site model comparing the “goodness of fit” between the models in order to accurately determine the K i . Statistical analyses provided by LIGAND allowed the determination of whether a single-site or multiple-site model should be used. For both peptides (α-helical CRF 9-41 and d-PheCRF 12-41 ), as well as for all compounds of this invention, data were fit significantly to a single site model; a two-site model was either not possible or did not significantly improve the fit of the estimated parameters to the data.
The results of the in vitro testing of the compounds of the invention are shown in Table 17. It was found, for a representative number of compounds of the invention, that either form of the compound, be it the free-base or the hydrochloride salt, produced essentially the same inhibition value in the binding assay.
A compound is considered to be active if it has an K i value of less than about 10000 nM for the inhibition of CRF. In Table 17; the K i values were determined using the assay conditions described above. The K i values are indicated as follows: +++=<500 nM; ++=501-2000 nM; +=2001-10000 nM.
TABLE 17
Example
Synth.
Inhibition
No.
Ex.
K i (nM)
1
1
++
2
++
3
++
4
2
+++
5
++
6
++
7
+++
8
+++
9
3
+++
10
+++
11
+++
12
++
13
+++
14
++
15
+++
16
4
+++
17
+++
18
+++
19
+++
20
+++
21
5
+++
22
++
23
+++
24
++
25
+++
26
+++
27
+++
28
+++
29
6
+++
30
7
+++
31
8
+++
32
+++
33
9
+++
34
10
+++
37
+++
49
12
+
50
13
+++
51
++
52
+
53
+
54
+
55
+++
56
14
+++
57
15
+++
58
16
+++
59
17
+++
60
++
61
18
+++
62
++
63
19
+
64
20
+
65
21
+
66
+
68
+
69
+
70
+
71
+
72
+
73
22
+++
74
+++
78
+
95
++
130
++
131
+
132
+
133
++
134
23
+++
135
+++
136
+++
137
+++
138
24
+++
139
25
+++
140
26
+++
141
+++
142
+++
143
+++
145
+
146
+
147
+++
148
+++
149
+++
150
+++
151
+++
152
+++
153
+++
154
+++
155
+++
156
+++
157
+++
158
+++
159
27
+++
160
28
+++
161
+++
162
+++
163
++
165
31
+++
166
34
+++
167
32
+++
168
35
+++
170
36
+++
171
38
+++
172
39
+++
173
40
++
174
41
+++
175
42
++
176
43
+++
177
33
++
178
44
+++
179
45
+
180
46
+++
181
47
+++
182
48
+++
183
49
+
184
++
185
51
+++
186
52
+++
187
+++
188
54
+++
189
55
+++
190
56
+++
191
57
+++
192
+++
193
+++
194
+++
195
+++
196
+++
197
++
201
+++
203
++
204
+
205
+++
206
+++
207
+++
208
+++
209
+++
210
++
211
+++
212
+++
213
+++
214
++
215
++
216
+++
217
+++
218
+++
219
+++
221
+++
222
58
++
223
++
224
63
+++
225
59
+++
226
+++
227
+++
228
++
229
+
230
60
+++
231
+
232
+++
236
+++
237
+++
238
+++
239
+++
240
+++
241
+++
242
29
++
243
+
244
+
245
+
246
+++
247
+++
248
+++
249
30
+
250
++
251
62
++
252
+
253
61
++
254
64
+++
255
74
++
256
66
+++
257
65
+++
258
68
+++
259
75
+++
260
69
+++
261
67
+++
262
70
+++
263
71
+++
264
77
+
265
76
+++
266
78
++
267
79
+++
268
+++
269
+++
270
+
271
+++
272
+
273
++
274
+
275
+++
276
+++
277
+++
278
+++
279
+++
280
+++
281
+++
282
+++
283
+
284
+++
285
+++
286
+++
287
++
288
+++
289
+++
290
+++
291
+++
292
+++
293
+++
294
+++
295
+++
296
+++
297
80
+++
298
82
+++
299
83
+++
300
84
+++
301
85
+++
302
86
+++
303
87
+++
304
88
+++
305
89
+++
307
91
+++
308
92
+++
309
93
+++
310
94
++
311
95
+++
312
96
+++
Inhibition of CRF-Stimulated Adenylate Cyclase Activity
Inhibition of CRF-stimulated adenylate cyclase activity was performed as described by G. Battaglia et al., Synapse 1:572 (1987). Briefly, assays were carried out at 37° C. for 10 min in 200 mL of buffer containing 100 mM Tris-HCl (pH 7.4 at 37° C.), 10 mM MgCl 2 , 0.4 mM EGTA, 0.1% BSA, 1 mM isobutylmethylxanthine (IBMX), 250 units/mL phosphocreatine kinase, 5 mM creatine phosphate, 100 mM guanosine 5′-triphosphate, 100 nM oCRF, antagonist peptides (concentration range 10 −9 to 10 −6m ) and 0.8 mg original wet weight tissue (approximately 40-60 mg protein). Reactions were initiated by the addition of 1 mM ATP/ 32 P]ATP (approximately 2-4 mCi/tube) and terminated by the addition of 100 mL of 50 mM Tris-HCl, 45 mM ATP and 2% sodium dodecyl sulfate. In order to monitor the recovery of cAMP, 1 μl of [ 3 H]cAMP (approximately 40,000 dpm) was added to each tube prior to separation. The separation of [ 32 P]cAMP from [ 32 P]ATP was performed by sequential elution over Dowex and alumina columns. Recovery was consistently greater than 80%.
Representative compounds of this invention were found to be active in this assay. IC 50 <10,000 nanomolar.
In Vivo Biological Assay
The in vivo activity of the compounds of the present invention can be assessed using any one of the biological assays available and accepted within the art. Illustrative of these tests include the Acoustic Startle Assay, the Stair Climbing Test, and the Chronic Administration Assay. These and other models useful for the testing of compounds of the present invention have been outlined in C. W. Berridge and A. J. Dunn Brain Research Reviews 15:71 (1990).
Compounds may be tested in any species of rodent or small mammal. Disclosure of the assays herein is not intended to limit the enablement of the invention.
The foregoing tests results demonstrate that compounds of this invention have utility in the treatment of imbalances associated with abnormal levels of corticotropin releasing factor in patients suffering from depression, affective disorders, and/or anxiety. The foregoing tests also demonstrate that compounds of this invention have utility in the treatment of uterine contraction disorders.
Compounds of this invention can be administered to treat said abnormalities by means that produce contact of the active agent with the agent's site of action in the body of a mammal. The compounds can be administered by any conventional means available for use in conjunction with pharmaceuticals either as individual therapeutic agents or in a combination of therapeutic agents. They can be administered alone, but are generally administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice.
The dosage administered will vary depending on the use and known factors such as the pharmacodynamic character of the particular agent, and its mode and route of administration; the recipient's age, weight, and health; nature and extent of symptoms; kind of concurrent treatment; frequency of treatment; and desired effect. For use in the treatment of said diseases or conditions, the compounds of this invention can be orally administered daily at a dosage of the active ingredient of 0.002 to 200 mg/kg of body weight. Ordinarily, a dose of 0.01 to 10 mg/kg in divided doses one to four times a day, or in sustained release formulation is effective in obtaining the desired pharmacological effect.
Dosage forms (compositions) suitable for administration contain from about 1 mg to about 100 mg of active ingredient per unit. In these pharmaceutical compositions, the active ingredient will ordinarily be present in an amount of about 0.5 to 95% by weight based on the total weight of the composition.
The active ingredient can be administered orally in solid dosage forms, such as capsules, tablets and powders; or in liquid forms such as elixirs, syrups, and/or suspensions. The compounds of this invention can also be administered parenterally in sterile liquid dose formulations.
Gelatin capsules can be used to contain the active ingredient and a suitable carrier, such as, but not limited to, lactose, starch, magnesium stearate, steric acid, or cellulose derivatives. Similar diluents can be used to make compressed tablets. Both tablets and capsules can be manufactured as sustained release products to provide for continuous release of medication over a period of time. Compressed tablets can be sugar-coated or film-coated to mask any unpleasant taste, or used to protect the active ingredients from the atmosphere, or to allow selective disintegration of the tablet in the gastrointestinal tract.
Liquid dose forms for oral administration can contain coloring or flavoring agents to increase patient acceptance.
In general, water, pharmaceutically acceptable oils, saline, aqueous dextrose (glucose), and related sugar solutions and glycols, such as propylene glycol or polyethylene glycol, are suitable carriers for parenteral solutions. Solutions for parenteral administration preferably contain a water soluble salt of the active ingredient, suitable stabilizing agents, and if necessary, buffer substances. Antioxidizing agents, such as sodium bisulfite, sodium sulfite, or ascorbic acid, either alone or in combination, are suitable stabilizing agents. Also used are citric acid and its salts, and EDTA. In addition, parenteral solutions can contain preservatives such as benzalkonium chloride, methyl- or propyl-paraben, and chlorobutanol.
Suitable pharmaceutical carriers are described in “Remington's Pharmaceutical Sciences”, A. Osol, a standard reference in the field.
Useful pharmaceutical dosage-forms for administration of the compounds of this invention can be illustrated as follows:
Capsules
A large number of units in the form of capsules are prepared by filling standard two-piece hard gelatin capsules each with 100 mg of powdered active ingredient, 150 mg lactose, 50 mg cellulose, and 6 mg magnesium stearate.
Soft Gelatin Capsules
A mixture of active ingredient in a digestible oil such as soybean, cottonseed oil, or olive oil is prepared and injected by means of a positive displacement into gelatin to form soft gelatin capsules containing 100 mg of the active ingredient. The capsules are washed and dried.
Tablets
A large number of tablets are prepared by conventional procedures so that the dosage unit is 100 mg active ingredient, 0.2 mg of colloidal silicon dioxide, 5 mg of magnesium stearate, 275 mg of microcrystalline cellulose, 11 mg of starch, and 98.8 mg lactose. Appropriate coatings may be applied to increase palatability or delayed adsorption.
The compounds of this invention may also be used as reagents or standards in the biochemical study of neurological function, dysfunction, and disease. | The present invention provides novel compounds, compounds and pharmaceutical compositions thereof, and methods of using same in the treatment of affective disorders, anxiety, depression, post-traumatic stress disorders, eating disorders, supranuclear palsy, irritable bowel syndrome, immune suppression, Alzheimer'disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, or fertility problems. The novel compounds provided by this invention are those of formula:
wherein R 1 , R 3 , R 4 , R 5 , Z, Y, V, X, X′, J, K, L, and M are as defined herein. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/EP01/14864, filed Dec. 17, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention:
[0003] The invention relates to a method and an apparatus for smoothing items of clothing.
[0004] Numerous methods and apparatuses for smoothing items of clothing exist. For example, it is known to press the fabric of the item of clothing to be smoothed by pressure with a flat object. The prior art irons or ironing presses may be used for such a purpose. In addition, for smoothing sensitive items of clothing, in particular, it is known to subject them to heat and steam, whereby the fibers of an item of clothing are made to relax and, as such, the creases can be eliminated. An apparatus for applying this method is known, for example, from German Published, Non-Prosecuted Patent Application DE 3119560. However, this smoothing method disadvantageously has only a very slight smoothing effect because the fibers of the item of clothing are only made to relax and are not necessarily smoothed. In addition, the fibers of an item of clothing may become so permanently creased over time that the crease is impressed in the fiber structure such that, without being subjected to external mechanical action, the fiber in the relaxed state tends to assume the creased state. In such a case, without mechanical action, a smoothing method can achieve a smoothing effect only with the aid of steam and heat.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a method and apparatus for smoothing items of clothing that overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that achieves an improved smoothing effect while gently treating the item of clothing to be smoothed.
[0006] With the foregoing and other objects in view, there is provided, in accordance with the invention, a method for smoothing items of clothing, including the steps of providing an item of clothing, providing at least one gas jet for supplying a stream of a gas, and subjecting the clothing item at least in one portion to the at least one gas jet in a direction not parallel to the one portion.
[0007] The use of a gas jet, which is, preferably, an air jet and exerts a force on the item of clothing to be smoothed, allows a smoothing effect to be achieved with little effort, at the same time treating the item of clothing very gently. The gas jet allows the fabric of the item of clothing to be pressed into in specific places or a tensile force to be exerted on the entire item of clothing, whereby it is stretched. As such, any creases that may exist are smoothed. The smoothing effect of the gas jet can be increased by making the fabric of the item of clothing relax before the smoothing operation or at the beginning of a smoothing operation by moistening and heating the fabric of the item of clothing. For such a purpose, water vapor can be mixed in with the gas jet and directed in this way onto the fabric. Furthermore, it is possible to sprinkle the item of clothing with water, it being possible for the water to be sprinkled by the nozzle with which the gas jet is directed onto the item of clothing, or by a nozzle of its own, which is not used for generating the gas jet.
[0008] The at least one gas jet necessarily has the effect that a force is exerted on the item of clothing. As a result, the item of clothing can be moved in a disadvantageous way, and, possibly, crumpled thereby. This can be prevented, for example, by using a gas jet having a high outflow velocity but a small diameter. Such a configuration has the overall effect of not exerting a great force on the item of clothing by the gas jet, and the clothing is, therefore, influenced little in its position. Nonetheless, a high stretching effect on the fabric can be achieved in a small area on the item of clothing, and, consequently, a high smoothing effect. In this respect it may be provided that, in the case of suspended items of clothing, the deflection caused by the gas jet is compensated at least partly by the suspension of the item of clothing being drawn slightly toward the nozzle from which the gas jet is flowing.
[0009] In accordance with another mode of the invention, the clothing item is supported from a side of the clothing item opposite the gas jet.
[0010] The item of clothing is, advantageously, supported while it is subjected to the gas jet. The item of clothing can, consequently, be prevented from being moved by the force of the gas jet. Furthermore, this allows a stronger gas jet to be used and, consequently, a better smoothing effect to be achieved. The support may take place by fixed supports, such as, for example, at least one supporting surface. If the item of clothing is moved, for example, by running through a number of treatment stations, such supports may also be set up such that they can be moved along with the item of clothing. For example, at least one supporting roller mounted rotatably about an axis aligned substantially perpendicularly to the direction of movement of the item of clothing may be used.
[0011] In accordance with a further mode of the invention, the item of clothing is supported by a gas jet. In such an embodiment, the item of clothing is subjected to at least one gas jet from both sides. As such, impressions in the fabric that may occur in the case of fixed supports can be avoided. Furthermore, the smoothing effect is intensified because a force from a gas jet is exerted from both sides.
[0012] In accordance with an added mode of the invention, the clothing item is supported with an air-permeable supporting surface.
[0013] In accordance with an additional mode of the invention, the clothing item is disposed between two air-permeable surfaces.
[0014] In accordance with yet another mode of the invention, the gas jet acts on both sides of the item of clothing to exert a total force on the clothing item that is equal in an amount in opposing directions.
[0015] In accordance with yet a further mode of the invention, the gas jet exerts a force on both sides of the item of clothing such that a total force on the clothing item is equal in opposing directions.
[0016] The gas jets acting from both sides may be coordinated with one another, in particular, such that the portion of the item of clothing situated in between is deformed in a specific manner in order to achieve a good smoothing result. For such a purpose, the force exerted from both sides by the gas jets may be distributed over a specific surface area in each case with a non-uniform force distribution. The force distributions over the surface areas on both sides may be set differently so that, in one portion of the item of clothing, the force exerted on the portion from a first side is greater than the force exerted from the other side and, in a portion lying alongside, the force exerted from the second side predominates. As such, the item of clothing can be deformed in a defined way so that, for example, it assumes a crinkled form, or elevations to one side or the other form in the item of clothing. For example, a gas jet that widens conically and is internally hollow may be used from one side, with the result that it exerts a force in an annular area on the surface of the item of clothing, and a gas jet that generates force exclusively in a small punctiform or circular area is used from the other side, the punctiform or circular area being located within the annular area of the force exerted from the opposite side. Such a configuration has the effect that the fabric of the item of clothing is stretched and smoothed between the annular area and the punctiform or circular area lying in it. Instead of a punctiform or circular surface pressure of the one gas jet, a substantially linear surface pressure may also be chosen. Generally, force effect acting in different directions in adjacent areas allows the fabric to be stretched and smoothed in these areas.
[0017] In accordance with yet an added mode of the invention, the forces acting from both sides may be coordinated such that the item of clothing is held in a specific local area and, in particular, the item of clothing is prevented from coming into unwanted contact with other parts, whereby soiling or crumpling can be prevented. Because the force of a gas jet used decreases as it becomes more distant from the nozzle, the configuration, alignment, and outflow characteristics of nozzles lying opposite one another and directed toward one another can create a control system that attempts to keep the items of clothing at a specific location between the nozzles.
[0018] In this respect, however, it may also be provided that the location of the item of clothing or of a portion of the item of clothing is sensed and the sensed location is used as an input variable of a control system, which controls the gas jets acting on the item of clothing from different sides such that the item of clothing or the portion of the item of clothing is always located at a predetermined set location or set locational area. The location sensing may be carried out by light barriers or reflection light barriers, it also being possible for other methods of distance measurement or location sensing, for example, by ultrasound, to be used.
[0019] The interaction of the forces exerted on the item of clothing from both sides and the force distribution over the surface area allows the fabric of the item of clothing to be stretched in a gentle but, at the same time, forcible way, and, consequently, to achieve a great smoothing effect. In this respect, the force distribution and/or the total force exerted from the individual sides may be varied over time so that a changing deformation is achieved, which may have advantageous effects on the smoothing operation.
[0020] In accordance with yet an additional mode of the invention, the at least one gas jet and the clothing item are moved with respect to one another.
[0021] In accordance with again another mode of the invention, a heated gas stream is supplied with the at least one gas jet.
[0022] In accordance with again a further mode of the invention, water vapor is supplied with the gas stream from the at least one gas jet.
[0023] In accordance with again an added mode of the invention, at the end of a smoothing operation of the clothing item, substantially dry and heated air is initially supplied to the clothing item with the at least one gas jet and substantially dry and non-heated air is subsequently supplied to the clothing item with the at least one gas jet.
[0024] In accordance with again an additional mode of the invention, the clothing item is initially moistened.
[0025] In accordance with still another mode of the invention, the clothing item is moistened before subjecting the clothing item to the at least one gas jet.
[0026] In accordance with still a further mode of the invention, at least one of an outflow speed, a volume flow, and a directional distribution of the at least one gas jet is changed when subjecting the clothing item to the gas stream of the at least one gas jet.
[0027] With the objects of the invention in view, there is also provided a method for smoothing items of clothing, including the steps of providing an item of clothing, providing at least one gas jet for supplying a stream of a gas, and directing the gas stream towards at least one portion of the clothing item at an angle to the one portion.
[0028] With the objects of the invention in view, there is also provided an apparatus for smoothing items of clothing, including a treatment housing defining a treatment space therein, devices disposed in the housing for placing an item of clothing inside the treatment space, a blower for generating a gas flow, and nozzles communicating with the blower for generating a gas stream in the housing, the nozzles being disposed in the housing and being aligned to direct the gas stream generated by the gas flow from the blower at the clothing item.
[0029] In accordance with still an added feature of the invention, there is provided a moistening device communicating with at least one of the nozzles for moistening the gas stream.
[0030] In accordance with a concomitant feature of the invention, the nozzles are aligned to direct the gas stream at an angle to the clothing item, in other words, the nozzles are aligned to direct the gas stream to at least a portion of the clothing item in a direction not parallel to the portion of the clothing item.
[0031] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0032] Although the invention is illustrated and described herein as embodied in a method and apparatus for smoothing items of clothing, it is, nevertheless, not intended to be limited to the details shown because 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.
[0033] 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
[0034] [0034]FIG. 1 is a cross-sectional view of a first embodiment of an apparatus according to the invention for smoothing items of clothing;
[0035] [0035]FIG. 2 is a fragmentary, cross-sectional view through an apparatus for disposing items of clothing for use in the smoothing apparatus of FIG. 1; and
[0036] [0036]FIG. 3 is a cross-sectional view of a second embodiment of an apparatus according to the invention for smoothing items of clothing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown an apparatus for washing and smoothing items of clothing 2 of all kinds, such as items in the form of shirts or pants, has a cuboidal or cabinet-like housing 1 , which serves for receiving the items of clothing 2 to be smoothed. Disposed within the housing 1 on two mutually opposite inside walls there is, respectively, a closed transporting belt 3 mounted in a circulating manner, one of the transporting belts 3 being illustrated in plan view in FIG. 1. The two transporting belts 3 may be driven in the same direction and with the same circulating speed in the clockwise sense. Disposed between the transporting belts 3 are non-illustrated connecting struts, fastened to which are suspending devices 4 on which the items of clothing 2 to be smoothed are suspended. The suspending devices 4 have substantially the form of a clothes hanger. As a result, in particular, items of outer clothing of all kinds can be suspended thereon.
[0038] The transporting belts 3 are disposed in the upper region of the housing 1 and have the form of a rectangle. As a result, the items of clothing 2 can be moved upward on the left side, to the right at the top, downward on the right side and to the left at the bottom. At the bottom of the left-hand side wall of the housing 1 , two oppositely disposed compressed air nozzles 7 are disposed such that the items of clothing can be moved by the transporting belts 3 upward through the intermediate space between the compressed air nozzles 7 . Above the compressed air nozzles 7 , hot air nozzles 6 are disposed one above the other on the left-hand side wall, the hot air nozzles 6 only being disposed however on the outer side of the path of movement of the items of clothing 2 . As a result, the items of clothing can only be acted on by the hot air nozzles from one side. The compressed air nozzles 7 and the hot air nozzles 6 are connected to a generator 5 , which has a blower and can generate air jets of different temperatures and with different pressures. The generator 5 has an air inlet inside the housing 1 and an air inlet 17 outside the housing 1 , with which fresh air can be drawn in.
[0039] Disposed on the right-hand side wall are liquid nozzles 8 for spraying washing liquid and rinsing liquid. The liquid nozzles 8 are, likewise, connected to the generator 5 , which furthermore has a pump for delivering liquids. The generator 5 has, for the feeding of liquid, a non-illustrated fresh water feed, which can be connected to a fresh water source or a water connection in a household, and is connected, furthermore, to a sump 18 within the housing 1 . The sump 18 is formed in a false floor 25 , which is disposed at the bottom within the housing 1 and is shaped such that all the liquid from the upper part of the housing 1 collects at the bottom in the sump 18 . The false floor 25 also has the function of dividing off a dry space, in which the generator 5 is accommodated. Also disposed in the dry space is an outflow pump 12 , the inlet of which opens into the sump 18 and the outlet 13 of which leads to the outside and can be connected to a wastewater connection, in particular, of a household.
[0040] The generator 5 is set up such that the liquid nozzles 8 can be supplied with liquid either that the generator 5 has drawn in from the sump 18 or that originates from the fresh water feed. Furthermore, the generator 5 has a heating device for the liquid pumped to the liquid nozzles 8 .
[0041] Represented in section in FIG. 2, by way of example, is a suspending device 4 , which has a hollow connecting portion 23 and a hanger portion 24 , which is connected to the latter at the bottom, extends perpendicularly to the plane of the drawing, and has a length corresponding substantially to the width of an item of clothing 2 . The hanger portion 24 is hollow and has openings distributed around its periphery. The suspending devices 4 are connected to the generator 5 by devices not represented, such that the interior space of the connecting portion 23 and of the hanger portion 24 can be supplied with hot air in the same way as the hot air nozzles 6 .
[0042] With the apparatus according to the invention represented in FIG. 1, items of clothing 2 can be first washed, dried, and, finally, smoothed, without it being necessary for the items of clothing 2 to be taken out of the apparatus. Firstly, the items of clothing 2 are suspended on the suspending devices 4 . For such a purpose, the suspending devices 4 may be removed from the housing 1 , the items of clothing 2 hung on the suspending devices 4 and the latter subsequently suspended again in the housing 1 on the connecting struts between the transporting belts 3 . After the housing 1 has been closed, the washing operation is initiated. For such a purpose, the transporting belts 3 are set in motion to move the items of clothing 2 clockwise through the housing, and the generator 5 is activated by a non-illustrated controller such that it passes fresh water from the fresh water feed to the liquid nozzles 8 . In this case, the water is passed through a non-illustrated flushing-in device, into which detergent in either powdered and/or liquid form can be filled. The detergent is, in this case, flushed into the housing 1 . As soon as a set level of liquid is reached in the housing 1 or a specific predetermined amount of liquid has been fed in, the generator 5 stops the feed of fresh water and begins to remove water from the sump 18 and pass it to the liquid nozzles 8 , the water being heated up to a set temperature. The water, now mixed with the detergent, is made to circulate as washing liquid and may, additionally, also be sprayed onto the items of clothing 2 from inside through the suspending devices 4 . In such an operation, dirt is flushed out of the items of clothing 2 .
[0043] Subsequently, in a rinsing phase, the washing liquid is pumped out into a wastewater connection by the outflow pump 12 . Subsequently, the items of clothing 2 are rinsed, in order to remove the washing liquid from them. For this purpose, fresh water is pumped to the liquid nozzles 8 in a number of rinsing cycles and the water together with the rinsed-out washing liquid is pumped away by the outflow pump 12 . The rinsing effect can be intensified if, at the end of each rinsing cycle, the liquid feed to the liquid nozzles 8 is interrupted and the compressed air nozzles 7 are supplied with compressed air. When the items of clothing 2 are moved between the compressed air nozzles 7 , they are pressed together by the compressed air jets, whereby the rinsing liquid is squeezed out of them. As such, scarcely any residues of the washing liquid or contaminants remain after the rinsing cycle. As a result, a smaller number of rinsing cycles or less rinsing liquid is required. The air passed to the compressed air nozzles 7 may also be heated in the process, whereby the liquid drawn up from the items of clothing 2 flows out more easily and, consequently, the water removal by compressed air at the end of the rinsing cycles can be intensified.
[0044] The rinsing is followed by a drying and smoothing step. Firstly, the items of clothing 2 are dried to a defined moisture content. For such a purpose, heated air is passed to the hot air nozzles 6 . At the same time, the housing rear wall 15 is cooled with fresh water from the fresh water connection. As such, the moisture extracted from the items of clothing 2 condenses on the rear wall 15 and runs into the sump 18 , from which it can be pumped away together with the cooling water for the rear wall 15 by the outflow pump 12 . In such a case, the air inside the housing 1 is made to circulate, for which purpose the generator 5 draws in the air inside the housing 1 .
[0045] Furthermore, there is the possibility of removing moisture from the items of clothing 2 to the desired moisture content based upon the exhaust air principle, in that, air is constantly blown out from the interior of the housing 1 by a blower or fan 14 . In this way, the moisture extracted from the items of clothing 2 is discharged, the generator 5 having to draw in air from the outside. However, this method requires the apparatus to be set up in an adequately ventilated room in order to carry away the discharged moisture. The two possibilities, either of condensing the moisture in the apparatus and pumping it away or of discharging it, allow the operator to decide between the two variants in accordance with the respective conditions. The condensing of the moisture in the apparatus has the advantage that the room in which it is set up does not have to be ventilated. As an advantageous result, there is no loss of energy for heating the room in which it is set up, for example, in winter. In summer, on the other hand, the exhaust air variant may be chosen, which does not require any fresh water for cooling the rear wall 15 and less energy for heating the dry air.
[0046] When the desired moisture content has been reached, the smoothing operation can be commenced. For such a purpose, the items of clothing 2 are subjected to hot compressed air with the aid of the compressed air nozzles 7 , whereby they are fully dried. In the moist state, the fabric of the items of clothing 2 is still relaxed. As a result, it can be smoothed much better. The smoothing takes place by the force exerted by the compressed air jets from the compressed air nozzles 7 on the items of clothing. This force can be set to a desired effect by setting the pressure of the air passed to the compressed air nozzles 7 . In particular, the force is set such that the items of clothing 2 do not flutter, but, instead, the portion of an item of clothing 2 respectively located between the compressed air nozzles 7 is stretched tight.
[0047] For example, the two compressed air nozzles 7 may exert differently distributed surface forces on the items of clothing. As a result, the forces acting on a specific part of an item of clothing 2 from both sides do not cancel one another out. The surface force profiles of the forces exerted by the two compressed air nozzles 7 are, advantageously, complementary to one another. As a result, for example, in the areas in which a high surface force is generated by the left-hand compressed air nozzle 7 , a low surface force is generated by the right-hand compressed air nozzle 7 , and vice-versa. In this respect, the forces are configured such that the items of clothing are held approximately midway between the two compressed air nozzles 7 .
[0048] As such, stretching forces that stretch the individual fabric portions of the item of clothing 2 , and, thereby, smooth them, can be exerted on an item of clothing 2 by compressed air. This operation is repeated every time a specific item of clothing 2 is passed between the two compressed air nozzles 7 . During this operation, furthermore, heated hot air can be directed onto the items of clothing by the hot air nozzles 6 . In this respect, it should be ensured that hot air is expelled only with little pressure, in order not to lead to fluttering or crumpling of the items of clothing 2 . The items of clothing 2 are, further, dried during this smoothing operation, the extracted moisture, as described above, either condensing on the cooled rear wall 15 and being pumped away by the outflow pump 12 or collected in the appliance and returned to the next washing process, or blown out by the blower 14 .
[0049] As soon as the items of clothing 2 are fully dried, they are moved further in the housing 1 , though now only cold air is blown in through the hot air nozzles 6 and/or the compressed air nozzles 7 . This achieves the effect that the smoothed items of clothing 2 are cooled down and are less sensitive to creasing because the fabric crumples more easily in the hot state. Furthermore, an operator is prevented from burning on hot parts inside the housing 1 . After the items of clothing 2 and the apparatus have cooled down, the items of clothing 2 can be removed.
[0050] To smooth the items of clothing 2 without a prior washing cycle, the items of clothing may be moistened with a little fresh water from the liquid nozzles 8 . As a result, the fabric of the items of clothing 2 is made to relax. After that, the items of clothing 2 can be smoothed and dried as described above.
[0051] Represented in FIG. 3 is an apparatus for washing and smoothing items of clothing 2 according to a second embodiment. In this embodiment, a device for the preliminary mechanical removal of moisture from the items of clothing 2 is additionally provided, by which liquid can be removed mechanically from the items of clothing at the beginning of the drying phase. As a result, less energy has to be expended for the drying. Furthermore, separate nozzles are provided for the various treatment liquids or gases.
[0052] In the same way as in the first embodiment, the apparatus has a housing 1 , two transporting belts 3 , suspending devices 4 for items of clothing 2 , and an outflow pump 12 with an outlet 13 . Also disposed in the housing 1 there is, likewise, a false floor 25 , in which a sump 18 with a lint filter 16 is formed and which divides off a dry space at the bottom in the housing 1 . However, in this embodiment, the generator 5 is set up only for generating compressed air, which is heated if need be and is passed to the compressed air nozzles 7 . Also disposed in the dry space underneath the false floor 25 is a washing device 19 , which is connected to the sump 18 and a non-illustrated fresh water feed and has a liquid pump and a heating device. The washing device 19 is set up such that it can remove liquid either from the fresh water feed or from the sump 18 and pass it on to various nozzles, it being possible for the liquid to be heated and, in particular, for liquid removed from the fresh water feed to be vaporized. Also provided in the washing device is a flushing-in device, with which detergent can be flushed into the housing 1 .
[0053] Connected to the washing device 19 are wetting nozzles 9 , washing nozzles 10 , rinsing nozzles 11 , and hot steam nozzles 6 , which are disposed on the right-hand side of the housing 1 . The wetting nozzles 9 are supplied with fresh water and serve for wetting dry items of clothing 2 . The washing nozzles 10 are supplied with washing liquid, in particular, heated washing liquid, which is made to circulate, in particular, through the sump 18 , and serve for washing the items of clothing 2 . The rinsing nozzles 11 are supplied with cold fresh water and serve for rinsing out the washing liquid from the items of clothing 2 . The hot steam nozzles 6 are supplied with heated water vapor, which is obtained from fresh water, and serve for steaming the items of clothing 2 .
[0054] As in the case of the previous exemplary embodiment, disposed at the bottom of the left-hand inside wall of the housing 1 are two mutually opposite compressed air nozzles 7 , which are connected to the generator 5 . Disposed over the compressed air nozzles 7 is a moisture-absorbing nonwoven 20 , which is mounted near the inside wall by two deflecting rollers such that it can be driven like a conveyor belt and, thereby, moves parallel to the path of movement of the items of clothing 2 .
[0055] The moisture-absorbing nonwoven 20 is of a highly absorbent material and is driven at the same speed as the items of clothing 2 . As a result, the portion respectively lying on the inside is moved upward together with the items of clothing 2 . Disposed on the side of the transporting belt 3 opposite from the moisture-absorbing nonwoven 20 is a pressing roller 21 , which is provided with a compliant coating. The distance between the pressing roller 21 and the moisture-absorbing nonwoven 20 can be changed. As a result, it is possible either to press the items of clothing 2 between the pressing roller 21 and the moisture-absorbing nonwoven 20 as they are moved through or to move the items of clothing 2 through without them being touched by the moisture-absorbing nonwoven 20 . Provided at the lower deflecting roller of the moisture-absorbing nonwoven 20 is a squeezing roller 22 , which is disposed at such a small distance from the lower deflecting roller that the moisture-absorbing nonwoven 20 is strongly pressed together between the lower deflecting roller and the squeezing roller 22 , and, in this way, liquid contained in the moisture-absorbing nonwoven 20 is squeezed out.
[0056] For washing and smoothing the items of clothing 2 , they are suspended in the housing 1 as described above by the suspending devices 4 . In the second exemplary embodiment, too, the transporting belts are moved clockwise. Firstly, the items of clothing 2 are wetted with fresh water by the wetting nozzles 9 . Subsequently, the items of clothing 2 are moved further to the washing nozzles 10 , by which they are sprayed with washing liquid that is generated in the washing device 19 by flushing in detergent in fresh water. The washing liquid is pumped out of the sump 18 by the washing device 19 in circulation, heated and sprayed onto the items of clothing 2 so that contaminants are flushed out.
[0057] After the washing, the washing liquid is pumped away by the outflow pump 12 and the items of clothing 2 are rinsed so as to rinse out the washing liquid and residues of the contaminants. For such a purpose, fresh water is sprayed onto the items of clothing 2 by the rinsing nozzles 11 and pumped away in a number of rinsing cycles. The rinsing operation may take the same form as in the previous exemplary embodiment.
[0058] After the rinsing, moisture is further removed mechanically from the items of clothing 2 by the moisture-absorbing nonwoven 20 . For such a purpose, the distance between the moisture-absorbing nonwoven 20 and the pressing roller 21 is reduced to such an extent that the item of clothing 2 moved through is pressed by the pressing roller 21 against the moisture-absorbing nonwoven 20 . As this happens, the highly absorbent material of the moisture-absorbing nonwoven 20 extracts further moisture from the item of clothing 2 . The moisture taken up by the moisture-absorbing nonwoven 20 is squeezed out again between the lower deflecting roller and the squeezing roller 22 . As a result, the part of the moisture-absorbing nonwoven 20 that is actually in contact with the item of clothing 2 always contains as little moisture as possible to be able to extract as much moisture as possible from the item of clothing 2 . This purely mechanical type of moisture removal requires no heat, for the generation of which considerable energy is required disadvantageously. As a result, with the aid of the moisture-absorbing nonwoven 20 , the moisture content of the items of clothing 2 can be reduced with particularly little expenditure of energy.
[0059] In addition, with this type of moisture removal based upon the absorbent effect of the moisture-absorbing nonwoven 20 , considerable moisture can be extracted from the items of clothing 2 just with a small pressing pressure. As a result, the items of clothing 2 are not crumpled and, nevertheless, the moisture is largely removed from them. The pressing pressure may be adjustable by changing the distance between the pressing roller 21 and the moisture-absorbing nonwoven 20 , in particular, in dependence on the fabric and the thickness of the items of clothing 2 .
[0060] After the preliminary removal of moisture by the moisture-absorbing nonwoven 20 , the items of clothing 2 are further dried with hot air. This takes place in the same way as in the previous exemplary embodiment. The smoothing operation is commenced as soon as the items of clothing have the suitable moisture content. If moisture has already been adequately removed from the items of clothing by the moisture-absorbing nonwoven 20 , the items of clothing 2 can be smoothed immediately after the preliminary mechanical removal of moisture. If the preliminary mechanical removal of moisture was not adequate, the items of clothing 2 are dried with warm or hot air from the compressed air nozzles 7 to the suitable moisture content. The smoothing is performed by subjecting the items of clothing to hot steam from the hot steam nozzles 6 , whereby the fabric of the items of clothing 2 is heated and made to relax. Subsequently, the items of clothing 2 are passed through between the two compressed air nozzles 7 . The compressed air emerging from the compressed air nozzles 7 has the effect that the fabric of the items of clothing 2 is stretched and smoothed, the smoothing operation and the compressed air jets used corresponding to the previous exemplary embodiment.
[0061] The hot steam nozzles 6 make it possible in the case of the second embodiment to smooth the items of clothing 2 without prior soaking. For such a purpose, for example, already washed and dried items of clothing 2 can be steamed in the apparatus and, then, smoothed and dried as described above.
[0062] After a specific time, the hot steam discharge of the hot steam nozzles 6 is stopped. The items of clothing are, then, just subjected to hot compressed air from the compressed air nozzles 7 to dry them fully during the smoothing. As soon as the desired moisture content is reached, the items of clothing are just subjected to cold air to cool them down as in the previous exemplary embodiment. After that, the items of clothing 2 can be removed from the housing 1 . | To improve a smoothing effect on items of clothing by subjecting the items to moisture and heat and, thereby, relaxing the fabric of the clothing items to reduce creases, an apparatus and a method of smoothing includes subjecting the items of clothing, preferably, in a heated and moistened state, to at least one gas jet, in particular, a compressed air jet, which is not aligned parallel to the clothing item and which exerts a force on the clothing item. Advantageously, the clothing item is subjected to gas jets from both sides. | 3 |
FIELD OF THE INVENTION
[0001] The invention concerns a solar cell-string, wherein a “string” describes a multitude of solar cells connected with each other by electrically conductive strips.
BACKGROUND OF THE INVENTION
[0002] Correspondingly a known solar cell-string comprises the following features:
The string presents a multitude of solar cells arranged with a distance one after the other, adjacent solar cells are connected by at least two electrical conductor tracks (conductive paths), each conductor track is with a first section firmly connected to an upper surface of a solar cell and with a second section firmly connected to a lower surface of the adjacent solar cell.
Usually a pair (2) of conductor tracks is connecting the upper surface of a solar cell with a lower surface of an adjacent solar cell. At the beginning and/or end of the string electrical connections are provided.
[0006] Usually the conductor tracks comprise a base body and a solderable coating. The conductor tracks are in these cases soldered onto the solar cells.
[0007] To process single solar cells with conductive paths to a complete solar cell-string different processing stages and processing steps are necessary. Thereby it is essential to ensure an exact positioning of the single solar cells and the single conductive paths, so that also the combination of a series of solar cells with a series of conductor tracks takes place in the desired and necessary orientation (arrangement). This is difficult inter alia because the solar cells are extremely thin (approximately 200 μm) and brittle and the conductor tracks with a width of for example 0.5 to 3 mm and a thickness of not more than 0.2 to 1 mm are slender ribbons, that cannot be brought into the desired surface contact with the upper/lower surface of the solar cells so easily.
[0008] It is known to transport the conductor tracks through a suction device to the solar cell and place them there, as well as subsequently to fix them by a holding down device onto the solar cells, also during the subsequent soldering process. The hold down clamps are being lifted again only after the respective solar cell has left the soldering station.
[0009] An according device with a holding down device is known from DE 10 2006 007 447 A1. The holding down device consists of a frame that has bearing surfaces on both its edge sections, that are supported by conveyor belts in the operating position and have a window in which or next to which down-holding heads are arranged that each have a down-holding pin and are mounted pivotable at the frame. The pins press onto the conductive path when the holding down device is superimposed onto the conductive path thereby pressing the conductor track onto the solar cell. Thereby it is important that the force with which the conductor tracks are fixed is only effective in one direction. Said pins are being supported in so called down-holding heads that are hinged pivotably at the frame.
[0010] The known holding down device is very complex in terms of construction; the pins lead to very small pressure-points, wherein the conductor track can easily be damaged. Furthermore an adjustment of the compressive force with respect to the surface of the conductor track is impossible and can incidentally only be done individually through the down-holding heads. As a result the known solar cell-string has no sufficient surface connection between conductor track and solar cell.
SUMMARY OF THE INVENTION
[0011] The object of the invention is to provide a solar cell-string with an optimized connection of conductor track and solar cell.
[0012] The solar cell-string according to the invention differs from the known string in that each conductor track has, on its first section, a series of spherically shaped indentations at a distance to each other.
[0013] “Spherically shaped” (calotte like) means that the indentation is no unidirectional indentation (in the technical sense) as obtained by a needle as in the state of the art, but describes an indentation in the conductor track that extends over a certain surface area of the conductive path.
[0014] This requires holding down devices with according geometry, for example spherically bodies, ball or oval shaped, mounted to the end portion of springs, that press on the conductor track causing corresponding three-dimensional indentation (the spherically shaped indentation) in the conductor track. The ratio of depth (vertical to the conductor track surface) to width (largest width parallel to the conductor track-surface) is typically <1:1, for example <1:2 or <1:3 or <1:5 or <1:7 or <1:10. In the case of an acicular prick the ratio is >1:1.
[0015] Preferably the indentation extends completely within the according conductor track, that means the indentation extends just until shortly before the edge of the according surface of the conductor track.
[0016] The term “spherically shaped indentation” includes in its most general meaning indentations with planar surfaces; however indentations with curved wall sections (zones) are preferred, because the accordingly formed pressure-bodies exert forces in different directions on the conductive path, so that both the effect of the press-on (hold down) and the subsequent connection of conductor track and solar cell surface is improved.
[0017] The press-on of the conductor track onto the solar cell can additionally be improved if a press-on body is used, that has a profiled (textured) surface by which an indentation is formed that has a correspondingly structured (textured) surface for example a latticed wall section.
[0018] Thereby various compression forces in different pressure directions are transmitted by the holding down device onto the conductor track and from the conductor track onto the solar cells, so that the solder connection during the subsequent soldering process is sustainably improved, in particular a substantially higher surface contact between conductor track and solar cell is achieved, which is important for the electrical conduction.
[0019] As explained above the concrete geometry of the indentation is in particular dependent of the geometry of the holding down device that is being held more ore less stationary relative to the conductor track during the press-on step. Insofar the indentation can for example have a circular cross-section in the area of the free surface of the associated conductive path, but also an oval cross-section or a cross-section with evolvent-like edges.
[0020] The height of the indentation (vertically to the surface of the solar cell) is dependent from the thickness of the conductor track, the compressive force with which the holding down device is pressing onto the conductor track as well as the geometry of the pressure body. Usually the maximum height of the indentation (vertically to the surface of the solar cell and conductor track) corresponds to a maximum of 70% of the overall thickness of the conductor track (viewed in the same direction as the indentation) wherein a value of 10% is sufficient to obtain the desired pressure distribution. Typical values are 10-50% or 10-30%.
[0021] The distance of the indentations (in longitudinal direction of the corresponding conductor track) is according to one embodiment between 1.0 to 3.0 cm.
[0022] The cross-section of the indentation at the free surface of the conductor track is in particular 0.5 to 5 mm 2 with common values of 0.5 to 2 mm 2 .
[0023] Further features of the invention result from the features of the sub-claims as well as the other application documents.
[0024] The invention is explained in more detail below by one embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] This shows, each in schematic representation:
[0026] FIG. 1 : A lateral view of a solar cell-string,
[0027] FIG. 2 : A topview onto a solar cell of the string,
[0028] FIG. 3 : A topview of a conductor track of the solar cell according to FIG. 2 ,
[0029] FIG. 4 : A cross section of the conductor track according to FIG. 3 ,
[0030] FIG. 5 : A lateral view of a holding down device.
[0031] In the figures components which are similar or with similar effects are represented with identical characters.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 shows—strongly schematic—a solar cell-string made of four solar cells 10 , that are connected by conductor tracks 12 , wherein each conductor track is firmly connected with a first section 12 o to an upper surface 10 o of a solar cell 10 and with a second section 12 u to a lower surface 10 u of the adjacent solar cell 10 , by soldering.
[0033] Electric connections at the end-face are schematically represented by numeral 14 .
[0034] FIG. 2 shows a topview onto a solar cell 10 according to FIG. 1 wherein two conductor tracks 12 being parallel to one another with a clearance between them are extending across the upper surface 10 o of the solar cell 10 can be seen.
[0035] FIG. 3 shows in an enlarged scale compared with FIG. 2 , but also only schematic, spherically-shaped indentations 16 between edges 12 r of the conductor track 12 . The indentations 16 extend centered within the conductor track 12 . This results in a very good pressure distribution when depressing with the according holding down device ( FIG. 5 ) and by that a good contact pressure of the conductor track 12 onto the solar cell 10 .
[0036] In the top view the spherical-shaped indentations 16 have approximately an oval cross-section. The distance between adjacent indentations 16 is approximately 3 to 5 times of the opening width of the indentation 16 within the area of the free upper surface 12 f of the conductor track 12 .
[0037] FIG. 3 shows the area of the spherically-shaped indentations 16 in a cross-sectioned view. The curved edges 16 g of the indentations 16 can be seen, wherein the maximum height of the indentations 16 is in this case approximately half the thickness d of the conductor track 12 . The indentation 16 shown in FIG. 4 on the right is slightly tilted with respect to the indentation displayed on the left, which is supposed to clarify that the indentions 16 not always have an exactly symmetrical geometry under the given technical conditions and not always an exactly centered position on the conductive path, but can also, as in 16 ′ in FIG. 2 , extend somewhat eccentric.
[0038] Despite this it is desired that the indentations 16 extend completely within the corresponding conductor track that means being circumferentially limited by the free upper surface 12 f of the conductor track 12 .
[0039] Together with the curved edges this results in an optimized pressure distribution with the aid of the corresponding holding down device during transport and subsequent soldering process.
[0040] FIG. 5 shows and embodiment of a possible holding down device. At a crossbeam 20 a spiral-spring 22 is hinged that bears a spherical body mounted at its free end, in this case shaped as a ball. Body 24 is made of glass fiber reinforced polymer that is resistant up to 400° C., alternatively from ceramic/porcelain with a temperature resistance >400° C. The material of the body 24 can therefore be applied in a soldering station without any problem. Body 24 which presses over a certain area onto an according soldering strip (a conductor track 12 ) allows a multidimensional force distribution onto the conductor track 12 under the influence of the spring 22 , or onto the corresponding solar cell-string respectively, where groove (indentation) 16 , shown in FIG. 4 in a cross-section results, from which body 24 can be removed without any problem after the soldering process. With respect to the desired compressive force it is advantageous if the body is arranged eccentrically to the mounting of the spring 22 and the crossbeam 20 , as shown in FIG. 5 , therefore not only developing an unidirectional force as in the case of a pure vertical load onto the conductor track 12 .
[0041] Obviously a series of holding down devices identified above are arranged at the crossbeam 20 to produce a multitude of corresponding press-on areas available on the according conductor track sections. | The invention concerns to a solar cell-string, wherein a “string” describes a series of solar cells which are connected by electrical conducting strips. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a clothing steam ironing apparatus, particularly to one suitable for ironing clothing while the clothing is hanging.
[0003] 2. Description of the Related Art
[0004] Steam ironing for clothing has advantages of high efficiency, good ironing effect, and no bad influence to the surface and texture of the clothing. Further, due to elimination of the need of a flat bench, hanging arrangement for steam ironing is especially convenient.
[0005] However, some disadvantages exist in prior ironing apparatus in hanging arrangement. For example, because there is no support at the back side of the hanging clothing, the ironing operation is a bit difficult and the clothing will not be ironed as smooth as it would be by ironing with pressure (such as, the back side of the clothing is supported by a rigid body). Thus the ironing efficiency and effect may not satisfy the increasing demand nowadays.
[0006] In addition, prior clothing steam ironing apparatus could be only used in clothing ironing, and could not perform other useful function like dust elimination. Accordingly, prior ironing apparatus only has a single function.
SUMMARY OF THE INVENTION
[0007] The present invention has been made to overcome or alleviate at least one aspect of the above mentioned disadvantages.
[0008] According to an aspect of the present invention, there is provided a clothing steam ironing apparatus, comprising an ironing component with an ironing panel. Steam ejection holes for ejecting steam to iron clothing and air suction holes for generating a suck force to the clothing are provided in the ironing panel.
[0009] Preferably, the ironing component further comprises a steam chamber and an air chamber separated from the steam chamber, the steam chamber being in fluid communication with the steam ejection hole and the air chamber being in fluid communication with the air suction hole.
[0010] Preferably, the ironing component is provided with an air vent being in fluid communication with the air chamber, a fan is provided in the air chamber.
[0011] Preferably, a dust collection device equipped with a filter is provided between the fan and the air suction hole.
[0012] Preferably, the steam ejection holes are located at the center of the ironing panel and the air suction holes are located at the periphery of the ironing panel.
[0013] Preferably, the clothing steam ironing apparatus further comprises a mount for providing steam.
[0014] Preferably, a vertical telescopic pole bracket is provided in the mount.
[0015] Preferably, the clothing steam ironing apparatus further comprises a fan control switch for switching the fan on and off and for adjusting the velocity of the wind blown by the fan.
[0016] According to another aspect, present invention provides a clothing steam ironing apparatus, comprising a mount including a steam generating device therein and an ironing head which connects at an end of a steam pipe led from the mount and connects with the steam generating device through the steam pipe; wherein the ironing head comprises a steam chamber and an air suction chamber separated from the steam chamber; steam ejection holes connecting with the steam chamber and air suction holes connecting with the air suction chamber are dispersedly formed in an ironing panel of the ironing head; a fan is mounted in the mount; an air discharge port of the fan is in fluid communication with an air vent formed in a housing of the mount; an air intake port of the fan connects with one end of an air intake pipe, the other end of the air intake pipe connects with the air suction chamber of the ironing head.
[0017] Preferably, the clothing steam ironing apparatus further comprises a dust collection device which is provided in the mount and located between the air intake port of the fan and the air intake pipe, or the dust collection device is provided in the air suction chamber.
[0018] According to another aspect, the present invention provides a clothing steam ironing apparatus with cleaning function, the apparatus comprises a mount including a steam generating device therein, the mount is equipped with a vertical telescopic pole bracket, a steam pipe connects with the steam generating device at one end and connects with an ironing head at the other end, wherein the ironing head comprises a steam ejection chamber and an air suction chamber; steam ejection hole connecting with the steam chamber and air suction hole connecting with the air suction chamber are formed in an ironing panel of the ironing head; a fan is mounted in the air suction chamber; a dust collection device with a filter is provided between the fan and the air suction hole, and an air vent for the air suction chamber is provided in a housing of the ironing head at the rear lower side of the fan.
[0019] According to yet another aspect, present invention provides a clothing steam ironing apparatus, comprising a mount including a steam generating device therein and an ironing head which connects at an end of a steam pipe led from the mount and connects with the steam generating device through the steam pipe; wherein the ironing head comprises a steam chamber and an air suction chamber separated from the steam chamber; steam ejection holes connecting with the steam chamber and air suction holes connecting with the air suction chamber are dispersedly formed in an ironing panel of the ironing head; the steam chamber is in fluid communication with the steam pipe and the steam ejection holes, the air chamber is in fluid communication with the air suction holes; a fan is mounted in the ironing head; an air intake port and an air discharge port of the fan are in fluid communication with the air chamber and an air outlet formed in the ironing head, respectively.
[0020] Compared with existing technology, present invention is advantageous in at least following aspects:
[0021] Due to the presence of the air suction holes, the ironing side of the clothing will stick to the ironing panel when the ironing panel contacts the clothing to be ironed. The operator could move the ironing apparatus when ironing the clothing, so it is convenient for the user to iron the clothing; meanwhile, the clothing could be ironed smooth. Therefore, both of the ironing efficiency and effect are enhanced.
[0022] By combining air suction holes and dust collection device, the clothing, as well as bedding, sofa and seat cushion could be dusted when the ironing panel of the ironing head contacts them. Furthermore, by virtue of the high temperature of the steam, the ironing apparatus of present invention further provide a sterilization function, so that the hazard to health of human, especially old people and children, incurred by the dust, pollen, acarus and other pollutants might be reduced. Thus, the clothing will undergo a cleaning and sterilizing process when being ironed by the ironing apparatus of present invention.
[0023] In a preferred embodiment, a fan control switch is provided, which enables steam ironing and dusting operations simultaneously, or independently.
BRIEF DESCRIPTION OF THE DRAWING
[0024] FIG. 1 is a schematic view of the configuration of the clothing steam ironing apparatus according to a first embodiment of present invention;
[0025] FIG. 2 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a first embodiment of present invention;
[0026] FIG. 3 is a schematic view of the configuration of the clothing steam ironing apparatus according to a second embodiment of present invention;
[0027] FIG. 4 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a second embodiment of present invention;
[0028] FIG. 5 is a schematic view of the configuration of the clothing steam ironing apparatus according to a third embodiment of present invention;
[0029] FIG. 6 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a third embodiment of present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] Preferred embodiments of the present invention will be described hereinafter in detail with reference to the attached drawings, wherein the like reference numerals refer to the like elements throughout the specification. These embodiments should not be construed as being limited to the embodiment set forth herein, rather for illustrative purpose.
[0031] In description hereafter, “clothing steaming ironing apparatus” may be referred to as “clothing steam hanging ironing apparatus”. Thus, though presented in different expressions, the two terms have substantially same meaning.
[0032] As illustrated in FIGS. 1 , 2 , the first embodiment of the clothing steam ironing apparatus according to present invention comprises an ironing component 3 which includes an ironing panel (better seen in FIG. 2 ). Steam ejection holes 7 and suction holes 8 are provided in the ironing panel, and during use, the steam is ejected from the steam ejection holes 7 to iron the clothing while the suction holes 8 inhale air to generate a sucking force to the clothing.
[0033] In clothing steam ironing apparatus according to present invention, due to the sucking force provided by the suction holes 8 , the side of the clothing being ironed is stuck to the ironing panel closely. The operator could move ironing component while ironing the clothing, which is convenient for the user on the one hand, and on the other hand, the fabric of the clothing could be ironed smooth. Therefore, both of the ironing efficiency and effect are enhanced.
[0034] In prefer embodiment of present invention, as illustrated in FIG. 2 , the ironing component 3 further comprises a steam chamber 5 and an air suction chamber 6 separated from the steam chamber 5 . The steam chamber 5 is in fluid communication with the steam ejection holes 7 , and the air suction chamber 6 is in fluid communication with the suction holes 8 .
[0035] It should be noted that, the configuration of the steam chamber and the air suction chamber taught above is a preferred embodiment of present invention, but present invention is not limited to that and those skilled in the art could adopt any possible ways. In other words, any suitable configuration that could provide an appropriate channel for conveying steam and air to the ironing panel could be employed as alternatives to the configuration illustrated in FIGS. 1-2 .
[0036] Actually, referring to FIG. 4 , another configuration of steam chamber and air suction chamber is illustrated. In the embodiment of FIG. 4 , a dust collection and filter 13 is provided between the suction holes 8 and the fan 9 inside the air suction chamber 6 .
[0037] Referring to FIG. 2 again, according to the first embodiment of present invention, ironing component 3 is provided with an air outlet 10 which is in fluid communication with the air suction chamber 6 . Alternatively, the air outlet 10 could be provided in the mount 1 . Accordingly, the location of the air outlet shown in FIG. 2 shall not be construed as a limit to present invention. Actually, according to another embodiment of present invention, the air outlet 10 could be formed in the mount 1 as illustrated in FIG. 5 as well.
[0038] FIG. 2 illustrates that the fan 9 is provided in the air suction chamber 6 . The air intake port and the air discharging port of the fan 9 are in fluid connection with the air suction chamber 6 and the outlet 10 , respectively. The intake of air is achieved by the rotation of the fan 9 . To control the fan, a fan control switch (not shown) is provided for starting up and turning off the fan and for adjusting the wind speed outputted by the fan. Thus, an operator could select a suitable wind speed which corresponds to the force of the sucking force as desired, and switch the fan on and off independently. That is, the switch enables a flexible control over the fan, the operator could select use or not to use the fan during ironing process, or the operator could use the fan to dust the clothing only, i.e., without ironing the clothing.
[0039] According to the first embodiment of present invention, as illustrated in FIG. 2 , the steam ejection holes 7 are dispersedly formed in center of the ironing panel, and the suction holes 8 are formed at the periphery of the ironing panel. Correspondingly, in the first embodiment, the steam chamber 5 and the air suction chamber 6 are separated from each other, and more specifically, the centrally positioned steam chamber 5 are surrounded by the air suction chamber 6 .
[0040] According to the first embodiment, the mount 1 is used to provide steam, that is, a steam generator such as configured as a water tank with an electric heater therein is provided in the mount 1 . A steam pipe 2 connects with the steam outlet of the steam generator and is led from the mount 1 , preferably, the steam pipe 2 is a flexible heat-resistant and heat insulation pipe. The other end of the steam pipe 2 communicates with the steam chamber 5 . It should be understood that present invention is not limited to the steam generator and steam pipe configuration as above, those skilled in the art could configure the steam generator otherwise and arrange the steam pipe elsewhere according to the requirement of actual application.
[0041] According to the first embodiment of present invention, a vertical telescopic pole bracket 4 is provided in the mount 1 as a bracket for placing the ironing component and for hanging the clothing. The bracket 4 , being of a telescopic pole, is advantageous in storing the ironing apparatus when not in use, and in allowing the height of the bracket to be adjusted, which is convenient for ironing work. Per the actual application, those skilled in the art could employ a fixed type mount or a movable one.
[0042] FIGS. 3 , 4 illustrate a second embodiment of present invention. In FIGS. 3 , 4 same elements are denoted by same reference sign, for the purpose of clarity, the description about same elements will not be repeated.
[0043] FIG. 4 illustrates the control switch 12 of the fan. According to the second embodiment of present invention, the configuration of the steam chamber 5 and the air suction chamber 6 is different from that in the first embodiment. More specifically, though the steam chamber 5 and the air suction chamber 6 are separated from each other too, as illustrated in FIG. 4 , the area that the steam chamber 5 contacts the ironing panel is much larger than the area that the air suction chamber 6 contacts the ironing panel. Correspondingly, the locations of the steam ejection holes 7 and suction holes 8 are also different from that in the first embodiment. In the second embodiment, the steam ejection holes 7 and the suction holes 8 are formed at the upper side and the lower side of the ironing panel respectively.
[0044] In addition, in order to improve the dust cleaning effect, a dust collection device 13 with a filter is provided between the fan 9 and the suction holes 8 . Preferably, the dust collection device 13 is a vertical flat box-like body, with a front end and a rear end opened. The filter for preventing the dust entering into the dust collection device 13 from leaving is mounted in the inside of the rear end opening of the flat box-like body. The dust collection device 13 is inserted and fitted in the air suction chamber 6 though an opening at the underside of a housing of the ironing component 3 . The dust collection device 13 could be integrally detached from the ironing component 3 , so that the user could dump the dust accumulated in the dust collection device and clean the filter. An air vent 11 is provided in the housing of the ironing component 3 at the rear lower side (or rear upper side) of the fan 9 , the air drawn into the air suction chamber 6 by the fan 9 though the air suction holes 8 flow out through the air vent 11 . The air flow as discussed above will generate a sucking force acted on the clothing to be ironed or cleaned, meanwhile serve as a cooling air flow for the fan.
[0045] In FIGS. 5 , 6 , the third embodiment of present invention is illustrated, and the elements same with that of the first and second embodiment are denoted by the same reference signs. For the same configurations, the descriptions will be omitted.
[0046] Referring to FIG. 5 , in accordance with the third embodiment of present invention, the location of the fan 9 is different from that in the first and second embodiments. More specifically, the fan 9 is provided in the mount 1 . The air discharging port of the fan 9 is in fluid communication with the air outlet 10 formed in a housing of the mount 1 , and the air intake port of the fan 9 connects with a flexible intake pipe 14 . The other end of the intake pipe 14 is in fluid communication with the air suction chamber 6 of the ironing component 3 .
[0047] Besides, according to the third embodiment of present invention, a suction adjusting valve 15 is provided in the ironing component 3 . The valve 15 could be configured as a ring body and mounted at the lower end of the ironing component 3 . An air inhaling hole is formed in the ring body of the valve 15 , and a corresponding air inhaling hole communicating with the air suction chamber 6 could be provided in the ironing component 3 . By rotating the ring body, the air flow through the two air inhaling holes could be adjusted, up to the maximum flow rate or be reduced to zero (closed up). Thus the sucking force acted on the clothing to be ironed could be adjusted to meet various ironing requirements for different materials of the clothing.
[0048] Preferably, a filter 16 is provided in the housing of the mount 1 and fits with the air outlet 10 , so that the air discharged by the fan 9 is filtered by the filter 16 . To facilitate the cleaning work, the filter 16 preferably is removably mounted in the housing of the mount.
[0049] According to present invention, the fan could be provided in the ironing component or be provided in the mount, correspondingly, the dust collection device could be arranged in the ironing component or be arranged in the mount. As a basic teaching of the principle of present invention, those skilled in the art could readily envisage other modifications suitable for actual need.
[0050] Although several exemplary embodiments have been shown and described, it would be appreciated by those skilled in the art that various changes or modifications may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the appended claims and their equivalents. | Disclosed is a clothing steam ironing apparatus, comprising an ironing component ( 3 ) with an ironing panel, steam ejection holes ( 7 ) for ejecting steam to iron a clothing and air suction holes ( 8 ) for generating a suck force to the clothing are provided in the ironing panel. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/KR2012/011034 filed on Dec. 17, 2012, which claims priority form Korean Patent Application No. 10-2011-0143934 filed with Korean Intellectual Property Office on Dec. 27, 2011, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a non-aqueous electrolyte solution for a lithium secondary battery, which includes a dinitrile compound in which a hetero atom is substituted at a main chain to prevent a swelling phenomenon of the battery and a lithium secondary battery including the same.
[0004] 2. Description of the Related Art
[0005] Recently, attention on an energy storing technique is increasing more and more. As the application field of the energy storing technique is enlarged to a cellular phone, a camcorder and a notebook personal computer (PC), and by extension, to an electric vehicle, requirements on a battery having a high energy density, which is used as the power supply of an energy electronic device, are increasing. A lithium secondary battery is the most appropriate battery satisfying the above-described requirements, and researches on the lithium secondary battery are actively conducted nowadays.
[0006] Among recently applied secondary batteries, a lithium secondary battery developed in the early 1990s includes an anode formed by using a carbon material etc. for absorbing and releasing lithium ions, a cathode formed by using an oxide including lithium, etc. and a non-aqueous electrolyte solution including an appropriate amount of a lithium salt dissolved in a mixed organic solvent.
[0007] The organic solvent widely and presently used in the non-aqueous electrolyte solution includes ethylene carbonate, propylene carbonate, dimethoxyethane, gamma butyrolactone, N,N-dimethylformamide, tetrahydrofuran, acetonitrile, etc. However, the above described solvents may generate a gas due to the oxidation of an electrolyte when stored at a high temperature for a long time. In this case, the structure of the battery may be deformed, or an internal short may be generated because of an internal heating due to an overcharge or an over-discharge to induce the ignition or the explosion of the battery.
[0008] Recently, in order to solve the above-described limitations, methods for improving the stability of the battery at a high temperature by (1) using a porous polyolefin-based separator having a high melting point and hardly melting at a high temperature surroundings or (2) mixing a flame-retardant solvent or an additive with an electrolyte, have been attempted.
[0009] However, the thickness of the porous polyolefin-based separator is commonly required to be increased to accomplish the high melting property. Accordingly, the loading amounts of the anode and the cathode relatively decrease, and the decrease of the capacity of the battery becomes inevitable. In addition, since the melting point of the polyolefin-based separator formed by using PE, PP is about 150° C., the separator may be molten due to the rapid internal heating caused by the oxidation of the electrolyte during over-charging. In this case, an internal short of the battery may be induced and the ignition and the explosion of the battery may be inevitable.
[0010] Recently, various researches on developing an electrolyte having new components including an additive have been conducted to solve the above-described limitations. For example, a nonflammable gas having a boiling point of 25° C. or less may be added, a phosphoric acid ester may be added into a carbonate to confirm the nonflammability of the electrolyte, or 30% or more of a nonflammable solute of a perfluoroalkyl or a perfluoro ester may be added into the electrolyte. However, when the nonflammable gas is injected into the electrolyte, the volume of the battery may increase, and a complicated electric assembling process maybe required to be conducted. In addition, when the phosphoric acid ester is added into the electrolyte, the performance of the battery may be deteriorated due to a high reduction potential. When the perfluoro compound is added into the electrolyte, a lithium salt may be precipitated from the organic solvent electrolyte.
[0011] In order to improve the above-described limitations, researches on an electrolyte including an amide compound, which exhibits a wide electrochemical window and a high thermal and chemical stability and solves the limitation on the evaporation, the ignition of the electrolyte due to the use of the common organic solvent, have been accelerated.
PRIOR ART LITERATURE
Patent Literature
[0012] (Patent Literature 1) Japanese Patent Publication No. 1997-259925
[0013] (Patent Literature 2) Japanese Patent Publication No. 2006-179458
[0014] (Patent Literature 3) Japanese Patent Publication No. 2005-190873
[0015] (Patent Literature 4) U.S. Pat. No. 6,797,437
SUMMARY OF THE INVENTION
[0016] An aspect of the present invention provides a non-aqueous electrolyte solution for a lithium secondary battery, including an additive for suppressing the swelling phenomenon of the battery due to a gas generated during storing at a high temperature and a lithium secondary battery including the same.
[0017] Hereinafter, the present invention will be described in detail. The terms and words used in the present specification and claims should not be interpreted by only common or dictionary definition, but should be interpreted as a meaning and concept coincide with the technical spirit of the present invention basing upon the principles that an inventor may appropriately define the concept of a term to explain his invention by the best way.
[0018] According to an aspect of the present invention, there is provided a non-aqueous electrolyte solution for a lithium secondary battery. The non-aqueous electrolyte solution includes an ionizable lithium salt, an amide compound represented by the following Chemical Formula 1, a dinitrile compound including a hetero atom as a substituent in a main chain and an organic solvent.
[0000]
[0019] In Chemical Formula 1, R represents one selected from the group consisting of a halogen substituted alkyl group having 1 to 20 carbon atoms, a halogen substituted alkylamine group having 1 to 20 carbon atoms, a halogen substituted alkenyl group having 2 to 20 carbon atoms and a halogen substituted aryl group having 6 to 12 carbon atoms.
[0020] R 1 and R 2 independently represent one selected from the group consisting of a hydrogen atom, a halogen atom, an alkyl group having 1 to 20 carbon atoms, an alkylamine group having 1 to 20 carbon atoms, an alkenyl group having 2 to 20 carbon atoms and an aryl group having 6 to 12 carbon atoms. At least one of R 1 and R 2 is an alkoxy group represented by —O(CH 2 ) p CH 3 , and p is an integer of 0 to 8.
[0021] X represents one selected from the group consisting of carbon, silicon, oxygen, nitrogen, phosphor and sulfur, in which i) o represents 1 when X is the oxygen or the sulfur, ii) o represents 2 when X is the nitrogen or the phosphor, and iii) o represents 3 when X is the carbon or the silicon.
[0022] Particularly, commonly used salts in an electrolyte for a lithium secondary battery may be used without limitation as the ionizable lithium salt for the non-aqueous electrolyte solution and an anion of the ionizable lithium salt may include at least one selected from the group consisting of F − , Cl − , Br − , I − , NO 3 − , N(CN) 2 − , BF 4 − , ClO 4 − , PF 6 − , (CH 3 ) 2 PF 4 − , (CF 3 ) 3 PF 3 − , (CF 3 ) 4 PF 2 − , (CF 3 ) 5 PF − , (CF 3 ) 6 P − , CF 3 SO 3 − , CF 3 CF 2 SO 3 − , (CF 3 SO 2 ) 2 N − , (FO 2 ) 2 N − , CF 3 CF 2 (CF 3 ) 2 CO − , (CF 3 SO 2 ) 2 CH − , (SF 6 ) 3 C − , (CF 3 SO 2 ) 3 C − , CF 3 (CF 2 ) 7 SO 3 − , CH 3 CO 2 , SCN and (CF 3 CF 2 SO 2 ) 2 N.
[0023] In addition, the amide compound of Chemical Formula 1 included in the electrolyte in accordance with exemplary embodiments may include N-methoxy-N-methyl 2,2,2-trifluoroethyl carbamate, N-methoxy-N-methyl 2-fluoroethyl carbamate, N-methoxy-N-methyl pentafluoropropyl carbamate, N-methoxy-N-methyl 2-perfluorohexyl carbamate, N-methoxy-N-methyl 6-perfluorobutylhexyl carbamate, etc.
[0024] In this case, a relative molar ratio of the amide compound to the lithium salt may be in a range of 1-8:1, and more particularly, in a range of 2-6:1.
[0025] In the electrolyte solution in accordance with exemplary embodiments, the dinitrile compound including the hetero atom substituent at the main chain may be represented by the following Chemical Formula 2.
[0000] NC—C n H 2n (XR 3 R 4 )—C m H 2m —CN [Chemical Formula 2]
[0026] In Chemical Formula 2, X represents oxygen, nitrogen or sulfur, and when X is the oxygen or the sulfur, R 4 is not present. R 3 and R 4 represent an alkyl group having 1 to 12 carbon atoms or a halogen substituted alkyl group having 1 to 12 carbon atoms, and n and m represent an integer of 1 to 6.
[0027] In exemplary embodiments, the dinitrile compound of Chemical Formula 2 may be one or a mixture of two or more among 3-methoxy glutaronitrile, 3-ethoxy glutaronitrile, 3-dimethylamino glutaronitrile, thiomethoxy succinonitrile, and 2,2,2-trifluoroethoxy glutaronitrile and may not be limited to these compounds.
[0028] In exemplary embodiments, an amount of the dinitrile compound is 0.1 wt % to 10 wt %, particularly, 0.1 wt % to 9 wt %, and more particularly, 0.1 wt % to 7 wt % based on a total amount of the non-aqueous electrolyte solution. When the amount of the dinitrile compound is less than 0.1 wt %, the preventing effect of the battery swelling due to the addition of the dinitrile compound may not be sufficiently obtained, and when the amount of the dinitrile compound exceeds 10 wt %, a lifetime at a high temperature during processing a charging/discharging cycle at a high temperature may be largely deteriorated.
[0029] When the dinitrile compound including the hetero atom substituent at the main chain is included in the electrolyte in accordance with exemplary embodiments, the hetero atom may capture a metal ion to reduce the reaction between a dissociated metal ion and the electrolyte. Accordingly, a better preventing effect on the battery swelling may be obtained when comparing with the electrolyte including common dinitrile compounds.
[0030] In exemplary embodiments, commonly included organic solvents in an electrolyte for a lithium secondary battery may be used without limitation as the organic solvents for the non-aqueous electrolyte solution. Typically, the organic solvent may be at least one selected from the group consisting of propylene carbonate (PC), ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), ethyl methyl carbonate (EMC), methylpropylene carbonate, dipropyl carbonate (DPC), dimethyl sulfoxide, acetonitrile, dimethoxyethane, diethoxyethane, vinylene carbonate, sulfolane, γ-butyrolactone, propylene sulfite and tetrahydrofuran. Particularly, the ethylene carbonate and the propylene carbonate, which are cyclic carbonates, among the organic solvents are preferably used because the solvents have a high viscosity and a high dielectric constant, and dissociate the lithium salt in the electrolyte easily. More preferably, an appropriate amount of a linear carbonate having a low viscosity and a low dielectric constant such as the dimethyl carbonate and the diethyl carbonate may be mixed with the cyclic carbonate solvent, to obtain an electrolyte solution having a high electric conductivity. The amount of the organic solvent may be 10 wt % to 90 wt % based on the total amount of the electrolyte solution.
[0031] The electrolyte in accordance with example embodiments may be usefully applied for manufacturing an electrochemical device such as a lithium secondary battery. Particularly, a lithium secondary battery manufactured by injecting the non-aqueous electrolyte solution for the lithium secondary battery in accordance with exemplary embodiments into an electrode structure including a cathode, an anode and a separator disposed between the cathode and the anode, may be provided. In this case, the cathode, the anode and the separator constituting the electrode structure may be commonly used elements for the manufacture of the lithium secondary battery.
[0032] As an active material of the cathode, a transition metal oxide including lithium may be preferably used, for example, one or a mixture of two or more selected from the group consisting of LiCoO 2 , LiNiO 2 , LiMnO 2 , LiMn 2 O 4 , Li(Ni a Co b Mn c )O 2 (0<a<1, 0<b<1, 0<c<1, a+b+c=1), LiNi 1-y Co y O 2 , LiCo 1-y Mn y O 2 , LiNi 1-y Mn y O 2 (O=y=1), Li(Ni a Mn b CO c )O 4 (0<a<2, 0<b<2, 0<c<2, a+b+c=2), LiMn 2-z Ni z O 4 , LiMn 2-z Co z O 4 (O<z<2), LiCoPO 4 and LiFePO 4 . In addition, a sulfide, a selenide, a halide, etc. may be used besides the oxide.
[0033] As an active material of the anode, a commonly used material possibly absorb and release lithium ions such as a carbon material, a lithium metal, silicon, tin, etc. may be used.
[0034] A metal oxide having a potential with respect to lithium of 2V or less, such as TiO 2 and SnO 2 may be used. Preferably, the carbon material may be used and the carbon material may include both a low crystalline carbon and a high crystalline carbon. The low crystalline carbon typically includes soft carbon and hard carbon, and the high crystalline carbon typically includes a high temperature baked carbon such as natural graphite, kish graphite, pyrolytic carbon, mesophase pitch based carbon fiber, meso-carbon microbeads, mesophase pitches, petroleum or coal tar pitch derived cokes, etc. In this case, the anode may include a binder. The binder may include various binder polymers such as vinylidene fluoride-hexafluoropropylene copolymer (PVDF-co-HFP), polyvinylidene fluoride, polyacrylonitrile, polymethyl methacrylate, etc.
[0035] As the separator, commonly used porous polymer film of the common separator may be used. The porous polymer film may be formed by using a polyolefin-based polymer such as an ethylene homopolymer, a propylene homopolymer, an ethylene/butene copolymer, an ethylene/hexene copolymer, an ethylene/hexane copolymer, an ethylene/methacrylate copolymer, etc. The porous polymer film may be used alone or by integrating two or more films. The separator may be a common porous nonwoven fabric such as a glass fiber having a high melting point, and a nonwoven fabric of polyethylene terephthalate fiber, etc. However, the separator is not limited to the above described kinds.
[0036] The shape of the lithium secondary battery may not be specifically limited and may be a cylindrical shape using a can, a square shape, a pouch shape, a coin shape, etc.
[0037] The non-aqueous electrolyte solution may suppress the generation of a gas while storing a battery at a high temperature, may prevent a swelling phenomenon. As a result, the present invention may provide a battery having a good charging/discharging performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0039] FIG. 1 is a graph illustrating the thickness changes of batteries after full-charging the batteries to 4.2V in accordance with Example 3 and Comparative Example 2 and then, storing in an oven at 90° C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. However, the exemplary embodiments of the present invention may be modified to various other forms and the scope of the present invention should not be interpreted to the following exemplary embodiments. The exemplary embodiments of the present invention are provided in order to fully explain the present invention for a person having an average knowledge in the art.
EXAMPLES
[0041] I. Method for Preparing Electrolyte
Example 1
[0042] (First step) Synthesis of a dinitrile compound including a hetero atom substituent in a main chain
[0043] Into a tetrahydrofuran solution, 0.7 g of sodium hydride was added. After cooling to 0° C., 3 g of 3-hydroxyglutaronitrile dissolved in a tetrahydrofuran solvent was slowly dropped. After completing the dropping, dimethyl sulfate was slowly added dropwise and stirred at 0° C. for 15 minutes. After stirring at room temperature for 6 hours, the reactant was extracted using water and dichloromethane and distilled under a reduced pressure to obtain 3-methoxy glutaronitrile (yield 82%).
[0044] (Second Step) Synthesis of an Amide Compound Represented by Chemical Formula 1
[0045] 1.44 g of methoxymethylamine hydrochloride and 1.75 g of triphosgene were mixed with a methylene chloride solution and cooled to 0° C. 3.13 g of triethylamine was slowly added dropwise. After completing the dropping, the temperature was increased to room temperature and stirring was continued for 1 hour. After completing the reaction, methylene chloride was removed by filtration. Tetrahydrofuran was added to thus obtained product, and thus produced salt was filtered. The filtrate was distilled under a reduced (vacuum) pressure to obtain 2 g of N-methoxy-N-methyl chloroformate.
[0046] Then, 0.78 g of sodium hydride was added to a tetrahydrofuran solution, and 1.7 g of a 2,2,2-trifluoroethanol solution was slowly added dropwise at a low temperature. After completing the dropping, stirring was continued for 2 hours and 2 g of N-methoxy-N-methyl chloroformate obtained at the previous step was slowly added dropwise at a low temperature. After completing the reaction, a small amount of water was added, and the tetrahydrofuran solution was evaporated. Then, an extraction process was conducted using methylene chloride and water. After the extraction, a distillation process was conducted under a reduced (vacuum) pressure to obtain N-methoxy-N-methyl 2,2,2-trifluoroethyl carbamate (yield 72%).
[0047] (Third Step) Preparing an Electrolyte Solution
[0048] 5.8 g of N-methoxy-N-methyl 2,2,2-trifluoroethyl carbamate obtained at the second step and 2 g of LiPF 6 were added into a round-bottomed flask and stirred slowly for 2 hours under a nitrogen gas atmosphere to produce 7.8 g of a solution (A). A solution (B) obtained by mixing ethylene carbonate and ethylmethyl carbonate by a volume ratio of 2:1, and the solution (A) were mixed by a weight ratio of 3:7. 5 wt % of 3-methoxy glutaronitrile obtained at the first step based on the total mixture solution was added to the mixture to prepare an electrolyte solution.
Example 2
[0049] (Second Step) Synthesis of an Amide Compound Represented by Chemical Formula 1
[0050] 0.35 g of sodium hydride was added into a tetrahydrofuran solution and then, 0.5 g of a 2-fluoroethanol solution was slowly added dropwise at a low temperature. After completing the dropping, stirring was continued for 2 hours. Then, 0.9 g of N-methoxy-N-methyl chloroformate obtained at the second step in Example 1 was slowly added dropwise. After completing the reaction, a small amount of water was added. The tetrahydrofuran solution was distilled and an extraction process was conducted using methylene chloride and water. After completing the extraction, distillation under a reduced (vacuum) pressure was conducted to obtain N-methoxy-N-methyl 2-fluoroethyl carbamate.
[0051] (Third step) Preparing an Electrolyte Solution
[0052] 5.2 g of N-methoxy-N-methyl 2-fluoroethyl carbamate obtained at the (second step) and 2 g of LiPF 6 were added into a round-bottomed flask and stirred slowly for 2 hours under a nitrogen gas atmosphere to produce 7.2 g of a solution (A). A solution (B) obtained by mixing ethylene carbonate and ethylmethyl carbonate by a volume ratio of 2:1, and the solution (A) were mixed by a weight ratio of 3:7. 5 wt % of 3-methoxy glutaronitrile obtained at the first step of Example 1 based on the total mixture solution was added to the mixture to prepare an electrolyte solution.
Comparative Example 1
[0053] An electrolyte solution was prepared through conducting the same procedure described in Example 1 except for adding 3 wt % of vinylene carbonate and 2 wt % of fluoroethylene as additives instead of 3-methoxy glutaronitrile at the (third step) in Example 1.
[0054] II. Manufacture of Secondary Battery
Example 3
[0055] (Manufacture of a Cathode)
[0056] LiCoO 2 as a cathode active material, synthetic graphite as a conductive material, and polyvinylidene fluoride as a binder were mixed by a weight ratio of 94:3:3. Then, N-methyl pyrrolidone was added to prepare a slurry. The slurry was coated on an aluminum foil and dried at 130° C. for 2 hours to manufacture a cathode.
[0057] (Manufacture of an Anode)
[0058] Synthetic graphite as an anode active material, a conductive material, and a binder were mixed by a weight ratio of 94:3:3. Then, N-methyl pyrrolidone was added to prepare a slurry. The slurry was coated on a copper foil and dried at 130° C. for 2 hours to manufacture an anode.
[0059] (Assembling of a Secondary Battery)
[0060] The cathode and the anode manufactured as described above were cut by 1 cm 2 , and a separator was interposed between the cathode and the anode. The electrolyte solution prepared in Example 1 was injected to manufacture a lithium secondary battery.
Example 4
[0061] A secondary battery was manufactured through conducting the same procedure described in Example 3 except for using the electrolyte solution of Example 2 instead of the electrolyte solution of Example 1.
Comparative Example 2
[0062] A secondary battery was manufactured through conducting the same procedure described in Example 3 except for using the electrolyte solution of Comparative Example 1 instead of the electrolyte solution of Example 1.
[0063] III. Evaluation on Physical Properties
[0064] In order to evaluate the stability of the batteries manufactured in Examples 3 and 4 and Comparative Example 2, the physical properties of the electrolytes were evaluated according to the following methods.
[0065] Experiment 1: Test on Safety
[0066] Each of the batteries manufactured by Examples 3 and 4 and Comparative Example 2 was full-charged to 4.2V and stored at 90° C. for 4 hours. The initial thickness and the thickness change after the storing were measured, and the result is illustrated in the following Table 1. The thickness change (Δt) was illustrated as a relative value when the thickness increase of the battery of Comparative Example 2 was set to 100%.
[0000]
TABLE 1
Δt (%)
Example 3
61
Example 4
65
Comparative Example 2
100
[0067] As illustrated in Table 1, the thickness increase (the swelling phenomenon) of the batteries in accordance with the present invention (Examples 3 and 4) after storing for a long time at the high temperature was found to be largely suppressed when comparing with that of the battery of Comparative Example 2. When about 5 wt % of 3-methoxy glutaronitrile was added based on the total amount of the electrolyte, the swelling at a high temperature was confirmed to improve by about 30% or more (see FIG. 1 ).
[0068] Experiment 2: Evaluation on Charging/Discharging Performance
[0069] Each of the batteries according to Examples 3 and 4 and Comparative Example 2 was charged at 25° C. at a constant current of 0.5 C=400 mA. After the voltage of the battery becomes 4.2V, an initial charging was performed until a charging current value became 50 mA at a constant voltage value of 4.2V. The initially charged battery was discharged until the battery voltage became 3V at the constant current of 0.2 C, and the discharge capacity at this time was set to an initial capacity. The initial capacity values of battery obtained for each battery are illustrated in Table 2.
[0000]
TABLE 2
Initial capacity
Example 3
1045
Example 4
1043
Comparative Example 2
1039
[0070] As illustrated in Table 2, the initial capacity of battery for the batteries of Examples 3 and 4 was found to be increased when comparing with that for the battery of Comparative Example 2. | A non-aqueous electrolyte solution includes an electrolyte solution including an amide compound and a lithium salt, and a dinitrile compound substituted by a hetero atom at a main chain, and a lithium secondary battery includes the non-aqueous electrolyte solution. By using the non-aqueous electrolyte solution, a lithium secondary battery having an improved swelling phenomenon and an increased charging/discharging performance may be provided. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for aiming and firing a gun. More particularly, the invention relates to a device for assisting a quadriplegic to aim and fire a rifle, crossbow, or shotgun.
People suffering from quadriplegia experience total paralysis below the waist, and total or partial paralysis below the neck. If the paralysis is total, the quadriplegic cannot move the hands and arms. If the paralysis is only partial, the quadriplegic can move the arms, but cannot grip with the fingers.
The prior art includes devices for supporting, aiming, and firing guns by persons who are not handicapped. See, for example, U.S. Pat. Nos. 882,988: 2,731,829; 3,827,172; 4,012,860; 4,333,395; 4,841,839; and 5,067,268.
The prior art also includes a device designed for a handicapped user. U.S. Pat. No. 4,802,612 discloses a support device for sporting apparatus. The apparatus comprises a front support plate and a back support plate which are adjustably attached to each other with belts, so as to securely sandwich the wearer. An across-the-shoulder strap extending from the front support plate to the back support plate, and a bar extending outwardly and upwardly from the front support plate, for attaching a fishing rod holder, a gun rest, or a camera support are provided. A pivotal bar rod lock and a line-and-hook vise are also disclosed. A gun rest can be attached to the support device by a pivot or swivel arrangement, thereby enabling the user to move the gun laterally. However, a quadriplegic could not use this device as disclosed, because the gun rest does not include a frame for holding the gun; and because, if such a frame were provided, as disclosed e.g. by U.S. Pat. No. 882,988, 3,827,172, 4,012,860, or 4,333,385, the assembly would be too heavy and bulky to be attached to the body of the quadriplegic. Moreover, since a quadriplegic is unable to grasp an object, he or she would be unable to use any of the devices disclosed by these and other prior-art patents.
A need therefore exists for apparatus which a quadriplegic can use for target practice and/or hunting. The present invention provides such apparatus for partially-paralyzed quadriplegics who, while unable to use their fingers to grip an object, are able to move their arms and thereby their open hands.
SUMMARY OF THE INVENTION
In general, the present invention provides a shooting platform for enabling a quadriplegic seated in a wheelchair to aim and fire a rifle, crossbow, or shotgun. The shooting platform comprises a turntable on which is mounted a frame for holding the rifle, crossbow, or shotgun. Means for rotating the turntable, and for aiming and firing the rifle, crossbow, or shotgun are mounted on the turntable, and are constructed and arranged to respond to pressure exerted by an open hand of the quadriplegic seated in the wheelchair.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a first embodiment of a shooting platform made in accordance with the principles of the present invention, as viewed from an oblique angle.
FIG. 2 is a front view of the platform shown in FIG. 1.
FIG. 3 is a side view of a portion of the platform shown in FIG. 1.
FIG. 4 is a side view of a portion of the platform shown in FIG. 1, showing a gun or crossbow, and a quadriplegic seated in a wheelchair.
FIG. 5 is a top plan view of a portion of the platform shown in FIG. 1, showing certain features of the platform not shown in FIG. 1.
FIG. 6 is a cross-sectional view of the platform shown in FIG. 1, taken along the cutting line 6--6.
FIG. 7 is an enlarged view of portions of the platform shown in FIG. 1.
FIG. 8 is an enlarged view of a second embodiment of a portion of the platform shown in FIG. 1.
FIG. 9 is an enlarged exploded view of a portion of the platform shown in FIG. 1, showing certain features not shown in FIG. 1.
FIG. 10 is a side view of a portion of the platform shown in FIG. 3, showing a feature of the invention not shown in FIG. 3.
FIG. 11 is a wiring diagram for a second embodiment of a shooting platform made in accordance with the principles of the present invention.
FIG. 12 is a schematic representation of a portion of a second embodiment of a shooting platform made in accordance with the principles of the present invention, as viewed from an oblique angle.
FIG. 13 is a cross-sectional view of the platform shown in FIG. 1, taken along the cutting line 13--13.
DETAILED DESCRIPTION OF THE INVENTION
More specifically, reference is made to FIGS. 1-3, wherein is shown a first embodiment of a shooting platform made in accordance with the principles of the present invention, and generally designated by the numeral 2.
The shooting platform 2 comprises lower and upper first and second horizontal base plates 4 and 6, respectively. The upper second base plate 6 is mounted on and rotatably connected to the lower first base plate 4 by a roller bearing 8, which is disposed within a first sprocket 11 (FIG. 5) fastened to the first base plate 4 by sprocket mounts 11a. A second sprocket 12 (FIG. 5) is mounted to a first elongated vertical member 14 which extends upward through a plate bearing 16 disposed in the second base plate 6. Preferably, the first elongated vertical member 14 is a rod. Even more preferably, the rod 14 is a round rod. Extending farther upward, the rod 14 passes through a pillow-block bearing 18 to terminate at and be fastened to a first horizontal revolving plate 20 having notches 20a in the edge thereof. Fastened to the outer edge of the first revolving plate 20 for reciprocal rotation therewith is a second horizontal revolving plate 24 having at least three upstanding vertical studs 26 fastened to the upper surface thereof, for disposition of an open hand therebetween.
A second elongated vertical member 28 is mounted to the upper surface of the second base plate 6. Preferably, the second elongated vertical member is a bar. Even more preferably, the second elongated vertical member is a square bar. To the upper end of the bar 28 is mounted a brake 30 for locking the first revolving plate 20 in a desired position. The locking operation is effected by gravity insertion of the brake 30 in a particular notch 20a in the first revolving plate 20.
A third elongated vertical member 32, mounted on the second base plate 6 and disposed between and fastened to the rod 14 and to the bar 28, provides support for the rod 14 and first vertical bar 28. Preferably, the third elongated vertical member 32 is a bar. Even more preferably, the bar 32 is a square bar.
An idler sprocket 34 (FIG. 5) is mounted to the lower surface of the second base plate 6, between the first and second base plates 4 and 6.
A chain 36 connects the first and second sprockets 11 and 12 to one another (FIG. 5). Tension on the chain 36 is effected by the idler sprocket 34. The first sprocket 11 is fixed; the second sprocket 12 rotates in response to the turning of the rod 14. Rotation of the rod 14 in either direction is effected by the turning of the first and second revolving plates 20 and 24. The first revolving plate 20, which is substantially larger than the second revolving plate 24, acts to provide a mechanical advantage in the turning of the plates 20 and 24. The second revolving plate 24 is turned in response to hand movement by the user's hand inserted between the studs 26 . Thus the user, by turning the second revolving plate 24, can change the position of the second base plate 6 and thereby the orientation of the platform 2 as desired. The first base plate 4 provides a stable foundation for the platform 2. The first and second plates 4 and 6 are locked in the position shown in FIG. 1 by a turnbuckle 10, to stabilize the platform 2 while it is being transported from one location to another location.
A first support plate 38 is mounted on a fourth elongated vertical member 40 supported by the second base plate 6 (FIGS. 6-9). The fourth elongated vertical member 40 is preferably a bar, and even more preferably a square bar. A horizontal connecting member 40a is fastened to the second horizontal base plate 6 and to the fourth elongated vertical member 40.
A threaded sleeve 46 is movably disposed in a slot 38a of the first support plate 38, and a threaded rod 44 is disposed in and engages the threaded sleeve 46. An end of the threaded rod 44 is connected to a support bracket 94 and mounted to a gear box 48 provided with a crank 56. Mounted on the gear box 48 is a swivel 50, which includes arms 50a having therein openings 50c, a bushing 50d, and a bolt 50b disposed in the bushing 50d and the openings 50c. A second support plate 98 is fastened to the bushing 50d. The crank 56 enables the user to raise or lower the second support plate 98, which supports a crossbow 58 (FIG. 4). The support bracket 94 supports the a gun or crossbow 58 when the gun or crossbow is not in use. The gun or crossbow 58 may be fastened to the second support plate 98 by a bracket 100.
In a first embodiment (FIG. 9), a first cross-member 62 is attached to the threaded sleeve 46. A second support member 64 is fastened perpendicularly to the first support plate 38. The first and second cross-members 62 and 68 are slidably and resiliently connected to one another by at least one spring and preferably by a pair of springs 70 in which are disposed a pair of bolts 72. The bolts 72 slide freely in holes 74 within the first cross-member 62. The shock-absorber against the recoil of the springs 70 act as a shock-absorber against the recoil of the gun 58 when the gun a crossbow is fired.
In a second embodiment (FIG. 8), the recoil of the gun or crossbow 58 is absorbed by a piston 96a slidably disposed in a cylinder 96 of a compressed gas. The preferred gas is air. The cylinder 96 and piston 96a are fastened to support member 64 and sleeve 46, respectively. The cylinder 96 and piston 96a resiliently connect the second support 64 and threaded sleeve 46 to one another by compression of the gas in response to the recoil of the gun or crossbow and movement of the threaded sleeve 46, and by decompression of the gas thereafter as the gun or crossbow 58 and the threaded sleeve 46 return to their initial positions.
Reference is now made to FIG. 4, in which is shown a quadriplegic individual 13 seated in a wheelchair 17 resting on the second base plate 6. The gun or crossbow 58, having a stock 47, forearm 45a, barrel 45, trigger 46, and trigger guard 49 is clamped to the second support plate 98 by the bracket 100. The quadriplegic 13 uses an arm 13a and a hand 13b to move a trigger-activator 102 connected to the trigger 46 by a roller pin (not shown), thereby firing the gun 58. The first support member 94 will provide additional support for the gun or crossbow 58 when the gun or crossbow is not in use. Aiming of the gun or crossbow 58 is effected by manipulation of the swivel 50 and crank 56, using the open hand.
A second trigger guard 49a is fastened to the forearm 45a and stock 47, to prevent accidental activation of the trigger-activator 102.
Reference is now made to FIG. 10, in which is shown a ramp 102 for loading the wheelchair 17 (FIG. 4) onto and off of the second base plate 6.
While the wheelchair 17 can be immobilized by a handbrake (not shown), wheelchair stops 80 and 81 (FIG. 4) are beneficially provided for locking the wheelchair 17 into a desired stationary position.
Reference is now made to FIG. 5, which shows a wingnut 88, plate 86, threaded rod 90, bracket 84, spring 82, and idler arm 92. As the wingnut 88 is turned against the plate 86, the threaded rod 90 is drawn in either direction, to tighten or loosen the spring 82, which thereby tightens or loosens the idler sprocket 34 supported by the idler arm 92. The idler arm 92 is in turn supported by a rod 92a. The foregoing procedure serves to adjust, i.e. tighten or loosen, the chain 36, while maintaining continuous tension on the chain 36 and sprockets 11 and 12.
Reference is now made to FIGS. 11-13, in which is shown a second embodiment of a shooting platform made in accordance with the principles of the present invention. In this embodiment the turntable is rotated by a motor 104. More specifically, the upper second horizontal base plate 6 is rotated by an electric motor 104 powered by an electric battery 106. The electric motor 104 is turned on and off by an electrical switch 108 which is responsive to pressure from the palm or open hand of the quadriplegic. The motor 104 may beneficially be a reversible electric motor, whereby the base plate 6 may be rotated in either of two directions.
The electrical second embodiment of the present invention also includes a gear box 110, a housing 112 for the motor 104 and gear box 110, and a shaft 114 connecting the gear box 110 to the sprocket 36. | A shooting platform for quadriplegic. The platform has a frame for holding a rifle crossbow, or shotgun. The frame is mounted on a turntable which is rotatable by the quadriplegic seated in a wheelchair, using only the palm of a hand. The gun or crossbow is also aimed and fired by the quadriplegic, using only the palm of a hand. | 5 |
This application is a continuation-in-part of U.S. patent application Ser. No. 08/188,188, filed on Jan. 28, 1994, and now abandoned.
The present invention is generally directed to a method and apparatus for controlling the flow of fluid from a source to a patient and removal of fluids from the patient through connections with surgical procedures of various types or, more generally, in connection with medical treatments. The flow of fluid to and from a patient through a fluid infusion or extraction system is many times critical to the procedure being performed, such as in ophthalmic microsurgery in which surgical instruments such as electromechanical or pneumatically driven cutters and phacoemulsification instruments are commonly employed. These instruments require a source of fluid to infuse a surgical site and a source of negative pressure to evacuate the infused liquid and debris from the site.
A number of medically recognized techniques has been utilized for lens removal and among these, a popular technique is phacoemulsification, irrigation and aspiration. This method includes the making of a corneal incision, which is typically cauterized to reduce bleeding, and the insertion of a handheld surgical implement which includes a needle which is ultrasonically driven in order to emulsify the eye lens. Simultaneously with this emulsification, a fluid is inserted for irrigation of the emulsified lens and a vacuum provided for aspiration of the emulsified lens and inserted fluids.
The hereinabove described phacoemulsification techniques are well-known in the field of ophthalmology going back to the late 1960s and the work of Dr. Charles Kelman. A full discussion of phacoemulsification is found in Chapter 11, "The Mechanics of Phacoemulsification; Chapter 12, "The Phacoemulsification Procedure"; Chapter 13, "Cataract removal by Phacoemulsification"; and Chapter 14, "Small Pupil Phacoemulsification Techniques of The Surgical Rehabilitation of Vision--An Integrated Approach to Anterior Segment Surgery, edited by Lee T. Norman, W. Andrew Maxwell and James A. Davison, Gower Medical Publishing, New York, N.Y., 1992, ISBN O-397-44693-4. Chapters 11-14 thereof are incorporated herein in their entirety by reference.
Currently available phacoemulsification systems are manufactured and sold by Optical Micro Systems, Inc., of North Andover, Massachusetts, under the trademarks "DIPLOMATE", "DIPLOMATE MMP", "OPSYS" and "OPSYS MMP". These systems have control units that include a variable speed peristaltic pump, a vacuum sensor, an adjustable source of ultrasonic power and a programmable microprocessor with operator-selected presets for controlling aspiration rate, vacuum and ultrasonic power levels.
Many surgical instruments and controls in use today linearly control the vacuum or linearly control the flow of aspiration fluid. This feature allows the surgeon to precisely "dispense" or control the "speed" at which he/she employs, either the vacuum or the flow, but not both. However, there often are times during surgery when the precise control when one of the variables (vacuum, aspiration rate, or ultrasonic power) is desired over the other. The experienced user, understanding the relationship between the vacuum and the flow, may manually adjust the preset variable appropriately at the console in order to obtain an acceptable performance. However, if this adjustment is overlooked, then the combination of both high vacuum and high flow can cause undesirable fluidic surges at the surgical site with possible damage inflicted on the patient.
It should be apparent that the control of hand-held surgical instruments for use in phaco surgery is complex. Phacoemulsifier apparatus typically comprises a cabinet, including a power supply, peristaltic pump, electronic and associated hardware, and a connected, multi-function and handheld surgical implement, or handpiece, including a hollow slender-like needle tube as hereinabove described, in order to perform the phacoemulsification of the cataractous lens.
It should be appreciated that a surgeon utilizing the handheld implement to perform the functions here-in-above described requires easy and accessible control of these functions, as well as the ability to selectively shift or switch between at least some of the functions (for example, irrigation and irrigation plus aspiration) as may arise during phacoemulsification surgery.
In view of the difficulty with adjusting cabinet-mounted controls, while operating an associated hand-held medical implement, control systems have been developed such as described in U.S. Pat. No. 4,983,901. This patent is to be incorporated entirely into the present application, including all specification and drawings for the purpose of providing a background to the complex controls required in phacoemulsification surgery and for describing apparatus which may be utilized or modified for use with the method of the present invention.
To further illustrate the complexity of the control system, reference is also made to U.S. patent application Ser. No. 961,138, filed Oct. 14, 1992, for "Foot Pedal Control with User Selectable Operational Ranges". This patent application is to be incorporated in the present application by this specific reference thereto, including all specifications and drawings for the purpose of further describing the state of the art in the field of this invention.
Further procedures and problems in connection with phacoemulsification, irrigation and aspiration methods and apparatus are discussed in U.S. Pat. No. 5,154,696.
It should thus be apparent, in view of the complex nature of the control system of fluids and ultrasonic power in the case of phacoemulsification procedures, that it is desirable for a surgeon to have a system which is programmable to serve both the needs of the surgical procedure and particular techniques of the surgeon, which may differ depending on the experience and ability of the surgeon.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method is provided for controlling aspiration of fluids from an eye during a surgical procedure, which includes: placing a handpiece in an operational relationship with an eye for aspiration of fluids therefrom; and aspirating fluid from the eye through a handpiece at a selected rate and during aspiration, sensing a vacuum level corresponding to an occluded condition of the handpiece.
The occluded condition restricts aspiration of fluid flow through the handpiece and accordingly, in accordance with the present invention, a selected rate of aspiration through the handpiece is variably controlled in response to the sensed vacuum level.
As this procedure applies to operating a phacoemulsification system, the aspiration rate may be increased in response to an occluded condition of the handpiece or decreased in response to an occluded condition of the handpiece.
Depending upon a physician preference, the aspiration may be increased to accelerate or enhance the removal of the occlusion from the handpiece. This is, of course, dependent upon the characteristics of the material occluding the handpiece. That is, with experience, a physician can more expeditiously remove an occlusion in the handpiece by increasing the aspiration rate. In this manner the physician can control the rate of increase (aspiration rise) of vacuum to a desired vacuum leve. On the other hand, again depending upon the occluding material, the physician may wish to reduce the aspiration rate, for example, to maintain stability of the eye during removal of the occluded material.
In addition, with regard to a method for operating a phacoemulsification system, in accordance with the present invention, ultrasonic power being provided to the handpiece may be variably controlled in response to a sensed vacuum level in the handpiece corresponding to an occluded condition. This control may be increasing the power to the handpiece when an occluded condition is signaled or, alternatively, decreasing the ultrasonic power being provided to the handpiece when an occluded condition is sensed.
Whether the power is increased or decreased depends in part on the technique of the physician and the characteristics of the material, i.e., for example, the hardness of a cataract being removed.
The present invention also encompasses a method for controlling irrigation fluid to an eye during a surgical procedure. In this method, the handpiece is placed in an operative relationship with an eye for introducing irrigation fluid into the eye and aspiration of fluid from the eye, and the handpiece is provided irrigation fluid at a selected pressure.
During aspiration of fluid from the handpiece, a vacuum level corresponding to an occluded condition of the handpiece is sensed, and in response to this sensed vacuum level, irrigation is provided to the handpiece at a different selected pressure.
More particularly, the step of providing irrigation fluid to the handpiece at a selected pressure includes positioning a plurality of irrigation fluid supplies at different heights above the handpiece and fluidly communicating one of the irrigation fluid supplies to the handpiece. The step of providing irrigation fluid to the handpiece at a different selected pressure includes fluidly communicating another of the irrigation fluid supplies to the handpiece while stopping communication of the one irrigation fluid supply to the handpiece.
With regard to phacoemulsification procedures, the present invention encompasses a method for operating a phacoemulsification system, having a phacoemulsification handpiece, an ultrasonic power source, a vacuum source, a source of irrigating fluid, and a control unit having a vacuum sensor for controlling ultrasonic power provided to the handpiece and aspiration of irrigation fluid from the handpiece.
The operating method includes the steps of placing the handpiece in an operative relationship with an eye for phacoemulsification procedures and thereafter supplying irrigation fluid from the irrigation fluid source to and through the handpiece and into the eye. Ultrasonic power is provided from the ultrasonic power source to the handpiece for performing the phacoemulsification procedure, and a vacuum is provided to the handpiece for aspirating irrigation fluid from the eye through the handpiece at a selected rate.
During the fluid aspiration step, a vacuum level in the handpiece corresponding to an occluded condition is sensed, and thereafter, in response to the sensed vacuum level in the handpiece corresponding to the occluded condition of the handpiece, at least one of the provided ultrasonic power and the rate of aspirating irrigation fluid is variably controlled.
Phacoemulsification apparatus, in accordance with the present invention generally includes a handpiece for introducing irrigation fluid to an eye and aspirating fluid from the eye. Means are provided for introducing irrigation fluid to the handpiece at a plurality of pressures and a variable speed pump connected in fluid communication with the handpiece is provided for aspirating, by vacuum, irrigation fluid from the handpiece.
A sensor is connected in fluid communication with the handpiece for sensing vacuum levels in the hand-piece, and a control unit responsive to the sensed vacuum levels in the handpiece is provided for selecting one of the plurality of pressures of irrigation fluid introduced to the handpiece.
More particularly, a phacoemulsification hand-piece may be included, and a power source connected thereto is provided for supplying ultrasonic power to the handpiece. In this instance, the control unit is responsive to the sensed vacuum level in the handpiece for veering at least one of the speed of the pump, the ultrasonic power level provided to the handpiece and the pulse duty cycle of the ultrasonic power provided to the handpiece by the power source.
Means may be provided for introducing irrigation fluid into the handpiece at a plurality of pressures and, in this embodiment, the control unit is responsive to the sensed vacuum levels in the handpiece for selecting one of the plurality of pressures of irrigation fluid introduced into the handpiece.
More specifically, the means for providing an irrigation fluid includes a plurality of containers and a valve interconnected between each of the containers and handpiece. Means are also provided for disposing the containers at different heights over the handpiece when the control unit is connected to the valve, for causing the valve to control fluid communication between each of the containers and the handpiece.
Still more particularly, the phacoemulsification apparatus, in accordance with the present invention, may include a control unit which is responsive to the sensed vacuum levels of the handpiece wherein a pulse duty cycle of the ultrasonic power is provided to the handpiece by the power source. In this instance, the control unit may be connected to the handpiece for first providing an ultrasonic power and first pulse duty cycle until a first predetermined power level of the handpiece is exceeded and thereafter providing ultrasonic power at a second, and greater, pulse duty cycle until a second, and greater, predetermined power level of the handpiece is exceeded. Optionally, thereafter, ultrasonic power may be provided to a third, and still greater, pulse duty cycle until a third, and still greater, predetermined power level of the handpiece is exceeded, and thereafter providing power at a pulse duty cycle greater than the third duty cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will be better understood by the following description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a functional block diagram of a phacoemulsification system in accordance with the present invention;
FIG. 1A is a functional block diagram of an alternative embodiment of a phacoemulsification system in accordance with the present invention which includes apparatus for providing irrigation fluid at more than one pressure to a handpiece;
FIG. 2 is a flow chart illustrating the operation of the occluded-occluded mode of the phacoemulsification system with variable aspiration rates;
FIG. 3 is a flow chart illustrating the operation of the occluded-occluded mode of the phacoemulsification system with variable ultrasonic power levels;
FIG. 4 is a flow chart illustrating the operation of the variable duty cycle pulse function of the phacoemulsification system; and
FIG. 5 is a flow chart illustrating the operation of the occluded-unoccluded mode of the phacoemulsification system with variable irrigation rates;
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, and particularly to FIG. 1 thereof, there is shown, in functional block diagram form, a phacoemulsification system indicated generally by the reference numeral 10. The system has a control unit 12, indicated by the dashed lines in FIG. 1 which includes a variable speed peristaltic pump 14, which provides a vacuum source, a source of pulsed ultrasonic power 16, and a microprocessor computer 18 that provides control outputs to pump speed controller 20 and ultrasonic power level controller 22. A vacuum sensor 24 provides an input to computer 18 representing the vacuum level on the output side of peristaltic pump 14. Suitable venting is provided by vent 26.
The components of the system 10 are available from various sources. For example, the power source 16 is available from ALCON (Series 10000) as is the power level controller (also Series 10000). The computer 18 may an NEC 8085 and the pump speed controller 20 may be a Pittman GM9434H777. The vacuum sensor 24 may be a Sensym SCX100DN and the vent 26 may be an LDI model 11-12-3-BV -24 .
The control unit 12 supplies ultrasonic power on line 28 to a phacoemulsification handpiece 30. (Which may be an ALCON model 590-2000-501.) An irrigation fluid source 32 (Which may be an ALCON model 10000) is fluidly coupled to handpiece 30 through line 34. The irrigation fluid and ultrasonic power are applied by handpiece 30 to a patient's eye which is indicated diagrammatically by block 36. Aspiration of the eye 36 is achieved by means of the control unit peristaltic pump 14 through lines 38 and 40.
The computer 18 responds to preset vacuum levels in output line 42 from peristaltic pump 14 by means of signals from the previously mentioned vacuum sensor 24. Operation of the control unit in response to the occluded-unoccluded condition of handpiece 30 is shown in the flow diagram of FIG. 2.
As shown in FIG. 2, if the handpiece aspiration line 38 is occluded, the vacuum level sensed by vacuum sensor 24 will increase. The computer 18 has operator-settable limits for aspiration rates, vacuum levels and ultrasonic power levels. As illustrated in FIG. 2, when the vacuum level sensed by vacuum sensor 24 reaches a predetermined level as a result of occlusion of the handpiece aspiration line 38, computer 18 instructs pump speed controller 20 to change the speed of the peristaltic pump 14 which, in turn, changes the aspiration rate. It will be appreciated that depending upon the characteristics of the material occluding handpiece 30, the speed of the peristaltic pump 14 can either be increased or decreased. When the occluding material is broken up, the vacuum sensor 24 registers a drop in vacuum level, causing computer 18 to change the speed of peristaltic pump 14 to an unoccluded operating speed.
In addition to changing the phacoemulsification parameter of aspiration rate by varying the speed of the peristaltic pump 14, the power level of the ultrasonic power source 16 can be varied as a function of the occluded or unoccluded condition of handpiece 30. FIG. 3 illustrates in flow diagram form the control of the ultrasonic power source power level by means of computer 18 and power level controller 22. It will be appreciated that the flow diagram of FIG. 3 corresponds to the flow diagram of FIG. 2 but varies the phacoemulsification parameter of the ultrasonic power level.
With reference to FIG. 4, there is shown a flow diagram depicting the control of the ultrasonic power source 16 to produce varying pulse duty cycles as a function of selected power levels. As shown in FIG. 4, and by way of illustration only, a 33% pulse duty cycle is run until the power level exceeds a preset threshold; in this case, 33%. At that point, the pulse duty cycle is increased to 50% until the ultrasonic power level exceeds a 50% threshold, at which point the pulse duty cycle is increased to 66%. When the ultrasonic power level exceeds 66% threshold, the power source is run continuously, i.e., a 100% duty cycle. Although the percentages of 33, 50 and 66 have been illustrated in FIG. 4, it should be understood that other percentage levels can be selected to define different duty cycle shift points.
Turning back to FIG. 1A, there is shown an alternative embodiment 50 of a phacoemulsification system, in accordance with the present invention, and which incorporates all of the elements of the system 10 shown in FIG. 1, with identical reference characters identifying components, as shown in FIG. 1.
In addition to the irrigation fluid source 32, a second irrigation fluid source 33 is provided with the sources 32, 33 being connected to the line 34 entering the handpiece 30 through lines 32a, 33a, respectively, and to a valve 35. The valve 35 functions to alternatively connect line 32a and source 32 and line 33a and source 33 with the handpiece 30 in response to a signal from the power level controller 22 through a line 35a.
As shown, irrigation fluid sources 32, 33 are disposed at different heights above the handpiece, providing a means for introducing irrigation fluid to the handpiece at a plurality of pressures, the head of the fluid in the container 33 being greater than the head of fluid in the container 32. A harness 42, including lines of different lengths 44, 46, when connected to the support 48, provides a means for disposing the containers 32, 33 at different heights over the handpiece 30.
The use of containers for irrigation fluids at the various heights is representative of the means for providing irrigation fluids at different pressures, and alternatively, separate pumps may be provided with, for example, separate circulation loops (not shown) which also can provide irrigation fluid at discrete pressures to the handpiece 30 upon a command from the power controller 22.
With reference to FIG. 5, if the handpiece aspiration line 38 is occluded, the vacuum level sensed by the vacuum sensor 24 will increase. The computer 18 has operator-settable limits for controlling which of the irrigation fluid supplies 32, 33 will be connected to the handpiece 30. It should be appreciated that while two irrigation fluid sources, or containers 32, 33, are shown, any number of containers may be utilized.
As shown in FIG. 5, when the vacuum level by the vacuum sensor 24 reaches a predetermined level, as a result of occlusion of the aspiration handpiece line 38, the computer controls the valve 35 causing the valve to control fluid communication between each of the containers 32, 33 and the handpiece 30. It should be appreciated that, depending upon the characteristics of the material occluding the handpiece 30 as hereinabove described and the needs and techniques of the physician, the pressure of irrigation fluid provided the handpiece may be increased or decreased. As occluded material 24, the vacuum sensor 24 registers a drop in the vacuum level causing the valve 35 to switch to a container 32, 33, providing pressure at an unoccluded level. As noted hereinabove, it should be appreciated that more than one container may be utilized in the present invention, as an additional example, three containers (not shown) with the valve interconnecting to select irrigation fluid from any of the three containers, as hereinabove described in connection with the FIG. 1A container system.
Although there has been hereinabove described a method for controlling aspiration of fluids, a method for controlling irrigation fluid, and a method for operating a phacoemulsification, as well as phacoemulsification apparatus, in accordance with the present invention, for the purpose of illustrating the manner in which the invention may be used to advantage, it should be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations, or equivalent arrangements which may occur to those skilled in the art, should be considered to be within the scope of the present invention as defined in the appended claims. | A method for controlling aspiration and irrigation fluids in an eye during a surgical procedure includes placing a handpiece in an operative relationship with an eye for introducing irrigation fluid and aspiration of fluid from the eye. Irrigation is provided at diverse pressures and aspiration is controlled on the basis of vacuum levels sensed in the handpiece corresponding to an occluded condition of the handpiece. Additionally, during phacoemulsification procedures, ultrasonic power provided to the handpiece may by varied in response to the vacuum levels corresponding to an occluded condition of the handpiece. Apparatus for performing the method of the invention is also provided. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This regular utility patent application is a continuation-in-part of application Ser. No. 09/258,205, filed Feb. 26, 1999, now U.S. Pat. No. 6,095,283, based on Provisional Patent Application Ser. No. 60/102,897, filed on Oct. 2, 1998. The disclosure of U.S. Pat. No. 6,095,283 is incorporated herein by reference thereto.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to specific types of handgrip devices that are adapted for use in combination with ladders for fall protection. The combination of ladder and handgrip arrays comprised of a plurality of parallel handgrip rungs configured in accordance with the present invention forms an opening through which the ladder user can safely pass while horizontally gripping the horizontally disposed handgrip rungs. The characterization “walk-through” includes—depending on the ladder and structure or apparatus to be climbed—all methods of pass-through, including crawling through and the like.
2. Description of the Related Art
A so-called “through” ladder requires a climber getting off at the top to step through the ladder in order to reach a landing. “Walk-through” fixed ladders are also well known; they typically include a flared section at the top through which the climber walks. See the prior art device in FIGS. 8 and 9 which will be more fully described below.
Fall protection is mandatory through OSHA regulations on fixed ladders over 20 feet tall in general industry and 24 feet tall in construction. The addition of a post or a rail in the center or at the side of the ladder creates an impediment to circumvent so an outside fitting is safer. Ladders could be upgraded by having climbing safety devices installed as extra protection. About half of the ladders in use are less than 20 feet high so such improvements would serve the purpose well if no fall protection exists for these ladders.
One problem with the flared walk-through ladder is that the climber routinely holds a side rail while descending until the moment the flared section is reduced to 16 inches in width. Unless users observe the need to place the hands closer to the body in order to grasp the side rails or rungs on the main body of the ladder, a person will grasp at thin air and will be subject to a fall at that moment if he has transitioned his feet and assumed the location of the handhold by getting ready to release the other hand.
Moreover, when 2½-3 inch width angle iron is used as the side rail, only a push-pull pinch grip can be made on the side rails and any fall at the walk-through portion of the ladder is likely to be catastrophic in its outcome. In fact, the ability to hold any vertical shape of the side rails sufficiently to regain balance is not possible. The problems with side rail holdings are several.
First, the hand slides down due to the weight of the body. Second, the force of arresting a free fall up to three feet, i.e., the length of the arm, is dynamic. From rope tests, it is known that the maximum force of a moving rope which can be held is 50 pounds and the least is approximately 10 pounds, both far below a person's body weight. These references are found in the ISFP Newsletter of October, 1996.
Third, a swing fall into the side of the ladder produces an impact of the body with the ladder since the body's center of gravity has to move eight inches from center to side because a ladder rung is 16 inches long. If a person is standing far over to the side, then a movement of 16 inches will occur with an even higher swing fall collision which further tends to destabilize the hand grip.
Fourth, some ladder side rails are impossible to encircle with the hand, e.g., three-inch angle irons or two-inch flange I-beams. Because these shapes cannot be encircled with the hand for a good grip, only a pinch grip can be used and no fall arrest is remotely possible. With two-inch or 2½ inch widths, grips are possible but, due to the factors described above, the grip cannot become an effective grasp under foreseeable methods of climbing on these ladders and a catastrophe must necessarily follow, if the climber falls.
Fifth, the ground or surface below a fixed ladder is almost always unyielding, thus providing the maximum possible deceleration upon impact and therefore the greatest injury to a falling worker.
Sixth, ladders constitute the primary cause of injurious occupational falls based on current OSHA statistics. Since these statistics include portable ladders as well as fixed ladders, it is evident that a climber, who loses his balance on a ladder, needs all the help possible to maintain a grasp that can be reasonably effective if a foot were to slip at the most vulnerable transition points on the ladder.
All climbers eventually misstep no matter how well they are trained. Usually, the climber is preoccupied about achieving the purpose for which the ladder is climbed, not the actual climbing of the ladder. Therefore, exposure to fall hazards cannot be expected to be controlled effectively solely by training workers to climb ladders with the utmost attention to human factors and back-up safety features.
Typical of walk-through ladders in the prior art is the fixed ladder illustrated in FIGS. 8 and 9. A lower section of a walk-through ladder L is shown below a surface A which schematically represents a level to which a climber C is ascending from a lower surface G. The ladder L includes side rails 1 with a plurality of round foot rungs 2 . By way of example, each rung 2 can be 16 inches long at a minimum and ¾ to one inch in diameter. Each side rail 1 can be 2½ inches wide by ⅜ inch to ½ inch in thickness or any size or shape which provides a power grip with materials, such as carbon steel or aluminum, being selected appropriately for the ladder length, usage and environment.
As best shown in FIG. 9, the ladder L at its top above the surface A flares outwardly to form a walk-through section W. The architecture of the walk-through section W may vary depending upon requirements. However, the walk-through section W has parallel vertical side rails 21 and 22 forming an opening O generally, in order to meet code requirements, spaced apart at a distance one from the other about 24 to 30 inches.
As it is also seen in FIG. 9, the walk-through opening O is minimally 3½ feet in height. In this case, if the climber C is about 5′8″ tall, the opening O may be about four feet high.
In FIG. 9, the climber C ascends the ladder L normally. As the climber C negotiates his way into and through the opening O, as indicated by arrows R, onto the surface A, the climber's feet may slip. The vertical side rails 21 and 22 of FIG. 8, regardless of shape or configuration, cannot be grasped without great risk of the climber's grip sliding and/or opening up, depending upon the nature of the slip. Furthermore, a free fall can develop from zero to twice the climber's arm length, resulting in an impact on any grip that the climber C may have. In addition, a swing to one side of the ladder L may result in an impact against the side rails 1 of the ladder L. Consequently, the climber's grip cannot be maintained and a hard fall to the surface G below usually occurs, resulting in serious injury or death.
SUMMARY OF THE INVENTION
In the disclosure of U.S. Pat. No. 6,095,283, the teaching of which is incorporated herein by reference thereto, applicant describes an invention relating to a modification of walk-through ladders, namely, providing a second plurality of horizontal grasping rungs associated with the walk-through section which ordinarily does not have any such rungs. These extra rungs are provided for the climber to maintain a continuum of hand grips on the ladder. Such additional rungs are situated above the highest ladder rung. These higher horizontal grasping rungs are easier for the climber to grab and hold than the vertical side rails during passage up into and down from the walk-through section of the ladder, if a foot of the climber slips during such mounting and dismounting of the ladder.
What applicant has found is that the grasping rung system that can be used to advantage in the systems specifically exemplified in U.S. Pat. No. 6,095,283 also have application in combination with ladders found on tank cars, off-road equipment, railcars, marine applications, such as where rope ladders are used for embarkation and debarkation, manholes, ladders, and platforms. The addition of the horizontal grab bars in accordance with the present invention in effect creates a “through ladder” where the climber passes through an opening between two grab bar devices allowing the horizontal grasps/grips to be horizontally grasped/gripped during departure from a ladder top onto a wide array of apparatuses.
Thus, herein invention comprises a ladder having a top and comprised of a first plurality of rungs defining a first plane. The first plurality of rungs has a top rung having a first end and a second end at the top end of the ladder rungs. The herein invention further comprises a walk-through section at or proximate the top end of the ladder comprising:
(a) a second plurality of parallel handgrip rungs defining a second plane and having top and bottom hand grip rungs;
(b) a third plurality of parallel handgrip rungs defining a third plane and having top and bottom hand grip rungs; said second plane corresponding substantially to said third plane.
The bottom hand grip rung of said second plurality of parallel handgrip rungs is situated proximate the first end of the top rung of said first plurality of rungs at the top end of the ladder and the second plurality of parallel hand grip rungs forms one side of the walk-through section. The bottom hand grip rung of the third plurality of parallel handgrip rungs is situated proximate the second end of the top rung of said first plurality of rungs at the top end of the ladder and the third plurality of parallel hand grip rungs forms the other side of said walk-through section. The second and third planes are substantially parallel to the first plane. The walk-through section may be permanently or movably attached to the ladder or structure or apparatus to be climbed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of an actual walk-through ladder in accordance with the invention.
FIG. 2 is a front elevational view of an actual walk-through ladder in accordance with the invention.
FIG. 3 is a front elevational view of an actual walk-through ladder in accordance with the invention.
FIG. 4 is a front elevational view of an actual walk-through ladder in accordance with the invention.
FIG. 5 is an alternative further design of the present invention.
FIG. 6 is a side elevational view of an embodiment of the present invention.
FIG. 7 is a rear elevational view of an embodiment of the present invention.
FIG. 8 is a schematic perspective view of an embodiment of the present invention.
FIG. 9 is a schematic perspective view of an embodiment of the present invention.
FIG. 10 is a front side elevational view of an embodiment of the present invention.
FIG. 11 is a side elevational view of an embodiment of the present invention.
FIG. 12 is a front side view of the top end of the ladder of the embodiment of the invention of FIG. 11 .
FIG. 13 is a side elevational view of a bunk bed embodiment of the present invention.
FIG. 14 is a front elevational view of the bunk bed embodiment of FIG. 13 of the present invention.
FIG. 15 is a side elevational view of a single grab bar and a retractable single pole embodiment of the present invention.
FIG. 16 is a front elevational view of the retractable single pole embodiment of FIG. 15 of the present invention.
FIG. 17 is a side elevational view of a double grab bar embodiment of the present invention.
FIG. 18 is a front elevational view of the double grab bar embodiment of FIG. 17 of the present invention.
FIG. 19 is a perspective elevational view of a removable grab bar embodiment of the present invention.
FIG. 20 is a side elevational view of an embodiment of the present invention.
FIG. 21 is a front elevational view of the top of the ladder of the embodiment of the invention of FIG. 20 .
FIG. 22 is a schematic perspective view of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a second plurality of parallel, horizontal grasping rungs 15 are provided in association with the opening O in the walk-through section W of the fixed ladder L, thus allowing a climber C to grab one of the rungs 15 in the same fashion as the grasp enabled by the first plurality of rungs 2 in the lower climbing section of the ladder L.
As seen in FIG. 3, the rungs 15 may be placed outside of the side rails 21 and 22 of the walk-through section W. Thus, the horizontal grasping rungs 15 may be in the same plane as the opening O but affixed to the side rails 21 and 22 and extending outwardly therefrom rather than into the opening O of the walk-through section W.
As seen in FIG. 1, the present invention is applicable to job-made ladder L by bolting the rungs 15 at one end to vertically oriented uprights 23 and 24 which extend above the surface A and are aligned parallel to the side rails 21 and 22 . Rungs 15 can be either built into new ladders at the time of fabrication or retrofitted to existing ladders.
The purpose of the improvement of the present invention is to provide rung-like grab-bars with spacing similar to the ladder rungs 2 which are further down in the lower section of the ladder L. Thus, the climber C who has the task of climbing up or down the ladder L can do so with greater security by holding onto the horizontal grasping rungs 15 rather than onto the vertical uprights 23 and 24 or the side rails 21 and 22 which cannot be grasped effectively for even short time periods if the climber's feet slip during mounting or dismounting from the walk-through section W. Dismounting is typically to a landing onto a roof, mezzanine, platform, parapet or other surface A that may be flat or sloped.
The results of a lost grip on the side rails 21 and 22 at the top of the ladder L can be catastrophic with long falls to the ground G or to a lower platform, thus resulting in serious injury or death in many cases each year. This kind of accident can occur even if there is a protective ladder cage (not shown) or if the climber's protection cable (not shown) has been disconnected.
It is preferable that the horizontal grasping rungs 15 associated with the walk-through section W be long enough for the climber's hand, either bare or gloved, to hold preferably 4 to 5 inches and up to 6 inches of the rung 15 . Also, a diameter of about 1.5 inches is preferred for the rungs 15 . Alternatively, rungs 15 of 0.75 inch diameter or other sizes may be welded or bolted for uniformity with the other rungs 2 to meet codes that require this uniformity over ergonomics.
Ordinarily after a slip, the hand of the climber C cannot hold the vertical side rail 21 or 22 long enough to regain his balance. Thus, a power grip is now required in the 1992 ANSI A14.3 Code Section. Such a power grip cannot be achieved with the prior art ladder which use side rail 2 of flat material with dimension of either ⅜″×2″ or ⅜″×2½″.
The preferred material may be galvanized steel, stainless steel, aluminum, fiberglass polymer, or any other sturdy substance capable of holding the human body when the material is bolted onto the ladder L. Improved fastening devices can be used to permit a mechanical attachment without the need to drill holes through the ladder L to attach metal bolts thereto. Instead, a single coupling 25 , shown schematically in the first embodiment in FIG. 1, could be used for easy fitting of the rungs 15 on each side of the opening O to the side rails 21 and 22 of the walk-through section W.
The assembly including the walk-through section W with the horizontal grasping rungs 15 can be bolted together or welded with seamless joints in such a way that the welds will not break under a normal load or through corrosion or by any other reasonably destructive means.
The embodiment illustrated in FIG. 2 recognizes that the codes generally call for the flared walk-through section W at the top of the fixed ladder L to broaden outwardly from the rungs 2 , which have a 16-inch minimum clear width, to the opening O, which has a clear width of 24 to 30 inches. The additional rungs 15 for climbing protection on the ladder L are accommodated in the opening O which is essentially a higher clear space up to 36 inches in width. However, as one skilled in the ladder art will readily appreciate, the opening O may be decreased in width for safety if it is so desired. In the structures and apparatuses illustrated in FIGS. 5, 6 , 7 and 10 - 19 the opening formed by the handgrip arrays is dependent on the structure or apparatus being climbed as well as ladder size and placement.
Because of the capability of the climber C to span 36 inches which is the maximum allowed by the 1992 A14.3 Code Section without loss of gripping power, the present invention is valuable for increasing safety. If an authority determines that the flaring of the walk-through section W is unnecessary for safety and permits the present invention to be placed inside the flared walk-through section W, thereby narrowing the opening O, the improvement can be of great help to the climber C without sacrificing his ability to dismount properly, even if necessary to do edgewise, because of the increased hand grasping power allowed by the invention. Thus, the climber C can remount the ladder L for descent more easily and safely since the spacing and location of the rungs 2 and 15 are uniform for the entire length of the ladder L and the walk-through section W in FIG. 2 .
The width of a climber's hips ranges from 11.1 to 16.4 inches across the front and a climber's buttocks range from 7.6 to 14.0 inches from front to back according to U.S. Army Mil-Std. 1472C (1980). Tools on the climber's body can add to these dimensions, so fitting in sideways helps minimize the climber's contact with the vertical uprights 23 and 24 in FIG. 1 .
If there are railings 26 as seen in FIG. 4, along the side rails 21 and 22 , a fitting 27 may be added to allow the plurality of rungs 15 to be mounted to the side rails 21 and 22 inside the walk-through section W. This fourth embodiment helps the climber C to pull himself manually onto the surface A. Conversely for descent, the closer accessibility of the grasping rungs 15 will be helpful for maintaining confidence of gripping power as the climber C turns around to face the ladder L for descent.
This application is specifically directed to other uses for the horizontal grasping rungs 15 as grab bars which are contemplated for any location where a comfortable handhold is needed to support balance, e.g., on machinery, cranes, platforms, and the like. Such contemplated uses are exemplified in part by reference to FIGS. 5, 6 , 7 and 10 to 22 , inclusive. The combination of rung arrays affixed either temporarily or permanently to structures or apparatuses that are climbed using ladders allows the user to obtain the advantage of a “walk-through” opening created by the parallel handgrip arrays which, in turn, provide for horizontal handgripping by the climber as the opening is traversed. The rung arrays may alternatively be affixed to the ladders that are used to climb on or over the involved structures or apparatuses.
It should be apparent to persons of ordinary skill in the ladder art that numerous variations of the preferred embodiments described hereinbefore may be utilized and that, while this invention has been described fully and completely with special emphasis upon preferred embodiments, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. In particular, the architecture of the walk-through section of the present invention can be used advantageously with numerous types of ladders, as will be appreciated by persons of ordinary skill in the ladder art and is not limited to fixed and/or flared walk-through ladders. | Structures and apparatuses such as tank cars that have ladders associated therewith are disclosed which have, at the ladder top, two arrays of a plurality of horizontal rungs suitable for a climber using a ladder to horizontally grip by hand. The arrays form an opening through which a climber can leave or access the ladder while gripping the horizontal handgrip rungs of the arrays. The cross-section of the horizontal handgrip rungs is substantially round and should not exceed 2 inches in diameter. The preferred cross-section of the rungs is within the range of from about ¾″-1″ in diameter. | 4 |
FIELD OF THE INVENTION
The invention relates to a method and apparatus for the production of molded meat or meat-like products, i.e. protein products. Such protein products include meat products, e.g. sausages, frankfurters, re-formed meats and meat balls which may be prepared from comminuted meat, known in the art as "meat paste" or "meat emulsion", and meat-like products based on non-animal protein, e.g. comminuted soya or wheat.
BACKGROUND OF THE INVENTION
In the preparation of such products, it is desirable to keep costs to a minimum. It is for this reason that skinless products such as sausages may be preferred to sausages with skins, since the cost applying an edible skin to a sausage can amount to a substantial proportion of the total manufacturing costs. By "skinless" is meant a product free from an external supporting membrane of e.g. collagen or natural gut.
A conventional method of producing skinless products involves the use of a permeable cellulose casing which may be inedible, or at least unacceptable for consumption. This is filled with e.g. meat paste, formed into links, heat processed to form a heat coagulated protein skin and then cooled, after which the cellulose casing is removed. In United Kingdom Pat. No. 1,422,344 there is described a process in which the filled casing is treated with an edible acid which reacts with protein at the surface of the meat paste to form a skin, prior to removal of the casing. This may avoid the necessity for heat processing to provide a coagulated skin, but the disposable casings are relatively expensive and their use is labor intensive.
It has been proposed to prepare a skinless product without the use of casings. One advantageous method of doing this is to treat the surface of e.g. a sausage, after it has been shaped, with a suitable fluid, for example an edible acid which reacts with protein and precipitates to form a cohesive surface for the sausage paste. In U.S. Pat. No. 3,503,756 there is disclosed a process in which a meat emulsion is extruded, and then treated in an acid bath, either before or after cutting into suitable lengths for frankfurters or the like. The treating of the extruded meat does however present handling difficulties.
In United Kingdom Pat. No. 1,441,494 there is disclosed a system in which an edible acid is introduced onto a meat emulsion before it is passed through an extrusion tube, so as to lubricate the emulsion as it passes through the tube, and also to form a cohesive skin for the product as it is extruded. The acid may be introduced through a sintered metal filter.
With this arrangement, as with many extrusion processes, there is the problem of controlling the weight of the product, which must be cut from the extruded length. Moreover, since extrusion and cutting take place after the acid has been introduced, the ends of a product will not be provided with a coagulated skin.
It has been proposed, e.g. in U.S. Pat. No. 2,897,745, to mold a sausage in a rigid re-usable mold. In this arrangement however, it is necessary to cook the product while in the mold, and this may take a considerable time--for example several minutes.
It is known, from for example U.S. Pat. No. 3,940,217, to insert certain treating liquids into a mold prior to injection of the product forming material--in that case a slurry. This does not however ensure an even distribution of the liquid over the product, due for example to gravity effects.
SUMMARY OF THE INVENTION
Viewed from one aspect, the invention provides a method of producing a molded meat or meat-like product having a fluid treated surface, wherein molding is effected in a rigid mold cavity having a permeable wall through which is introduced the fluid for treating the surface of the product.
Viewed from another aspect the invention provides apparatus for producing a molded meat or meat-like product, comprising a rigid mold having a cavity, and means for introducing product-forming material into the cavity, wherein the cavity has a permeable wall, and means are provided for introducing through the cavity wall a fluid for treating the surface of a product.
Thus, in the preparation of a skinless sausage for example, an edible acid at ambient or elevated temperature may be introduced through the permeable wall of the cavity where it reacts with the protein of the meat to provide a cohesive surface. The introduction may be simultaneous with molding of the product.
The term "an edible acid" is intended to cover an acid which is permitted for use in connection with foodstuffs and which does not result in the production of inedible products. Such acids include organic acids, e.g. acetic acid, malic acid, ascorbic acid and citric acids, and inorganic acids, e.g. hydrochloric acid and phosphoric acid. The acid may generally be employed in the form of a simple aqueous solution with a pH of between 1.0 and 3.0, e.g. dependent on the availability of soluble protein content for precipitation; the higher the content, the higher the numerical value of the pH. The optimum pH can readily be determined by simple experimentation. In the case of British style sausages, a pH of about 1.5 may ordinarily be convenient, but for frankfurters a pH of about 2.5 may be adequate.
Other fluids may of course be employed, depending on the operation intended to be carried out. Thus, for example, a liquid solution containing coloring matter, flavoring, or smoke extracts to color or flavor the surface of a product, may be employed. Such fluids could be used with or without edible acids. Some smoke extracts for example may themselves serve to produce a coagulated skin. If required, hot water or steam could be used to heat the surface of the product and form a heat-coagulated cohesive surface, the permeability of the mold wall allowing contact of product material and heating medium, to give efficient heating.
The means for introducing product forming material into the mold cavity may comprise a nozzle movable into the cavity, if the material is to be injected under pressure into the cavity. This is especially suitable for sausages where the material is in the form of a paste. A plunger may be provided for compressing material within the mold cavity and for closing the end of the mold cavity.
The permeable wall of the cavity may be provided by constructing the mold of permeable material, for example sintered material such as stainless steel, or plastics material such as high density polyethylene. It is not of course essential that the entire mold be of permeable material nor that all surfaces defining the cavity be permeable. It is only necessary for a sufficient area to be permeable to allow fluid to be applied to the required parts of a product. Generally, however, it will be desirable to treat the entire surface of a product. Preferably, therefore, means for closing the ends of e.g. a cylindrical mold cavity, are permeable.
The mold could be in the form of a relatively thin-walled shell or tube, such as a cylinder and the means for introducing fluid through the cavity wall, i.e. the wall of the shell, could comprise a spray nozzle, arranged to spray in a circuit around the shell to ensure that all the required surface of a product in the cavity is coated with liquid. Alternatively an array of stationary nozzles could be disposed around the shell to ensure the required coverage.
The mold, whether in the form of a shell or for example a more substantial block of permeable material, could be disposed in a bath of the fluid to be applied to the surface of a product, so that the permeable wall is exposed to the fluid. In a particularly advantageous arrangement a permeable mold is disposed within a non-permeable housing, e.g. of stainless steel or a suitable plastics material, and seated so that no substantial leakage can occur. The housing is filled to capacity with the required fluid, e.g. acid. The porosity of the permeable cavity wall is chosen such that no substantial amount of fluid can pass through it until external pressure is applied to the fluid within the housing mold. Fluid is then injected into the housing by means of a suitable injection system. The excess pressure created causes fluid to pass through the permeable wall into the cavity. The quantity of fluid introduced through the permeable wall will depend on the quantity injected into the housing, and will generally correspond thereto.
The mold may comprise a body of permeable material having a cavity extending therethrough, open at both ends--e.g. a hollow sintered stainless steel cylinder. A movable plunger may be provided for closing one end of the cavity. This may also serve to compress the product forming material during molding and/or to eject a formed product. The other end may be closed by suitable means such as an end capping device, or a further plunger. Preferably, the faces of the plunger and end closing means are permeable to ensure that the ends of a product can be treated with fluid. Means may be provided to ensure that fluid reaches these permeable faces, for example an injector system or a passageway interconnecting these faces and a reservoir surrounding the mould.
The plunger and the end closing means may be suitably shaped to give a required end configuration to the product, or they could have flat surfaces. The cavity could have any desired cross-section, for example square or triangular although it will frequently be circular.
Advantageously, apparatus in accordance with the invention is arranged for continuous operation. Preferably the mold is arranged for relative movement with respect to a plurality of stations where various operations are carried out, for example filling the cavity with material; compressing the material with the plunger; injecting fluid; ejecting a formed product; and returning the plunger to its initial position prior to re-filling of the cavity. In the case of a mold body open at both ends, such as a cylinder, it will be necessary to close the end opposite the plunger before compression and fluid injection. Thus an end cap could be urged into position by suitable means. Alternatively, the mold body could move continuously with respect to a solid base plate closing one end. Such a base plate could be suitably apertured to allow for e.g. filling the cavity and ejecting the product. The base plate could be provided with a groove of rounded cross-section, or another suitable cross-section, to shape the end of a product. This groove could be provided with permeable material, e.g. an insert of sintered metal.
It has been found that an end cap may be adequate for hard products such as British sausages, whereas a continuous base plate may be necessary for softer products such as frankfurters.
Preferably, the relative movement of the mold with respect to the various operating stations is rotational, it advantageously being the mold which moves. A number of molds may be moved synchronously, being at different stages of processing at any given time. A number of molds could be processed contemporaneously, moving in a group from station to station. It may be convenient to have four or eight molds processed together, this being the number of e.g. sausages usually packed together in the United Kingdom.
The apparatus may comprise a rotatable member on which are provided a plurality of housings, with their associated molds. For each housing there will be provided means for allowing the injection of fluid. Where two or more molds are to be processed together, they could be provided in a common housing, or in separate housings--fed from the same injection system or simultaneously from separate systems.
The housing may be fabricated from e.g. stainless steel, or e.g. comprise a block of plastics material. In this latter arrangement, the block--whether of one or more components--could have a cavity formed therein, defining a housing in which a permeable mold such as a sintered cylinder can be mounted, spaced from the walls of the cavity so as to provide a reservoir for fluid. One or more passages could extend through the block to allow for injection of fluid into the reservoir, from a suitable injection port, or a plurality of such ports.
In one preferred arrangement, the rotatable member itself comprises a block of plastics in which a plurality of cavities are provided to accommodate the required number of molds. The cavities may extend parallel to the axis of the member, being spaced around the member. A plurality of cavities could be grouped together, whether circumferentially or radially, depending on the number of molds to be treated together. In one preferred embodiment the member rotates about a horizontal axis.
A further rotatable member having a plurality of product receiving means, such as open-ended cavities extending therethrough, may be used for additional treating of the products formed in the molds. Thus, the further member could pass through a bath. Products could be ejected from the molding apparatus, into a paraxial cavity in the further rotatable member, passed through the bath, and then moved on for further processing. The bath could contain washing water, or for example further acid for treating a frankfurter and causing protein coagulation throughout the product.
Similar rotatable members, which could be in the form of a solid block, or a fabricated unit, could be used for drying--with air being passed over the products e.g. axially of the rotatable member; for cooking or smoking--with hot air, steam or smoke being passed over the products; or for freezing--with e.g. nitrogen being blown over the products. When used for freezing, cooking, drying or the like, the rotatable member should preferably be disposed in a sealed compartment through which the relevant medium such as air or nitrogen can be passed. The member may be arranged so that as it rotates, portions pass out of the compartment--through suitable seals--and then back into it, once again through suitable seals. This allows access to the receiving means, to enable receiving and subsequent ejection of products.
Since the members preferable rotate about a horizontal axis, the products will tend to move relative to their receiving means, i.e. cavities, during rotation so as to ensure even treatment. Thus for example even cooking and a constant surface coloration may be obtained.
Products may be passed from the rotatable members in direct series, being ejected from one cavity for example, into another on the following drum, wheel or other rotatable member. Finally processed products could be passed from a rotatable member directly onto a conveyor for further operations such as packing.
Rotary apparatus of the type described above, for use in washing, drying, cooking or freezing food products, is of itself advantageous, and could be used in applications other than in association with the moulding apparatus in accordance with the present invention.
Where a number of products are formed at the same time, they may be e.g. washed, dried, frozen, etc. contemporaneously, and then finally ejected onto a conveyor or the like as a unit, ready for packing with the minimum of further collating, handling etc.
Weight control of the products may be provided by metering the quantity of e.g. meat paste injected into the molds by means of a suitable portioning device e.g. a rotary valve. Since it is common to sell sausages in packets of a given weight, rather than individually, a single metering device may provide the meat paste to be supplied via e.g. a multiple tube injector to a number of molds to be processed together, corresponding to the number of sausages--or other products--to be packaged together. In this manner there will be the correct weight in the package, even if the sausages differ marginally in weight from one another.
It has been found that, particularly in the case of sintered metal molds which become saturated with acid, after the product has been ejected, residual acid may remain on the inner walls of the cavity. When e.g. meat paste is injected for a subsequent product, a skin may form without further acid injection. To avoid forming a double skin or compressing the product after a skin has formed, it may be necessary to have the acid injection, and paste compression stages very close to the meat paste injection stage, for example, almost simultaneous therewith.
It might be desirable to take advantage of this effect and to have a fluid injection stage before the product forming material is inserted into the mold cavity. The permeable nature of the cavity wall will hold the fluid in position, so that even coverage of the eventual product will be obtained; compression should take place without delay. A subsequent injection of fluid, e.g. acid, may still be desirable, for example to provide further protein coagulation; an excess of acid, i.e. acid still remaining on the cavity walls, will assist in motility during product ejection. Indeed, the presence of such excess acid, whether or not merely as a residual amount from skin formation, is an advantage as far as lubrication is concerned. On the other hand, should the presence of excess fluid be a disadvantage in certain applications, means could be provided for washing or wiping excess acid from the surface of the cavity walls. It might be possible to assist ejection of a product, not by means of a lubricating liquid, but by air or another gaseous medium. This could provide an e.g. air cushion to reduce friction. The air could be introduced through the permeable cavity walls, as with the other fluids discussed herein.
Although the invention is particularly advantageous in the production of skinless products, it is also applicable to the production of e.g. sausages with skins, i.e. with a supporting membrane which is not merely a coagulation of protein on the surface of the product. Thus, at the same time as e.g. meat paste is introduced into the mold cavity--or possibly even before--a skin forming substance could also be introduced so that it will lie between the meat paste and the cavity walls. The fluid introduced through the cavity walls will be such as to react with the skin-forming substance so as to produce the required skin.
Thus a viscous collagen mass could be extruded into the cavity, and treated with alkaline ammonia, saline solution or another appropriate food grade reagent. Co-extrusion apparatus could be employed so that the collagen mass is extruded as a thin tube or membrane around the meat paste as this is being extruded into the cavity. It might be advantageous to push the collagen mass through a fan-tail type of tube which will create a degree of fibre orientation. The extrusion tube for the collagen mass--i.e. the outer tube in co-extrusion apparatus--could rotate, so that there will be a biaxial orientation of the fibre/fibril collagen mass whilst it is passing down the length of the tube. The collagen mass, as it is extruded, will be forced tightly against the cavity wall by the bulk of material injected into the cavity, i.e. the meat paste, and subsequently by compression when a plunger is activated to shape and compress the product.
After forming, and ejection from the molding apparatus, the product may be dried to reduce the moisture content of the collagen casing to a level of, say, less than 20%. The time duration is dependent on the solids content of the collagen mass and the type of dryer, air temperature and velocities which are used. Rotary apparatus of the type described earlier, may be employed in the drying stage.
BRIEF DESCRIPTION OF DRAWINGS
Some embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:
FIG. 1 is a front elevation of a first embodiment of apparatus in accordance with the invention;
FIG. 2 is a plan view of the apparatus;
FIG. 3 is an enlarged view of part of the apparatus shown in FIG. 1;
FIG. 4 is a partial section on the line IV--IV of FIG. 3;
FIG. 5 is a partial section on the line V--V of FIG. 3.
FIG. 6 is a partial section on the line VI--VI of FIG. 3;
FIG. 7 is a partial section on the line VII--VII of FIG. 3;
FIG. 8 is a rear elevation of a base plate for use in a modified form of the apparatus of FIGS. 1 to 7;
FIG. 9 is a partial section on the line IX--IX of FIG. 8; and
FIG. 10 is a schematic view of an alternative embodiment of apparatus in accordance with the invention.
DETAILED DESCRIPTION
Referring now to FIGS. 1 to 7, the apparatus includes a frame 1 on which is mounted a rotatable cylindrical drum 2, on an axle 3 for driven rotation in a counter-clockwise direction about a horizontal axis as shown by the arrow on FIGS. 1 and 3. The drum 2 is in the form of a block of high density polyethylene, although it could be of nylon or any other suitable material. The drum material is impervious.
Around the perimeter of the drum 2 are provided twenty four cylindrical, open ended cavities 4 of circular cross-section, extending parallel to the axis of rotation. As shown in FIG. 4 for example, in each of these is mounted a cylindrical mold body 5 in the form of an open ended tube of circular cross-section. The external diameter of the mold body 5 is less than the diameter of the cavity 4, for example by a few millimeters, so as to provide a reservoir 6 defined by the annular space between the two. The ends of the reservoir are sealed by a packing piece 7 and an O-ring 8 respectively.
The cavities 4 are grouped together in pairs, and with each pair is associated an acid injector port 9, provided with a ball-valve sealing system (not shown). The injector port communicates with its two associated reservoirs 6 by means of a passage 10 (FIG. 5), communicating with an axially extending passage 11 (FIG. 3), and thence via cross-bores 12, suitably position along cavity 4, with the reservoirs 6.
Each mold body 5 is of stainless steel, having a permeable, sintered portion 13, and a solid portion 14. Within the mold body is sealably and slidably positioned a plunger generally indicated at 15, which may be of stainless steel. The end face of plunger 15 is formed by a sintered stainless steel insert 16 threaded into a cavity 17 in the plunger 15. The insert has a concave domed face, to shape the end of a product. The cavity 17 communicates by means of crossbores 18 with a circumferential groove 19 in the outer surface of the plunger 15. Bores 20 extend through solid portion 14 of the mold body 5, and communicate with a circumferential groove 21 therein, arranged to co-operate with the groove 19 in the plunger 15. There is thus fluid communication between reservoir 6 and the cavity 17 in plunger 15. O-ring seals 22 and 23 in the plunger and mold body respectively, prevent leakage during fluid injection.
In operation, the drum 2 is rotated stepwise to selectively bring the pairs of associated mold bodies 5 with their associated plungers 15, to a number of operating stations. These are marked A, B, C, and D on FIG. 3.
At station A, the plunger 15 is in the position shown in FIG. 4. A pair of injector tubes 24 are inserted into the mold bodies 5, one for each of an associated pair, by means of suitable apparatus driving an arm 25 carrying a frame 26 on which the tubes are mounted. The tubes are guided through apertures in a stationary mounting plate 27.
An emulsion 28 containing sausage meat of a plastic consistency is injected through the tubes by means of a suitable metering valve 28', feeding the two tubes 24 simultaneously. The tubes 24 retract as injection takes place, frame 26 moving away from the drum 2. The injection of the emulsion, in which salt and water soluble protein of the meat have been extracted during a blending or chopping up operation, produces a protein smear deposited on the inner surface of the mold bodies. When the cavities in the mold bodies 5 have been filled with emulsion, the tubes 24 are fully retracted, and the drum indexed round to bring the pair of mold bodies to station B. Here the position is as shown in FIG. 5.
An end capping device 29 supported on plate 27 is moved into position against both mold bodies by suitable means such as a pneumatic unit 30. This device includes a block 31 provided with a pair of sintered stainless steel inserts 32 mounted therein. The inserts have concave domed faces to shape the end of the products. The inserts communicate with a passageway 31' so that fluid can be passed through them.
At the same time as the end capping device 29 is moved into position, a tamping plate 33 is moved forward by suitable means to contact the pair of associated plungers 15 and urge them down their mold bodies to compress and compact the emulsion, to form the products, i.e. sausages 34.
The reservoirs 6, and cavities in the plungers 15 and end capping device are already filled to capacity with a suitable edible acid for example of pH 1.5, and the sintered parts are saturated. As the products are formed, an acid injector nozzle 35, which has been moved into sealing engagement with the injector port 9--provided with a sealing ring 36--by suitable means such as a pneumatic device 37 mounted to frame 1, is used to inject additional acid into the reservoirs 6 and plunger cavities 17. The acid injection system communicates with passages 31' in end capping device 31 via an external line (not shown), and additional acid is therefore also passed into there. Thus acid passes through the permeable, sintered parts 13, 16 and 32 defining the mold cavities, and onto the surfaces of the products 34 to react with the protein and form a cohesive surface. As is evident in the drawings and as described herein, at least a major portion of the surface area of the cavity walls formed by parts 13, 16 and 32 is porous or fluid permeable. Thus, fluid introduced therethrough is effective to treat at least a major portion of the surface of the proteinaceous product shaped therein.
The injector nozzle 35, end capping device 31, and tamping plate 33 are then withdrawn, and the drum 2 indexed round until the pair of mold bodies, with products 24 therein, reach station C. During this period--which may be for example 6 or 7 seconds--the acid penetrates the required depth into the product surfaces to form an acceptable cohesive surface.
Adjacent the station C is a second cylindrical drum 38 of high density polyethylene, mounted on an axle 39 for rotation in a clockwise direction as shown by the arrows on FIGS. 1 and 3, about an axis parallel to that of drum 2. This second drum 38 includes twenty four, axis-parallel, open ended cavities 40 of circular cross-section, corresponding to cavities 4 in drum 2. The radial positions of the axes of cavities 40, and their circumferential spacing, is identical to cavities 4 in drum 2. The cavities 40 have smooth interior surfaces, and their diameter is a few millimeters greater than that of the products 34, i.e. than the internal diameter of mold bodies 5.
The drums 2 and 38 are indexed synchronously, so that when a pair of cavities 4 with molded products 34 arrive at station C, they are aligned with a pair of empty cavities 40, as shown clearly in FIG. 6. At this stage, push rods 41 are urged forwards by suitable means, to push plungers 15 along the mold bodies 5, to eject the formed sausages into cavities 40. An intermediate position is shown in FIG. 6, with the sausage 34 in the process of being ejected.
Following this, push rods 41 are retracted out of the cavities and drum 2 is indexed round to bring the pair of mold bodies 5 to station D. At this station, as shown in FIG. 7, a pair of return rods 42, carried by frame 26 and guided through apertures in plate 27, are inserted into the mold bodies, urging the plungers 15 back to their original position as shown in FIG. 4. The return rods are then retracted and the drum indexed round to bring the pair of mold bodies to station A, so that the complete process can be repeated.
At the same time as the pair of mold bodies 5 moves away from station C to station D after product ejection, the drum 38 is indexed round to bring a fresh pair of cavities into registry with the next pair of mold bodies being indexed into station C on drum 2. The cavities on drum 38, when they have received products 34, thus continue rotary movement.
The bottom portion of the drum 38 passes through a bath 43 containing a washing fluid such as water. Thus, as the drum 38 is indexed round, the products 34 lying loosely in cavities 40 are therefore washed. After passing out of the bath 43, as the drum continues to be indexed, the washed products 34 are moved round to station E. During this period, any excess washing fluid will drain back into bath 43. Means may be provided to retain products in cavities 40 during treatment.
At station E, the pair of products, which have been processed and washed together, are ejected onto a conveyor belt 44 by means of ejector rods 45 carried by an extension 46 of frame 26. The rods 45 are then withdrawn and a fresh pair of washed products indexed into position for ejection.
The conveyor belt 44 which is driven around shafts 47 and 48, comprises a number of individual trays 49, each designed to receive the two products which are ejected simultaneously at station E. These products are then carried by the conveyor for further processing--i.e. packaging.
The above apparatus is particularly suitable for British sausages, and other products where the emulsion or paste is of a fairly thick consistency. In the case of products where the emulsion consistency is lower--for example in the manufacture of frankfurters--it may be necessary to close the end of the mold bodies 5, at positions other than merely at station B where compression takes place. It may be particularly desirable to keep the emulsion under compression during movement of the product from station B to station C, i.e. while the acid treated emulsion sets.
Thus, in a modification of the above described embodiment, the end capping device 29 is omitted and instead a circular base plate 50, as shown in FIG. 8, is employed. The drum 2 slides round over this base plate, and the mold bodies 5 are thus closed, apart from in certain positions. Thus, arcuate apertures 51 and 52 are provided to allow for operation of the return and filling apparatus at stations D and A, and the ejection apparatus at station C, respectively. The plate 50 will be positioned between drums 2 and 38 at station C.
To provide a rounded end shape for the product, the plate 50 includes an annular groove of curved cross-section as shown in FIG. 9. This groove 53 is defined by a sintered stainless steel insert 54, at least in the region of station B where acid injection takes place. The groove might be omitted between stations C and B, if desired. Acid may be positively injected through the insert 54, as for the end capping device 29, or reliance may be made on a general flow of acid through sintered portion 13 of mold body 5, to bring acid into the insert 54.
In the production of a frankfurter the acid could have a pH of 1.5 when injected at station B to provide a skin. The bath 43 could then be filled with acid of pH 2.5, to provide coagulation throughout the product. Alternatively, an acid of pH 2.5 could be used initially, a longer dwell time then being required. The speed of drum rotation, or the distance between acid injection and product ejection stations, can be chosen appropriately.
The drums 2 and 38 are rotated synchronously by suitable means in the above described embodiments, and operations at the various stages are synchronized, so that continuous operation is possible, and sausages or frankfurters will be produced and fed onto conveyor 44 in pairs, at time intervals corresponding to the time for one indexing of the drums. Although in the above described embodiments, two products are processed together, any such number could be processed, for example 4, 5, 8 or 10, depending on the required number of products to be packaged together.
In the alternative embodiment illustrated in FIG. 10, a plurality of mold units 55 are disposed on a rotary wheel 56. Each unit comprises sintered metal mold 57 in a sealed housing 58 for fluid. The bases of the cavities in the mold 57 communicate with pneumatic tubes 59 connected to a source of air.
At station A', a nozzle 60 injects material 61 such as meat emulsion into the cavity of the mold 57. At station B' an end former 62 is used to compress the material, and at the same time an injector nozzle 63 is used to inject e.g. acid into the housing 58 through inlet 64 so that fluid permeates through the mold 57 to the surface of the molded product.
At station C' air is supplied through tube 59, so as to eject the molded product from the mold cavity under air pressure.
The sintered stainless steel components could be of any desired permeability, depending for example on the viscosity of the fluid to pass through them. A typical permeability would be 1.0×10 -8 cm 2 , which might result in a pressure of 1 psi to drive the acid through the cylinder. Different permeabilities might be required for the plunger and end closing means and possibly higher pressures--say up to 9 psi. At least the surfaces of the sintered--or other permeable--components which contact the products, should be smooth.
Higher permeabilities--say up to 70×10 -8 cm 2 --might mean that the acid or other fluid would not need positive injection and would simply soak through. Thus, a sintered mold could merely be passed through a bath of e.g. acid.
It might also be desirable to inject acid directly into a sintered metal unit, without there being a surrounding reservoir. Thus, the mold units 5 could completely fill their cavities 4.
The quantity of acid injected depends on many factors, but it has been found that a quantity of say 1/2 to 1 cm 3 may be sufficient to give 0.3 mm coagulated surface for a standard sausage. The injection system ensures that only a predetermined quantity of acid is used; the meat injector system allows for constant weight products.
Although rotary apparatus in particular has been described, linear apparatus could be employed.
The invention extends also the products made by a method or apparatus in accordance with the invention. It will be appreciated that as described above in relation to frankfurters, the invention is applicable to products which are treated throughout, rather than merely in a surface layer. | A method and apparatus for the production of molded meat or meat-like products, for example sausages. The surface of the product is treated with a fluid, which could be for coloring or flavoring purposes, but is advantageously e.g. an edible acid adapted to react with protein in the product to form a cohesive surface and enable the use of a separate skin to be avoided. The mold includes a permeable wall, for example of sintered stainless steel, through which the fluid can be introduced. In a preferred embodiment the wall is defined by a hollow cylinder disposed in a non permeable housing containing the fluid. An end cap closes one end of the cylinder and a plunger compresses the material to form the product. At the same time additional fluid is injected through a nozzle into the housing, to cause a corresponding quantity of fluid to pass through the cylinder wall and treat the surface of the product. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is an application filed under 35 U.S.C. §111(a) claiming benefit pursuant to 35 U.S.C. §119(e)(1) of the filing date of Provisional Application 60/189,491 filed Mar. 15, 2000 pursuant to 35 U.S.C. §111(b).
FIELD OF THE INVENTION
[0002] The present invention relates to a process for treating sodium aluminosilicate.
[0003] The present invention enables separation of sodium from sodium aluminosilicate, which is usually disposed of or not used effectively. Examples of such aluminosilicate include red mud and sodalite, which is produced during production of alumina or aluminum; zeolites, which are employed in a variety of uses; and naturally occurring zeolites and sodalite. In the present invention, sodium can be recovered and recycled, and a residue which does not contain sodium can be effectively used as a raw material for cement.
BACKGROUND OF THE INVENTION
[0004] A typical component containing sodium aluminosilicate is red mud, which is a by-product of aluminum hydroxide or alumina production. Approximately 800 kg of red mud is produced for every 1 ton of alumina. Red mud predominantly comprises sodium aluminosilicate, which contains Al 2 O 3 , SiO 2 , and Na 2 O; and Fe 2 O 3 . Red mud also comprises other components in an amount of a few percent, such as TiO 2 , quartz, alumina hydrate, and a lime compound. Red mud may be used as a raw material for producing cement or iron. However, red mud contains excessive Na to be used as a raw material for cement, and excessive Al to be used as a raw material for iron. Therefore, red mud is considered difficult to use, and has hitherto been disposed of as industrial waste without putting to effective use.
[0005] Japanese Patent Application Laid-Open (kokai) No. 50-16608 discloses a process for recovering useful components (Fe, Na, and Al) from red mud. In the process, a CaO-containing component is added to red mud at a predetermined ratio. The resultant mixture is melted through reducing thermal treatment, and the molten mixture is separated into iron and slag, and Na and Al components are recovered from the slag through alkali elution. However, in the process, only 60-70% of the Na present in the red mud is actually recovered, leaving a considerable amount of Na in the residue. Thus, the residue cannot be effectively used as, for example, a raw material for cement. In the process, red mud containing approximately 40% iron is thermally treated, and therefore a large quantity of heat is required.
[0006] Other examples of sodium aluminosilicate include zeolites, which are employed in a variety of uses. Zeolites are generally used as a carrier which supports a metal catalyst or a noble metal. Alternatively, zeolites are used for carrying out ion exchange. Some zeolites are subjected to regeneration treatment and reused, but in most cases, zeolites serving as carriers are disposed of as industrial waste after removal of toxic or useful components.
[0007] As described above, various methods for effectively using some sodium aluminosilicate have been proposed, but actually, residue after removal of useful components or sodium aluminosilicate per se is not put to effective use and is disposed of.
[0008] In view of the foregoing, an object of the present invention is to provide a process for treating sodium aluminosilicate, in which a useful Na component is recovered from components of sodium aluminosilicate, and a substance which is disposed of as a residue can be effectively used as a raw material for cement due to very low Na content.
SUMMARY OF THE INVENTION
[0009] In order to effectively use sodium aluminosilicate which is disposed of without effectively or never being used, the present invention provides a process for treating sodium aluminosilicate, in which an Na component is recovered at a high rate from a variety of sodium aluminosilicates and a useful substance containing a very small amount of Na is obtained. The process comprises
[0010] (1) A calcium compound is added to sodium aluminosilicate and they are mixed. Examples of calcium compounds include a single calcium compound such as calcium oxide, calcium carbonate, calcium hydroxide, or calcium sulfate; a mixture thereof; and another mixture containing these calcium compounds. Of these compounds, calcium oxide is preferably added to sodium aluminosilicate. When a calcium component of a calcium compound which is added to a sodium aluminosilicate is represented by “CaO,” and a sodium component and a silicon component of the sodium aluminosilicate are represented by “Na 2 O” and “SiO 2 ,” respectively, the ratio by mol of CaO to Na 2 O (CaO/Na 2 O) or (preferably “and”) the ratio by mol of CaO to SiO 2 (CaO/SiO 2 ) is about 1-5, preferably about 2-4. No particular limitation is imposed on the particle sizes of sodium aluminosilicate and a calcium compound which is added, but they have a particle size of about 1-300 μm, preferably about 60 μm or less. The mixture of sodium aluminosilicate and a calcium compound may be in a dried state or a wet state, but preferably in a wet state.
[0011] (2) The mixture obtained in (1) is subjected to thermal treatment by use of a heating unit such as a kiln at about 800-1,400° C., preferably about 1,000-1,350° C. No particular limitation is imposed on the form of the mixture that is thermally treated, and the mixture may assume a powder form or a pellet form. The time for thermal treatment is about 5-180 minutes, preferably about 20-80 minutes.
[0012] (3) Exhaust gas of high temperature which is generated in the heating unit is employed for producing steam in a boiler, and energy is recovered from waste heat.
[0013] (4) The thermally-treated product obtained in (2) is subjected to elution treatment with water (or an aqueous solution), to thereby elute and recover sodium. When elution treatment is carried out, the amount of water (or an aqueous solution) which is employed is about 1-30 times the weight of the thermally-treated product, preferably about 10-20 times the weight. The elution temperature is about 50° C. or higher, preferably about 70° C. or higher. The elution time is about 10-120 minutes, preferably about 60-90 minutes.
[0014] (5) The slurry obtained in (4) is separated into solid and liquid by use of a filtering unit. The resultant cake is further washed with water. The above-filtrate and the solution which is obtained through washing of the cake is effectively used, as a sodium-containing solution, in a process in which an alkali solution must be used. The cake (hereinafter a residue after elution of sodium may be referred to as “residue after sodium recovery”) is recycled as a raw material for cement. The solution which is obtained through washing of the cake may be employed in the elution treatment of the thermally-treated product obtained in (2).
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 shows an embodiment of the process of the present invention.
[0016] [0016]FIG. 2 is a diagram showing an example of the configuration of units for carrying out the process of the present invention (Part 1).
[0017] [0017]FIG. 3 is a diagram showing an example of the configuration of units for carrying out the process of the present invention (Part 2).
[0018] [0018]FIG. 4 is a diagram showing an example of the configuration of units for carrying out the process of the present invention (Part 3).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In the present invention, sodium aluminosilicate may be sodalite, which is discharged during production of aluminum hydroxide, alumina, and metallic aluminum; zeolites, which have been employed in a variety of uses; or naturally-occurring or synthesized zeolites or sodalite.
[0020] Sodalite which is discharged during production of aluminum generally contains Na 2 O, Al 2 O 3 , SiO 2 , and impurities such as Fe 2 O 3 in amounts of about 18-25 wt. %, about 31-38 wt. %, about 28-35 wt. %, and about 5 wt. % or less, respectively. Typical examples of zeolites are represented by the following chemical formulas: CaO.Al 2 O 3 .4SiO 2 .6.5H 2 O, Na 2 O.Al 2 O 3 .2SiO 2 .4.5H 2 O, and Na 2 O.Al 2 O 3 .2.5SiO 2 .6H 2 O.
[0021] Sodium aluminosilicate may be obtained through bauxite treatment, as red mud containing an iron component. In the present invention, sodium aluminosilicate which is separated from an iron component is preferably used. Sodium aluminosilicate which is preferably used in the present invention contains a sodium aluminosilicate component in an amount of about 90 wt. % or more, preferably about 95 wt. % or more, and an iron component as reduced to Fe 2 O 3 in an amount of about 10 wt. % or less, preferably about 5 wt. % or less. In bauxite treatment, there is known a method for obtaining sodium aluminosilicate which is separated from an iron component. Even when sodium aluminosilicate containing an iron component and other metallic components is used, the sodium aluminosilicate does not raise any problems. However, when sodium aluminosilicate containing a sodalite component in large amounts is used, the energy which is consumed for per unit weight of sodium aluminosilicate can be reduced.
[0022] Examples of calcium compounds which may be used include calcium oxide, calcium carbonate, calcium hydroxide, calcium sulfate, and a mixture thereof. Of these, calcium oxide is preferably used. When a calcium compound is mixed with sodium aluminosilicate and the mixture is thermally treated, the reaction between the calcium compound and the sodium aluminosilicate proceeds, converting a sodium component into a compound which can be eluted with water. The resultant elutable product may be a product containing sodium aluminate.
[0023] When a calcium component of a calcium compound which is added to sodium aluminosilicate is represented by “CaO,” and a sodium component and a silicon component of the sodium aluminosilicate are represented by “Na 2 O” and “SiO 2 ,” respectively, the ratio by mol of CaO to Na 2 O (CaO/Na 2 O) and/or the ratio by mol of CaO to SiO 2 (CaO/SiO 2 ) are generally about 1 or more, preferably about 1-5, more preferably about 2-4. When the ratio is less than 1, a sodium component of sodium aluminosilicate cannot be sufficiently converted into an elutable compound. In contrast, when the ratio is very high, a compound which is difficult to elute is produced, and thus the elution percentage of a sodium component may be reduced.
[0024] When sodium aluminosilicate is mixed with a calcium compound, these compounds are preferably crushed so as to make them into particles of small sizes. No particular limitation is imposed on the particle size, but each compound preferably contains particles having a particle size of about 1-300 μm, more preferably about 80 μm or less, much more preferably about 60 μm or less. When the particle has a smaller size, the elution percentage of sodium can be increased. However, not all particles are required to have a particle size falling within the above range. When particles having a particle size falling within the above range account for at least about 60 wt. %, preferably at least about 80 wt. %, the elution percentage can be increased. It has been elucidated that regulation of particle size is effective for increasing the elution percentage of sodium and obtaining a residue containing a sodium component in an amount of about 1% or less. However, the particles do not need to be made very small, in view of cost.
[0025] Sodium aluminosilicate may be mixed with a calcium compound in a dried state. However, they are preferably mixed in a wet state by adding water, since a portion of CaO is dissolved in a liquid phase in the form of Ca(OH) 2 and substitution-reaction of Na of sodalite with Ca occurs in a liquid phase before thermal treatment. When sodium aluminosilicate is mixed with a calcium compound in a wet state, the mixture can be pelletized, which is preferable. When the mixture is pelletized, generation of dust is prevented during thermal treatment, and pellets are transferred with ease. Even when mixed particles are pelletized, the reactivity of the pellet depends on the particle size before pelletization, and thus the particles preferably have a particle size falling within the above-described range.
[0026] A mixture of sodium aluminosilicate and a calcium compound is heated generally at about 800-1,400° C., preferably at about 1,000-1,350° C. The heating temperature greatly affects the elution percentage of a sodium component after heating. Therefore, in order to produce a compound which is easy to elute, the heating temperature must be set within a certain range. The mixture may be heated in the atmosphere. No particular limitation is imposed on the heating time, but the time is generally about 5-180 minutes, preferably about 20-80 minutes. No particular limitation is imposed on the rate of temperature increase, but the rate is generally about 10-30° C./minute. The heated product may be rapidly or gradually cooled. No particular limitation is imposed on the type of heating unit, but industrially, a kiln is advantageous (hereinafter a substance which is produced through the aforementioned thermal treatment may be referred to as a “thermally-treated product”).
[0027] After completion of thermal treatment, the thermally-treated product is preferably crushed for carrying out elution with ease.
[0028] Elution is carried out with water or an aqueous solution. No particular limitation is imposed on the amount of water or aqueous solution, but the amount is preferably about 1-30 times the weight of the thermally-treated product, more preferably about 10-20 times the weight. When hot water is used, elution can be accelerated. Hot water which is used generally has a temperature of about 50°C. or higher, preferably about 70° C. or higher. No particular limitation is imposed on the elution time, but the time is about 5-120 minutes, preferably about 60-90 minutes.
[0029] As described above, in the present invention, sodium aluminosilicate is mixed with a calcium compound, the resultant mixture is thermally treated, and a sodium component is eluted. As a result, the amount of sodium component of a residue after elution can be considerably reduced. When the above-described conditions are appropriately chosen, the amount of sodium in a residue can be reduced to about 1% or less, about 0.6% or less, about 0.1% or less, and particularly about 0.01% or less. As a result, a residual solid product after recovery of sodium, which predominantly contains calcium silicate, can be used as a raw material for cement. In addition, when the amount of sodium recovered from sodium aluminosilicate is calculated as a recovery percentage of sodium, in the present invention, the recovery (extraction) percentage can attain about 95% or more, further about 99% or more, and particularly about 99.9% or more. Conventionally, such a high recovery (extraction) percentage of sodium is not known to be attainable. However, in the present invention, the amount of sodium in a residual solid product after recovery of sodium can be reduced to about 1% or less, and thus the solid product can be used as a raw material for cement. This fact enhances the utility of the present invention.
[0030] In the case in which the thermally-treated product is subjected to elution treatment with water or an aqueous solution, when an alumina component is eluted together with a sodium component, the resultant elution solution per se can be recycled in bauxite treatment (e.g., Bayer's process). As a result, separating the sodium and alumina components becomes unnecessary. On the other hand, even when an alumina component remains in a residue after elution, the residue can be used as a raw material for cement and raises no problem. When a residue after elution contains no alumina component, the residue is preferably used as a raw material for cement.
[0031] An embodiment of the process of the present invention will be described in reference to FIG. 1. The treatment process mainly comprises thermal treatment and elution.
Thermal Treatment Process
[0032] Various sodium aluminosilicates and CaO serving as an additive are supplied to a mixing device 1 , such as a kneader or a kneading machine, through a line 11 and a line 12 , respectively. The aluminosilicates and CaO are mixed well in the mixing device. The resultant mixture is supplied to a heating unit 2 , such as a kiln, through a line 13 , and thermally treated at about 1,000-1,350° C. The thermally-treated product is fed to a cooling unit 3 , such as a rotary cooler or a steel belt cooler, through a line 14 and cooled. Thereafter, the resultant product is supplied to a crusher 4 such as a hammer mill through a line 15 , and crushed therein.
Elution Process
[0033] The product which is crushed in the crusher 4 in the thermal treatment process is supplied to an elution unit 5 through a line 16 . Water (or an aqueous solution) is also supplied to the elution unit 5 through a line 17 . The mixture is stirred in the unit and subjected to elution treatment at about 50-100° C. The resultant slurry in the elution unit 5 is discharged through a line 18 , and the slurry is separated into solid and liquid in a solid-liquid separation unit 6 , such as a horizontal belt filter or a rotary drum filter. The thus-obtained filtrate containing sodium serving as a useful component is discharged through a line 20 and recycled. The thus-separated cake is washed with washing water, and discharged through a line 21 . The resultant residue after recovery of sodium predominantly contains calcium and silica, and contains sodium in an amount of about 1% or less, and thus the residue can be effectively used as a raw material for cement. The washing water which is used for washing the cake is removed through the line 20 and recycled.
[0034] FIGS. 2 to 4 show specific examples of the structure of apparatuses for carrying out the process of the present invention. The process is illustrated by means of these three figures. As shown in these figures, a predetermined amount of sodalite having a predetermined particle size is supplied to a mixing device 31 through a sodalite hopper 32 . Also, a predetermined amount of CaO having a predetermined particle size is supplied to the mixing device 31 through a CaO hopper 33 , a CaO crusher 34 , and a CaO feeder 35 which constantly supplies CaO. These compounds are mixed in the mixing device 31 , and the mixture is fed to a kiln 37 through a feeder 36 and thermally treated at a predetermined temperature. The thermally treated product is cooled in a cooling unit 38 , and then crushed in a crusher 39 . Subsequently, the crushed product is subjected to elution treatment in an elution container 40 by use of hot water. After elution, the resultant slurry is separated into filtrate and cake in a filtering unit 41 . After being treated in a filtrate separator 42 and an evaporator 43 , the filtrate is used in an alumina production process, such as Bayer's process. The cake is fed to a drying unit 45 through a cake-receiving container 44 , and discharged into a dried cake receiver 46 . The dried cake is used as a raw material for cement. Reference numeral 47 represents a bag filter.
EXAMPLES
[0035] Unless otherwise indicated herein, all parts, percents, ratios and the like are by weight.
Test Example 1
[0036] Table 1 shows analytical values of sodalite obtained in a desilication process which is added to Bayer's process for producing aluminum hydroxide alumina. The sodalite, CaO having a particle size of 53 μm or less, and water were fed into a mixing device. The amount of water was 40% on the basis of the entirety of the mixture. In this case, when a silicon component of the sodalite was represented by “SiO 2 ,” the ratio by mol of CaO to SiO 2 ; i.e., CaO/SiO 2 , was 3. The mixture was thermally treated in a kiln at 1,200° C. for a residence time of 30 minutes. Subsequently, the thermally treated product was fed to a cooling unit. After being cooled, the product was crushed by use of a crusher.
[0037] The thus-crushed product was fed to an elution tank, and water was added in an amount of 20 times the weight of the thermally treated product (the crushed product). The mixture was stirred well at 90° C. for 60 minutes, and the mixture was subjected to elution treatment. Thereafter, the obtained slurry was fed to a filtering unit, and the slurry was separated into solid and liquid. The separated cake was washed well with water.
[0038] The thus-recovered solution and the cake were chemically analyzed for the Na content to calculate the recovery percentage of sodium and the concentration of sodium remaining in the cake. As a result, the recovery percentage of sodium was found to be as high as 99.9%, and the concentration of sodium remaining in the insoluble residue was as low as 0.01% (dry). Therefore, a useful product which can be used as a raw material for cement was obtained.
TABLE 1 Analytical Values Of Sodalite Item SiO 2 (wt %) Al 2 O 3 (wt %) Na 2 O (wt %) Ig-loss Analytical value 33.8 34.9 23.0 8.3
Test Example 2
[0039] The same sodalite as used in Test Example 1 and CaO having a particle size of in excess of 300 μm were fed into a mixing device, and these compounds were mixed. In the same procedure as in Test Example 1, the ratio by mol of CaO to SiO 2 ; i.e., CaO/SiO 2 , was 3. The resultant mixture was thermally treated in a kiln at 1,200° C. for 60 minutes. Subsequently, the thermally treated product was fed to a cooling unit. After being cooled, the product was crushed by use of a crusher.
[0040] The thus-crushed product was fed to an elution tank, and water in an amount of 20 times the weight of the thermally treated product (the crushed product) was added to the crushed product. The mixture was stirred well at 90° C. for 60 minutes, and then subjected to elution treatment. Thereafter, the thus-obtained slurry was fed to a filtering unit, and the slurry was separated into solid and liquid. The separated cake was washed well with water.
[0041] The thus-recovered solution and the cake were chemically analyzed for the Na content to calculate the recovery percentage of sodium and the concentration of sodium remaining in the cake. As a result, the recovery percentage of sodium was found to be 22.5%, and the concentration of sodium remaining in the insoluble residue was found to be 8.81% (dry).
Test Example 3
[0042] The same sodalite as used in Test Example 1 and CaO having a particle size of 53 μm or less were fed into a mixing device, and these compounds were mixed. In the same manner as in Test Example 1, the ratio by mol of CaO to SiO 2 ; i.e., CaO/SiO 2 , was 3. The resultant mixture was thermally treated in a kiln at 800° C. for a residence time of 30 minutes. Subsequently, the thermally treated product was fed to a cooling unit. After being cooled, the product was crushed by use of a crusher.
[0043] The thus-crushed product was fed to an elution tank, and water in an amount of 20 times the weight of the thermally treated product (the crushed product) was added to the crushed product. The mixture was stirred well at 90° C. for 60 minutes, and the mixture was subjected to elution treatment. Thereafter, the thus-obtained slurry was fed to a filtering unit, and the slurry was separated into solid and liquid. The separated cake was washed well with water.
[0044] The thus-recovered solution and the cake were chemically analyzed for the Na content to calculate the recovery percentage of sodium and the concentration of sodium remaining in the cake. As a result, the recovery percentage of sodium was found to be 61.8%, and the concentration of sodium remaining in the insoluble residue was found to be 4.33% (dry).
Test Example 4
[0045] Testing was carried out by use of synthetic zeolite 4A which had been used previously. Table 2 shows analytical values of the synthetic zeolite 4A. The zeolite and CaO were fed into a mixing device, and these compounds were mixed. In this case, when a silicon component of zeolite was represented by “SiO 2 ,” the ratio by mol of CaO to SiO 2 ; i.e., CaO/SiO 2 , was 3. The mixture was thermally treated in a kiln at 1,200° C. for 60 minutes. Subsequently, the thermally treated product was fed to a cooling unit. After being cooled, the product was crushed by use of a crusher.
[0046] The thus-crushed product was fed to an elution tank, and water in an amount of 20 times the weight of the thermally treated product (the crushed product) was added to the crushed product. The mixture was stirred well at 90° C. for 60 minutes, and the mixture was subjected to elution treatment. Thereafter, the thus-obtained slurry was fed to a filtering unit, and the slurry was separated into solid and liquid. The separated cake was washed well with water. The thus-recovered solution and the cake were chemically analyzed for the Na content to calculate the recovery percentage of sodium and the concentration of sodium remaining in the cake. As a result, the recovery percentage of sodium was found to be as high as 93.4%, and the concentration of sodium remaining in the insoluble residue was found to be as low as 0.66% (dry). Therefore, a useful product which can be used as a raw material for cement was obtained.
TABLE 2 Analytical Values Of Zeolite (used synthetic zeolite 4A) Item SiO 2 (wt. %) Al 2 O 3 (wt. %) Na 2 O (wt. %) Ig-loss Analytical value 36.7 30.7 17.7 21.0
[0047] As described above, the present invention exhibits the following effects.
[0048] (1) Sodium serving as a useful component can be recovered almost completely from sodium aluminosilicate contained in waste or unused natural resource.
[0049] (2) A raw material for cement containing sodium in very low amounts can be produced from sodium aluminosilicate contained in waste or unused natural resource.
[0050] While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | The present invention provides a process for treating sodium aluminosilicate which includes adding a calcium compound to sodium aluminosilicate; thermally treating the mixture of the sodium aluminosilicate and the calcium compound; and eluting the thermally-treated product with water or an aqueous solution to thereby solubilize a sodium component of the sodium aluminosilicate, recover sodium, and obtain a useful product containing sodium in very small amounts. The elution percentage of sodium can be increased by optimizing heating and elution conditions. | 2 |
FIELD OF THE INVENTION
The present invention relates to an enhanced oil recovery process with combined injection of water and of gas in a reservoir.
The process according to the invention finds applications notably for improving the displacement of petroleum fluids towards producing wells and therefore for increasing the recovery ratio of the usable fluids, oil and gas, initially in place in the rock.
BACKGROUND OF THE INVENTION
There are many processes, referred to as primary, secondary or tertiary type processes, allowing to recover hydrocarbons in reservoirs.
The recovery is referred to as primary when the petroleum fluids are produced under the sole action of the energy present in-situ. This energy can result from the expansion of the fluids under pressure in the reservoir: expansion of the oil, saturated with gas or not, expansion of a gas cap above the oil reservoir, or an active water table. During this stage, if the pressure in the reservoir falls below the bubble point of the oil, the gas phase coming from the oil will contribute to increasing the recovery ratio. Natural drainage recovery scarcely exceeds 20% of the fluids initially in place for light oils and it is often below this value for heavy oil reservoirs.
Secondary recovery methods are used to prevent too great a pressure decrease in the reservoir. The principle of these methods consists in supplying the reservoir with an external energy. Fluids are therefore injected into the reservoir through one or more injection wells in order to displace the usable petroleum fluids (referred to as “oil” hereafter) towards production wells. Water is often used as the displacement fluid. Its efficiency is however limited. A large part of the oil remains in place notably because the viscosity thereof is often higher than that of water. Furthermore, the oil remains trapped in the pore contractions of the formation as a result of the great interfacial tension difference between the latter and the water. Finally, the rock mass is often heterogeneous. In this context, the water injected will flow through the most permeable zones to reach the producing wells without sweeping large oil zones. These phenomena induce a great recovery loss.
Pressurized gas can also be injected into a reservoir for secondary recovery, gas having the well-known property of displacing appreciable amounts of oil. However, if the formation is heterogeneous, the gas being much less viscous than the oil and the water in place, it will flow through the rock by following only some of the most permeable channels and will rapidly reach the producing wells without the expected displacement effect.
It is also well-known to combine water and gas injections according to a method referred to as WAG method (Water Alternate Gas). According to this method, water and gas are injected successively as long as the petroleum fluids are produced under economical conditions. The purpose of water slugs is to reduce the mobility of the gas and to widen the swept zone. Many improvements have been proposed for this technique: surfactants can be added to the water in order to decrease the water-oil interfacial tension, a foaming agent can be added to the water: the foam formed in the presence of the gas significantly reduces the mobility thereof. Such a method is for example described in U.S. Pat. No. 3,893,511. The applicant's patent FR-2,735,524 also describes an improved process consisting in adding an agent reducing the interfacial tension between the water and the gas to at least one of the water slugs alternately injected. Under the effect of this agent, alcohol for example, the oil cannot spread on the water film covering the rock mass. The oil remains in the form of droplets that slow the displacement of the gas down. The applicant's patent FR-2,764,632 describes a process comprising alternate injection of gas slugs and of water slugs wherein a pressurized gas soluble in both water and oil is added to at least one of the water slugs. The production stage comprises releasing the pressure prevailing in the reservoir so as to generate gas bubbles that drive the hydrocarbons out of the pores of the rock mass.
These secondary recovery techniques lead to recovery ratios of 25 to 50% of the oil initially in place.
The purpose of tertiary recovery is to improve this recovery ratio when the residual oil saturation is reached. This designation is applied to the injection, into a reservoir, of a miscible gas, of a microemulsion, of steam, or to in-situ combustion.
The definition of these primary, secondary and tertiary recovery techniques and their chronological application during production of a reservoir date from several years. Pressure maintenance techniques are currently used from the start of reservoir development and fluid injection techniques previously referred to as tertiary are carried out before a marked decline of the initial pressure of the reservoir.
More than 30% of the hydrocarbon fields produced contain acid compounds such as CO 2 and H 2 S. Development of these fields requires treating processes allowing the usable gases to be separated from the acid gases. The carbon dioxide coming from these plants is often discharged into the atmosphere, thus increasing the climate disturbances and the greenhouse effect. Hydrogen sulfide management is problematic because of the high toxicity of this gas. It is generally converted to solid sulfur by means of a Claus chain. This process requires a high investment on which a return is not secured in times where the world production of solid sulfur exceeds the needs. Reinjection of these acid gases in the reservoir after complete or partial solubilization in an aqueous phase, which can be all or part of the production water, fresh water or a brine from a groundwater table, sea water or others, affords two advantages: it allows to get rid of the acid gases at a low cost, without any polluting atmospheric discharge, and to increase the reservoir productivity.
SUMMARY OF THE INVENTION
The process intended for enhanced recovery of a petroleum fluid produced by a reservoir according to the invention aims, through combined injection of an aqueous phase and of a gas from an external source or, as far as possible, at least partly of acid gases coming from effluents from the reservoir itself, to increase the hydrocarbon recovery ratio.
The process comprises continuous injection, through an injection well, of a sweep fluid consisting of an aqueous phase to which a gas at least partially miscible in the water and in the petroleum fluid has been added, with permanent control, at the head of the injection well, of the ratio of the flow rates of this aqueous phase and of the gas forming the sweep fluid so that the gas is in a state of saturation or of oversaturation at the bottom of the injection well.
The sweep fluid can be formed either at the well bottom with separate transfer of the constituents to the injection zone, or at the well head.
A means arranged in the injection well can be used to create a pressure drop, for example a valve or a pipe restriction, and thus to increase the dissolution ratio of the gas in the water. A packing placed in the injection well in order to intimately mix the gas and the aqueous phase of the sweep fluid also increases the pressure drop and the dissolution ratio.
According to an embodiment, a multiphase rotodynamic type pump is for example used to compress the gas, to pressurize the aqueous phase and to intimately mix this aqueous phase and the pressurized gas prior to injecting the mixture into the injection well.
To ensure that the gas is at least in a state of saturation (preferably of oversaturation at the well bottom), data produced by state detectors at the well bottom (permanently installed pressure detectors, temperature detectors, etc.) are preferably used to check that the gas of the sweep fluid is at least in a state of complete saturation.
The gas in the sweep fluid contains at least one acid gas such as carbon dioxide and/or hydrogen sulfide and possibly, in variable proportions, other gases: methane, nitrogen, etc. These gases can be taken from effluents coming from a reservoir, an operation carried out in a treating plant suited to separate them from other gases otherwise usable, or they can come from chemical or thermal plants burning lignite, coal, fuel oil, natural gas, etc.
The aqueous phase used to form the sweep fluid can for example be water coming from an underground reservoir (a groundwater table for example, or a brine produced during development of a reservoir), or any other water readily available (sea water).
According to another embodiment, a surfactant is added to the aqueous phase in order to favour dispersion of the gas and/or one or more surfactants can be added thereto in order to increase the solubility of the gas in the sweep fluid.
According to another embodiment, the sweep fluid is for example injected into one or more greatly deflected wells, horizontal wells or wells with a complex geometry located for example at the base of the reservoir and the petroleum fluid is produced for example through one or more deviated wells or wells of complex geometry that can be located at the top of the reservoir.
The process can be implemented from the start of the reservoir development. The aqueous phase preferably injected on the periphery of the producing zone sweeps the porous medium containing the hydrocarbons to be recovered. At the beginning of this circulation, the carbon dioxide, much more soluble in oil than in the water injected, goes from the sweep fluid to the petroleum fluid, causing swelling and decreasing the viscosity thereof. These two phenomena favour an increase in the recovery of the hydrocarbons in place. When the fluid gets closer to the production wells, its pressure falls under the combined effect of the pressure drops linked with the flow and of the natural depletion of the reservoir. If the pressure is lower than the bubble-point pressure of the water containing the solubilized gas, gas bubbles will form by nucleation in the pores of the rock mass and drive the oil contained therein towards the most permeable zones where it will be swept. Not only does this phenomenon increase the overall recovery ratio of the oil in place, but it also decreases the time required to reach a given recovery ratio.
The invention also relates to a system intended for enhanced recovery of a petroleum fluid extracted from a reservoir, by continuous injection into the reservoir of a sweep fluid consisting of an aqueous phase mixed with a gas at least partially miscible in the aqueous phase and in the petroleum fluid, which comprises a sweep fluid conditioning unit and a control unit allowing permanent control of the conditioning unit, suited to control the ratio of the flow rates of this aqueous phase and of the gas forming the sweep fluid that has reached the well bottom, so that the gas is in a state of saturation or oversaturation. The system preferably comprises state detectors placed in the injection zone to measure thermodynamic parameters and connected to the control unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the process according to the invention will be clear from reading the description hereafter of non limitative examples, with reference to the accompanying drawings wherein:
FIG. 1 shows a first embodiment of the process where the sweep fluid is formed at the well bottom in the injection zone,
FIG. 2 shows a second embodiment of the process where the sweep fluid is formed at the surface, and
FIG. 3 shows an embodiment where the gas in the sweep fluid consists of acid fractions of gas coming from the subsoil or produced by process units or thermal plants burning various materials.
DETAILED DESCRIPTION OF THE INVENTION
The recovery process which is the object of the present invention comprises four stages:
1. Preparation of the Sweep Fluid
Although this is not limitative, gases that are readily available and not used otherwise, such as carbon dioxide CO 2 or hydrogen sulfide H 2 S, are preferably used.
The carbon dioxide mixed with the aqueous phase (referred to as water hereafter) reacts according to the balanced reaction:
CO 2 +H 2 O⇄H 2 CO 3
giving carbonic acid. The solubility of the carbon dioxide in the water depends on the salinity of the water, on the temperature and on the pressure. The dissolution ratio of CO 2 increases with the pressure and decreases with the temperature. In the pressure and temperature range found for injection applications, typically a pressure ranging from 75 to 300 bars (7.5 to 30 MPa) and a temperature ranging from 50 to 100° C., the effect of the pressure is preponderant. In other words, the dissolution ratio of carbon dioxide at the bottom of an injection well is higher than the dissolution ratio at the surface despite the temperature increase due to the geothermal gradient.
At pressures below 100 bars, CO 2 dissolves less in salt water than in pure water. At a higher pressure, the salinity affects the solubility of the gas much less. In pure water, under a pressure of 150 bars (15 MPa) and at a temperature of 70° C., the solubility of CO 2 is about 4.5% by weight (45 kg CO 2 are dissolved in 1 m 3 water). Dissolution of the acid gas in the water leads to a viscosity increase, which improves the water/oil mobility ratio. The dissolution ratio of hydrogen sulfide in water is higher, approximately by a factor of 2, than that of carbon dioxide, whatever the temperature, the pressure and the composition of the aqueous phase. By way of example, under a pressure of 150 bars and at a temperature of 70° C., the solubility of H 2 S is about 8.3% by weight (83 kg H 2 S are dissolved in 1 m 3 water). The acid gases coming from the petroleum production mainly contain carbon dioxide, it is the solubility of this gas that will be limitative when the mixture is dissolved in an aqueous fluid.
2. Injection of the Sweep Fluid
An important point which makes the process according to the invention particularly efficient for sweeping a reservoir is that the sweep fluid is so injected that at the well bottom, in the injection zone, the water solution injected is at least saturated and preferably oversaturated with gas.
The volumes of acid gases and of water that can be reinjected into the reservoir can be available in a ratio that is much higher than the solubility ratio of the acid gas in the water. This ratio can evolve during development or according to production constraints. The pressure increase at the bottom of the injection well is partially compensated by a temperature increase linked with the geothermal gradient. However, the effect of the pressure is generally greater, all the more so since the fluid injected does not reach the thermal equilibrium conditions while flowing.
For this saturation or oversaturation condition at the well bottom to be permanently met, an injection system that can be placed entirely at the surface or also comprise elements at the well bottom is used.
According to the embodiment shown in FIG. 1, the sweep fluid is produced by a conditioning unit PA and its constituents are separately transferred to the injection zone at the well bottom. The gas G is compressed by a compressor 1 and injected through an injection tube 2 to the bottom of injection well IW, while the water W coming from a pump 3 is injected into the annular space 4 between the casing and injection tube 2 . Mixing of the two phases takes place below packer 5 above the injection zone. The injection pressures of compressor 1 and of pump 3 are determined by a control device 6 .
According to a preferred embodiment, for gas injection requiring a high pressure at the well head, mixing is preferably performed at the surface before injection. This simultaneous injection permits an increase in the weight of the liquid column in the injection well and a significant reduction of the required gas pressure. In order to obtain the required saturation and preferably oversaturation condition at the well bottom, the mixture obtained at the well head must be highly oversaturated with acid gases and particularly homogeneous, the gas being dispersed in the liquid phase.
A conventional compression and pumping device (FIG. 2) known to specialists can therefore be used to inject the sweep fluid in a state of saturation or oversaturation in the well bottom. In this case, the acid gases are compressed in a compressor 1 in successive stages and cooled between two compression sections. In parallel, the water W is pressurized by a pump 3 to a pressure equal to that applied by compressor 1 . The gas G and the liquid W are then fed into a static or dynamic mixer 7 having a sufficient efficiency to allow total dispersion of the gas in the liquid. Downstream from mixer 7 , the mixture can be compressed by an additional pump 8 in order to allow either dissolution of an additional amount of gas, or injection of the sweep fluid into well IW. The acid gases, heated during compression, can for example be cooled by means of heat exchangers (not shown) prior to being fed into mixer 7 so as to favour their dissolution.
A rotodynamic type multiphase pump can advantageously replace a conventional reinjection chain and fulfil the following three functions: compress the gas, pressurize the liquid phase and intimately mix the two phases. A rotodynamic mutliphase pump suited for this type of application is described in patents FR-2,665,224 (U.S. Pat. No. 5,375,976) filed by the applicant or FR-2,771,024 filed by the applicant. By its design, this type of pump can inject into a well a two-phase mixture consisting of saturated carbonate water and of excess gaseous carbon dioxide without any cavitation problem.
It is also possible to introduce an additional pressure drop in the injection line in the form of a throttling valve or of a restriction of the injection line. According to a particular embodiment, a packing is also provided in injection well IW in order to improve mixing of the constituents while inducing an additional pressure drop. In either case, state detectors SS are preferably used, which are lowered onto the well bottom, in the injection zone, to measure various thermodynamic parameters: pressures, temperatures, etc., and are connected to control device 6 . A transmission system suited to transmit to the surface signals coming from detectors permanently installed in wells for reservoir monitoring, notably state detectors permitting, for example, the temperatures and pressures prevailing at the well bottom to be known, is notably described in patent U.S. Pat. No. 5,363,094 filed by the applicant. Control device 6 adjusts the flow rates and their ratio in this case according to the conditions prevailing in situ.
According to the embodiment shown in FIG. 3, the system is suited to form a mixture, saturated or oversaturated at least partially by controlled recombination of effluents pumped from the reservoir through one or more production wells PW of the reservoir. These effluents generally contain a liquid phase consisting of water W and oil O, and a gas phase G. The effluents are thus passed through a water-oil-gas separator S 1 . The gas phase G, possibly completed by external supply, flows through a separator S 2 intended to separate the gases recoverable for other applications from the acid gases to be recycled. The water W coming from separator S 1 is then recombined with the acid gases recovered in a controlled mixing device M so as to form the saturated or oversaturated mixture under to conditions prevailing at the well bottom.
If the pressure required to inject the fluid into the rock mass is lower than the liquefaction pressure of CO 2 , a liquid phase and a gas phase will be present in the injection well. The user must make sure that dispersion of the gas reaches a maximum level and that the gas slugs circulating in the injection well are carried along by the liquid column at the well bottom, in other words that the liquid velocity is higher than the upflow velocity of the gas slugs in order to prevent segregation in the injection well.
It is also possible that the pressure required to inject the fluid into the rock mass is higher than the liquefaction pressure of CO 2 . The liquefied gas will be intimately mixed with the water and an emulsion consisting of fine droplets of liquefied gas in water will then be injected.
A small proportion of a surfactant favouring dispersion of the gas bubbles is preferably added to the aqueous phase. In order to reduce the excess gas in relation to the saturation conditions prevailing at the surface, the solubility of the carbon dioxide in the water can be increased by adding thereto additives favouring its dissolution, such as monoethanolamine, diethanolamine, ammonia, sodium carbonate, potassium carbonate, sodium or potassium hydroxide, potassium phosphates, diaminoisopropanol, methyldiethanolamine, triethanolamine and other weak bases. The concentration of these additives in the water can range from 10 to 30% by weight. It has been noticed that a solubility agent such as monoethanolamine added to the water in a proportion of 15% by weight increases for example by a factor of 7 the solubility of CO, in water. The injection wells can be vertical or horizontal wells. In general, if the reservoir is not very thick, it can be advantageous to inject carbonate water into greatly deflected or horizontal wells. The aqueous phase can be injected at the base of the reservoir to be drained by means of one or more horizontal wells and the liquid hydrocarbon phase can be recovered at the top of the reservoir by means of one or more horizontal wells. For thick reservoirs, the injection and production wells will be vertical, and sweeping of the hydrocarbons in place will be performed parallel to the limits of the reservoir. Wells with a more complex geometry can be used without departing from the scope of the present invention.
3. Reservoir Sweeping
The recovery principle according to the invention allows to supply the reservoir with additional energy. Simultaneous injection of water and acid gases affords many advantages.
The carbonate water solubilizes the soluble carbonates present in the rock, calcite and dolomite, by forming soluble bicarbonates according to the reactions:
Ca CO 3 +H 2 CO 3 ⇄Ca (HCO 3 ) 2
Mg CO 3 +H 2 CO 3 ⇄Mg (HCO 3 ) 2
This partial dissolution of the carbonates leads to a permeability increase of the porous medium, whether a sandstone, in which dissolution will attack the cements and the calcic deposits often present around quartz grains, or a limestone formation in which the porous connection will be improved. The permeability gain resulting from dissolution of the carbonates can be significant, as it is well-known to specialists.
It is also well-known that carbonate water prevents swelling of the clays often present in petroleum reservoirs. This effect is particularly noticeable for clays whose base ion is sodium. Calcium dissolution also has an effect on stabilization of clays with sodium ions by replacing the sodium by calcium, which gives more stable clays that withstand flow without crumbling and clogging the porous medium.
The viscosity of the water increases when the CO 2 dissolves therein. The volume of this carbonate water increases by 2 to 7% according to the concentration of the dissolved gas and its density slightly decreases. The global effect of the decrease of the density contrast between the water and the oil reduces gravity segregation risks. In parallel, the water/oil mobility ratio is improved through the oil/water viscosity ratio decrease. These facts contribute to significantly improving the efficiency with which the water sweeps the oil.
Carbon dioxide is much less soluble in water than in reservoir oils. This solubility depends on the pressure, the temperature and the characteristics of the oil. Under certain conditions, the carbon dioxide can be partially or totally miscible with the hydrocarbons. When it is injected into the reservoir in the form of carbonate water, the carbon dioxide will preferably go from the water to the oil.
Dissolution of the carbon dioxide in oil leads to a significant volume increase. With the same dissolution ratio of the carbon dioxide, this phenomenon will be more noticeable for light oils than for heavy oils.
Dissolution of the carbon dioxide in oil also leads to a decrease in its viscosity. This decrease is more significant when the amount of CO 2 increases. An oil with a high initial viscosity will be more sensitive to this phenomenon. By way of example, the viscosity of an oil having an API gravity of 12.2 (0.99 g/cm 3 ) and a viscosity of 900 mPa.s at ambient pressure and at a temperature of 65° C. will fall to 40 mPa.s under a pressure of 150 bars of CO 2 . Under similar conditions, the viscosity of an oil with an API gravity of 20 (0.93 g/cm 3 ) will fall from 6 to 0.5 mPa.s.
Swelling and viscosity decrease of the oil favour an increase in the recovery of the hydrocarbons initially in place in the reservoir. They also allow to accelerate the hydrocarbon recovery process.
The carbonate water is at least saturated with CO 2 when it is injected into the reservoir. In the porous medium, the pressure of the fluid injected will fall because of the pressure drops linked with the flow. When the pressure is lower than the bubble-point pressure of the water containing the solubilized gas, gas will be released. Nucleation of the carbon dioxide bubbles will preferably take place in contact with the rock and specifically in zones with a high rock/liquid interface concentration. These zones correspond to low-permeability rocks; swelling and migration of the gas bubbles will expel the oil trapped in the small-diameter pores of the rock. This phenomenon significantly increases the proportion of the hydrocarbons displaced during production.
The recovery process as described above finds an advantageous application when production of a reservoir with a double porosity system, such as fractured reservoirs, is started. A simple representation of such reservoirs is a set of rock blocks of decimetric or metric size having small-diameter pores and saturated with oil, connected together by a network of fractures providing a passage for the flow of fluids of several ten micrometers on average.
Two types of fractured reservoirs can be typically distinguished: reservoirs whose rock is water wet, and reservoirs of average wettability or oil wet reservoirs (for example certain carbonate rock massifs).
When these reservoirs are subjected to water injection within the scope of improved recovery of petroleum effluents, the water will preferably invade the fractures. The water will then tend to imbibe the low-permeability blocks by driving the oil trapped in the pores towards the fracture network. If the reservoir is water wet, imbibition will take place under the effect of the capillary forces and of gravity. If the reservoir is oil wet, only gravity will favour the imbibition phenomenon.
When carbonate water is injected into the fractured medium, in the case of a water wet reservoir, displacement of the oil by imbibition in low-porosity blocks is followed by expansion of the carbon dioxide when the pressure is lower than the bubble-point pressure of the carbonate water. The development of gas bubbles trapped in the low-permeability rocks induces a highly increased oil recovery.
In the case of a reservoir of average water wettability or of an oil wet reservoir, the phenomenon of imbibition by water will be less efficient, the capillary forces do not favour displacement of the oil by water. The carbon dioxide released during depletion advantageously replaces the water and invades the matrix blocks.
Development of the reservoir can comprise injection and depletion cycles. During the injection period, production is stopped or decreased whereas carbonate water injection is maintained in order to raise the pressure in the reservoir above the bubble-point pressure of the water and thereby to increase the concentration of the carbon dioxide available. This injection period is followed by a period of production and of partial depletion of the reservoir.
4. Production
In the course of time, the hydrocarbons produced have increasing acid gas concentrations. As mentioned above, these gases are advantageously separated from the otherwise usable gas and reinjected into the reservoir. If the gas processing and refining plants are close to the producing wells, the gas and the oil are separated by successive expansions in separating drums S 1 , S 2 (FIG. 3) located near to the production zone. If the heavy crude refining plant is too far away from the production zone, the crude containing the gas can be transported under pressure. CO 2 , which noticeably decreases the viscosity of heavy oil, advantageously replaces a fluxing agent.
Comparative tests have been carried out in the laboratory on oil-impregnated cores selected and suited to represent a fractured reservoir. They were placed in a containment cell associated with a pressurized fluid circulation system of the same type, for example, as those described in patents FR-2,708,742 (U.S. Pat. No. 5,679,885) or FR-2,731,073 (U.S. Pat. No. 5,679,885) filed by the applicant, and subjected to various tests wherein they were swept by a gas phase under the aforementioned gas saturation or oversaturation conditions. These tests have allowed to show the efficiency of the process according to the invention.
For the same temperature, it has been observed that an increasing concentration of CO 2 in the carbonate water induces a great increase in the recovery of the oil in place. This increase is very marked when the sweep fluid is oversaturated with gas. | Process intended for enhanced recovery of a petroleum fluid by combined injection of an aqueous phase saturated with acid gases. The process esentially consists in continuously injecting, into the oil reservoir, a mixture of an aqueous phase and of a gas at least partially soluble in the aqueous phase and at least partially miscible with the petroleum fluid, by controlling the ratio of the flow rates of the aqueous phase and of the gas so that the latter is always in a state of saturation or oversaturation at the bottom of the injection well(s). The aqueous phase saturated or oversaturated with gas comes into contact with the petroleum fluid present in the reservoir. The gas dissolved in the aqueous phase is at least partially transferred to the liquid hydrocarbon phase, thus causing swelling and viscosity reduction of this phase, which favors migration of the petroleum fluid towards a production zone. Acid fractions of effluents coming from the subsoil or from chemical or thermal industries are preferably used as such gases. The process can be applied for an enhanced recovery of hydrocarbons in reservoirs. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60/636,083, filed Dec. 15, 2004.
SEQUENCE LISTING
[0002] Non-Applicable.
BACKGROUND—FIELD OF INVENTION
[0003] This invention relates to an aerodynamic means that mitigate wind generated vortices and wind loads in the wall edge areas of a building, in a simple, effective, and economical way, applicable for both new constructions and retrofits of existing buildings.
BACKGROUND—DISCUSSION OF PRIOR ART
[0004] Conventional wall construction practices normally result in a wall edge configuration that tends to generate strong edge vortex and subjects the wall edge area to severe outward suction loads and high risk of wind induced damage. Traditionally, structural strengthening methods have been relied upon, to counter this severe suction force and mitigate damage risk. The wall edge vortex suppressor disclosed herein functions to reduce the suction force and thus mitigates wind damage risk, through passive flow control techniques that eliminate or suppress the wall edge vortex, which is the prime cause for the high suction force.
SUMMARY OF THE INVENTION
[0005] This invention discloses an aerodynamic means that mitigate strong vortices and high loads induced by wind on the wall edge area of a building, in a simple, effective, and economical way, applicable and convenient for both new constructions and retrofits of existing buildings. This is achieved by using elongated devices of appropriate configurations mounted along a wall edge, therefore to intervene with the wind flow and suppress edge vortex. Examples of such configurations include wall edge cap, windscreen and wind spoiler. These devices primarily comprise of elongated members mounted to a wall edge and defining a new exterior configuration of a building corner, and appropriate means to attach and secure the elongated member to a building corner.
[0006] Herein wall edge refers to an edge at which two terminating wall surfaces intersect at an approximately right angle and form a convex corner of a building. Vortex formation and extreme wind load are inherent around a building corner, where abrupt change in wall surface orientation occurs along the flow path such that the accelerated wind flow around a corner severely separates from the downstream wall surface. A wall edge vortex suppressor intervenes and modifies the wind flow around the corner of a building. It mitigates flow separation, prevents vortex formation or suppresses its strength, and ultimately reduces the wind force exerted on the wall area adjacent to the edge where most initial wind damages to a wall system occur.
OBJECTS AND ADVANTAGES
[0007] Several objects and advantages of the present invention are:
to provide wall edge devices which suppress edge vortex formation and reduce wind loads on wall cladding in a building corner area; to provide wall edge devices which reduce wind loads generally on a wall system that are transferred from the wall cladding; to provide wall edge devices which stabilize wind flow around wall corners and minimize cyclic loads on wall components resulting from recurring winds, reducing the chances of damage due to material fatigue; to provide wall edge devices which possess the desired aerodynamic performance for a more wind resistant building structure while maintaining aesthetic and waterproofing functionality under both extreme and recurring weather conditions.
[0012] Further objects or advantages are to provide wall edge devices which protect a wall system from wind and rain damage, and which are still among the simplest, most effective and reliable, and inexpensive to manufacture and convenient to install. These and still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 schematically shows a cross-sectional view for one of the preferred embodiments of wall edge cap, being mounted to both sides of a wall edge.
[0014] FIG. 2 illustrates an alternative configuration of wall edge caps, being mounted to each side of a wall edge separately.
[0015] FIG. 3 schematically shows a cross-sectional view for one of the preferred embodiments of wall edge windscreen. FIG. 3A is view 3 A from FIG. 3 , exemplifying face perforation and edge serration of a windscreen.
[0016] FIG. 4 exemplifies alternative configuration of wall edge windscreens.
[0017] FIG. 5 schematically shows a cross-sectional view for one of the preferred embodiments of wall edge wind spoiler. FIG. 5A is view 5 A from FIG. 5 , exemplifying an longitudinally continuous support with face perforation for a wind spoiler.
[0018] FIG. 6 illustrates an alternative configuration of wall edge wind spoilers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIG. 1 illustrates a preferred configuration of wall edge cap 10 , in a cross-sectional top view. The wall edge cap's arch shape, or any other similar shape of gradual slope change or modest curvature, eliminates or reduces the abrupt change in surface orientation along the flow path around a building corner 105 where two exterior wall surfaces 100 intersect. This will mitigate edge vortex formation and result in the reduction of aerodynamic forces, primarily the outward suction force, exerted on the downwind wall areas adjacent to the edge. Multiple straight segments can also be used to approximate an arched exterior shape for a wall edge cap. The exterior surfaces of the wall edge cap can be optionally perforated to enhance the device's vortex-suppressing effects, as described for edge screens later in this application.
[0020] Any appropriate means to attach and secure the devices to wall surfaces are allowable if it does not significantly affect or alter the exterior shape of the device in a way that detriments the vortex-suppressing function. For example, a set of cleats and fasteners 80 as illustrated in FIG. 1 can be used for securing the apparatus.
[0021] FIG. 2 shows an alternative configuration of a wall edge cap assembly 20 that functions in a similar fashion as that illustrated in FIG. 1 . Multiple straight segments can also be used to approximate the curved exterior shape.
[0022] FIG. 3 illustrates a preferred configuration of wall edge screen 30 in a cross-sectional top view. The perforated face protrudes outwardly from the wall corner 105 , preferably along the axis of symmetry. The wall edge screen employs a venting mechanism to suppress the vortex formation and vortex induced suction force. The perforated face of a wall edge screen generally reduces the flow acceleration around the corner. At the same time it facilitates pressure equalization across the screen face and around the wall corner 105 through a “bleeding” or venting effect, which prevents vortex formation around and behind the outer edge of the windscreen. It also breaks the flow around the corner down to small, random and unorganized eddies, and leads to dissipation of kinetic energy. Optional outer edge serration of the windscreen provides similar effects of flow breakdown and kinetic energy dissipation. View 3 A form FIG. 3 is shown in FIG. 3A to illustrate an example for face perforation and edge serration of a wall edge windscreen.
[0023] FIG. 4 shows an alternative configuration of a wall edge windscreen assembly 40 . The perforated faces form an approximately symmetrical arrangement, each forming an angle to a wall 100 . Although, the perforated face shown here forms a right angle to a wall surface, the acceptable angles range from the limit case as in FIG. 3 (aligning with axis of symmetry) to that of about 45° with respect to the wall on the same side.
[0024] FIG. 5 illustrates a preferred configuration of wall edge wind spoiler 50 , again in a cross-sectional top view. The wind spoiler uses yet another mechanism to mitigate vortex formation around a wall corner 105 of a building. The raised and bent spoiler plate 52 forces the wind flow around the wall corner to conform approximately to the exterior wall surfaces, and thus suppresses flow separation and vortex formation. The resulting effect is the reduction of the wind suction force on the wall area downwind of the wall corner 105 . A plurality of methods is suitable for supporting the raised spoiler plate to the wall corner, as long as the support members do not collectively obstruct the airflow path between the raised spoiler plate and the wall corner. A preferred option is to use significantly perforated, longitudinally continuous, plate-like supports 54 as exemplified in FIG. 5A , which provide additional effects of flow breakdown and kinetic energy dissipation as described above for edge windscreens.
[0025] FIG. 6 shows an alternative configuration to form an edge wind spoiler assembly 60 . The raised and bent plates 62 can be configured with multiple straight segments as shown herein or with curved ones. The end segment of the raised plate shall preferably be approximately in parallel with one of the walls 100 secured thereto. The perforated double plates 64 serve as supports to the raised plate segments and as a corner wind screen.
[0026] The devices can be made of any durable materials that provide mechanical strength and stiffness sufficient to sustain high winds and other weather elements over time. These include, but are not limited to, sheet metal, acrylic, and for the edge cap treated solid wood, etc. Extrusion, or cold form where applicable or other appropriate methods, can be used to manufacture the devices. A generally symmetric shape is preferred for a wall edge vortex-suppressing device in that wind can come from either side of a building corner. However, deviation from a symmetric configuration is allowable for any practical purposes as far as the alteration does not deviate from the spirit of this disclosure for wall edge vortex-suppressing devices.
[0000] Installation and Operation
[0027] Any appropriate means to attach and secure the devices to wall surfaces are allowable if it does not significantly affect or alter the exterior shape of the device in a way that detriments the vortex-suppressing function. For example, a set of cleats and fasteners can be used for securing the apparatus to the wall, as illustrated in the above figures.
[0028] An embodiment of this invention is a passive flow control device for wall edges. Once configured and installed properly, it stays functioning in such a way that it mitigates vortex formation around a wall edge and reduces wind loads on the wall, whenever the wind blows towards a building bearing such wall edge devices, and requires no active operational intervention.
CONCLUSION, RAMIFICATIONS, AND SCOPE
[0029] It is apparent that wall edge vortex suppressors of this invention provide advantageous devices for mitigating wall edge vortex and wall suction, and are still among the simplest, most effective and reliable, inexpensive to manufacture and convenient to install, with little, if any, maintenance required.
[0030] The present invention provides a simple and unique method for improving building wind resistance, not only suitable for new constructions but also for retrofit on existing buildings.
[0031] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various changes, modifications, variations can be made therein without departing from the spirit of the invention. Wall edge vortex suppressors can be made of any reasonably durable material with any appropriate means of fabrication as long as a configuration according to the spirit of this invention is accomplished to support the described working mechanism and to provide the associated functionality. Any appropriate conventional or new mounting method can be used to secure a wall edge vortex suppressor to a building corner without departing from the spirit of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | An apparatus disposed along and attached to a wall edge to mitigate wind-generated vortices and suction loads on the wall, suitable and convenient for both new constructions and retrofits of existing buildings. Preferred configurations are described and include such types as wall edge cap, wall edge windscreen and wall edge wind spoiler, each utilizing a distinctive primary aerodynamic mechanism, often with optional secondary mechanisms to enhance vortex-suppressing effects. | 4 |
The present invention relates to an erogenic stimulator with a suction cup and optionally with an associated chamber for either suction control or insertion of a vibrating unit.
BACKGROUND OF THE INVENTION
This invention pertains to sexual or erogenous stimulation devices in general and, more particularly, to a self-retained device for simultaneous use by two sexual partners such that the erotic areas of both such users are concurrently excited.
GENERAL BACKGROUND
Marital or sexual aids have been known and used throughout the centuries. Generally, such aids have been designed either for self-stimulation or for the stimulation of one party only. However, some aids satisfy two partners at the same time. This latter type of aid or stimulators is designed primarily for use by a female user and often incorporates a flexible phallic shaped stimulator secured to a base. Variations of this type of stimulator include two such phallic shapes linearly secured to opposite sides of a common or intermediate flange. Unfortunately, because of the co-linear nature of these opposite shapes, the simultaneous use of such a device by two partners requires some gymnastic-like maneuvers.
Also, it is common for these devices to not be self-retaining, that is, when one end is retained in the vagina or anal cavity, the other end is free to stimulate of the other person. Instead, these devices rely upon a series of straps in order to hold and retain the device in place on one user for proper use on the other person. However, fastening such straps prior to use is cumbersome and discomforting and causes undesirable delay.
U.S. Pat. No. 5,690,603 to Kain discloses a self-retaining stimulator, that is, when one end is retained in the vagina or anal cavity, the other end is free to stimulate the other person.
OBJECTS OF THE INVENTION
It is thus an object of the present invention to provide a marital or sexual aid that is capable of simultaneously stimulating the erotic areas of both users.
It is a further object of this invention to provide an aid that is self-retaining such that straps or other holding devices are not required, thereby eliminating any delay and discomfort.
A further object of this invention is to provide a device that is capable of being used by partners of the same sex or of the opposite sex.
Still another object of this invention is to provide a device that is capable of flexing as needed but which returns to its original position upon its release.
Yet another object of this invention is to provide an aid that is smoothly contoured for comfort.
An additional object is to stimulate the clitoris of one of the users with a suction element during sexual play with the stimulator.
A further object of the present invention is to develop a suction chamber which co-acts with the suction element thereby enhancing the sexual play with the stimulator.
SUMMARY OF THE INVENTION
In one embodiment, the erogenic stimulator includes a first elongated, resilient, cylindrical end region (typically a phallic shape) with a first end extending from a proximal base end and a second resilient, cylindrical, bulbous end region also extending from a proximal base end. The bulbous distal end is connected via a reduced diameter neck to that base. The base is further connected to the first end region. The base, the first phallic end and the second bulbous end extend upwards from the base forming a truncated substantially U-shaped stimulator. The stimulator includes a concave suction element on the base in a curved portion of the truncated U-shape. Other features include: a passageway from that bottom of the concave suction element through said base, into which may be inserted either a plug or a vibratory element. The plug/vibratory element closes the base end of the passageway thereby permitting expansion and contraction of the passageway dependent upon a predetermined condition of the suction opening of the passageway. If the suction element contacts the skin or erogenous region of one user and the plug/vibratory element blocks the passageway, a rocking or undulation of the stimulator suctions and evacuates, alternatively, air through the suction opening of the passageway. This suction and evacuation of air further energizes the skin or erogenous region of the user. The base may have a cut-away for removal of the plug/vibratory element.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects of the present invention can be found in the detailed description of the preferred embodiments when taken in conjunction with the accompanying drawings in which:
FIG. 1 diagrammatically illustrates a side elevational view of the erogenic stimulator aid including both the suction cup as well as the suction passageway and vibrator or closure plug;
FIG. 1B shows the removable plug or vibrating element to be disposed within the passageway;
FIG. 1C and FIG. 1D diagrammatically illustrate a stepped passageway and a treaded passageway;
FIG. 1E diagrammatically illustrates a one-way valve in the passageway;
FIG. 2 diagrammatically illustrates a front elevational view of the erogenic stimulator;
FIG. 3 diagrammatically illustrates a rear elevational view of the stimulator;
FIG. 4 diagrammatically illustrates a top view of the stimulator; and
FIG. 5 diagrammatically illustrates a bottom view of the stimulator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a erogenic stimulator or martial aid.
Similar numerals designate similar items throughout the drawings and specification. FIG. 1A diagrammatically illustrates stimulator 10 having a first elongated, resilient and generally cylindrical end region 12 . In the preferred embodiment, end region 12 has a phallic shape. First end region includes a first distal end 14 and a first proximal base end generally identified at end portion 16 . Stimulator 10 includes a second resilient and generally cylindrical end region 18 sized for receipt in an anal or vaginal cavity. Second end region 18 includes a second bulbous distal end 20 and a second proximal base end generally near portion 22 . This bulbous distal end 20 is connected via a reduced diameter neck portion or neck 24 between the bulbous end 20 and the second proximal base end 22 . The second end region includes the bulbous element, the neck and the base end 22 . Neck 24 enables bulbous end region 20 to flex thereat. Bulbous end 20 is adapted to permit the muscle groups of one of the partners using the stimulator to hold the second end in place during use. An alternative construct of the invention eliminates the neck and bulbous nature of second end 18 .
Stimulator 10 includes a base 30 connected intermediate first proximal base end 16 and second proximal base end 22 . First end region 12 and second end region 18 extend upwards from base 30 and forms a truncated, substantially U-shape stimulator. The U-shape is truncated since the second end region 18 is smaller in length then the first end region 12 . Hence one of the legs of the U-shaped stimulator is truncated or shorter compared to the other leg. The U-shaped stimulator has a curved region 33 . The U-shape of stimulator 10 may also be considered to be an L-shape due to the truncated nature of the bulbous end 18 . The L-shape is rotated such that the intersection between the upper leg of the L-shape and the base of the L-shape is the location of the suction cup 32 . Reference to a U-shaped stimulator is meant to cover an L-shaped stimulator herein.
A concave suction element 32 is mounted, attached or formed as part of the base in curved portion 33 of the truncated U-shape stimulator. Suction element 32 rises above or is formed on curve 33 of the U-shaped stimulator 10 . Concave suction element 32 has a outer rim 34 rising above surface 35 of curve portion 33 of the truncated U-shape stimulator in the preferred embodiment. Outer rim 34 may be a circle, oval, ellipse, triangle, square, polygon, rectangle or a diamond shape. The suction element may have a low rise rim and be primarily formed by a depression in base 30 .
Concave suction element 32 has an interior space 36 . In one embodiment (an alternative embodiment), a passageway 38 leads from the base of interior 36 of suction element 32 and extends outboard or away from the suction element 32 and exits base 30 opposite curve portion 33 of the concave U-shape stimulator. Accordingly, passageway 38 has a first opening at the base of suction element 32 and a second opening on base 30 opposite curve region 33 of the truncated U-shape.
A removable plug or a vibrating element 40 is sized to fit snugly within passageway 38 and to extend either fully or partially into passageway 38 as shown by arrow 41 in FIG. 1A . In order to assist the user to remove or insert removable plug/vibrator element 40 , base 30 may have a cut-away 50 about the second opening 49 of passageway 38 . One type of small, cylindrical vibratory element is a MAGIC BULLET vibrator. Passageway 38 may extend at various angles from suction element 32 . Auxiliary passageway 60 (an angled chamber) is shown in FIG. 1A with a dash-dot-dash line as an alternative route. Rather than a vertical passage, angled passageway 60 also works. Passageway 60 has an opening 61 generally opposite curved portion 33 of truncated U-shaped stimulator 10 . A cut-away 63 may also be provided at opening 61 of chamber 60 . Chamber 60 is sized to receive fully or partially a vibrating element. The vibratory element may be longer than passageway 38 , 60 . If the element slightly extends into the bottom of the suction element bowl 36 , removal is easier.
FIG. 1B shows that removable plug 40 or vibrating element 40 has been partially inserted into passage 38 .
In operation, one partner places bulbous distal end 20 in an anal or vaginal cavity and the first cylindrical end region 12 , preferably having a phallic shape, is inserted into an anal or vaginal cavity of the other partner.
When removal plug or vibratory unit 40 is inserted into passageway 38 , passageway 38 is partially closed. When in use, concave suction element 32 contacts the skin and erogenous zones of one of the partners. When suction element 32 (particularly rim 34 ) is in contact with skin or other erogenous body zone, and the stimulator 10 moves or rotates due to thrusting or rocking motion of one partner with respect to the other partner, suction is created and then released in truncated cavity 38 shown in FIG. 1B . Air is trapped when suction opening 37 is closed. If open, air is ejected from the passage. Thereafter upon close contact to the skin or erogenous zone, the passageway draws air therein enhancing the suction at element 32 . Without the passageway 38 , 60 , suction is developed by flexing action of cup 32 on the skin or erogenous zone. Therefore, the suction element 32 enhances the sexual play of the users. The degree of suction is controlled by the inserted location of plug or element 40 . The inclusion of a vibratory element 40 or a removable plug also affects the sexual play of the users. Cut-away 50 permits the plug to be removed or vibratory unit to be removed from chamber 38 . The predetermined condition of the suction opening (or suction cup rim) depends upon an open or closed position with respect to the skin or erogenous zone.
FIG. 1C shows that passageway 38 with at least one step 70 which may be used to seal the vibratory unit or the removable part securely in the passageway. Multiple steps may be used. FIG. 1D shows that passageway 38 is threaded. The steps may provide a tactile indication of plug/vibrator depth.
FIG. 1E diagrammatically illustrates a one-way valve 50 in the passageway 38 . The valve and valve stem 50 may be similar to the one-way valve and valve stem used on beach balls and other common manually inflatable items. The common valve and valve stem 50 extends from the distal end of passage 38 . When cap 54 is withdrawn from the cap seat on the valve stem 56 , air may flow out of passageway 38 due to compression at suction cup end 32 , 34 . The one way air valve 50 permits flow of air outbound from passage 38 . One way valve 50 is opened when radial compression is applied to stem region 56 , which compression opens valve 52 in the stem. Operationally, when the valve cap 54 is withdrawn from the valve stem seat, air may flow outboard of the passageway 38 , but not inward into the passageway due to the one-way action of valve 52 . When the cap is on the valve stem seat, air flow is generally prohibited.
FIG. 2 shows a front elevational view of stimulator 10 with cutout 50 in the base 30 and shows the location of exit opening 49 of passageway 38 .
FIG. 3 shows a rear view of stimulator 10 .
FIG. 4 is a top view showing stimulator 10 and generally round or oval rim 34 of suction element 32 .
FIG. 5 is a bottom view of stimulator 10 shown through passage 38 .
Stimulator 10 may be constructed of a rather rigid material such as hard plastic, rubber, or the like. However, it is preferable for stimulator 10 to be constructed of a more compressible or resilient material, such as soft plastic or a foam material, of the type that is capable of retaining its shape and rigidity during use, but which is not so un-bending or inflexible as to be uncomfortable. Silicone is a good material to use. Also, an outer continuous covering or coating which is both smooth and slippery over such material would further enhance the enjoyment of stimulator 10 . Preferably, stimulator 10 is a unitary item wherein the base, the first end region and the bulbous second end region are all one piece and all made of the same flexible resilient material. Finally, it is anticipated that the angles of the legs of the truncated U-shape, that is, the general angle between the phallic end and bulbous end, would be in the range of from 60 to 80 degrees, more or less, so as to provide the most comfort during use, however, such angle may be as sharp as 45 degrees or as great as 90 degrees in some instances.
Of course, the actual length and diameter of phallic end and bulbous end can vary as needed depending on the needs of the partners. In this fashion, it is anticipated that different sizes of these ends can be offered which correspond with different sizes of the suction element and the neck portion or region so that stimulator 10 can conform to the needs and comfort levels of the intended users. The base at the curved region of the truncated U-shape may be larger or smaller than shown in relation to the phallus end and the bulbous end.
The claims appended hereto are meant to cover modifications and changes within the scope and spirit of the present invention. | The erogenic stimulator includes a first resilient end region (phallic) extending from a base and a second resilient bulbous end region extending therefrom. The bulbous end is connected via a reduced diameter neck to the base. The base and first and second ends form a truncated substantially U-shaped stimulator. A concave suction element is formed on the base in the curved portion of the U-shape. A passageway may be included from the concave suction element through the base into which may be inserted either a plug or a vibratory element. The plug/vibratory element closes the base end of the passageway thereby permitting expansion and contraction of the passageway dependent upon a predetermined condition at the suction opening of the passageway. If the suction element contacts the skin or an erogenous region and blocks the passageway, the rocking stimulator suctions and evacuates, alternatively, air through the suction opening of the passageway. | 0 |
This is a continuation of copending application Ser. No. 07/881,615 filed on May 12, 1992.
FIELD OF THE INVENTION
This invention relates to the continuous casting and rolling of slabs and more particularly to an integrated intermediate thickness caster and a hot reversing mill.
BACKGROUND OF THE INVENTION
Since the advent of the continuous casting of slabs in the steel industry, companies have been trying to marry the hot strip mill to the continuous caster through an inline arrangement so as to maximize production capability and minimize the equipment and capital investment required. The initial efforts in this regard consisted of integrating continuous casters producing slabs on the order of 6 inches to 10 inches with existing continuous or semi-continuous hot strip mills. These existing hot strip mills included a reheat furnace, a roughing train (or a reversing rougher) and a six or seven stand finishing mill with a capacity of 11/2 to 5 million tons per year. This mill arrangement is the present day design of large steel company mills and it is unlikely that new hot strip mills of this design would ever be built due to the high capital cost. However, the quest for low cost integrated caster-hot strip mills is not solved by current designs. Further, such prior art integrated mills were extremely inflexible as to product mix and thus market requirements.
These difficulties gave rise to the development of the so-called thin slab continuous hot strip mill which typically produces 1,000,000 tons of steel per year as specialized products. These mills have been integrated with thin slab casters on the order of 2 inches or less. Such integrated thin slab casters are enjoying increased popularity but are not without serious drawbacks of their own. Significant drawbacks include the quality and quantity limitations associated with the so-called thin slab casters. Specifically, the trumpet type mold necessary to provide the metal for the thin slab can cause high frictional forces and stresses along the surface of the thin wall slab which leads to poor surface quality in the finished product. Further, the 2 inch strip casters are limited to a single tundish life of approximately 7 heats because of the limited metal capacity of the mold.
Most importantly, the thin casters by necessity have to cast at high speeds to prevent the metal from freezing in the current ladle arrangements. This, in turn, requires the tunnel furnace which is just downstream of the slab caster to be extremely long, often on the order of 500 feet, to accommodate the speed of the slab and still be able to provide the heat input to a thin slab (2 inches) which loses heat at a very high rate. Since the slab also leaves the furnace at a high speed, one needs the multistand continuous hot strip mill to accommodate the rapidly moving strip and roll it to sheet and strip thicknesses. However, such a system is still unbalanced at normal widths since the caster has a capacity of about 800,000 tons per year and the continuous mill has a capacity of 2.4 million tons/year. The capital cost then approaches that of the earlier prior art systems that it was intended to replace.
In addition, the scale loss as a percentage of slab thickness is substantial for the 2 inch thin cast slab. Because of the extremely large furnace, one must provide a long roller hearth which becomes very maintenance intensive because of the exposed rotating rollers.
The typical multistand hot strip mill likewise requires a substantive amount of work in a short time which must be provided for by larger horsepower rolling stands which, in some cases, can exceed the energy capabilities of a given area, particularly in the case of emerging countries. Thin slab casters likewise are limited as to product width because of the inability to use vertical edgers on a 2 inch slab. In addition, such casters are currently limited to a single width. Further problems associated with the thin strip casters include the problems associated with keeping the various inclusions formed during steelmaking away from the surface of the thin slab where such inclusions can lead to surface defects if exposed. In addition, existing systems are limited in scale removal because thin slabs lose heat rapidly and are thus adversely effected by the high pressure water normally used to break up the scale.
In addition, this thin strip process can only operate in a continuous manner, which means that a breakdown anywhere in the process stops the entire line often causing scrapping of the entire product then being processed.
It is an object of our invention to integrate an intermediate thickness slab caster with a hot reversing mill. It is a further object to adopt a system which balances the rate of the caster to the rate of the rolling mill. It is also an object of our invention to adopt a system using less thermal and electrical energy. It is still a further object to adopt an automated system with small capital investment, reasonable floor space requirements, reasonably powered rolling equipment and low operating costs.
SUMMARY OF THE INVENTION
Our invention provides for a versatile integrated caster and mini-mill capable of producing on the order of 650,000 finished tons a year and higher. Such a facility can produce product 24" to 120" wide and can routinely produce a product of 800 PIW with 1000 PIW being possible. This is accomplished using a casting facility having a fixed and adjustable width mold with a straight rectangular cross section without the trumpet type mold. The caster has a mold which contains enough liquid volume to provide sufficient time to make flying tundish changes, thereby not limiting the caster run to a single tundish life. Our invention provides a slab approximately twice as thick as the thin cast slab thereby losing much less heat and requiring a lesser input of Btu's of energy. Our invention provides a slab having a lesser scale loss due to reduced surface area per volume and permits the use of a reheat or equalizing furnace with minimal maintenance required. Further, our invention provides a caster which can operate at conventional caster speeds and conventional descaling techniques. Our invention provides for the selection of the optimum thickness cast slab to be used in conjunction with a hot reversing mill providing a balanced production capability. Our invention has the ability to separate the casting from the rolling if there is a delay in either end. In addition, our invention provides for the easy removal of transitional slabs formed when molten metal chemistry changes or width changes are made in the caster.
All of the above advantages are realized while maintaining the advantages of a thin caster which include low ferrostatic head, low weight of slab, straight molds, shorter length molds, smaller required mold radius, low cooling requirements, low burning costs or shear capacity, and simplified machine constructions.
Our invention provides an intermediate thickness slab caster integrated with a hot strip and plate line which includes a reheat or equalizing furnace capable of receiving slabs directly from the caster, from a slab collection and storage area positioned adjacent the slab conveyor table exiting the continuous caster or from another area. A feed and run-out table is positioned at the exit end of the reheat furnace and inline with a hot reversing mill having a coiler furnace positioned on either side thereof. The mill must have the capability of reducing the cast slab to a thickness of about 1 inch or less in 3 flat passes. The combination coil, coiled plate, sheet in coil form or discrete plate finishing line extends inline and downstream of the hot reversing mill with its integral coiler furnaces. The finishing facilities include a cooling station, a down coiler, a plate table, a shear, a cooling bed crossover, a plate side and end shear and a piler.
To achieve the necessary balance between the hot reversing mill and the caster, it is necessary to produce slabs having a thickness between 3.5 inches to 5.5 inches, preferably between 3.75 inches to 4.5 inches, and most preferably to about 4 inches. The slabs are reduced to about 1 inch or less in 3 flat passes on the hot reversing mill before starting the coiling of the intermediate product between the coiler furnaces as it is further reduced to the desired finished product thickness. In order to provide the capability of making coiled plate, discrete plate and sheet in coil form up to 1000 PIW and higher, slab width may vary from 24 to 120 inches.
A preferred method of operation includes feeding a sheared or torch cut slab from the caster onto a slab table which either feeds directly into a reheat or equalizing furnace or into a slab collection and storage area adjacent to the slab table. The preferred method further includes feeding the slab directly into the furnace from the slab table. However, the method allows for the feeding of a previously collected and stored slab into the furnace for further processing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the prior art thin strip caster and continuous hot mill;
FIG. 2 is a schematic illustrating the intermediate thickness strip caster and inline hot reversing mill and coiler furnace arrangement;
FIG. 3 is a time-temperature graph for a two inch thick slab from solidification to rolling;
FIG. 4 is a time-temperature graph for a four inch thick slab from solidification to rolling; and
FIG. 5 is a bar chart comprising the peak power demands of the subject invention to a thin strip caster and continuous rolling mill.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The prior art thin strip caster and inline continuous hot strip mill is illustrated in FIG. 1. The slab caster 10 consists of a curved trumpet mold 12 into which molten metal is fed through entry end 14. An electric furnace, the ladle station and the tundish (not shown) which feeds the continuous caster 10 are also conventional. The slab caster 10 casts a strand on the order of 2 inches or less which is cut into slabs of appropriate length by a shear or a torch cut 16 which is spaced an appropriate distance from the curved mold 12 to assure proper solidification before shearing. The thin slab then enters an elongated tunnel furnace 18 where the appropriate amount of thermal input takes place to insure that the slab is at the appropriate temperature throughout its mass for introduction into the continuous hot strip 20 located downstream of the tunnel furnace. The typical continuous hot strip 20 includes five roll stands 21 each consisting of a pair of work rolls 23 and a pair of backup rolls 24. Roll stands 21 are spaced and synchronized to continuously work the slab through all five roll stands. The resultant strip of the desired thickness is coiled on a downcoiler 22 and is thereafter further processed into the desired finished steel mill product.
The thin strip caster and continuous hot strip mill enjoy many advantages but have certain fundamental disadvantages, such as no room for error in that the continuous hot strip mill is directly integrated with the caster with no buffer therebetween to accommodate for operating problems in either the caster or the continuous hot strip mill.
In addition, the thermal decay is substantially greater for a two inch slab as compared to a four inch slab. This then requires a long tunnel furnace for the two inch slab to assure the appropriate rolling temperature. This is illustrated in FIG. 3 where the energy requirements expressed through a temperature-time curve for a two inch slab is illustrated. With a two inch thick cast slab, the mean body temperature of the as-cast slab is only 1750° F., which is too low a temperature to begin hot rolling. Since there is virtually no reservoir of thermal energy in the center of the slab due to its thin thickness, additional heat energy is required to attain the required mean body temperature of 2000° F. for hot rolling. Accordingly, since the thin slab is approximately 150 ft. long, it generally is heated in a long tunnel furnace. Such a furnace must provide the heat energy of approximately 120,000 BTU per ton to bring the steel up to a mean body temperature of 2000° F. for hot rolling and in addition, provide additional energy to establish the necessary heat gradient required to drive the heat energy into the slab in the time dictated by the two inch caster/rolling mill process.
Specifically, FIG. 3 represents the subject matter discussed above. FIG. 3 represents the energy required to heat a 2" slab to 2000° F. in a tunnel furnace. The area between points A and B under the curve represents the additional energy required to force the temperature of the slab to 2000° F. Further, point A is at 1750° F. and represents the mean body temperature of the slab prior to entering the tunnel furnace. Point B represents the 2000° F. rolling temperature. Additionally, the cross-hatched area between points A, B, and C represents the energy added to the slab (approximately 120,000 btu/ton) to raise the mean body temperature.
In addition, while the two inch thick slab is travelling slowly through the tunnel furnace, the atmosphere of the furnace is forming "mill scale" on the exposed surface of the thin slab. This mill scale is detrimental to the quality of the finished sheet and most difficult to remove prior to rolling. Often the mill scale is rolled into the slab by the multistand continuous mill. Ordinarily, mill scale can be removed by the aggressive application of high pressure water sprays. However, with the two inch thick slab, such sprays will tend to quench the steel to an unacceptable temperature for rolling defeating the reheating process. On the other hand, the four inch slab is, of course, one half the length and has one half of the exposed surface and accordingly less of a build-up of scale. Further, this scale can be easily removed by the high pressure water sprays without affecting the slab temperature due to the reservoir of heat energy inside the four inch slab as discussed hereinafter.
As with the two inch thick slab, during the casting process external cooling is used to create a solid shell to contain the liquid core, which is essentially at the tundish temperature of 2800° F. As the shell builds up, the liquid core is consumed and the slab becomes solid through its thickness. This established the metallurgical length of the caster. For a four inch slab, there is a temperature gradient from the center of the slab (2800° to 2600° F.) to the surface, with a mean temperature of 2300° F., see FIG. 4. If the slab is now put into an isothermal enclosure, the high internal temperature gradient that was necessary to remove the solidification enthalpy, provides sufficient thermal energy to affect a mean slab body temperature of 2000° F. This equalization process, in the isothermal enclosure, is effected immediately after the cast slab has solidified and is cut to length prior to the entry into the furnace.
The time required to do this is determined by the square of the distance the heat must diffuse (at most, half the slab thickness) and the thermal diffusivity of the solidified mass. Because the mean body temperature before equalization was 2300° F. and the mean body temperature after equalization need only be 2000° F. to permit the steel to be hot rolled, there is an excess enthalpy of about 120,000 BTU's per ton of steel. This heat energy can be used to maintain the integrity of the isothermal enclosure, that is, compensate for losses associated with establishing the isothermal environment within the enclosure and accordingly, little or no external heating of the enclosure is required.
FIG. 4 represents, in particular, the isothermal equalizing enclosure for a 4" thick slab for a rolling mill furnace. The line between points D and E represents entrance to the equalizing enclosure. Point A represents the 2300° F. mean body temperature and point B represents the 2000° F. rolling temperature. The line between points A and B represents the isothermal environment and the cross-hatched area represents the stored energy in a slab of approximately 120,000 btu/ton.
One of the distinct advantages of this invention is the lower electric power costs of the subject invention as compared to the two inch thick caster/continuous rolling mill as previously described and similar processes. FIG. 5 illustrates this point by comparing the peak power surges (19000 kilowatts) of the multistand continuous rolling mill to the peak (9000 kilowatts) for the reversing mill of this invention. Since the power company's billing contract consists of two parts--"demand" and "consumed power", it is the "demand" portion that is the most costly when the process requires high peak loads over a short period of time. High demand equates to higher power costs. FIG. 5 illustrates four coils being rolled from a two inch slab at the high peak loads on a four stand finishing mill in about the same time it takes to roll two coils from a four inch slab at the lower peak loads on the hot reversing mill in nine passes each.
Additionally, and perhaps of more importance, is the fact that many power companies cannot provide for the high peak loads, as illustrated in FIG. 5, due to the limits of generator and line capacity. This is of particular concern to emerging countries where the power grids are weak and the transmission lines are long. This invention is directed to solving this problem, by providing emerging countries with a low capital cost productive mini mill steel plant compatible with their present power systems and existing infrastructure.
FIG. 5 represents, specifically, a comparison of peak rolling loads of 2" and 4" continuous cast slabs. The area underneath the four large cyclical peaks represents the kilowatts (in thousands) required for a multi stand continuous finishing mill with a slab of 2"×46.6"×148 ft.--1000 piw--rolled to 0.100" thick. The two sets of smaller peaks represent the kilowatts (in thousands) required for a hot reversing mill for a 4"×46.6"×75 ft.--1000 piw--rolled to 0.100" thick.
Even in sophisticated systems where demand gets averaged over say 15 minute intervals, the demand for a four or five stand continuous finishing mill receiving a two inch slab is still substantially greater than for a hot reversing mill receiving a four inch slab.
The intermediate thickness slab caster and inline hot strip and plate line of the present invention is illustrated in FIG. 2. One or more electric melting furnaces 26 provide the molten metal at the entry end of our combination caster and strip and plate line 25. The molten metal is fed into a ladle furnace 28 prior to being fed into the caster 30. The caster 30 feeds into a mold (curved or straight) 32 of rectangular cross section.
A torch cutoff (or shear) 34 is positioned at the exit end of the mold 32 to cut the strand of now solidified metal into a 3.5 to 5.5 inch thick slab of the desired length which also has a width of 24 to 120 inches.
The slab then feeds on a table conveyor 36 to a slab takeoff area where it is directly charged into a furnace 42 or is removed from the inline processing and stored in a slab collection and storage area 40. The preferred furnace is of the walking beam type although a roller hearth furnace could also be utilized in certain applications. Full size slabs 44 and discrete length slabs 46 for certain plate products are shown within walking beam furnace 42. Slabs 38 which are located in the slab collection and storage area 40 may also be fed into the furnace 42 by means of slab pushers 48 or charging arm devices located for indirect charging of walking beam furnace 42 with slabs 38. It is also possible to charge slabs from other slab yards or storage areas. Because the intermediate thickness slabs retain heat to a much greater extent than the thin slabs, temperature equalization is all that is required in many modes of operation. Of course, where slabs are introduced from off line locations, the furnace must have the capacity to add BTU's to bring the slabs up to rolling temperatures.
The various slabs are fed through the furnace 42 in conventional manner and are removed by slab extractors 50 and placed on a feed and run back table 52. Descaler 53 and/or a vertical edger 54 can be utilized on the slabs. A vertical edger normally could not be used with a slab of only 2 inches or less.
Downstream of feed and run back table 52 and vertical edger 54 is a hot reversing mill 56 having an upstream and a downstream coiler furnace 58 and 60, respectively. Cooling station 62 is downstream of coiler furnace 60. Downstream of cooling station 62 is a coiler 66 operated in conjunction with a coil car 67 followed by a plate table 64 operated in conjunction with a shear 68. The final product is either coiled on coiler 66 and removed by coil car 67 as sheet in strip or coil plate form or is sheared into plate form for further processing inline. A plate product is transferred by transfer table 70 which includes a cooling bed onto a final processing line 71. The final processing line 71 includes a plate side shear 72, plate end shear 74 and plate piler 76.
The advantages of the subject invention come about as the result of the operating parameters employed. The cast strand should have a thickness between 3.5 inches to 5.5 inches, preferably between 3.75 inches to 4.5 inches and most preferably to about 4 inches thick. The width can generally vary between 24 inches and 100 inches to produce a product up to 1000 PIW and higher.
The slab after leaving walking beam furnace 42 is flat passed back and forth through hot reversing mill 56 in no more than three passes achieving a slab thickness of about 1 inch or less. The intermediate product is then coiled in the appropriate coiler furnace, which in the case of three flat passes would be downstream coiler furnace 60. Thereafter, the intermediate product is passed back and forth through hot reversing mill 56 and between the coiler furnaces to achieve the desired thickness for the sheet in coil form, the coil plate or the plate product. The number of passes to achieve the final product thickness may vary but normally may be done in nine passes which include the initial flat passes. On the final pass, which normally originates from upstream toiler furnace 58, the strip of the desired thickness is rolled in the hot reversing mill and continues through the cooling station 62 where it is appropriately cooled for coiling on a coiler 66 or for entry onto a plate table 64. If the product is to be sheet or plate in coil form, it is coiled on coiler 66 and removed by coil car 67. If it is to go directly into plate form, it enters plate table 64 where it is sheared by shear 68 to the appropriate length. The plate thereafter enters a transfer table 70 which acts as a cooling bed so that the plate may be finished on finishing line 71 which includes descaler 73, side shear 72, end shear 74 and piler 76.
The following Examples illustrate the wide range of products that can be produced. It should be noted that the entry temperature into the rolling mill is necessarily higher (2300° F.) for the wider slabs than for the more narrow product widths (about 2000° F.) which more narrow widths in most facilities would represent the bulk of the product requirements.
EXAMPLE 1
A 74 inch wide×0.100 inch thick sheet in coil form is produced from a 4 inch slab of low carbon steel in accordance with the following rolling schedule:
__________________________________________________________________________EXAMPLE 137.193 tons 1005.PIWRolling Schedule HSM - 74.00-4.0000/.1000__________________________________________________________________________Mill Bite Strip ElapsedStand Gauge % Draft Angle Length Speed TimeName in. Red in. Deg. ft. FPM sec.__________________________________________________________________________FCE: 4.0000 .0 .0000 .00 74.00 .0 .00CM1: 2.6000 35.0 1.4000 17.57 113.85 628.0 15.88CM2: 1.5000 42.3 1.1000 15.56 197.33 628.0 39.73CM3:.8000 46.7 .7000 12.40 370.00 628.0 81.65CM4:.4518 43.5 .3482 8.74 655.15 700.0 144.56CM5:.2888 36.1 .1630 5.98 1024.84 950.0 216.66CM6:.2000 30.8 .0889 4.41 1480.22 1300.0 293.23CM7:.1467 26.6 .0533 3.42 2017.95 1500.0 382.69CM8:.1170 20.2 .0297 2.55 2529.91 1500.0 492.64CM9:.1000 14.5 .0170 1.93 2960.00 1500.0 611.04__________________________________________________________________________Mill Entry Exit Roll RMSStand Gauge Temp. Temp. Force Torque Horse Load TimeName in. Deg. F. Deg. F. lb × 10**6 lb-ft × 10**6 Power Ratio sec.__________________________________________________________________________FCE: 4.0000 2300.00 2300.00 .0000 .0000 0. .0000 .00CM1: 2.6000 2239.67 2241.03 4.1612 1.5802 24058. 2.0049 43.72CM2: 1.5000 2193.75 2201.54 4.6819 1.5727 23944. 1.9953 75.06CM3:.8000 2082.49 2084.68 5.4107 1.4435 21978. 1.8315 123.84CM4:.4518 2048.25 2057.04 4.8229 .8998 15269. 1.2724 93.76CM5:.2888 2012.50 1998.60 4.0827 .5142 11843. .9869 65.36CM6:.2000 1955.96 1957.08 3.5959 .3288 10364. .8637 53.39CM7:.1467 1914.11 1911.34 3.3138 .2299 8360. .6967 41.00CM8:.1170 1865.15 1854.39 2.7717 .1400 5092. .4243 18.90CM9:.1000 1807.26 1790.20 2.2795 .0846 3076. .2563 7.78__________________________________________________________________________ Distance/Length Ratio: .5000 Combination Mill RMS Production: 219.126 TPH Combination Mill Peak Production: 219.126 TPH Coiling Begins at Pass Number: 3 *CM3* Distance Between CFce #1 and Mill: 25.00 ft. Distance Between Mill and CFce #2: 25.00 ft. Coiling Furnace Diameter: 54.00 in. Coiling Furnace Temperature: 1750.00 Deg. F. Acceleration/Deceleration Rate: 200.00 FPM/sec Final Body Temperature at TS: 1790.20 Deg. F.
EXAMPLE 2
A 52 inch wide×0.100 inch thick sheet in coil form is produced from a 4 inch slab of low carbon steel in accordance with the following rolling schedule:
__________________________________________________________________________EXAMPLE 223.513 tons 1009.PIWRolling Schedule HSM - 46.61-3.9370/.1063__________________________________________________________________________Mill Bite Strip ElapsedStand Gauge % Draft Angle Length Speed TimeName in. Red in. Deg. ft. FPM sec.__________________________________________________________________________FCE: 3.9370 .0 .0000 .00 75.46 .0 .00CM1: 2.7559 30.0 1.1811 16.13 107.80 472.4 18.69CM2: 1.7520 36.4 1.0039 14.87 169.57 524.9 43.07CM3: 1.0000 42.9 .7520 12.86 297.08 590.6 78.71CM4:.5512 44.9 .4488 9.92 539.00 738.2 128.08CM5:.3091 43.9 .2421 7.28 961.27 984.3 192.43CM6:.2122 31.3 .0968 4.60 1399.83 1312.3 262.43CM7:.1599 24.6 .0523 3.38 1857.70 1312.3 353.36CM8:.1251 21.8 .0349 2.76 2375.57 1312.3 467.97CM9:.1063 15.0 .0188 2.03 2794.79 1312.3 595.75__________________________________________________________________________Mill Entry Exit Roll RMSStand Gauge Temp. Temp. Force Torque Horse Load TimeName in. Deg. F. Deg. F. lb × 10**6 lb-ft × 10**6 Power Ratio sec.__________________________________________________________________________FCE: 3.9370 2012.00 2012.00 .0000 .0000 0. .0000 .00CM1: 2.7559 2003.49 1999.79 2.7608 1.1177 12801. 1.4175 27.51CM2: 1.7520 1963.98 1958.37 2.6782 .9484 12069. 1.2027 28.04CM3: 1.0000 1888.64 1893.34 2.9541 .8209 11752. 1.0411 33.20CM4:.5512 1878.14 1884.83 3.3990 .7251 12976. 1.0809 51.84CM5:.3091 1864.68 1870.62 3.5767 .5536 13210. 1.1004 71.86CM6:.2122 1847.80 1843.65 2.5327 .2436 7749. .6455 27.08CM7:.1599 1818.39 1805.02 2.0859 .1445 4598. .3830 12.60CM8:.1251 1776.58 1757.60 2.0196 .1113 3542. .2950 9.54CM9:.1063 1728.86 1701.74 1.4785 .0582 1851. .1542 3.04__________________________________________________________________________ Distance/Length Ratio: .5000 Combination Mill RMS Production: 142.086 TPH Combination Mill Peak Production: 142.086 TPH Coiling Begins at Pass Number: 3 *CM3* Distance Between CFce #1 and Mill: 20.01 ft. Distance Between Mill and CFce #2: 20.01 ft. Coiling Furnace Diameter: 48.00 in. Coiling Furnace Temperature: 1742.00 Deg. F. Acceleration/Deceleration Rate: 656.17 FPM/sec Final Body Temperature at TS: 1701.74 Deg. F.
EXAMPLE 3
A 98 inch wide×nominal 0.187 inch thick coil plate is produced from a 4 inch slab of low carbon steel to an actual thickness of 0.177 inch in accordance with the following rolling schedule:
__________________________________________________________________________EXAMPLE 349.256 tons 1005.PIWRolling Schedule HSM - 98.00-4.0000/.1770__________________________________________________________________________Mill Bite Strip ElapsedStand Gauge % Draft Angle Length Speed TimeName in. Red in. Deg. ft. FPM sec.__________________________________________________________________________FCE: 4.0000 .0 .0000 .00 74.00 .0 .00CM1: 2.8500 28.8 1.1500 15.92 103.86 628.0 14.92CM2: 1.9000 33.3 .9500 14.46 155.79 628.0 34.81CM3: 1.2000 36.8 .7000 12.40 246.67 628.0 63.37CM4:.8000 33.3 .4000 9.37 370.00 700.0 101.84CM5:.4950 39.4 .3150 8.31 610.31 700.0 160.90CM6:.3377 30.4 .1473 5.68 876.52 1300.0 209.61CM7:.2528 25.1 .0849 4.31 1170.96 1500.0 265.19CM8:.2040 19.3 .0488 3.27 1450.98 1500.0 331.98CM9:.1770 13.2 .0270 2.43 1672.32 1500.0 398.88__________________________________________________________________________Mill Entry Exit Roll RMSStand Gauge Temp. Temp. Force Torque Horse Load TimeName in. Deg. F. Deg. F. lb × 10**6 lb-ft × 10**6 Power Ratio sec.__________________________________________________________________________FCE: 4.0000 2300.00 2300.00 .0000 .0000 0. .0000 .00CM1: 2.8500 2241.17 2240.50 4.6775 1.6096 24506. 2.0422 41.38CM2: 1.9000 2202.69 2206.31 5.0558 1.5789 24038. 2.0032 59.73CM3: 1.2000 2134.00 2132.39 5.5481 1.4833 22583. 1.8819 83.47CM4:.8000 1998.94 2004.54 5.5314 1.1128 18884. 1.5737 82.87CM5:.4850 1976.56 1971.51 6.4793 1.1498 19513. 1.6261 142.95CM6:.3377 1943.25 1948.71 4.8974 .5877 18523. 1.5436 104.13CM7:.2528 1923.51 1924.19 4.1044 .3694 13435. 1.1196 63.41CM8:.2040 1895.94 1890.14 3.3006 .2221 8077. .6731 28.00CM9:.1770 1859.62 1848.11 2.4641 .1216 4422. .3685 9.09__________________________________________________________________________ Distance/Length Ratio: .5000 Combination Mill RMS Production: 288.317 TPH Combination Mill Peak Production: 444.550 TPH Coiling Begins at Pass Number: 4 *CM4* Distance Between CFce #1 and Mill: 25.00 ft. Distance Between Mill and CFce #2: 25.00 ft. Coiling Furnace Diameter: 54.00 in. Coiling Furnace Temperature: 1750.00 Deg. F. Acceleration/Deceleration Rate: 200.00 FPM/sec Final Front Temperature at TS: 1848.11 Deg. F.
EXAMPLE 4
An 84 inch wide×0.140 inch thick coil plate is produced from a 4 inch slab of low carbon steel in accordance with the following rolling schedule:
__________________________________________________________________________EXAMPLE 442.219 tons 1005.PIWRolling Schedule HSM - 84.00-4.0000/.1400__________________________________________________________________________Mill Bite Strip ElapsedStand Gauge % Draft Angle Length Speed TimeName in. Red in. Deg. ft. FPM sec.__________________________________________________________________________FCE: 4.0000 .0 .0000 .00 74.00 .0 .00CM1: 2.7050 32.4 1.2950 16.36 109.43 628.0 15.45CM2: 1.7000 37.2 1.0050 14.40 174.12 628.0 37.09CM3: 1.0000 41.2 .7000 12.01 296.00 628.0 71.94CM4:.5910 40.9 .4090 9.17 500.82 700.0 121.62CM5:.3876 34.4 .2034 6.46 763.63 950.0 177.22CM6:.2733 29.5 .1143 4.84 1082.95 1300.0 235.45CM7:.2032 25.6 .0701 3.79 1456.45 1500.0 302.46CM8:.1600 21.3 .0432 2.98 1850.00 1500.0 385.21CM9:.1400 12.5 .0200 2.03 2114.29 1500.0 469.78__________________________________________________________________________Mill Entry Exit Roll RMSStand Gauge Temp. Temp. Force Torque Horse Load TimeName in. Deg. F. Deg. F. lb × 10**6 lb-ft × 10**6 Power Ratio sec.__________________________________________________________________________FCE: 4.0000 2300.00 2300.00 .0000 .0000 0. .0000 .00CM1: 2.7050 2240.37 2240.88 4.6421 1.7504 24985. 2.2213 51.59CM2: 1.7000 2198.43 2203.75 4.9834 1.6522 23582. 2.0966 73.12CM3: 1.0000 2111.30 2111.30 5.6252 1.5509 22137. 1.9681 115.63CM4:.5910 2081.04 2088.19 5.3408 1.1183 17792. 1.4826 98.21CM5:.3876 2051.80 2041.50 4.5043 .6583 14214. 1.1845 71.00CM6:.2733 2006.29 2007.07 3.9160 .4236 12515. 1.0429 57.90CM7:.2032 1971.36 1968.75 3.5466 .2958 10085. .8404 43.79CM8:.1600 1929.28 1921.25 3.1563 .2030 6922. .5768 25.87CM9:.1400 1879.66 1863.49 2.0924 .0896 3055. .2546 5.48__________________________________________________________________________ Distance/Length Ratio: .5000 Combination Mill RMS Production: 280.116 TPH Combination Mill Peak Production: 323.529 TPH Coiling Begins at Pass Number: 3 *CM3* Distance Between CFce #1 and Mill: 25.00 ft. Distance Between Mill and CFce #2: 25.00 ft. Coiling Furnace Diameter: 54.00 in. Coiling Furnace Temperature: 1750.00 Deg. F. Acceleration/Deceleration Rate: 200.00 FPM/sec Final Body Temperature at TS: 1863.49 Deg. F.
The intermediate thickness continuous caster and hot strip and plate line provide many of the advantages of the thin strip caster without the disadvantages. The basic design of the facility can be predicated on rolling 150 tons per hour on the rolling mill. The market demand will obviously dictate the product mix, but for purposes of calculating the required caster speeds to achieve 150 tons per hour of rolling, one can assume the bulk of the product mix will be between 36 inches and 72 inches. A 72 inch slab rolled at 150 tons per hour would require a casting speed of 61 inches per minute. At 60 inches of width, the casting speed increases to 73.2 inches per minute; at 48 inches, the casting speed increases to 91.5 inches per minute; and at 36 inches of width, the casting speed increases to 122 inches per minute. All of these speeds are within acceptable casting speeds.
The annual design tonnage can be based on 50 weeks of operation per year at 8 hours a turn and 15 turns per week for 6000 hours per year of available operating time assuming that 75% of the available operating time is utilized and assuming a 96% yield through the operating facility, the annual design tonnage will be approximately 650,000 finished tons. | A method and apparatus of making coiled plate, sheet in coiled form or discrete plate. The apparatus is an intermediate thickness slab caster and inline hot strip and plate line. The apparatus includes a continuous strip caster forming a strand of between about 3.5 and 5.5 inches thick; a shear for cutting the strand into a slab of desired length; a slab table including a slab takeoff operable transverse of the conveyor table; a slab collection and storage area adjacent to the slab conveyor table adapted to receive slab from the slab takeoff; a reheat furnace having an entry inline with both the slab conveyor table and the slab collection and storage area for receiving slabs from either; a feed and run back table at the exit of the reheat furnace; a hot reversing mill for reducing the slab to a thickness sufficient for coiling in a minimum number of flat passes; a pair of coiler furnaces located on opposite sides of the hot reversing mill; and a finishing line downstream of the pair of coiler furnaces. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to the art of batching and delivering continuous streams of discrete forms, and more particularly to an apparatus and method for batching a continuous stream of such forms (which may be individual sheets, signatures, multiple business forms, etc.) as they are delivered at high speed. The forms may be received directly from a printing press, collator, or other appropriate source.
The prior art contains numerous examples of devices which batch such streams of forms. Nevertheless, with continuous improvements in printing presses, collators, and so on, has come the need for ever increasing speeds and versatility in such batch delivery devices. This is particularly the case when the forms are numbered serially. That is, for unnumbered forms, it is usually satisfactory if the overall average count (e.g. 50 per box) is correct, although the count in any given box may differ. However with serially numbered forms, it is important that the number of forms in each batch is accurate, so that each batch will contain the correctly numbered forms for that batch. However, the faster the forms are delivered, the more difficult it is to intercept the stream of forms at just the right point each time to give the required accuracy.
Another problem resulting from increased delivery speed is the ability of the personnel operating the batch delivery apparatus to keep up with it. Many prior art devices require considerable operator participation during the forming, delivering, and removal of the batches. The abilities and stamina of the operator can thus impose upper limits on the speeds at which many of these devices can be operated.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for accurate batch delivery of continuous streams of forms. The invention fulfills the above requirements by providing accurately formed, counted, and stacked batches at speeds compatible with conventional high speed sources. This is accomplished by carefully shingling the forms into an accurate shingle, quickly and accurately interrupting the movement of the shingle at the proper count, minimizing the distortion of the shingle during its interruption, quickly forming and clearing the stack, and resuming the flow of the shingle.
As the stream of forms is supplied to the batch delivery apparatus, it is a rapidly moving, uniformly spaced series of discrete members. The present invention overlaps these forms serially to form a slower moving shingle which is formed into a stack at a subsequent station in the apparatus. However, in order to maintain an accurate count in each batch, it is essential that the shingle be accurate and uniform. This is accomplished by forcibly driving the individual forms down on top of one another by spiral screws which are driven synchronously with the delivery of each form thereto. The spirals drive the forms onto one another on a conveyor moving at a moderate speed. As the forms are being driven down, a pair of rollers catches each form in a nip at the conveyor to slow the forms instantly to the conveyor speed. The roller nip also assures that the forms are kept squared as they are shingled onto the conveyor. Dragger tapes and rotating kickers operate in conjunction with the spirals to assist further in forcibly driving the forms onto the conveyor at precisely uniform intervals in accordance with their receipt into the batch delivery apparatus. The kickers and tapes hold down and depress the buckle which tends to form in the middle of each sheet due to air trapped beneath as the sheet is driven down by the spirals. The accuracy and uniformity of the shingle are further enhanced by side patters or joggers which pat the side of the shingle as it is carried away from the spirals and kickers by the conveyor. Since this is the first conveyor on which the shingle appears, it is referred to as the first or shingling conveyor.
Somewhat downstream from the spirals the shingle of forms is transferred to a sweep conveyor which has a transverse roller approximately midway therealong to divert the conveyor and the shingle thereon through a modest angle, on the order of twenty degrees. This causes the leading edges of the forms to separate form (rise above) the forms beneath as the shingle is carried around this angle on the sweep conveyor.
At the location where the edges of the forms separate, a pair of rotating finger hooks follows the shingle and is adjusted for accurately and controllably engaging the separated edges of preselected froms to interrupt and stop further movement of the engaged forms. In view of the high speed at which the batch delivery apparatus operates, the finger hooks must operate quickly and accurately to be certain that exactly the right forms are stopped each time. Stoppage of the forms creates a gap which defines the end of one batch and the beginning of the next. As soon as the finger hooks have engaged and stopped the forms to generate this gap, the sweep conveyor is speeded up momentarily in order quickly to sweep the forms remaining downstream thereon away from the forms stopped by the finger hooks.
The finger hook structure is designed to engage and interrupt the shingle accurately but gently. That is, since the forms are often multiple copy forms containing pressure sensitive transfer media (e.g. carbon paper), it is important that the finger hooks leave no impression marks upon the forms. At the same time, it is essential that the forms be intercepted at exactly the right place in the shingle. The finger hooks are therefore arranged in assemblies located at several laterally adjustable locations across the path of the shingled forms. The finger hook assemblies are rotated in synchronization with the batch delivery apparatus so that the peripheral speed of the hooks is slightly faster than the speed at which the shingle moves on the sweep conveyor. Each hook is then adjusted and synchronized to start slightly behind the leading edge of a form immediately preceding a certain predetermined form. When the single is to be interrupted, the rotation of the finger hooks is abruptly halted just in time for the finger hook to catch the predetermined form. Considerable accuracy is thus afforded since the relative velocity between the finger hooks and the forms is quite small, providing a reasonably large time interval in which the mechanism may be operated to stop movement of the finger hooks to interrupt the shingle.
In the preferred embodiment each finger hook assembly includes finger hooks disposed 180° apart. These are cantilevered from a common mounting block by pairs of links which permit the finger hooks to "float", within limits, free of the mounting block. Thus, as the finger hooks engage the forms they rest lightly thereon with the pressure only of their own weight, so that no impression marks are made. The links provide a parallelogram-like suspension from the mounting block which also permits the finger hooks to seek the proper height for the number and thickness of forms present at that moment on the sweep conveyor. This suspension system also allows the finger hooks to drop subsequently toward the sweep conveyor surface as the downstream forms beneath the finger hooks are swept into the collection platform. This helps prevent the engaged forms from curling underneath the finger hooks during or following the sweep motion of the sweep conveyor.
The back sides of the finger hooks are curved to be generally coincident with the arc through which they move in order to reduce the likelihood that sharp corners or edges might mark pressure sensitive forms. The noses of the finger hooks are also tapered to assist in the proper entry between the separated leading edges of the forms. The tapered noses guide the form which is to be engaged smoothly onto the finger hooks so that no impression marks are made thereon.
The finger hook assemblies in the preferred embodiment are rotated once for each 10 forms which pass therebeneath, so that every fifth form is momentarily contacted by one or more finger hooks (according to how many laterally displaced finger hook assemblies are being used). Thus, the count may be done in multiples of five: if the shingle is not to be interrupted, the finger hook assemblies keep on rotating; if the desired count has been reached, the finger hook drive is interrupted, and the finger hooks braked, as indicated above, as soon as the finger hooks have rotated far enough to overtake the form they are to stop.
A vertically reciprocable tray or collection platform is positioned downstream from and somewhat below the sweep conveyor and receives the shingle as it is conveyed to it from the sweep conveyor. The shingle is formed into a stack on the ray, and the stack is jogged while on the platform to cause the forms to collect uniformly and squarely in the stack.
As soon as the stacking of a batch is completed, it must be quickly removed from the platform so that delivery of the forms to the platform may be resumed before too many of them back up behind the finger hooks. The platform is therefore quickly reciprocated downwardly to transfer the batch of forms onto a discharge conveyor. The discharge conveyor then quickly advances the stacked batch away from the platform and the platform quickly rises again to its original position.
As soon as the collection platform has resumed its normal position the finger hooks resume their rotation to release the forms for advancement onto the collection platform. This completes one machine cycle.
As the next batch is forming on the platform, the machine operator removes an earlier formed batch from the discharge conveyor. The discharge conveyor operates intermittently, moving forward quickly each time a batch is removed from the collection platform, and then stopping quickly. This carries the batches forward periodically toward the discharge end of the batch delivery apparatus for convenient removal by the machine operator while the batches are stationary.
In order to assist with the "make ready" (preliminary adjustments and setting up of the machine), the present invention also includes an intermediate conveyor located between the shingling and sweep conveyors. The intermediate conveyor operates at the same speed as the shingling and sweep conveyors when the forms are passing to the collection platform. However, when the finger hooks are stopped to interrupt the stream of forms, the shingling and intermediate conveyors are driven at a speed approximately half their normal speed. This slows the rate of delivery of forms to the finger hooks to prevent an excessive accumulation of forms at the hooks during the collection platform clearance phase.
The batch delivery apparatus thus operates in essentially two modes. In the first mode the conveyors all operate at the same speed and the shingle passes regularly and uninterruptedly onto the collection platform where the forms are jogged into a well-formed stack. Previously formed stacks (batches) of forms wait motionless on the discharge conveyor for removal. A counter registers the machine cycles (or other appropriate input) to count the forms as they pass through the apparatus.
When the desired count is reached, the counter triggers a cycle control mechanism for the batch delivery apparatus which places it in a second operational mode. In this mode the finger hooks are stopped to engage the separated leading edges of the forms on the sweep conveyor to stop further movement of these forms in order to interrupt their flow as part of the batching operation discussed above. The second mode also causes the shingling and intermediate conveyors to be operated at half speed, and causes the sweep conveyor to be driven momentarily faster than its speed in the first mode in order to sweep itself clear of those forms not caught by the finger hooks. Following this sweep the sweep conveyor returns to its original speed for the duration of the second mode.
Following the rapid sweep of forms from the sweep conveyor, and during the latter part of the second mode, the collection platform reciprocates downwardly to deposit the now completed batch onto the discharge conveyor, and this and the other batches on the discharge conveyor are then quickly cycled forward one step. The now clear collection platform is then quickly raised to its original position and the batch delivery apparatus is returned to the first mode for resumption of delivery of the shingled forms to the collection platform.
It is therefore an object of the present invention to provide a batch delivery apparatus which delivers accurately sized and counted batches from continuous streams of forms supplied at high speed; which employs spiral screws to drive the forms individually onto a shingling conveyor to form an accurate and uniformly spaced shingle; which uses kickers to assist the spirals in the formation of an accurate shingle; which uses nip wheels to stop and form the forms into an accurate shingle; which uses rotating finger hooks which are gravitationally biased toward the shingle to seek the proper height with respect thereto, according to the thickness of the forms, for interrupting the shingle each time a batch is to be formed; which moves the finger hooks into position on the shingle at nearly the same speed at which the shingle is moving; which separates the leading edges of the forms in the shingle to assist the finger hooks in accurately interrupting the flow of the shingle for forming batches of accurate and uniform count; which employs a two speed conveyor to slow delivery of the shingle during the second mode of operation to prevent accumulation of an inordinate number of forms at the finger hooks; which incorporates finger hooks which may be interposed into the shingle accurately and rapidly, and without marking a pressure sensitive form; which properly batches and stacks the forms before delivery from the machine so that high speed operation is possible without overwhelming the machine operator; and to accomplish the above objects and purposes in a versatile apparatus readily suited for use with a wide variety of machines adapted for the production of a continuous stream of forms.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic side view of the batch delivery apparatus illustrating the relative positions of the major components;
FIGS. 2A and 2B are enlarged detail views of the FIG. 1 assembly, FIG. 2A illustrating the upstream portion and FIG. 2B the downstream portion of the apparatus, the near side wall being removed;
FIG. 3 is a diagrammatic illustration showing the formation and delivery of the shingle of forms on the conveyor;
FIG. 4 illustrates portions of the mechanism on the receiving end of the batch delivery apparatus, including the mechanism for accommodating forms of different sizes and thicknesses;
FIG. 5 is a general view illustrating portions of the conveyor and side jogger drives;
FIG. 6 is a fragmentary view showing the throat over the intermediate and sweep conveyors;
FIG. 7 is a fragmentary plane view taken on line 7--7 of FIG. 5, illustrating the side jogger drive coupling;
FIG. 8 is a fragmentary sectional view taken on line 8--8 in FIG. 2A;
FIG. 9 is a fragmentary sectional view taken on line 9--9 in FIG. 2B;
FIG. 10 is an enlarged fragmentary detail of the spiral screws, hold down wheels, tapes, and kicker mechanisms;
FIG. 11 is a view of the spiral and kicker assembly of FIG. 10 taken on the view line 11--11 of FIG. 2A;
FIG. 12 is a fragmentary detail of the finger hook mechanism;
FIG. 13 is a view of the finger hook mechanism taken on view line 13--13 in FIG. 12;
FIGS. 14-16 illustrate sequentially the operation of the finger hooks as they engage the shingle to interrupt the movement thereof;
FIG. 17 is a fragmentary detail of the clutch and drive mechanism for the finger hooks;
FIG. 18 is a fragmentary sectional view taken on line 18--18 of FIG. 17; and
FIG. 19 is a block diagram illustrating the control for the batch delivery apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The batch delivery apparatus 20, illustrated overall in FIG. 1, is positioned adjacent a device such as a collator 22 for delivering a continuous stream of discrete forms 25 to the batch delivery apparatus 20. In order to maintain precise synchronization between the batch delivery apparatus 20 and the collator 22, the collator provides the main drive for the batch delivery apparatus through a drive chain 26.
Collator 22 typically includes a pair of cutoff cylinders 27 (several sizes being illustrated in FIG. 1) which sever a continuously supplied web into the discrete forms 25. As used herein, the term "forms" is meant broadly to include single layer sheets or tickets, multiple layers, signatures, etc.
As the forms 25 leave the cutoff cylinders 27, they are received between infeed conveyors 28 which move at a velocity slightly faster than the velocity of the forms as they exit from the cutoff cylinders 27. The purpose of the increased velocity of infeed conveyors 28 is to separate the forms 25 from one another to facilitate shingling thereof as they are subsequently overlapped onto a shingling conveyor 30.
FIG. 4 illustrates generally an eccentric adjusting device 32 which is provided for adjusting the relative vertical positions between conveyors 28 and 30. An eccentric adjusting device 33 adjusts the pressure between infeed conveyors 28 for gripping the forms. Such eccentric adjustments are commonly known in the art for this purpose and are therefore not discussed further.
In order to cause the forms 25 to overlap onto one another in an accurate and uniformly spaced shingle 34 on conveyor 30, the forms are affirmatively driven onto conveyor 30 by means of rotating spiral screws 35 located at the upstream end thereof. With reference to FIGS. 1, 3, 10, and 11, the screws are synchronously driven by drive chain 26 to execute one revolution per form. Thus each formm is positively driven down onto conveyor 30 regardless of any tendency to fly or float as a result of the very high speed at which the batch delivery apparatus 20 and collator 22 may be operated.
Proper formation of the shingle of forms is further aided by means of hold down wheels 17 and hold down straps 38 (FIG. 2A) which guide the leading edges of the forms down onto the shingling conveyor 30. As will be appreciated, at normal press operating speeds these forms are literally flying through the air as they are discharged by infeed conveyors 28. Wheels 37 and straps 38 thus assist in guiding the forms onto conveyor 30. The wheels form a nip with conveyor 30 to catch and align the forms thereon, and the straps 38 guide the forms into the nip and also help retard the forms to the much slower speed of conveyor 30. In the preferred embodiment, the hold down straps 38 are flexible strips of polyurethane approximately 3/4 inch wide and 3/16-1/4 inch thick.
Proper formation of the shingle 34 is further enhanced by kickers 40 which are synchronized to depress the tail ends of the forms 25 near their centers to drive them down onto conveyor 30 before the leading edges of the subsequent forms arrive. This asures that air trapped beneath the forms as their sides are driven down by the spirals will not prevent the forms from stacking properly onto one another, and that the proper and uniform spacing of the forms into the shingle 37 will therefore be accomplished. The straps 38 are also positioned near the centers of the forms to assist in depressing them.
As discussed earlier, the forms may be of many different lengths, as suggested by the differently sized cutoff cylinders 27 illustrated in FIG. 1. Likewise, the forms may be of many different widths, and the various elements of the batch delivery apparatus 20 are therefore laterally adjustable to accommodate the particular width of form being processed. This is accomplished by mounting the various components, such as the spiral screws 35 and kickers 40, on guide shafts and slotted drive shafts extending across the width of the machine, so that these components may be placed as desired. For example FIGS. 10 and 11 show a drive shaft 42 for the drive assemblies 43 of the spiral screws 35. Shaft 42 has a slot 44 in which a key (not shown) in each assembly 43 is engaged. A slotted guide shaft 47 receives an adjustment screw 48 for locking the drive assembly in the desired position. Adjustment screw 48 has a head 49 by which is may be easily tightened or loosened, and it is retained in position by means of a holding spring 51. Such adjustment means are employed throughout the batch delivery apparatus 20, as may be seen from the drawings, and will therefore not be discussed further.
Once the shingle 34 is formed, shingling conveyor 30 delivers the shingle to an intermediate conveyor 55. Both conveyors 30 and 55 are driven at either a first speed or a second speed which is half the first speed. In either case the conveyors are driven from collator 22 by means of drive chain 26. The choice of drive speeds is effected by a conventional counter 56 (FIG. 19) which operates to count the number of forms being received by the batch delivery apparatus 20. The forms may be counted in any manner, and in the present invention are counted by means of counting contacts 57 (FIG. 4) actuated by a cam 58 which is synchronously driven with the spiral screw drive assemblies 43 to provide one pulse for each cycle or rotation of the spiral screws 35. The counter then functions as a cycle control means to place the batch delivery apparatus 20 in a first mode until the desired count is reached. Upon reaching the desired count, the counter cycles the batch delivery apparatus momentarily into a second mode in order to terminate collection of the forms in one batch and to initiate the formation of a new batch.
When the cycle control shifts the batch delivery apparatus into the second mode, the shingling and intermediate conveyors 30 and 55 are driven at half their first mode speed in order to reduce the rate at which the forms 25 arrive at intermediate conveyor's downstream end. The change in speed may be effected by any conventional drive system. In the preset invention an overrunning clutch is continuously connected to drive conveyors 30 and 55 at this half rate speed. An electromagnetic clutch is then actuated to drive the conveyors at full speed for operation in the first mode, and simply disengaged for operation in the second mode. When the electromagnetic clutch is engaged the conveyors overrun the overrunning clutch, and when the electromagnetic clutch is disenaged the conveyors slow to the speed of the overrunning clutch, at which point the drive through the overrunning clutch resumes.
Intermediate conveyor 55 delivers the shingled forms to a sweep conveyor 60 for subsequent delivery to a collection platform 65 on which the forms 25 are stacked into discrete batches 66. Sweep conveyor 60 is driven at the same speeds as shingling conveyor 30 and intermediate conveyor 55 when the batch delivery apparatus is in the first mode. When the batch delivery apparatus is shifted to the second mode, sweep conveyor 60 is momentarily driven at a much greater speed to sweep the forms on the downstream end thereof quickly onto the collection platform 65. Following this sweep, conveyor 60 returns to its original speed (usually well before termination of the second mode).
As with the rest of the batch delivery apparatus 20, sweep conveyor 60 is driven from drive chain 26. This drive is through an overrunning clutch, and when conveyor 60 is to be driven at its sweep speed, a sweep motor 67 (FIG. 5) is energized to drive conveyor 60 at its sweep speed through a chain 68. During this higher speed operation, conveyor 60 simply overruns its overrunning clutch. Of course, any other well-known drive system may be used for this purpose.
In order to interrupt the flow of forms 25 in the shingle 34 as each batch is being completed on collection platform 65, the batch delivery apparatus 20 includes finger hook assemblies 70 approximately midway therealong. As shown in FIGS. 12-16, assemblies 70 each include a supporting block member 72 on which a pair of finger hooks 75 is supported by links 76. The links 76 are arranged in pairs on either side of each finger hook 75 and are pivoted at 77 to form a movable parallelogram configuration between the finger hooks 75 and supporting members 72. The movable parallelogram configurations permit limited displacement of the finger hooks 75 with respect to the supporting members 72, as is illustrated in FIGS. 12 and 14-16. In FIG. 12, the right hand finger hook member is shown in solid lines in the position it assumes under the influence of gravity, and the opposite position is shown in phantom. This freedom of movement includes a radial component which allows the finger hooks 75 to move naturally and freely under the force of gravity to the proper operating position according to the number and thicknesses of forms being processed by the batch delivery apparatus 20. This is illustrated in FIGS. 14-16, and discussed further below.
The finger hook assemblies 70 are supported and rotated on a finger hook drive shaft 80 at a speed which causes the noses 82 of the finger hooks 75 to move at a velocity slightly greater than that of the shingle 34 when in contact therewith. The back side curvature 83 of the finger hooks is preferably coincident with the arc through which they move, and the finger hook noses 82 are tapered to facilitate entry into the shingle. In addition, the extended portions 85 of the finger hooks 75 are broad shovel-like members 85 which distribute contact with the forms 25 over a wide area. Consequently, the pressures at the points of conact with the forms are very light since they are distributed over wide areas and support only the small weight of the movably mounted finger hooks 75. Point impact forces are also reduced since the finger hooks 75 move at a velocity similar to that of the shingle 34.
In operation, a Maxwell collar 87 (FIGS. 8 and 17) permits the finger hook drive shaft 80 to be adjusted with respect to the shingle 34 so that the initial contact between a given finger hook 75 and a particular form, such as form 25a (FIG. 14), occurs with the finger hook nose 82 slightly behind the leading edge of the form 25a. Then, during operation of the batch delivery apparatus 20, the finger hook 75 remains well ahead of a particular predetermined form 25b due to the hook's slightly greater velocity, as illustrated in FIG. 15. If the shingle is to be interrupted at this point, rotation of the finger hook assembly 70 is then abruptly halted. Form 25b catches up with the now stationary finger hook 75 and is caught and stopped thereby. Subsequent forms 25c and 25d, etc., are also caught to stop movement thereof. This creates a gap in the flow of the shingle to assist in separating one batch from the next. As suggested earlier, this occurs as the batch delivery apparatus 20 is placed in its second mode, and continues until it is restored to its first mode.
Upon restoration to the first mode, the finger hook assemblies 70 once again resume their rotation, and the forms again proceed freely therepast. In the preferred embodiment, finger hook assemblies 70 are rotated once for each ten forms 25 which pass by in the shingle 34. Thus, a finger hook 75 contacts every fifth form. The count may therefore be in any multiple of five.
The movement of the finger hook assemblies 70 is regulated by an indexing clutch 90 and brake 91 illustrated in FIGS. 8, 17, and 18. Clutch 90 includes a driven wheel 92 which is synchronously driven in conjunction with the batch delivery drive train powered from collator 22 by drive chain 26. Driven wheel 92 rotates a pair of rods 94 which are axially slidably mounted in wheel 92. An axially movable collar 95 grips and mounts the rods 94 and rotates with the rods in response to the drive from driven wheel 92. A yoke 97 carries rollers 98 in a groove 99 in collar 95 for axially displacing collar 95 against a return spring 101 when a solenoid 103 is actuated to move yoke 97 through a crank 104. When solenoid 103 causes yoke 97 to move collar 95 against spring 101 (in a direction to the right as viewed in FIG. 17), collar 95 withdraws the rods 94 from corresponding axially aligned openings (not shown) therefor in an output wheel 105. Output wheel 105 is driven by the rods 94 when the rods are engaged in the openings therein, and withdrawal of the rods interrupts the drive thereto to interrupt the drive to the finger hook drive shaft 80 and the finger hook assemblies 70 mounted thereon. A brake 91 is engaged just after solenoid 103 is energized in order to stop rotation of shaft 80 and to hold it in position to interrupt the shingle 34.
As indicated earlier, the cycle control for the batch delivery apparatus 20 receives its input from the contacts 57 illustrated in FIG. 4. When the proper count is reached, the solenoid 103 and brake 91 are energized to stop rotation of the finger hook assemblies 70 for interrupting the flow of the shingle 34. If the initial setup of the batch delivery 20 has been properly effected, by using the Maxwell collar 87 (FIGS. 8 and 17) to synchronize the finger hook assemblies 70 with the shingle 34, as illustrated in FIGS. 14 and 15, the batch delivery will function properly and will remain synchronized since all of the main drives are synchronously interconnected. However if fine adjustment of the timing for solenoid 103 and brake 91 is found necessary, this can be easily effected by loosening the lock screw 107 for the contacts 57 (FIG. 4) and rotating the contacts 57 to change their phase slightly with respect to cam 58.
Since the relative velocity between the forms 25 and finger hooks 75 is very small, timing is much less critical than it would be if the relative velocity were greater. That is, there is a longer time interval during which the rotation of the finger hooks may be stopped than would be the case if the relative speed between the shingle and finger hooks were greater.
FIGS. 6 and 16 illustrate one of a pair of steel straps 110 which are adjustably pivoted at 111 to define an opening or throat 115 above sweep conveyor 60. Throat 115 prevents the forms from riding and curling up around the finger hooks, and sets an upper limit on the number of forms which may stack up behind the finger hooks 75 when the batch delivery apparatus is in its second mode. When the forms encounter straps 110 they simply begin to taper upstream toward the intermediate conveyor 55.
Entry of the finger hooks 75 into shingle 34 is considerably facilitated by means of a roller 120 located somewhat downstream from the upstream edge of the sweep conveyor 60. Roller 160 diverts conveyor 60 and the shingle 34 thereon through a predetermined angle which causes the leading edges of the forms to separate momentarily from the shingled forms therebeneath, as shown in FIGS. 3, 14 and 15. The finger hook assemblies 70 are then positioned to engage the separated leading edges of the forms as they arrive and are separated at a location at or near roller 120. FIGS. 14 and 15 illustrate the entry sequence of the finger hooks 75 into the single 34, and FIGS. 16 and 2B show the stopped forms collecting at the interposed finger hooks at a somewhat later time during operation of the batch delivery apparatus in the second mode. In fact, FIG. 2B shows the phase immediately following the high speed sweep of conveyor 60 and the completion of a batch 66 of forms on the collection platform 65. Note that as the downstream forms beneath the finger hooks 75 have been swept out from underneath, the finger hooks have dropped to their lower limit, as shown in FIGS. 16 and 2B. This prevents the stopped and engaged forms from sliding or curling out under the finger hooks 75.
Proper entry of the finger hooks 75 into the shingle 37 is also aided by a side patter or jogger 122 (FIGS. 5 and 7) which is reciprocated against the shingle 34 on the intermediate conveyor 55 to square the shingle so that the individual forms thereon are precisely aligned. Thus, by the time the shingle reaches roller 120 it is an accurate, uniformly spaced and squared shingle.
Jogger 122 is reciprocated by means of a crank 123 which is connected through a link 124 to an eccentric 126 which is rotated by a drive chain 127 driven from the drive train in apparatus 20. As eccentric 126 rotates it causes link 124 to oscillate crank 123 which reciprocates the side jogger 122 toward and away from the shingle 34.
Proper ejection of the forms from sweep conveyor 60 onto platform 65 is aided by aluminum hold down wheels 129 which rest on top of the shingled forms 25 at the downstream end of conveyor 60 to assure proper frictional contact between the forms and conveyor. Roller 120 is located downstream from the upstream end of conveyor 60 so that those forms thereon which are not stopped by the finger hooks 75 will be largely or wholly on the sweep conveyor 60 rather than the intermediate conveyor 55. These forms, being downstream from the forms stopped by the finger hooks 75, are destined to be the last forms of the batch which is being completed, and proper and rapid delivery of these forms to that batch is therefore important. Since these forms are on sweep conveyor 60 rather than intermediate conveyor 55, conveyor 60 is able to eject them quickly onto platform 65 during the sweep motion of conveyor 60.
Proper formation of the batch 66 of forms 25 on platform 65 is assured by means of jogger bars 133 which form a back stop for the forms as they arrive on platform 65 and which are jogged by a vibrating jogger motor 134 (FIG. 2A). The jogger bars 133 are sized and adjusted to resonate at the vibrating frequency of the jogger motor to maximize the amplitude of the vibrations.
The batch of forms on platform 65 is also squared by a side patter or jogger 136 (FIG. 5) similar to side jogger 122 and connected by a link 137 (FIGS. 5 and 7) to the same eccentric 126 which drives jogger 122.
Collection platform 65 is actually a series of long parallel rectangular bars 140, as may be seen in FIG. 9. Bars 140 are supported by rods 141 extending from cross beams 143 which themselves are supported on arms 144 by resilient mounts 145. Arms 144 are pivoted at 147 to swing collection platform 65 upwardly and downwardly in response to a two-way collection platform drive cylinder 150. Cylinder 150 is assisted by counter balance springs 152 which offset some of the weight of collection platform 65 and its associated support members. The upper and lower positions for platform 65 are determined respectively by upper and lower limit stops 153 and 154 (FIG. 2B). When the batch delivery apparatus 20 is operating in the first mode, platform 65 is maintained in its upper position (shown in FIGS. 1, 2A, and in phantom in FIG. 2B). When the batch delivery apparatus 20 is operated to its second mode, upon completion of a batch 66, the platform 65 is moved quickly to its lower position (shown in solid lines in FIG. 2B) for removal of the batch therefrom, and then is returned to its upper position at the end of the second mode. The resilient mounts 145 permit rapid motion of the platform 65 by cushioning the shock as the platform reaches the stops.
When platform 65 is in its lower position, the batch is removed from the platform by a discharge conveyor 160. Conveyor 160 is actually a series of narrow conveyor chains 161 all moving synchronously and located between the individual platform bars 140 and rods 141, as may best be seen in FIG. 9. (In fact, all of the conveyors in the present invention are actually composed of groups of rather narrow discrete elements, such as tapes, all moving in parallel, as may be seen in FIG. 8). Discharge conveyor 160 includes spaced groups of pusher bars 163 removably engaged in the conveyor chain 161.
Thus, when the platform 65 is reciprocated downwardly through conveyor 160, the discharge coveyor drive motor 165 is energized to drive conveyor 160 causing pusher bars 163 to push the batch off of platform 65 and downstream toward the discharge end of the batch delivery apparatus 20. As soon as the batch is clear of the collection platform 65, the platform is again reciprocated upwardly and the batch delivery apparatus is returned to its first operational mode.
Operation of discharge conveyor 160 is intermittent and is controlled by a cam 167 which is rotated by the drive train between drive motor 165 and conveyor 160 (see FIG. 2B) to operate a switch 168 which controls the discharge conveyor drive motor 165. Preferably, the discharge conveyor drive train is adjusted to rotate cam 167 one complete revolution each time the discharge conveyor 160 is advanced a distance equal to the distance between successive groups of pusher bars 163. Switch 168 is then able to stop operation of motor 165 each time the pusher bars 163 are advanced one step to the position previously occupied by the row of pusher bars immediately ahead thereof. Optional dragger tapes 170, similar to hold down straps 38, help stop forward movement of the top of the stack or batch of forms 66 as conveyor 160 stops, to keep the upper forms from sliding off. Since the discharge conveyor operation is intermittent, it is relatively easy for the person unloading the batched forms to remove them during those time periods in which conveyor 160 is at rest.
FIG. 19 summarizes in block form the control circuitry for the batch delivery apparatus. As shown therein, and as discussed earlier, the contacts 57 provide one pulse to counter 56 for each form received in apparatus 20. The batch delivery apparatus 20 starts in the first mode, and counter 56 leaves it in the first mode until the desired count is reached.
When the desired count is reached, counter 56 places the apparatus in the second mode momentarily, to clear the batch, by triggering the finger hook control 176 to operate the finger hook indexing clutch 90 and the finger hook brake 91 as discussed earlier. This interrupts the shingle flow until it is restored when the apparatus is returned to the first mode.
The finger hook control 176 also causes the belt speed control 175 to shift from the first mode to the second mode. In the first mode the belt speed control 175 operates the shingling, intermediate, and sweep conveyors 30, 55, and 60 at the same speeds, as for example by means of the overrunning and electrically operable clutches discussed above. In the second mode the belt speed control 175 slows the shingling and intermediate conveyors to one half the first mode speed.
Similarly, the finger hook control 176 causes the sweep motor control 177 to energize sweep motor 67 momentarily at the start of the second mode to run the sweep conveyor 60 momentarily faster to complete the batch on the platform 65.
In turn, the sweep motor control 177 causes the platform cylinder control 178 to operate cylinder 150 to reciprocate the platform downwardly to its lower limit stop 154 at the start of the second mode.
The platform cylinder control 178 causes the discharge conveyor control 179 to energize the discharge conveyor drive motor 165 momentarily during this second mode operation to cause the discharge conveyor 160 to move forward one increment, as explained earlier. When conveyor 160 has completed this incremental motion, the discharge conveyor control 179 provides an output 180 (FIG. 19) signifying that the second mode clearance phase is completed. Output 180 then stops motion of the discharge conveyor 160 and also restores the batch delivery apparatus to the first mode by way of controls 175, 176, and 178, as illustrated in FIG. 19 and as discussed earlier.
As may be seen, therefore, the present invention provides numerous advantages. It is capable of operation at very high speeds and can be used with modern high speed machinery. This high speed capability is due in part to the formation of an accurate, uniformly spaced and squared shingle which permits precise interruption thereof by the specially designed finger hooks. The shingle is formed by spiral screws which positively force the forms down onto a shingling conveyor in proper timed sequence. Shingling is further assisted by the hold down wheels, hold down straps, kickers, and side patters.
The finger hooks themselves move quickly and accurately into the shingle without marking the forms. This is aided by the roller 120 which separates the leading edges of the forms in the shingle. Proper operation is also assisted by slowing of the shingling and intermediate conveyors during the sweep and collection platform clearing phase (mode 2), thus relieving congestion in the vicinity of the finger hooks.
While the form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | An apparatus and method are disclosed for receiving a continuous stream of forms at high speed and automatically stacking the forms into discrete batches of accurate count. The forms are first shingled into a uniform and accurate shingle by spiral screws, kickers, rollers, and hold down tapes which positively and forcefully drive the forms uniformly and accurately onto a conveyor. The forms are then stacked and collected on a vertically reciprocable tray until the desired count is reached, at which time finger hooks intercept and engage the shingle to stop the leading edges of the forms destined for the next batch. A conveyor diverting roller separates the leading edges of the forms for this purpose. Those forms downstream from the finger hooks are then quickly swept onto the elevator tray which deposits them on a discharge conveyor for delivery from the apparatus. | 1 |
REFERENCE TO CROSS-RELATED APPLICATION
This application is a Continuation-in-Part of U.S. patent application Ser. No. 11/560,864 filed Nov. 17, 2006, now U.S. Pat. No. 7,533,901 which is a Continuation-in-Part of PCT/IL2005/001174 filed Oct. 11, 2005, which claims priority benefits from U.S. patent application Ser. No. 11/162,827 filed Sep. 24, 2005, which claims priority benefits from U.S. Provisional Application No. 60/685,398, filed on May 31, 2005, herein incorporated by reference in its entirety.
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a device, a system, an article of manufacture, and a method for setting up a child safety seat in a vehicle and, in particular to a device, an article of manufacture, and a method, enabling a quick and efficient way to fasten and release the belt buckles which fix the child safety seat or child sitting in the child booster safety seat to the seat's location on the vehicle seat.
Buckling a child to a vehicle seat with the vehicle's seatbelts does not provide sufficient protection in case of an emergency braking or in an accident, for reasons such as the following:
The seatbelts are not sufficiently snug on a small body and do not comprise a sufficient downwards force.
The shoulder belt could lacerate the child's neck.
Most children are not mature enough to be seated in a seat designated for adults.
Children cannot bend their knees at the end of the seat when their backs are against the backrest of the seat.
In order to overcome these difficulties, the child booster safety seat, which is a seat that raises the child and provides a higher sitting height so the adult lap and shoulder belts fit better, has been available for approximately thirty five years.
The standard recommendation is to use child booster safety seats for children of ages 4 to 8, weighing 20 to 40 kg.
An example of the existing standard setting is shown in FIGS. 1 a and 1 b.
FIG. 1 a depicts a child safety seat, of child booster safety seat 13 , on a vehicle's back seat 11 near the backrest of the back seat 12 . On one side of the child booster safety seat 13 the vehicle's seatbelt 14 is disposed with a latch plate 15 attached to it and on the other side, a buckle 16 . Usually, the buckle 16 is disposed in the vehicle's back seat 11 suitably for the comfort of adult passengers.
FIG. 1 b depicts the instance in which a child 17 is properly seated with the vehicle's seatbelt 14 latched by connecting the latch plate 15 into the buckle 16 . This configuration makes the access of the buckles by two adult hands in order to latch them extremely difficult. The latching action becomes even harder when an additional safety seat or a baggage item such as a bag or suitcase is placed beside the buckle 16 .
Vehicle's seatbelt 14 is a continuous strap including an upper segment 14 d which crosses the child's chest diagonally, from one shoulder to the waist on the opposite side, through latch plate 15 and over the child's lap as a lap second segment 14 b
The left side of the illustration shows a magnified illustration of latch plate 15 which is connected to buckle 16 and a small segment of upper segment 14 d . Latch plate 15 has a slot 15 a through which vehicle's seatbelt 14 passes, and is actually the place at which the vehicle's seatbelt 14 is divided into both segments.
As used herein the specification and in the claims section that follows, the term “the seat belt total equivalent force exertion point” and the like refer to the point at which the total equivalent force is substantially exerted by the vehicle's seatbelt 14 on latch plate 15 .
The illustration shows the seat belt's total equivalent force exertion point marked as point 40 , which is disposed approximately in the center of the upper part of slot 15 a.
When a child is fastened in a safety seat, the possibility to quickly and easily unfasten the seatbelt's buckles is of utmost importance, especially when the child needs to be removed from the vehicle as quickly as possible. The duration of the belt buckles' release action in the existing situation may be critical in an emergency because of the limited access to the belt buckles.
FIG. 1 c depicts an option of the prior art in which rigid parts, such as latch plate 15 and buckle 16 , of a child restraint system are in contact with a child booster safety seat 13 . This contact, when a tension force is exerted on the restraint system, could exert forces in unwanted directions on the child booster safety seat 13 . In addition, this contact, especially when the structure of the child booster safety seat 13 in the area of contact is a rigid structure, could cause the child seated in the child booster safety seat 13 discomfort as a result of friction and being hit by the rigid parts of the restraint system.
There is therefore a need to improve the setup of a child booster safety seat in a vehicle and to ensure the possibility of speedy release of the seatbelts strapping the child into the child booster safety seat.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide a device, an article of manufacture, and a method to improve the setup of a child safety seat in a vehicle.
According to the present invention there is provided a method enabling a user to improve buckling and unbuckling of a child in a child booster safety seat in a vehicle, for use in conjunction with a conventional seatbelt restraint system, wherein the conventional seatbelt restraint system has a safety seatbelt, a latch plate and a buckle, wherein the latch plate of the conventional seatbelt restraint system has a slot through which the safety seatbelt of the conventional seatbelt restraint system passes, and wherein the latch plate of the conventional seatbelt restraint system operatively divides the safety seatbelt into two segments, a lap segment and a chest and shoulder segment, and wherein the buckle of the conventional seatbelt restraint system is located close to the motor vehicle's back seat near the backrest of the back seat, and wherein the latch plate of the conventional seatbelt restraint system can be comfortably connected and released, enabling safe restraining of a child in normal operation and in case of emergency, and enabling easy and safe release of the child from the child restraint system, the method including the steps of: (a) providing the user with a seatbelt adaptor, the seatbelt adaptor including: (i) a central lengthening device; (ii) an adaptor latch plate for attachment and detachment to the buckle of the conventional seatbelt restraint system, the adaptor latch plate disposed at a first end of the central lengthening device; and (iii) an adaptor buckle for attachment and detachment to the latch plate of the conventional seatbelt restraint system, the adaptor buckle disposed at a second end of the central lengthening device: (b) connecting the adaptor latch plate to the buckle of the vehicle's conventional seatbelt restraint system located near the vehicle's seat; and then; (c) seating the child in the child booster safety seat; and then (d) connecting the latch plate of the vehicle's conventional seatbelt restraint system to the adaptor buckle, wherein the vehicle's seatbelt is to be fastened on the child's body.
According to further features in the described embodiments the adaptor latch plate is configured for connecting to the buckle of the conventional seatbelt restraint system, and wherein the adaptor buckle is configured for connecting to the latch plate of the conventional seatbelt restraint system, that secures a child into the child booster safety seat within the motor vehicle, and wherein the length of the seatbelt adaptor is so dimensioned as to be suited to improve the latching of the buckle of the motor vehicle's conventional seatbelt restraint system.
According to further features in the described embodiments the geometrical characteristics of the child booster safety seat, the seatbelt adaptor, the latch plate of the conventional seatbelt restraint system, and the buckle of the conventional seatbelt restraint system are such that the maximum vertical displacement of the slot of the latch plate of the conventional seatbelt restraint system from an anchoring point of the buckle of the conventional restraint system to a vehicle frame of the vehicle when the latch plate of the conventional seatbelt restraint system is connected to the adaptor buckle, and the adaptor latch plate is connected to the buckle of the conventional seatbelt restraint system, is approximately six to eight centimeters above an upper surface of the child booster safety seat, the characteristics thereby enabling fast and easy release of the child from the child restraint system, and further enabling that in case of emergency braking, the lap segment of the seatbelt will exert an adducting force having a downward component and a backward component, relative to the vehicle, so as to adduct the child's lap downwards and backwards with regard to the child booster safety seat, and the chest and shoulder segment of the seatbelt will exert a backwards adducting force on a the child's chest.
According to further features in the described embodiments the geometrical characteristics of the child booster safety seat, the seatbelt adaptor, the latch plate of the conventional seatbelt restraint system, and the buckle of the conventional seatbelt restraint system are such that the maximum vertical displacement of the slot of the latch plate of the conventional seatbelt restraint system from an anchoring point of the buckle of the conventional restraint system to a vehicle frame of the vehicle when the latch plate of the conventional seatbelt restraint system is connected to the adaptor buckle, and the adaptor latch plate is connected to the buckle of the conventional seatbelt restraint system, is approximately eight to ten centimeters above an upper surface of the child booster safety seat, the characteristics thereby enabling fast and easy release of the child from the child restraint system, and further enabling that in case of emergency braking, the lap segment of the seatbelt will exert an adducting force having a downward component and a backward component, relative to the vehicle, so as to adduct the child's lap downwards and backwards with regard to the child booster safety seat, and the chest and shoulder segment of the seatbelt will exert a backwards adducting force on a the child's chest.
According to further features in the described embodiments the geometrical characteristics of the child booster safety seat, the seatbelt adaptor, the latch plate of the conventional seatbelt restraint system, and the buckle of the conventional seatbelt restraint system are such that the maximum vertical displacement of the slot of the latch plate of the conventional seatbelt restraint system from an anchoring point of the buckle of the conventional restraint system to a vehicle frame of the vehicle when the latch plate of the conventional seatbelt restraint system is connected to the adaptor buckle, and the adaptor latch plate is connected to the buckle of the conventional seatbelt restraint system, is approximately ten to twelve centimeters above an upper surface of the child booster safety seat, the characteristics thereby enabling fast and easy release of the child from the child restraint system, and further enabling that in case of emergency braking, the lap segment of the seatbelt will exert an adducting force having a downward component and a backward component, relative to the vehicle, so as to adduct the child's lap downwards and backwards with regard to the child booster safety seat, and the chest and shoulder segment of the seatbelt will exert a backwards adducting force on a the child's chest.
According to further features in the described embodiments the adaptor buckle includes no permanent bolt coupling.
According to further features in the described embodiments the latch plate of the conventional seatbelt restraint system to the adaptor buckle is done when there is baggage on the vehicle's seat, making the connecting difficult.
According to further features in the described embodiments the central lengthening device is an elastic device.
According to further features in the described embodiments the central lengthening device is a safety belt.
According to further features in the described embodiments the central lengthening device is a safety belt with adjustable length.
According to further features in the described embodiments the central lengthening device is a rigid device.
According to further features in the described embodiments the method further includes the step of: (e) testing to determine whether in a case of emergency braking the lap segment of the safety seatbelt will exert an adducing force having a downward component and a backward component relative to the vehicle, so as to adduct the child's lap downwards and backwards with regard to the child booster safety seat.
According to further features in the described embodiments the method further includes the step of: (e) testing to determine whether in a case of emergency break the slot of the latch plate of the conventional seatbelt restraint system which the safety seatbelt passes through, is located below the level of the child's waist.
According to still further features in the described embodiments the testing includes pulling the chest and shoulder segment in a direction in front of the child's chest diagonally, toward the shoulder of the child.
According to further features in the described embodiments the method further includes the step of: (e) before the connection of the adaptor latch plate to the buckle of the vehicle's conventional seatbelt restraint system located near the vehicle's seat, attaching the seatbelt adaptor to the child booster safety seat.
According to further features in the described embodiments the method further includes the step of: (e) disconnecting the vehicle's seatbelt latch plate from the buckle of the seatbelt adaptor.
According to further features in the described embodiments the seatbelt adaptor is selected from a set of a plurality of seatbelt adaptors, each of the seatbelt adaptors having a central lengthening device, with a different length.
According to the teaching of the present invention there is provided a seatbelt adaptor, for improving the buckling and unbuckling of a child in a child booster safety seat in a motor vehicle, wherein the motor vehicle has a conventional seatbelt restraint system for use of an adult, wherein the conventional seatbelt restraint system has a safety seatbelt, a latch plate and a buckle, wherein the latch plate of the conventional seatbelt restraint system has a slot through which the safety seatbelt of the conventional seatbelt restraint system passes, and wherein the latch plate of the conventional seatbelt restraint system operatively divides the safety seatbelt into two segments, a lap segment and a chest and shoulder segment, and wherein the buckle of the conventional seatbelt restraint system is located close to the motor vehicle's back seat near the backrest of the back seat, and wherein the latch plate of the conventional seatbelt restraint system can be comfortably connected and released, enabling safe restraining of a child in normal operation and in case of emergency, and enabling easy and safe release of the child from the child restraint system, the seatbelt adaptor including: (a) a rigid central lengthening device; (b) an adaptor latch plate for attachment and detachment to the buckle of the conventional seatbelt restraint system, the adaptor latch plate disposed at a first end of the central lengthening device; and (c) an adaptor buckle for attachment and detachment to the latch plate of the conventional seatbelt restraint system, the adaptor buckle disposed at a second end of the central lengthening device, wherein the adaptor latch plate is configured for connecting to the buckle of the conventional seatbelt restraint system, and wherein the adaptor buckle is configured for connecting to the latch plate of the conventional seatbelt restraint system, that secures a child into the child booster safety seat within the motor vehicle.
According to further features in described embodiments the adaptor buckle includes a mechanism base, having a mechanism base bottom surface, wherein the rigid central lengthening device has a rigid central lengthening device bottom surface, wherein the adaptor latch plate has an adaptor latch bottom surface, wherein the mechanism base, the rigid central lengthening device, and the adaptor latch plate, are made from one piece material, and wherein the mechanism base bottom surface, the rigid central lengthening device bottom surface, and the adaptor latch bottom surface, are lying operatively on one plane.
According to further features in described embodiments the seatbelt adaptor further includes: (d) an adaptor buckle indentation at a place at one end of the rigid central lengthening device close to an intersection of the rigid central lengthening device and the adaptor buckle; and (e) a release button mounted at second end of the rigid central lengthening device.
According to further features in described embodiments the seatbelt adaptor further includes: (f) a coupling means disposed on the seatbelt adaptor.
According to the teaching of the present invention there is provided a system for improving the buckling and unbuckling of a child in a child booster safety seat in a motor vehicle, wherein the motor vehicle has a conventional seatbelt restraint system for use of an adult, wherein the conventional seatbelt restraint system has a safety seatbelt, a latch plate and a buckle, wherein the latch plate of the conventional seatbelt restraint system has a slot through which the safety seatbelt of the conventional seatbelt restraint system passes, and wherein the latch plate of the conventional seatbelt restraint system operatively divides the safety seatbelt into two segments, a lap segment and a chest and shoulder segment, and wherein the buckle of the conventional seatbelt restraint system is located close to the motor vehicle's back seat near the backrest of the back seat, and wherein the latch plate of the conventional seatbelt restraint system can be comfortably connected and released, enabling safe restraining of a child in normal operation and in case of emergency, and enabling easy and safe release of the child from the child restraint system, the system including: (a) a child booster safety seat, having an upper surface for the child to sit upon; and (b) a seatbelt adaptor, the seatbelt adaptor including: (i) a rigid central lengthening device; (ii) an adaptor latch plate for attachment and detachment to the buckle of the conventional seatbelt restraint system, the adaptor latch plate disposed at a first end of the central lengthening device; and (iii) an adaptor buckle for attachment and detachment to the latch plate of the conventional seatbelt restraint system, the adaptor buckle disposed at a second end of the central lengthening device, wherein the adaptor latch plate is configured for connecting to the buckle of the conventional seatbelt restraint system, wherein the adaptor buckle is configured for connecting to the latch plate of the conventional seatbelt restraint system, that secures a child into the child booster safety seat within the motor vehicle, wherein the length of the seatbelt adaptor is so dimensioned as to be suited to improve the latching of the buckle of the motor vehicle's conventional seatbelt restraint system, and wherein the adaptor buckle includes a mechanism base, having a mechanism base bottom surface, wherein the rigid central lengthening device has a rigid central lengthening device bottom surface, wherein the adaptor latch plate has an adaptor latch bottom surface, wherein the mechanism base, the rigid central lengthening device, and the adaptor latch plate, are made from one piece material, and wherein the mechanism base bottom surface, the rigid central lengthening device bottom surface, and the adaptor latch bottom surface, are lying operatively at one plane.
According to further features in described embodiments the seatbelt adaptor further includes: (iv) a adaptor buckle indentation at a place at one end of the rigid central lengthening device close to an intersection of the rigid central lengthening device and the adaptor buckle; and (v) a release button mounted at second end of the rigid central lengthening device.
According to further features in described embodiments the seatbelt adaptor further includes: (vi) a coupling means disposed on said seatbelt adaptor; and (vii) a coupling means disposed on the child booster safety seat, wherein the seatbelt adaptor has a weight value, and wherein the seatbelt adaptor can be detached from the booster safety seat by a pulling force of value four times the value of the seatbelt adaptor weight value.
According to further features in described embodiments the child booster safety seat includes: (i) a lower anchors and tethers for children (LATCH) device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 a of the prior art illustrates an empty safety seat placed in the back seat of a medium sized passenger vehicle.
FIG. 1 b of the prior art illustrates a child seated in a safety seat, with the seatbelts fastened. The safety seat is installed in the back seat of a medium sized passenger vehicle.
FIG. 1 c is a schematic illustration of an option of the prior art, in which rigid parts, such as latch plate and buckle, of a child restraint system are in contact with a child booster safety seat.
FIG. 2 a is a schematic illustration of a preferred embodiment of a seatbelt adaptor with a strap of a fixed length.
FIG. 2 b is a schematic illustration of a preferred embodiment of a seatbelt adaptor with a strap of adjustable length.
FIG. 2 c is a schematic perspective illustration of a preferred embodiment of a seatbelt adaptor made as a rigid unit.
FIG. 2 d is a schematic illustration of a preferred embodiment of a seatbelt adaptor made as an elastic unit.
FIG. 2 e is a schematic illustration of a preferred embodiment of a seatbelt adaptor with an apparatus preventing the buckle release by a child.
FIG. 2 f is a schematic illustration of a preferred embodiment of a seatbelt adaptor attached to the vehicle's seatbelts.
FIG. 3 a depicts a front view of a child seated in a child booster safety seat, with the seatbelts fastened according to a preferred embodiment of the present invention.
FIG. 3 b is a schematic illustration of a preferred embodiment of the present invention depicting a front view of the necessary direction of the vertical force exerted by the seat belt during an emergency braking on a child seated in the child booster safety seat as depicted in FIG. 3 a.
FIG. 3 c is a schematic illustration of a preferred embodiment of the present invention depicting a detailed magnification of a part of FIG. 3 b.
FIG. 3 d is a schematic illustration of a preferred embodiment of the present invention depicting a side view of the necessary directions of horizontal and vertical forces exerted by the seatbelt during emergency braking on the child seated in a child booster safety seat.
FIG. 3 e is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point, when it is on a section line of the seat surface of the child booster safety seat with the surface of the backrest of the vehicle seat upon which the child booster safety seat is placed.
FIG. 3 f is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point, when it is on a section line of the seat surface of the child booster safety seat with the surface of the backrest of the child booster safety seat.
FIG. 3 g is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point, when it is at the intersection point of the upper part of the thigh of a child seated in the child booster safety seat with said child's waist.
FIG. 3 h is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point, when it is level with a plane parallel to the upper part of the thigh of a child seated in the child booster safety seat, with the force on the latch plate being exerted upwards relative to the vehicle.
FIG. 4 a is a schematic illustration of a preferred embodiment of the present invention depicting a side view of a part of the child restraint system and a child booster safety seat.
FIG. 4 b is a schematic illustration of section a-a of FIG. 4 a.
FIG. 4 c is a schematic illustration of section b-b of FIG. 4 a.
FIG. 5 a is a schematic isometric illustration of a preferred embodiment of one rigid part comprising three elements of a rigid seatbelt adaptor.
FIG. 5 b is a schematic side illustration of a preferred embodiment of a rigid seatbelt adaptor, with a section of an adaptor buckle envelope.
FIG. 6 a is a schematic perspective illustration of a preferred embodiment of a rigid seatbelt adaptor attached to a child booster safety seat resting on a back seat of a vehicle.
FIGS. 6 b and 6 c are schematic side view illustrations of a preferred embodiment of a rigid seatbelt adaptor attached to a child booster safety seat.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a seatbelt adaptor, a system, an article of manufacture and a method to improve the setup of a child safety seat in a vehicle.
The principles and operation of the seatbelt adaptor, the system, the method, and the article of manufacture according to the present invention may be better understood with reference to the drawings and the accompanying description.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings.
Unless otherwise defined, 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. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting.
The following list is a legend of the numbering of the application illustrations:
11 vehicle's back seat 12 backrest of the vehicle's back seat 13 child booster safety seat 13 a deep level 13 b less deep level 13 c booster seat backrest 13 e booster seat wall 13 f lower anchors and tethers for children (LATCH) device 14 vehicle's seatbelt (of the vehicle conventional seatbelt restraint system) 14 a lap first segment (of the vehicle conventional seatbelt restraint system) 14 b lap second segment, (of the vehicle conventional seatbelt restraint system) 14 c lap third segment (of the vehicle conventional seatbelt restraint system) 14 d upper segment (of a seatbelt of the vehicle conventional seatbelt restraint system) 15 latch plate (of the vehicle conventional seatbelt restraint system) 15 a slot (of a latch plate of the vehicle conventional seatbelt restraint system) 16 buckle (of the vehicle conventional seatbelt restraint system) 17 child 18 vehicle's anchoring seatbelt 19 connector 20 seatbelt adaptor 20 a seatbelt adaptor with a safety belt of a fixed length 20 b seatbelt adaptor with a belt of adjustable length 20 c rigid seatbelt adaptor 20 d elastic seatbelt adaptor 21 a safety belt of a fixed length 21 b belt of adjustable length 21 c rigid central lengthening device 21 bs rigid central lengthening device bottom surface 21 d elastic central lengthening device 22 adaptor latch plate 22 bs adaptor latch bottom surface 23 adaptor buckle 23 a adaptor buckle envelope 24 ring 25 device which prevents the buckle's release by a child 26 adaptor buckle indentation 27 release button 28 orifice 29 rigid part 29 a mechanism base 29 bs mechanism base bottom surface 30 L child left leg 30 R child right leg 40 a total equivalent force exertion point 41 upper surface of the vehicle's back seat 42 upper surface of the booster safety seat 43 virtual surface (on level with the child's legs) 44 surface of the vehicle's back seat backrest 45 surface of the booster seat backrest 46 point of contact between the upper part of the child's thighs and the front part of his waist 50 vehicle's frame 51 screw 52 anchoring point 54 magnetic coupling means 55 a Velcro coupling means first layer 55 b Velcro coupling means second layer 60 common bottom plane
Referring now to the drawings, FIG. 2 a is a schematic illustration of a preferred embodiment of a seatbelt adaptor with a safety belt of a fixed length 20 a with a safety belt of a fixed length 21 a . The safety belt of a fixed length 21 a lacks any practical resistance to flexion loads and can be identical or similar to the existing seatbelts already installed in the vehicle in which it will be installed as a matter of the material of which it is made and its dimensions, except for its length, which is fitted for its unique purpose. An adaptor latch plate 22 is disposed at one end of the safety belt of a fixed length 21 a and an adaptor buckle 23 is disposed at the other end of the safety belt of a fixed length 21 a . Adaptor latch plate 22 and adaptor buckle 23 are connectors which are compatible with the vehicle's seatbelt buckles and latches. Safety belt of a fixed length 21 a constitutes a central lengthening device, which mechanically connects adaptor latch plate 22 and adaptor buckle 23 , and determines the distance between them.
The adaptor latch plate 22 and the adaptor buckle 23 clearly must be adapted to the latch plate 15 and the buckle 16 installed in the vehicle. The internal mechanism and external form and dimensions of adaptor buckle 23 can be identical or similar to those of buckle 16 .
The operation of adaptor buckle 23 clearly should preferably be identical or similar to the operation of buckle 16 , and in any case, its operation must not be more complicated or time consuming, nor less convenient, and should not pose any new limitations.
This applies to all possible embodiments of seatbelt adaptor 20 according to the present invention.
This invention is not limited to the use of a specific safety belt and the adaptor latch plate 22 and the adaptor buckle 23 may be connected by many means, such as one or more chains, one or more strings, or as depicted later in FIGS. 2 b - 2 d.
This invention is not limited to the type of buckles which enable the connection of the seatbelt adaptor, to the vehicle's seatbelt and vehicle's seatbelt buckles.
The invention also includes the possibility of connecting the seatbelt adaptor directly to the anchoring point of the vehicle's safety belts.
FIG. 2 b is a schematic illustration of a preferred embodiment of a seatbelt adaptor with a belt of adjustable length 20 b with a belt of adjustable length 21 b . The difference in comparison with seatbelt adaptor of a fixed length 20 a is that in seatbelt adaptor with a belt of adjustable length 20 b has a belt of adjustable length 21 b . There are many ways to construct a belt of adjustable length, which anyone skilled in the art is familiar with. The current figure schematically illustrates a ring 24 to which the end of the adjustable length belt 21 b is connected through adaptor latch plate 22 .
FIG. 2 c is a schematic perspective illustration of a preferred embodiment of a rigid seatbelt adaptor 20 c , whose structure, and in particular whose rigid central lengthening device 21 c is practically non-bendable by reasonable bending moments which may be induced on it. Adaptor buckle 23 can include an adaptor buckle indentation 26 for the purpose of facilitating release, with the press of a finger, of a buckle of the motor vehicle conventional seatbelt restraint system.
In the rear part of adaptor buckle 23 is an orifice 28 , through which a latch plate of the motor vehicle conventional seatbelt restraint system can be inserted and removed, as well as a release button 27 which enables releasing a latch plate of the motor vehicle conventional seatbelt restraint system, by a single press of a finger.
Note: the release button 27 is a component which is included in all embodiments of the adaptor buckle according to the present invention.
FIG. 2 d is a schematic illustration of a preferred embodiment of a elastic seatbelt adaptor 20 d . Its structure and properties are similar to those of rigid seatbelt adaptor 20 c except for its elastic central lengthening device 21 d , which has elastic properties regarding the reasonable bending moments that may be induced on it.
FIG. 2 e is a schematic illustration of adaptor buckle 23 equipped with a device which prevents the buckle's release by a child 25 .
FIG. 2 f is a schematic illustration of rigid seatbelt adaptor 20 c connected to the vehicle's seatbelts. Adaptor latch plate 22 is connected to the buckle 16 of the vehicle conventional seatbelt restraint system and adaptor buckle 23 is connected to the latch plate 15 of the vehicle conventional seatbelt restraint system, through which the vehicle's seatbelt 14 passes. The vehicle's seatbelt 14 is originally designed to be used on an adult's waist and diagonally from one hip towards the opposite shoulder.
Child booster safety seats are in use because vehicle's seatbelts are not designed for children. Young children are too small for vehicle's seatbelts and too large for infant safety seats.
Millions of parents and caregivers use child booster safety seats as protection for their children who have outgrown their infant safety seats but aren't tall enough for vehicle's seatbelts.
The location in which latch plate 15 of the vehicle conventional seatbelt restraint system, through which the vehicle's seatbelt 14 passes, is connected to the vehicle's original buckle 16 of the vehicle conventional seatbelt restraint system, and the location according to the present invention of the connection between the latch plate 15 , through which the vehicle's seatbelt 14 passes, and the buckle of the rigid seatbelt adaptor with regard to the child booster safety seat and the child seated upon it, are of utmost importance.
Even though the present illustration describes a rigid seatbelt adaptor 20 c , any other embodiment of the seatbelt adaptor according to the present invention can also be used.
The requirements that the components of a safety system comprised of a child booster safety seat, a vehicle's seatbelt, a latch plate, and a buckle, must meet include the following:
Any contact between a component of the system and the child that could harm the child as a result of friction, injury, or any other cause, when in use under normal travel conditions, when buckling and releasing, and in the case of emergency braking or an accident, is prohibited.
When a vehicle slows down abruptly, for example during emergency braking or a collision, the vehicle's seatbelt segment that is in the child's lap must fasten the child to the seat, with combined force exerted downwards and backwards with regard to the vehicle's axes, namely force must be exerted towards the vehicle's seat and towards the backrest of the seat, upon which the seat is placed.
The vehicle's seatbelt must be able to be quickly and easily released in case of an emergency.
The location of the original buckle in a vehicle's seats is based on consideration of the forces exerted downwards and backwards on an adult seated in the seat, in case of need, and therefore the buckle is positioned low and close to the seat and its backrest. As a result, in many cases the requirement of fast release of the buckle, when used in conjunction with a child booster safety seat, is impaired, particularly when an additional child booster safety seat or other baggage item is also placed on the vehicle seat.
This problem has been known of for years, however no satisfactory solution has been found for it so far. Some parents have just given up on the possibility of connecting the vehicle's seatbelt and reasonably every time they seat their children in a safety seat, and have turned to the highly hazardous practice of fastening the buckles only once and seating and removing their children without unfastening the buckles.
The use of an existent lengthening strap for facilitating fastening and unfastening of the buckles is also hazardous. Many vehicle manufacturers have lengthening straps designed for larger passengers to buckle up in their vehicles. An example of this is Ford's seatbelt extender, which is a piece of seat belt material about 8 inches long with buckles on the ends of it that click into the existing seat belt buckles. Use of a seatbelt lengthening such as this is hazardous as it does not meet the requirement of adducting forces in the right directions.
According to the present invention, the child booster safety seat is used in conjunction with a seatbelt adaptor, whose qualities, and particularly whose length, are adapted to meet the safety requirements and also ensure that the location of the connection point of the latch plate 15 through which the vehicle's seatbelt 14 passes will be optimally practical. The optimal location is determined by the length of the seatbelt adaptor, which serves as a compromise between the minimal length which has an advantage with regard to the aforementioned force directions, and the maximal length which has an advantage with regard to the aforementioned convenience of unfastening. The boundaries of this field are from the shortest possible length defined by the size limitations of the components to the longest possible length that in case of emergency braking with exertion of force on the diagonal segment of the vehicle's seatbelt, the tension that is generated due to the high location of latch plate 15 does not generate a downwards adducting force in the vehicle's seatbelt segment resting in the child's lap.
The seatbelt adaptor can be connected to the buckle 16 and can be removed when an adult is seated and buckled up in the seat, or can be connected directly to an anchoring point in the vehicle.
In the case that the seatbelt adaptor is connected to an anchoring point within the vehicle, it can be of a fixed length that is a compromise between buckling up an adult and buckling up a child in a safety seat.
FIG. 3 a illustrates the front view of a child 17 seated in a child booster safety seat 13 , with the vehicle's seatbelt fastened according to a preferred embodiment of the present invention. The child 17 is seated in the child booster safety seat 13 and is buckled in a vehicle's seatbelt whose upper segment 14 d crosses the child's chest diagonally, from one shoulder to the waist on the opposite side, through latch plate 15 of the vehicle conventional seatbelt restraint system, and over the child's lap as a lap second segment 14 b of the vehicle conventional seatbelt restraint system, of the vehicle's seatbelt. The latch plate 15 connects to rigid seatbelt adaptor 20 c which is connected to the buckle 16 of the vehicle conventional seatbelt restraint system.
Note: even though this illustration shows a rigid seatbelt adaptor 20 c , this is not intended in any way to limit the use of any other type of seatbelt adaptors according to the present invention. This also applies to the illustrations shown in FIGS. 3 b - 3 h.
FIG. 3 b is a schematic illustration of a preferred embodiment of the present invention depicting a front view of the required direction of the vertical force Fv exerted by the seatbelt on the child seated in the child booster safety seat 13 , as described in FIG. 3 a . The child booster safety seat 13 , which is placed upon the vehicle's back seat 11 , seats a child whose right leg 30 R and left leg 30 L are shown in the illustration in section. This illustration shows the vehicle's seatbelt in further detail, with its diagonal segment, the upper segment 14 d reaching latch plate 15 , inside which it bends back over approximately 180 degrees and returns with the vehicle seatbelt lap third segment 14 c until bending over the child's right leg 30 R, continuing as an approximately horizontal lap second segment 14 b until bending back diagonally downwards over the child's left leg 30 L as vehicle's seatbelt lap first segment 14 a . Latch plate 15 of the vehicle conventional seatbelt restraint system, connects to rigid seatbelt adaptor 20 c , which is connected to buckle 16 of the vehicle conventional seatbelt restraint system. In case of emergency braking, tension T is generated in the vehicle's seatbelt, exerting adducting force Fv downwards relative to the vehicle and adducting the child's lap area downwards to the safety seat. The illustration shows three surfaces, the upper surface of the vehicle's back seat 41 , upon which the child booster safety seat 13 is placed, the upper surface of the booster safety seat 42 , upon which the child is seated, which can also be the upholstery of said child booster safety seat 13 or a cushion, and virtual surface 43 at level with the child's legs 30 L and 30 R, defining the boundaries for seatbelt lap segment 14 b.
The illustration also shows the gaps between these surfaces, with h 1 being the vertical gap between the upper surface of the vehicle's back seat 41 and the upper surface of the booster safety seat 42 , h 2 being the vertical gap between the upper surface of the booster safety seat 42 and the virtual surface 43 ; and h 3 being the vertical gap between the upper surface of the vehicle's back seat 41 and the virtual surface 43 .
FIG. 3 c is a schematic illustration of a preferred embodiment of the present invention enlarging a part of FIG. 3 b.
A total equivalent force exertion point 40 is the point at which the total equivalent force is exerted by the vehicle's seatbelt 14 of the vehicle conventional seatbelt restraint system, on latch plate 15 of the vehicle conventional seatbelt restraint system.
This illustration shows a section of latch plate 15 with both vehicle lap third segment 14 c and upper segment 14 d changing direction at approximately 180 degrees at an axis including total equivalent force exertion point 40 . For the tension force T in the vehicle's seatbelt to generate a downwards adducting force Fv in case of need, total equivalent force exertion point 40 must be sufficiently low with regard to the safety seat and the child's leg 30 R, otherwise the tension force T will create a distance between the seatbelt lap second segment 14 b and the child's legs and enable the child to be separated from the seat, causing severe harm to the child in case of emergency braking and an accident. The illustration also shows the vertical gap h 4 between the total equivalent force exertion point 40 and the upper surface of the booster safety seat 42 and vertical gap h 5 between the total equivalent force exertion point 40 and the virtual surface 43 .
FIG. 3 d is a schematic illustration of a preferred embodiment of the present invention showing a side view of the required directions of the vertical and horizontal forces that are exerted by the seatbelt on the child seated in the child booster safety seat 13 during an emergency braking. Proper location of the total equivalent force exertion point 40 , which was explained in the description of FIG. 3 c , will ensure the generation of a force with adducting components, downwards component Fv on the vertical plane and backwards component Fh on the horizontal plane with regard to the vehicle's axes, when tension force T is exerted. Proper location of the total equivalent force exertion point 40 ensures that gap h 5 is large enough when the total equivalent force exertion point 40 is on a lower plane than that of the virtual surface 43 or even on a lower plane than that of the upper surface of the booster safety seat 42 so that downwards adducting force component Fv is exerted in the case of need. Gap h 4 also depends on the geometric qualities of the child booster safety seat 13 , the seatbelt adaptor, the latch of the conventional seatbelt restraint system, and the buckle of the conventional seatbelt restraint system.
FIG. 3 e is a schematic illustration of a preferred embodiment of the present invention depicting a side view, with the geometrical dimensions of a rigid seatbelt adaptor 20 c ensuring that when a rigid seatbelt adaptor 20 c is connected between latch plate 15 of the vehicle conventional seatbelt restraint system, and buckle 16 of the vehicle conventional seatbelt restraint system, forming an integrative system including the vehicle's seatbelt 14 , passing through slot 15 a (see FIG. 1 b ) of the latch plate 15 with latch plate 15 connected to a rigid seatbelt adaptor 20 c , which is connected to buckle 16 connected to the vehicle's anchoring seatbelt 18 (or any other suitable device installed in the vehicle), whose other end includes a connector which is connected, for example by means of a screw 51 to an anchoring point 52 , which is connected directly to the vehicle's frame 50 , and force T is exerted on the vehicle's seatbelt upper segment 14 d in the suitable direction; the seat belt's total equivalent force exertion point 40 is on the section line of the upper surface of the booster safety seat 42 of the child booster safety seat 13 with the surface of the vehicle's back seat backrest 44 of the backrest of the vehicle's back seat 12 of the vehicle's back seat 11 on which the child booster safety seat 13 is placed.
This ensures that the forces exerted on a child seated in the booster seat, of any physical dimensions, no matter how small, by the seatbelt 14 will be in such directions that the child will be adducted downwards towards the child booster safety seat 13 and backwards towards the backrest of the vehicle's back seat 12 .
FIG. 3 f is a schematic illustration of a preferred embodiment of the present invention depicting a side view. The illustration and accompanying description are identical to those of the previous illustration, other than the fact that the geometrical dimensions of rigid seatbelt adaptor 20 c have been adapted for use with a child booster safety seat 13 which has a backrest 13 c on whose surface 45 the seated child can rest his back.
The geometrical dimensions of rigid seatbelt adaptor 20 c in this case ensure that the seat belt's total equivalent force exertion point 40 will be on the section line of the seat surface 42 of the child booster safety seat 13 with the surface 45 of the child booster safety seat 13 booster seat backrest 13 c.
FIG. 3 g is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point 40 , when it is near the intersection point of the upper part of the thigh of the child seated in the child booster safety seat 13 with said child's waist.
A more optimal utilization of the present invention, with respect to FIGS. 3 e and 3 f , can be achieved when the geometrical dimensions of rigid seatbelt adaptor 20 c enable extension of the integrated system as previously described so that the total equivalent force exertion point 40 is more distant from the vehicle's back seat 11 and the backrest of the vehicle's back seat 12 so that connection and disconnection of latch plate 15 to the rigid seatbelt adaptor 20 c is more convenient and safe.
The maximum length allowed in this case is such that the forces exerted on the child in case of emergency braking are downwards and backwards with regard to the vehicle, and this length is achieved when the total equivalent force exertion point 40 is approximately at the point of contact between the upper part of the child's thighs and the front part of his waist 46 .
The optional length addition, without exceeding the limitation defined above, with regard to the lengths shown in FIGS. 3 e and 3 f depends on the relevant dimensions of the child 17 seated strapped into the child booster safety seat 13 . One option of setting this length is by selecting a rigid seatbelt adaptor 20 c personally adapted to a known specific child 17 seated in a known specific child booster safety seat 13 in a known specific vehicle, similar to the manner of selection of standard personal safety accessories. The choice can also be made from a set of rigid seatbelt adaptors 20 c of different lengths at reasonable intervals.
A good method of selection is checking the selected rigid seatbelt adaptor 20 c by connecting it to the vehicle's restraining system, buckling the child 17 into the child booster safety seat 13 , tugging at the seatbelt's upper segment 14 d , and verifying that the lap second segment 14 b exerts forces in the necessary directions on the child 17 .
Suitable instructions for proper selection of a rigid seatbelt adaptor 20 c can be published much in the same way that instructions for use of child safety seats are published by seat manufacturers and vehicle manufacturers. This method selection can also apply to other seatbelt adaptors according to the present invention.
FIG. 3 h is a schematic illustration of a preferred embodiment of the present invention depicting a side view showing the seat belt's total equivalent force exertion point 40 when it is level with the virtual surface 43 , parallel to the upper part of the thigh of the child 17 seated in the child booster safety seat 13 , with force T being exerted upwards relative to the vehicle, on latch plate 15 of the vehicle conventional seatbelt restraint system, which is connected to a rigid seatbelt adaptor 20 c , connected to buckle 16 of the vehicle conventional seatbelt restraint system, connected to the vehicle's anchoring seatbelt 18 (or any other alternative apparatus installed in the vehicle), whose other end includes a connector 19 (see FIG. 3 g ), which is connected to the anchoring point 52 connected directly to the vehicle's frame 50 .
A rigid seatbelt adaptor 20 c can be selected to have a length suitable and safe for any child seated in a child booster safety seat 13 , according to safety regulations. Safety instructions for strapping children in booster safety seats in vehicles are published in safety regulations and in publications and recommendations of child booster safety seat manufacturers, vehicle manufacturers, and safety organizations. Perusing these instructions and regulations can teaches that different booster seats have different minimum child weight values for use with the seat, the lowest value at 15 kg, which is the approximate average weight of a three year old child.
Obviously, not every three year old child has the same physical dimension, and there is a distribution of dimensions. (One should also take into account that when force is exerted on a child's body by a seatbelt, there is a certain degree of squashing of the child's soft tissue, however seeing as this tissue is in proximity to the pelvic bone, the squashing is negligible for our concerns.) Therefore, the selection must be according to the dimensions of a child of a minimal weight of 15 kg, or a minimal age of three years, who has reasonable minimal dimensions. Dimension h 2 , being the vertical gap between the upper surface of the booster safety seat 42 and the virtual surface 43 , is the smallest likely size for a three year old child and in any case for any child weighing at least 15 kg, ensures that for every possible disposition of the anchoring point 52 , when the child is being strapped into the child booster safety seat 13 , the total equivalent force exertion point 40 will be lower than the virtual surface 43 , including a safety margin, as shown in the illustration by the arrow of radius R. In this case, slot 15 a of the latch plate 15 , including the total equivalent force exertion point 40 is horizontal and is all practically level with the virtual surface 43 .
Anthropometric research and measurements that we have conducted indicate that the dimensions of the smallest child which can be safely seated in a child booster safety seat include a thigh depth of 6 cm when the child is seated, which is essentially the dimension marked as h 2 in the illustration, and an abdominal depth of 12 cm, which is marked as d 1 in the illustration.
FIG. 4 a is a schematic illustration of a preferred embodiment of the present invention depicting a side view of a part of the child restraint system and a child booster safety seat 13 whose structure conforms to the restraint system. The illustration shows that the restraint system is in the groove located in the side of the child booster safety seat 13 . The material from which the structure of the safety seat is assembled in the area of the grove can be a material, such as rubber, that is suitable for contact with rigid parts, or any other material known to an expert in the field. This material can be suitable for restraining friction forces and blows inflicted by the rigid parts of the restraint system on the child booster safety seat 13 . The groove can be in one suitable side of the child booster safety seat 13 ; there can also be two grooves, one in each suitable side. The material that is suitable for restraining can also be on the possible contact areas of the rigid parts of the restraint system.
The present illustration child booster safety seat 13 equipped with a lower anchors and tethers for children device 13 f (LATCH), which is the American terminology for a device for attachment points for child safety seats in vehicles. The present invention is suitable for use with booster seats both equipped a lower anchors and tethers for children device and without.
FIG. 4 b is a schematic illustration of section a-a of FIG. 4 a . The section illustration shows that the structure of the child booster safety seat 13 has a groove with two levels of depth, deep level 13 a and less deep level 13 b . The restraint system touches the child booster safety seat 13 only in the area of less deep level 13 b.
FIG. 4 c is a schematic illustration of section b-b of FIG. 4 a . The section illustration shows that the structure of child booster safety seat 13 includes a groove with two levels of depth, deep level 13 a and less deep level 13 b . The restraint system touches the child booster safety seat 13 only in the area of less deep level 13 b . This structure of the child booster safety seat 13 causes only a portion of seatbelt 14 to touch child booster safety seat 13 when there is tension force in the restraint system, while the rigid parts, such as latch plate 15 of the vehicle conventional seatbelt restraint system, do not touch the child booster safety seat 13 and do not exert forces on it.
FIG. 5 a is a schematic isometric illustration of a preferred embodiment of rigid part 29 which comprises three elements of a rigid seatbelt adaptor 20 c.
A rigid central lengthening device 21 c is disposed between an adaptor latch 22 and a mechanism base 29 a , while all parts are a single unit and have a bottom side which is a shared bottom plane.
Mechanism base 29 a contains a locking and releasing mechanism, not shown in the present illustration, whose description here is strictly schematic and is in no way intended to limit the present invention to any specific type of locking and releasing mechanism.
As shown in the present illustration, there is no clear physical distinction between the mechanism base 29 a and the rigid central lengthening device 21 c as well as between the rigid central lengthening device 21 c and the adaptor latch 22 . The distinction between these three elements is according to each one's functionality, when for rigid seatbelt adaptors 20 c of different lengths, the rigid central lengthening device 21 c is the element that determines the difference in lengths.
FIG. 5 b is a schematic side illustration of a preferred embodiment of a rigid seatbelt adaptor 20 c , with a section of adaptor buckle envelope 23 a . This view shows the common bottom plane 60 which includes the adaptor latch bottom surface 22 bs , the adaptor central lengthening device bottom surface 21 bs , and the mechanism base bottom surface 29 bs . Furthermore, the present illustration also shows a part of a latch plate 15 of the vehicle conventional seatbelt restraint system. This structure ensures that in case of an emergency, when the seatbelt restraint system exerts tension forces T, they will act in very close approximation on one plane, parallel to plane 60 , and the forces exerted upon mechanism base 29 a will be practically identical to the forces that would have been exerted upon it without engagement of a rigid seatbelt adaptor 20 c in the vehicle conventional seatbelt restraint system. In this state, excessive concentration of bending forces on the adaptor central lengthening device 21 c , the adaptor latch 22 , and the mechanism base 29 a is avoided.
FIG. 6 a is a schematic perspective illustration of a preferred embodiment of a rigid seatbelt adaptor 20 c , attached to a child booster safety seat 13 which is resting on a vehicle's back seat 11 in close proximity to the backrest of the vehicle's back seat 12 .
When a rigid seatbelt adaptor 20 c or any other seatbelt adaptor according to the present invention is engaged with a buckle 16 of the vehicle conventional seatbelt restraint system, however is not connected to a latch plate of the vehicle conventional seatbelt restraint system, it is possible that the rigid seatbelt adaptor 20 c will tilt toward the vehicle's back seat 11 and will be hard to reach when buckling the child in the seat. To prevent this from happening, the rigid seatbelt adaptor 20 c is attached to the child booster safety seat 13 .
This illustration also shows the release button 27 and the indentation 26 of the rigid seatbelt adaptor 20 c . This illustration demonstrates how without the presence of the adaptor buckle indentation 26 , releasing the rigid seatbelt adaptor 20 c from buckle 16 could pose some difficulty.
FIGS. 6 b and 6 c are schematic side view illustrations of a preferred embodiment of a rigid seatbelt adaptor 20 c , attached to a child booster safety seat 13 resting on a vehicle's back seat 11 . Attachment of the rigid seatbelt adaptor 20 c to the child booster safety seat 13 is done by means of a coupling means.
FIG. 6 b demonstrates a magnetic coupling means 54 . A magnet is fixed to booster seat wall 13 e . Its magnetic force is applied to the metal components of rigid seatbelt adaptor 20 c , and attaches it to the seat.
FIG. 6 c demonstrates a Velcro coupling means, composed of Velcro coupling means first layer 55 a and Velcro coupling means second layer 55 b . The first layer is fixed to rigid seatbelt adaptor 20 c and the second layer is fixed to the external side of booster seat wall 13 e.
Note: Velcro is a brand name for a coupling means composed of two fabric layers. One layer typically includes a “hook” side, while the other layer includes a “loop” side.
This attachment can be achieved with any other suitable coupling means, as long as the attachment does not disrupt the orderly function of the seatbelt restraint system, namely does not generate disruptively large forces or any other disruption.
The description given for these illustrations is not strictly limited to use with rigid seatbelt adaptor 20 c , and can be applied to any seatbelt adaptor according to the present invention.
Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. | A seatbelt adaptor, a system, and a method for enabling a user to improve the buckling and unbuckling of a child in a child booster safety seat in a vehicle, for use in conjunction with a conventional seatbelt restraint system, the seatbelt adaptor comprising a central lengthening device, an adaptor latch plate, and an adaptor buckle and wherein the length of the seatbelt adaptor is suited to improve upon the latching of the buckle of the seatbelt that secures a child seated in the child booster safety seat within a vehicle. | 1 |
This is a 371 of PCT/EP03/01882 filed 2 Feb. 2003 (international filing date).
The invention relates to a multilayer laser-transfer film for durable inscription on components made from at least one backing layer, where on at least part of the underside of the backing layer there is a first adhesion layer, on which at least two pigment layers have been applied.
BACKGROUND OF THE INVENTION
Industrial labeling is one of the methods used for the identification marking of components on vehicles, on machinery, and on electrical and electronic devices, examples being model-identification plates, labels for process control, and guarantee badges and test badges.
Increasing importance is being attached to identification marking by means of laser labels or printed or coated metal plates, specifically in the automotive industry, in particular for high-quality markings. This method is used to place information and advice, such as tire pressure or fuel type, on a very wide variety of components in the automobile for its subsequent user. A laser label may also be used to convey important production data within upstream stages of manufacture.
For this use, the label may be inscribed with a bar code. A suitable reading device gives an assembly team the opportunity of using the bar code for read-off of information concerning model, color, and special equipment, directly on the manufacturing line.
Labels are used on the vehicle not only for this standard information but also for the placing of sensitive security data, such as chassis number and identification numbers. In the event of theft or an accident, this information is very important for tracing of a vehicle and of stages in manufacture.
The label material used therefore has to be highly counterfeit-proof, in order to prevent any attempt at manipulation. It has to be impossible to remove the label intact from the base to which it adheres.
Additional security is achieved by using highly breakable material in combination with high adhesive strengths. The adhesive strength of the material on the adhesion base is very significant. It is a decisive factor for resistance to any attempt at manipulation by removal.
Besides the standard material, there are modified labels intended to eliminate any possibility of imitating the material by using other safety features, such as embossments, holograms, or a lasting UV impression (footprint).
There are widely used high-performance controllable lasers for introducing markings, such as inscriptions, codings, and the like, using a burning process. Some of the requirements placed upon the material to receive the inscription, or used for the inscription process, are:
It has to be capable of rapid inscription. A high degree of spatial resolution capability has to be achieved. It has to be very simple to use. The decomposition products have to be non-corrosive.
For particular cases moreover, additional properties are demanded:
The markings produced by applying the laser have to have sufficient contrast to be capable of being read without error even under unfavorable conditions and over large distances. Heat resistance has to be high, for example extending above 200° C. Good resistance to weathering, water, and solvents is desirable.
Complete separation of labels from the substrate is possible using sharp, flat blades. The bond between adhesive mass and substrate exhibits particular weaknesses on plastics substrates, such as polyethylene or polypropylene.
Despite increased adhesive strength on metallic or coated substrates, it is also possible here to remove part of the labels without irreversible damage, by using specific tools. A specific tool with a blade can be passed under the label at a shallow angle. Careful cutting movements can lift an edge, producing what is known as a grab site. This method creates a point of attack, which facilitates release.
This means that labels have a fundamental disadvantage.
If printing, rather than a laser label, is used to apply the inscriptions to the component, third parties can easily remove the inscription by washing or scratching. Simple rubbing of the inscribed article on a second article, for example a packing, is also often sufficient to reduce the clarity of the individual letters or numerals.
It is an object of the invention to provide a multilayer laser-transfer film which permits rapid and precise inscription of any desired component, and which meets the abovementioned demand for improved security against counterfeiting, and which cannot be removed intact, even with the aid of a cutter, and which besides this in particular also has high contrast, high capability for resolution, high heat resistance, and good ease of use.
SUMMARY OF THE INVENTION
The invention therefore provides a multilayer laser-transfer film for durable inscription on components made from at least one backing layer, where at least two pigment layers comprising a laser-sensitive pigment are at least partially present on the side of the backing layer of the laser transfer film which is the location of the first adhesion layer and where the concentrations of the laser-sensitive pigment in the pigment layers vary.
DETAILED DESCRIPTION
Preferably, there are two pigment layers and especially the concentration of the laser-sensitive pigment in the first pigment layer, the pigment layer which is closer to the backing layer, is lower than the concentration of the laser-sensitive pigment in the second pigment layer.
Further preferably, there are three pigment layers and especially the concentration of the laser-sensitive pigment in the first pigment layer, the pigment layer which is closer to the backing layer, is lower than the concentration of the laser-sensitive pigment in the second pigment layer, and the concentration of the laser-sensitive pigment in the second pigment layer is in turn lower than the concentration of the laser-sensitive pigment in the outer pigment layer.
In further advantageous embodiments having more than three pigment layers, it is preferable when the concentration of the laser-sensitive pigment in any one pigment layer increases with the increased distance of the particular pigment layer from the backing layer.
In a particularly outstanding execution the concentration of the laser-sensitive pigment in the first pigment layer, the pigment layer which is closest to the carrier layer, is between 0.25% by weight to 0.75% by weight and especially 0.5% by weight, the concentration of the laser-sensitive pigment in the second pigment layer is between 0.75% by weight and 1.25% by weight and especially 1% by weight and also the concentration of the laser-sensitive pigment in the third pigment layer is between 1.5% by weight and 2.5% by weight and especially 2% by weight.
Further preferably the pigment layers comprise a glass flux pigment and an absorber as well as the laser-sensitive pigments.
The adhesive mass is preferably applied to the entire surface of the backing layer but, depending on the application, may also be coated onto part of the material. If the first pigment layer is applied, this may firstly have direct contact with the backing layer, but secondly may also lie upon the first adhesion layer, and specifically irrespective of whether the first pigment layer has likewise been applied to part of the material.
Similar factors apply to the second pigment layer, and also to any subsequent pigment layers. Each of the second and the subsequent pigment layers is coated onto the previously applied layers, onto part of the material or onto the entire surface, depending on the application. The result is very wide variations in the structure of the laser transfer film, depending on the nature of the application process, and also on the distribution of each of the underlying layers.
It is preferable that the matrix of the layers comprising the laser-sensitive pigment is likewise composed of the adhesive of the first adhesion layer, so that the first adhesion layer and the pigment layers form a single homogeneous layer. The laser-sensitive pigments have their distribution in various concentrations only in the periphery of the homogeneous layer, and specifically on the side facing away from the backing layer, and in particular in a comparatively narrow region of the homogeneous layer. Two or more boundary layers are accordingly formed.
For further improvement of the adhesion properties of the multilayer laser-transfer film on the component to receive an inscription, there is preferably a second adhesive layer applied to the second or third pigment layer comprising the laser-sensitive pigment.
A particular manner of application of the second adhesive layer is that of dots or screen print, or, where appropriate, an edge print, the result being that the transfer film can be adhesive-bonded to the substrate in any desired manner.
The thicknesses of the individual layers are preferably selected from the following ranges:
Backing layer
12 μm-240 μm, particularly 100 μm-200 μm
(preferably PET)
Adhesive mass
5 μm-45 μm, particularly 25 μm-35 μm
(preferably acrylate)
first pigment layer
1 μm-10 μm, particularly 2 μm-5 μm
second pigment layer
1 μm-10 μm, particularly 2 μm-5 μm
third pigment layer
1 μm-10 μm, particularly 2 μm-5 μm
The films intended for use as backing material according to the invention have to be transparent and/or translucent, and at least designed in such a way as to prevent any absorption of the laser beam, which would lead to their breakdown.
In particular, it is desirable that the backing material absorbs no light within the wavelength range from 530 to 1064 nm.
According to the invention, the backing materials used preferably comprise films which, in another excellent variant of the invention, are transparent, in particular monoaxially or biaxially stretched films based on polyolefins, i.e. films based on stretched polyethylene or on stretched copolymers, containing ethylene and/or polypropylene units, and, where appropriate, PVC films, films based on vinyl polymers, on polyamides, on polyester, on polyacetals, or on polycarbonates.
PET films in particular have outstanding suitability as backing.
According to the invention, the backing film used also comprises films based on stretched polyethylene or on stretched copolymers comprising ethylene and/or polypropylene units.
Monoaxially stretched polypropylene has a very high tensile stress at break and low longitudinal strain. Monoaxially stretched films based on polypropylene are preferred for producing the labels of the invention.
For the laser transfer films of the invention, particular preference is given to single-layer biaxially or monoaxially stretched films and multilayer biaxial or monoaxial films based on polypropylene which have a sufficiently strong bond between the layers, since delamination of the layers during use is disadvantageous.
Films based on rigid PVC or films based on plasticized PVC may be used for producing laser transfer films.
For the laser transfer films of the invention, it is preferable to use films based on rigid PVC.
Films based on polyester, for example polyethylene terephthalate, are likewise known and may also be used for producing the transfer films of the invention.
Polyesters are polymers whose skeletal units are held together by ester bonds (—CO—O—). The materials known as homopolyesters may be divided into two groups according to their chemical structure,
the hydroxycarboxylic acid types (AB polyesters), and the dihydroxy dicarboxylic acid types (AA-BB polyesters).
The former are prepared from just one single monomer, for example by polycondensing a ω-hydroxycarboxylic acid 1, or by ring-opening polymerization of cyclic esters (lactones) 2, for example
The structure of the latter arises, in contrast, by polycondensing two complementary monomers, for example a diol 3 and a dicarboxylic acid 4:
Branched and crosslinked polyesters are obtained by polycondensing tri- or polyhydric alcohols with polyfunctional carboxylic acids. Polycarbonates (polyesters of carbonic acid) are generally also regarded as polyesters.
Examples of AB-type polyesters (I) are polyglycolic acids (polyglycolides, R=CH2), polylactic acids (polylactides, R=CH—CH3), polyhydroxybutyric acid [poly(3-hydroxybutyric acid), R=CH(CH3)—CH2], poly(ε-caprolactone)s [R=(CH2)5], and polyhydroxybenzoic acids (R=C6H4).
AA-BB-type polyesters (II) which are purely aliphatic are polycondensates made from aliphatic diols and dicarboxylic acids, and are used, inter alia, as products having terminal hydroxyl groups (as polydiols) for preparing polyester polyurethanes (an example being polytetramethylene adipate; R1=R2=(CH2)4].
In quantity terms, the greatest industrial significance attaches to AA-BB-type polyesters made from aliphatic diols and from aromatic dicarboxylic acids, in particular the polyalkylene terephthalates [R2=C6H4, including polyethylene terephthalate (PET) R1=(CH2)2, polybutylene terephthalate (PBT) R1=(CH2)4, and poly(1,4-cyclohexanedimethylene terephthalate)s (PCDT) R1=CH2-C6H10-CH2], which are the most important representatives. These types of polyester can be given widely varying properties and be adapted to various application sectors through concomitant use of other aromatic dicarboxylic acids, (for example isophthalic acid) and, respectively, through the use of diol mixtures during the polycondensation.
Polyesters which are purely aromatic are the polyarylates, which include poly(4-hydroxybenzoic acid) (formula I, R=C6H4), polycondensates made from bisphenol A and phthalic acids (formula II, R1=C6H4-C(CH3)2-C6H4, R2=C6H4), or else those made from bisphenols and phosgene.
The adhesive mass of the first and second adhesion layer of the laser transfer films of the invention may be a self-adhesive mass based on natural rubber, on PU, on acrylates, or on styrene-isoprene-styrene block copolymers.
The use of adhesive masses based on natural rubber, on acrylates, or on styrene-isoprene-styrene is known, and is also described in the “Handbook of pressure sensitive adhesive technology, second edition, edited by Donatas Satas, Van Nostrand Reinhold, N.Y., 1989.
A particular self-adhesive mass used is a commercially available pressure-sensitive adhesive mass based on PU, or on acrylate, or on rubber.
An adhesive mass which has proven particularly advantageous is one based on acrylate hot-melt and having a K value of at least 20, in particular more than 30, obtainable by concentrating a solution of this mass to give a system processable as a hot melt.
The concentration process may take place in appropriately equipped tanks or extruders, and for the associated devolatilization process here particular preference is given to a vented extruder.
An adhesive mass of this type is presented in DE 43 13 008 A1 (=U.S. Pat. No. 6,613,870), the content of which is hereby incorporated herein by way of reference and is included in this disclosure and invention. The solvent is completely removed in an intermediate step from the acrylate masses prepared in this way.
At the same time, other volatile constituents are also removed. After coating of these masses from the melt, they have only small remaining contents of volatile constituents. Any of the monomers/mixes claimed in the abovementioned patent may therefore be adopted. Another advantage of the masses described in the patent is that they have a high K value and therefore a high molecular weight. The skilled worker is aware that systems with relatively high molecular weights can be crosslinked more efficiently. The result is a corresponding reduction in the content of volatile constituents.
The solution of the mass may comprise from 5 to 80% by weight, in particular from 30 to 70% by weight, of solvents.
It is preferable to use commercially available solvents, in particular low-boiling hydrocarbons, ketones, alcohols, and/or esters.
Preference is also given to the use of single-screw, twin-screw, or multiscrew extruders with one, or in particular two or more, devolatilizing units. In the adhesive mass based on acrylate hot melt there may be benzoin derivatives incorporated into the polymer, e.g. benzoin acrylate or benzoin methacrylate, or acrylic esters or methacrylic esters. Benzoin derivatives of this type are described in EP 0 578 151 A1.
The adhesive mass based on acrylate hot melt may, however, also have been chemically crosslinked.
In one particularly preferred embodiment, the self-adhesive masses used comprise copolymers made from (meth)acrylic acid and esters thereof having from 1 to 25 carbon atoms, maleic, fumaric and/or itaconic acid, and/or esters thereof, substituted (meth)acrylamides, maleic anhydride and other vinyl compounds, such as vinyl esters, in particular vinyl acetate, vinyl alcohols, and/or vinyl ethers.
The residual solvent content should be less than 1% by weight.
An adhesive mass found to be particularly suitable is a low-molecular-weight acrylate hot melt adhesive mass as available from BASF with the name acResin UV or Acronal®, in particular Acronal DS 3458. This adhesive mass has a low K value and undergoes a final crosslinking initiated by radiation chemistry in order to obtain properties appropriate to its use.
Another adhesive mass which may be used is composed of the group of natural rubbers or of the synthetic rubbers, or of a desired blend of natural rubbers and/or synthetic rubbers, where the natural rubber or the natural rubbers may in principle be selected from any of the available grades, such as crepe, RSS, ADS, TSR, or CV grades, depending on the purity level and viscosity level needed, and the synthetic rubber or the synthetic rubbers may be selected from the group consisting of the randomly copolymerized styrene-butadiene rubbers (SBR), the butadiene rubbers (BR), the synthetic polyisoprenes (IR), the butyl rubbers (IIR), the halogenated butyl rubbers (XIIR), the acrylate rubbers (ACM), the ethylene-vinyl acetate copolymers (EVA), and the polyurethanes, and/or blends thereof.
The rubbers may preferably also have thermoplastic elastomers added, at a proportion by weight of from 10 to 50% by weight, based on the total elastomer content, to improve processability.
Representatives which may be mentioned at this point are especially the particularly compatible styrene-isoprene-styrene (SIS) and styrene-butadiene-styrene (SBS) grades.
As tackifying resins, use may be made of any, without exception, of the adhesive resins which are known and described in the literature. Representatives which may be mentioned are the rosins and their disproportionated, hydrogenated, polymerized, or esterified derivatives and salts, the aliphatic and aromatic hydrocarbon resins, terpene resins, and terpene phenol resins. Any desired combinations of these and other resins may be used in order to establish the desired properties of the resultant adhesive mass. Express reference is made to the prior art presented in “Handbook of Pressure Sensitive Adhesive Technology” by Donatas Satas (van Nostrand, 1989).
Hydrocarbon resin is a collective term for thermoplastic polymers which are colorless to intensely brown in color, with a molar mass which is generally <2000.
They can be divided up into three major groups according to their source: petroleum resins, coal tar resins and terpene resins. The most important coal tar resins are the coumarone-indene resins. Hydrocarbon resins are obtained by polymerizing the unsaturated compounds which can be isolated from the raw materials.
Polymers which have appropriately low molecular weight and are obtainable by polymerizing monomers such as styrene or by polycondensation reactions (certain formaldehyde resins) are also regarded as hydrocarbon resins. Hydrocarbon resins are products whose softening range varies within wide boundaries from <0° C. (in the case of hydrocarbon resins liquid at 20° C.) to >200° C., and with density of from about 0.9 to 1.2 g/cm 3 .
They are soluble in organic solvents, such as ethers, esters, ketones, and chlorinated hydrocarbons, and insoluble in alcohols and water.
Rosin means a naturally occurring resin obtained from the crude resin from conifers. Distinction is made between three types of rosin: balsam resin, a residue from distilling turpentine oil, wood resin, an extract from conifer stumps, and tall resin, a residue from the distillation of tall oil. In volume terms, balsam resin is the most significant.
Rosin is a transparent brittle product, red to brown in color. It is insoluble in water, but soluble in many organic solvents, such as (chlorinated) aliphatic or aromatic hydrocarbons, esters, ethers, and ketones, and also in vegetable and mineral oils. The softening point of rosin is in the range from about 70 to 80° C.
Rosin is a mixture made from about 90% of resin acids and 10% of neutral substances (fatty acid esters, terpene alcohols, and hydrocarbons). The most important resin acids for rosins are unsaturated carboxylic acids of empirical formula C20H30O2, abietic, neoabietic, levopimaric, pimaric, isopimaric, and palustric acid, and also hydrogenated and dehydrogenated abietic acid.
The quantitative proportions of these acids vary as a function of the source of the rosin.
Plasticizers which may be used are any of the known plasticizing substances. These include, inter alia, the paraffinic and naphthenic oils, (functionalized) oligomers, such as oligobutadienes and -isoprenes, liquid nitrile rubbers, liquid terpene resins, vegetable and animal oils and fats, phthalates, and functionalized acrylates.
For thermal induction of chemical crosslinking, use may be made of any known thermally activatable chemical crosslinkers, for example accelerated sulfur or sulfur donor systems, isocyanate systems, reactive melamine resins, formaldehyde resins, and (optionally halogenated) phenol-formaldehyde resins, and/or reactive phenolic resin or reactive diisocyanate crosslinking systems, in each case with the appropriate activators, epoxidized polyester resins or epoxidized acrylate resins, or combinations thereof.
The crosslinkers are preferably activated at temperatures above 50° C., in particular at temperatures of from 100° C. to 160° C., very particularly preferably at temperatures of from 110° C. to 140° C.
IR radiation or high-energy alternating fields may also be used for a thermal excitation of the crosslinkers.
The adhesive masses intended for use according to the invention are intended to be transparent and/or translucent, and at least to be designed so as to avoid any absorption of the laser beam, which would lead to their breakdown.
In particular, it is desirable that the adhesive mass absorbs no light within the range of wavelengths from 530 to 1064 nm.
The first pigment layer in particular with glass flux pigment and absorber and the laser-sensitive pigment is preferably applied in the form of a solvent suspension, e.g. an isopropanol suspension, to the first adhesion layer, in particular at a thickness of from 2 μm to 5 μm.
The second pigment layer in particular with glass flux pigment and absorber and the laser-sensitive pigment is likewise preferably applied in the form of a solvent suspension, e.g. an isopropanol suspension, to the first pigment layer, and specifically at a thickness of from 2 μm to 5 μm.
The third pigment layer including in particular with glass flux pigment and absorber as well as the laser-sensitive pigment is likewise preferably applied in the form of a solvent suspension, e.g. an isopropanol suspension, to the first pigment layer, and specifically at a thickness of from 2 μm to 5 μm.
Laser-sensitive pigments here mean pigments which change their color under laser irradiation.
Suitable laser-sensitive additives are in particular color pigments and metal salts. Use is particularly made of pigments from TherMark, e.g. TherMark-Pigmente® 120-30 F (black), which are metal oxides, e.g. molybdenum trioxide. It is also possible to use mixtures of two or more pigments or blends of pigments with glass flux pigments; these are obtainable from Merck, and can lead to a sintering process.
The additive may also be used in addition to the preferred absorber titanium dioxide.
The amounts of these additives preferably admixed with the suspension for forming the layer (e.g. as described in DE G 81 30 861) are in particular of the order of size of from a few ppm to a maximum of 10% by weight, preferably from 0.1 to 10% by weight, in particular from 0.5 to 6% by weight, based on the total weight of the layer, very particularly advantageous concentrations specifically being 0.5% by weight, 1% by weight, 2.5% by weight, and 4% by weight.
Other laser-sensitive pigments with excellent suitability are various pigments from Merck (such as the pearl-luster pigments EM 143220 and BR 3-01).
The glass flux pigment and absorber used preferably comprise silicon dioxide or mixtures, such as BaO—CaO—SiO 2 .
The following particle size distribution for the glass flux pigments is advisable for an inventive laser transfer film:
Average grain size
Type
Description
[μm]
SM
Narrow distribution
2.5-3.5
UF
Dental powder, also silanized
0.7-1.5
The following distributions are possible, but their use is not preferred:
Average grain size
Type
Description
[μm]
K
Standard
3.0-30.0
FK
High powder purity
1.0-3.5
VT
Broad distribution
4.0-10.0
Glass powders as described above can be purchased from Schott, for example.
If the standard lasers are utilized, specifically the widely used Nd-YAG solid-phase lasers with wavelength 1.06 μm, the laser beam penetrates through the backing layer and the adhesion layer and impacts, in the pigment layers, the glass flux pigment and the absorber, and also the laser-sensitive pigment.
The desired transfer of the metal oxide onto the substrate to be inscribed takes place during the laser inscribing process, and the metal oxide is simultaneously coated here with a glass layer.
The result is a sintering process in which the laser-sensitive pigment is transferred to the substrate and bonds durably and stably to the substrate.
Sharp, high-contrast inscriptions and identification markings are obtained.
The known direct and indirect application methods are suitable for applying the adhesive mass to the backing material, and also for applying the at least two pigment layers.
Mention may be made of the Accugravur process, the doctor-blade process, the doctor roller process, the RCC process, the Super Reco process, the RAM process, and the use of an air brush and casting processes, and also screen-printing processes.
Acrylate hot melts may be applied to the backings mentioned not only by the standard application processes, such as direct coating from nozzles, by way of rolls, and the like, but also by the transfer process, as disclosed in DE 43 24 748 C2. In this case, the adhesive mass is first applied to a running continuous belt with antiadhesive properties and then transferred to the backing material in a laminating unit—using pressure and heat if required to improve anchoring of the mass.
It is also possible in principle to apply the adhesive mass from organic solvents or as an aqueous dispersion. However, the economic and environmental advantages of the hot melt supply form are well known.
The adhesive mass and the pigment layers may also be applied as points within a grid, by screen printing (DE 42 37 252 C2) in which case the small spots of adhesive may also vary in their size and/or distribution (EP 0 353 972 B1), or by gravure printing (DE 43 08 649 C2=U.S. Pat. No. 5,641,506) in coherent longitudinal or transverse bars, or by dot-matrix printing, or by flexographic printing.
It is preferable for both layers to be dome-like shapes from screen printing, or else to have been applied in some other pattern, such as grids, stripes, zigzag lines, or else by gravure printing, for example. They may also have been applied by spraying, for example, giving an application profile with some degree of non-uniformity.
In one preferred embodiment, these have been applied in the form of polygeometric domes.
The domes may have various shapes. Preference is given to flattened hemispheres. It is also possible for other shapes and patterns to be applied by printing onto the backing material, for example a printed image in the form of alphanumeric character combinations, or patterns such as grids, stripes, or else assemblies of domes, or zigzag lines.
Improved protection of the colorant component is achieved via the individual, in particular three, pigment layers. The concentration gradient provides distinct improvement in the sheathing and thus in the stability of a marking to external influences.
The inventive multilayer laser-transfer film exhibits excellent properties, in particular much better properties than those exhibited by the transfer films which have laser-sensitive pigments homogeneously distributed within the adhesive mass layer, where intensive laser beam/pigment/adhesive mass interaction takes place. The result is thermal stress, the results of which can extend to breakdown of the film (melting).
Another result can be a highly adverse effect on the adhesive mass, in terms of its temporary adhesion property (adhesive mass balling) and in terms of transfer of the pigments into or onto the component.
The result of the pigmented boundary layer toward the adhesion component is that the inventive film does not exhibit the adverse effects on coatings and plastics sheets (PP), but rather a durable inscription on the component.
Additional advantages result via lower pigment use when comparison is made with the homogeneous distribution of the pigment in the entire adhesive mass, and via the resultant reduction in the number of problems in pigment dispersion, and via very little laser beam/pigment/adhesive mass interaction.
A very good inscription result is achieved. In addition, the amount of fume generated is surprisingly small. Directly after inscription, the inscription characters were slightly wider but very high-contrast. After a polish, the contrast reduces slightly, but the outlines of the script become somewhat sharper.
The inventive film also gives excellent results when used on rough surfaces, e.g. on the ceramic base of fuses, or generally on glass.
Advantages become fully apparent in particular in the form of a stamped label, which can be applied to the component and irradiated by a laser. After inscription, it is peeled away. The procedure is complete.
The inventive laser transfer film may be supplied in the form of a continuous roll which has been wound up in the shape of an Archimedean spiral around at least one cardboard shell, and in the form of a stamped label. The latter can have any desired shape with excellent adaptation to the respective intended use.
The figures described below are used for more detailed illustration of the inventive film in particularly advantageous embodiments, but there is no intention of any resultant unnecessary restriction of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the structure of an inventive film in the form of a label, an additional second adhesive layer having been applied,
FIG. 2 shows the procedure for inscription of a component using the inventive film.
FIG. 1 shows the structure of an inventive film in the form of a label. The film is composed of the backing layer 1 , the first adhesive layer 2 , which has been applied to the entire surface of the backing material 1 , the first pigment layer 3 , which comprises a glass flux pigment, an absorber and a laser-sensitive pigment, the second pigment layer 4 , which comprises a glass flux pigment, an absorber and a laser-sensitive pigment and the third pigment layer 5 , which comprises a glass flux pigment, an absorber and a laser-sensitive pigment.
The difference between the individual pigment layers 3 , 4 , 5 is that the concentration of the laser-sensitive pigment increases from pigment layer 3 to pigment layer 5 .
The pigment layers 3 , 4 and 5 have likewise been applied over the entire surface.
An additional second adhesive layer 6 has been applied. This adhesive layer 6 has been applied to only part of the material in the form of individual domes.
These serve as retainer points or a positioning aid for the film on the substrate.
FIG. 2 discloses the procedure for inscription of a component 15 using the inventive film. First, the laser transfer film, ideally in the form of a label, is applied to the component 15 , thus achieving adhesion and securing of the label via the adhesion layer. The inscription then takes place by means of a laser, indicated by the cylinder 10 .
Once the inscription procedure has ended, the transfer film is removed, and the desired inscription 12 remains on the component and is in essence composed of individual points which in turn are composed of metal oxide deposits coated by a glass layer. | The invention relates to a multi-layer laser transfer film for the permanent labeling of components, comprising at least one support layer, whereby a first adhesive layer is at least partly provided on the underside of the support layer, characterised in that on the side of the support layer for the laser transfer film on which the first adhesive layer is provided, at least two pigment layers containing a laser-sensitive pigment are at least partly provided, whereby the concentration of the laser-sensitive pigment in the pigment layers varies. | 8 |
BACKGROUND INFORMATION
German Patent No. DE 196 26 576 describes an electromagnetically actuable fuel injection valve in which an armature coacts with an electrically excitable magnet coil for electromagnetic actuation, and the linear stroke of the armature is transferred via a valve needle to a valve closure element. The valve closure element coacts with a valve seating surface to form a sealing fit. Several fuel conduits are provided in the armature. Return of the armature is accomplished with a return spring.
The fuel injection valve described in German Patent No. DE 196 26 576 is disadvantageous especially with regard to relatively long closing times. Delays in the closing of the fuel injection valve are brought about by the adhesion forces acting between armature and internal pole, and because the magnetic field does not decay instantaneously when the excitation current is switched off. This results in metering times and metered volumes for the fuel that are worth improving. The generation of large closing forces by way of a high return spring force has the disadvantage of a high power requirement for excitation of the magnet coil. The output stage of an electrical control device must then be of correspondingly complex design.
SUMMARY OF THE INVENTION
The fuel injection valve according to the present invention has the advantage that the impact element joined to the valve needle converts the hydraulic momentum of the fuel, flowing in the spray-discharge direction through at least one fuel conduit in the armature or in the valve needle, into a more rapid closing motion.
The opening time remains largely unimpaired by the feature according to the present invention, since hydraulic flow is not yet present when the fuel injection valve opens. The faster detachment of the armature from the internal pole due to a momentum transfer from the fuel to the impact element results in shorter closing times for the fuel injection valve and thus in shorter fuel metering times and more precise metered fuel volumes.
It is advantageous to configure the impact element as an impact plate, since this shape is characterized by a low inert mass.
Also advantageous is the easy and economical manufacture of an integrally configured component comprising the valve needle and impact element, which can be manufactured, for example, as a turned part.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an axial partial section through an exemplary embodiment of a fuel injection valve according to the present invention.
FIG. 2 shows an enlarged portion in region II of FIG. 1 .
DETAILED DESCRIPTION
A fuel injection valve 1 depicted in FIG. 1 is, in particular, used for direct injection of fuel into the combustion chamber of a spark-ignited mixture-compressing internal combustion engine. Fuel injection valve 1 comprises a magnet coil 8 surrounded by a magnetic return-flow element 9 , a core 11 , and a housing element 15 that is welded to a nozzle element 2 . An armature 12 that is acted upon by a return spring 10 has at least one fuel conduit 16 (in the form of a bore in the exemplary embodiment) through which the centrally delivered fuel is guided, via an opening 13 between a valve needle 3 and nozzle element 2 , to the sealing fit.
Armature 12 is in working engagement with valve needle 3 , on which is arranged, downstream from fuel conduit 16 , an impact (baffle) element 17 . In the exemplary embodiment, impact element 17 is embodied in a disk shape, is configured integrally with valve needle 3 (e.g. as a turned part), and possesses a size such that there is at least a partial overlap of the cross section of fuel conduit 16 with impact element 17 when projected onto a plane. Because of its disk-shaped configuration, impact element 17 has only a small inert mass in relation to its impingement surface 20 . Valve needle 3 is configured at the spray-discharge end to form a valve closure element 4 . Valve closure element 4 forms a sealing fit with a valve seating surface 6 that is configured on a valve seat element 5 . The exemplary embodiment concerns an inward-opening fuel injection valve 1 . A spray-discharge opening 7 is configured in valve seat element 5 .
When fuel injection valve 1 is in the closed idle state, armature 12 is acted upon by return spring 10 oppositely to its linear stroke direction, in such a way that valve closure element 4 is held in sealing contact against valve seating surface 6 . Upon excitation of magnet coil 8 , the latter creates a magnetic field which moves armature 12 in the linear stroke direction against the spring force of return spring 10 . Armature 12 also entrains valve needle 3 , with impact element 17 conformingly mounted thereon, in the linear stroke direction. Valve closure element 4 , which in the exemplary embodiment is configured integrally with valve needle 3 , lifts off from valve seating surface 6 , and the fuel directed via fuel conduit 16 and opening 13 to the sealing fit can enter spray-discharge opening 7 .
When the coil current is shut off, armature 12 is released from core 11 by the force of return spring 10 after the magnetic field has sufficiently decayed; as a result, valve needle 3 that is in working engagement with armature 12 moves oppositely to the linear stroke direction, valve closure element 4 is placed onto valve seating surface 6 , and fuel injection valve 1 is closed.
FIG. 2 shows, in a partial, schematic axial sectioned depiction, fuel injection valve 1 according to the present invention in region II of FIG. 1 . The enlarged depiction shows only those components that are of substantial importance with reference to the present invention. Elements already described are labeled with identical reference characters, eliminating any need to repeat descriptions.
The opening operation of fuel injection valve 1 remains largely uninfluenced by the presence of impact element 17 . The flow that is created during opening becomes effective only in the upper region of the linear stroke, but this is compensated for by the magnetic force that has already been completely built up.
When the current exciting magnet coil 8 is switched off, armature 12 is accelerated in the spray-discharge direction by the coaction of various forces. In the embodiment of fuel injection valve 1 according to the present invention, the spring force of return spring 10 (which is weakly dimensioned) makes a contribution in this context to the total force, as does the momentum of the fuel flowing through armature 12 , which is transferred to impingement surface 20 of impact element 17 and thus to valve needle 3 . A slight back pressure which forms on the inflow side of armature 12 also contributes to rapid closing of fuel injection valve 1 .
The path of the fuel through fuel conduit 16 in armature 12 is indicated schematically in FIG. 2 by arrows 18 . When the fuel flows through an inner recess 14 of core 11 , it possesses a momentum p 1 =m*v 1 , where m is the mass and v 1 the flow velocity of the fuel in central recess 14 of fuel injection valve 1 . The cross section A 2 of bore 16 in armature 12 is very much smaller than the cross section A 1 of central recess 14 , resulting in a considerable increase in the velocity of the fuel and an elevation in momentum, as defined by the continuity equations A 1 *v 1 =A 2 *v 2 and A 1 *p 1 =A 2 *p 2 . The momentum p 2 of the fuel as it emerges from fuel conduit 16 in armature 12 is thus considerably greater than the momentum p 1 of the fuel in recess 14 .
If impact element 17 is arranged on valve needle 3 at a sufficiently short distance d from a spray-discharge-side armature end face 19 , the momentum p 2 of the fuel can be used to accelerate the component comprising armature 12 , valve needle 3 , and impact element 17 in the closing direction. The total momentum transferred is ideally 2*p 2 , since a momentum p 2 is respectively transferred when the stream of fuel strikes impingement surface 20 of impact element 17 , and when the stream of fuel is reflected. The distance d between armature end face 19 and impact element 17 must therefore be selected on the one hand so that the loss of fuel momentum due to turbulence and stream spreading is minimized, but on the other hand so that after striking impact element 17 , the stream of fuel is not reflected in such a way that it would again strike armature end face 19 , since as a result the momentum transfer in the closing direction would be overlain by a second momentum transfer in the opening direction. The intended effect of the momentum transfer would thereby be considerably attenuated.
The flow profile of the fuel is depicted schematically in FIG. 2 by directional arrows 18 . The stream of fuel can be further directed in the desired direction by way of a slight conical obliquity of impingement surface 20 of impact element 17 in the radial direction.
The present invention is not limited to the exemplary embodiment depicted, and can also be carried out in the context of a plurality of other designs for fuel injection valves 1 . Fuel conduit 16 can also extend at least partially through valve needle 3 . In the case of an outward-opening fuel injection valve 1 , a reversal of the flow direction of fuel conduit 16 is necessary. | A fuel injection valve, in particular for fuel injection systems of internal combustion engines, includes a magnet coil, an armature acted upon in a closing direction by a return spring, and a valve needle, in nonpositive engagement with the armature, for actuation of a valve closure element that, together with a valve seating surface, forms a sealing fit. At least one fuel conduit through which fuel flows is provided in the armature and/or in the valve needle. An impact element is mounted on the valve needle in the spray-discharge direction of the fuel conduit. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present invention claims benefit of priority to Germany patent application number DE 10 2008 042 602.4, filed on Oct. 6, 2008 and Germany patent application number DE 10 2009 002 709.2, filed on Apr. 29, 2009; the contents of each are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a method for manufacturing an implant, in particular an intraluminal endoprosthesis.
BACKGROUND OF THE INVENTION
Medical endoprostheses or implants for a wide variety of applications are known in large numbers from the prior art. Implants in the sense of the present invention are understood to be endovascular prostheses or other endoprostheses, e.g., stents, fastening elements for bones, e.g., screws, plates or nails, surgical suture materials, intestinal clamps, vascular clips, prostheses in the area of hard and soft tissue as well as anchoring elements for electrodes, in particular pacemakers or defibrillators.
Stents are used as implants especially frequently today for treatment of stenoses (vascular occlusions). They have a body in the form of a tubular, possibly perforated, or hollow cylindrical basic mesh, which is open at both longitudinal ends. The tubular basic mesh of such an endoprosthesis is inserted into the blood vessel to be treated and serves to support the blood vessel. Stents have become established for treatment of vascular diseases in particular. Through the use of stents, constricted areas in the vessels can be dilated, resulting in a wider lumen. Although an optimum vascular cross section, which is needed primarily for successful treatment, can be achieved by using stents or other implants, the permanent presence of such a foreign body initiates a cascade of microbiological processes, leading to a gradual overgrowth of the stent and in the worst case to a vascular occlusion. One approach to solving this problem consists of manufacturing the stent and/or other implants from a biodegradable material.
The term “biodegradation” is understood to refer to hydrolytic, enzymatic and other metabolic degradation processes in a living organism, where these processes are caused mainly by the body fluids coming in contact with the biodegradable material of the implant and leading to a to gradual dissolution of the structures of the implant containing the biodegradable material. The implant loses its mechanical integrity at a certain point in time through this process. The term “biocorrosion” is often used as synonymous with the term “biodegradation.” The terms “bioresorption” and “bioabsorption” refer to the subsequent resorption or absorption of the degradation products by the living organism.
Materials suitable for implants that are biodegradable in the body may contain polymers or metals, for example. The implant body may be made of several of these materials. These materials have in common their biodegradability. Examples of suitable polymer compounds are the polymers from the group comprising cellulose, collagen, albumin, casein, polysaccharides (PSAC), polylactide (PLA), poly-L-lactide (PLLA), polyglycol (PGA), poly-D,L-lactide-co-glycolide (PDLLA-PGA), polyhydroxybutyric acid (PHB), polyhydroxyvaleric acid (PHV), polyalkyl carbonates, polyorthoesters, polyethylene terephtalate (PET), polymalonic acid (PML), polyanhydrides, polyphosphazenes, polyamino acids and their copolymers as well as hyaluronic acid. Depending on the desired properties, the polymers may be present in pure form, in derivatized form, in the form of blends or as copolymers. Biodegradable metallic materials are based on alloys of magnesium and/or iron. The present invention preferably relates to implants whose biodegradable material contains at least partially a metal, preferably iron, manganese, zinc and/or tungsten, in particular an iron-based alloy (hereinafter simply “iron alloy”).
One goal in the implementation of biodegradable implants is to control degradability in accordance with the desired treatment and/or use of the respective implant (coronary, intracranial, renal, etc.). For many therapeutic applications, for example, an important target corridor is that the implant must lose its integrity after a period of four weeks to six months. The term “integrity.” i.e., mechanical integrity, is understood to refer to the property whereby the implant has hardly any mechanical losses in comparison with the undegraded implant. This means that the implant still has so much mechanical stability that the collapse pressure, for example, has declined only slightly, i.e., to 80% of the nominal value at most. The implant may thus retain its main function, namely keeping the blood vessel open, while retaining its integrity. Alternatively, integrity may be defined as meaning that the implant still has so much mechanical stability that it is hardly subject to any geometric changes in its stress state in the vessel; for example, it does not collapse to any significant extent, i.e., it still has 80% of the dilatation diameter under stress or, in the case of a stent, hardly any of the load-bearing struts are broken.
Implants with am iron alloy, in particular stents containing iron, are especially inexpensive and simple to manufacture. For treatment of stenoses, for example, these implants lose their mechanical integrity and/or supporting effect only after a comparatively long period of time, i.e., only after remaining in the treated body for approx. two years. This means that in this application, the collapse pressure of implants containing iron declines too slowly over a period of time.
Various mechanisms of controlling the degradation of magnesium implants have already been described in the prior art. For example, these are based on organic and inorganic protective layers or combinations thereof which present a resistance to the human corrosion medium and the corrosion processes taking place there. Approaches known in the past for solving this problem have been characterized in that barrier layer effects are achieved, based on a spatial separation, preferably free of defects, between the corrosion medium and the metallic material. These approaches result in a longer degradation time. Thus, the degradation protection is ensured by variously formulated protective layers and by defined geometric distances (diffusion barriers) between the corrosion medium and the degradable base material of the implant body (e.g., magnesium or Mg alloys). Other approaches are based on alloy components of the biodegradable material of the implant body, which influence the corrosion process by displacement of the position in the electrochemical voltage series. Other approaches in the field of controlled degradation induce intended breaking effects by applying physical changes (e.g., local changes in cross section) and/or chemical changes in the stent surface (e.g., multilayers with different chemical compositions locally). However, with the approaches mentioned so far, it is not usually possible to make the dissolution due to the degradation process and its resulting breakage of webs occur in the required time window. The result is that degradation of the implant begins either too early or too late or there is too much variability in the degradation.
SUMMARY OF THE INVENTION
Consequently, a feature of the present invention is to provide a method for manufacturing an implant, which will allow degradation of the implant in the desired target corridor, especially in the case of implants with an iron-based alloy in a shorter interval of time. The degradation should take place at a controllable point in time. Accordingly, the object of the invention is also to create such an implant.
The above feature is achieved by a method comprising the following steps:
a) preparing the body of the implant. b) incorporating hydrogen into at least a portion of the structure of the implant body near the surface.
In another aspect of the present invention an intraluminal endoprosthesis implant with a body including a metallic material, optionally iron, is provided by the methods described herein.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, the body of the implant comprises at least a portion of the implant, preferably the main portion of the implant which achieves the mechanical integrity of the implant.
The term “structure” as used below is understood to refer to the arrangement of the components of solids (solid states), in particular the arrangement of crystallites (grains), pores, amorphous regions and grain boundary regions of the implant body. Furthermore, the term “structure near the surface” is understood to refer to the volume range of the structure of the implant body extending from the surface down to a certain (slight) depth of the implant body. This volume range of the implant body extending from the surface down to a certain (slight) depth is also referred to as the “boundary layer of the implant body near the surface” or simply as “boundary layer.”
The advantage of the inventive method is that through the incorporation of hydrogen, preferably atomic hydrogen, embrittlement of the structure occurs, and is manifested in an increase in the strength of the structure near the surface and an associated worsening of the strain properties of this area of the structure. In this way, depending on the average grain size of the implant body material in the present case, local damage is induced in the material in the area of the implant body near the surface. The embrittling effect of hydrogen causes degradation to be accelerated in this region due to the accelerated dissolution of crystallites out of the composite structure in particular. The accelerated dissolution of crystallites is achieved in particular because the highest hydrogen concentration usually occurs at the grain boundaries. The grains dissolved out are removed from the surface of the implant through the surrounding body fluid as well as preferably corroding or dissolving. The remaining surface of the implant is roughened due by dissolving out the crystallites and/or being provided with a fissured structure. Subsequently there is an increased surface area, which contributes toward even more accelerated degradation of the implant.
Since the boundary layer enriched with hydrogen has a higher defect density than the structural areas underneath that, the structural areas near the surface have a lower elongation at break. Cracks occurring due to the higher defect density run from the boundary zone in the direction of the implant body that is not loaded with hydrogen, where they are stopped by the high crack-energy-absorbing capacity of the base material.
In a preferred exemplary embodiment, hydrogen is incorporated into the structure of a boundary layer arranged near the surface of the implant body, whereby the boundary layer has to a thickness of max. 15 μm.
The boundary layer arranged near the surface, having an increased concentration of hydrogen, must extend starting from the surface to an optimum depth, which is indicated for the respective application because there is the risk that in hydrogen loading over an excessive volume area, the implant may break due to delayed brittle fracture during or after a mechanical stress, e.g., in dilatation of the stent. The depth of loading is determined by the degree of deformation of the metal material, preferably the iron alloy, the recrystallization state and the resulting average particle size produced, the method by means of which the hydrogen is incorporated, the composition of the reagents involved as well as the composition of the volume of the implant body near the surface.
In another preferred exemplary embodiment, the average concentration of hydrogen in the structural areas of the implant body where the incorporation of hydrogen takes place is approx. 50 ppm to approx. 150 ppm after the conclusion of the incorporation. For comparison: the structural areas of the implant which are not additionally loaded with hydrogen have a max. hydrogen content of 15 ppm.
A hydrogen concentration within the stated concentration range in the respective structural areas near the surface has the result that, first, the hydrogen concentration is not selected to be too high; the surface areas are not dissolved immediately and directly from the implant, and furthermore, the degradation is accelerated. However, accelerated degradation may also be achieved even at low hydrogen concentration levels, e.g., in the range of 30 ppm, when the part of the implant body treated has an increased degree of deformation.
An especially simple and inexpensive method of achieving an incorporation of hydrogen in a portion of the structure of the implant body near the surface consists of pickling at least a portion of the implant body by means of an inorganic acid and then rinsing it in distilled water. The acids HCl and/or HNO 3 are especially preferably used for pickling. A subsequent rinsing in distilled water causes the pickling process to stop and thus stops further hydrogen incorporation into the structure of the implant body.
Furthermore, the structure of the body surface which has been roughened due to the pickling may also serve as a substance reservoir for another coating, which is to be described in greater detail below by means of an active pharmaceutical substance, which is incorporated in the form of nanoparticles or microparticles and may comprise, for example, substances to promote bone growth, such as calcium phosphates, temporary contrast agents and/or cell-growth-inhibiting substances and/or radioactive substances. Furthermore, lubricants may be effectively incorporated into the roughened structure to reduce the coefficient friction in a catheter.
Essential process parameters of the pickling process by means of which the degradation properties can be adjusted include the pickling medium composition, the pickling temperature and the pickling time. Furthermore, material parameters of the implant body also play a role, in particular the composition of the material, the deformation state, the grain size and the composition of the material at the surface and/or in the immediate vicinity of the surface.
In another exemplary embodiment, as an alternative to pickling or after the pickling step, at least a portion of the implant body is immersed in an acidic to basic electrolyte system for the incorporation of hydrogen, and then is connected to the cathode of a voltage source, which is preferably acted upon with a current density approx. 0.5 A/dm 2 to approx. 2 A/dm 2 . The implant body is therefore electrically connected to connecting wires containing titanium, for example. A counter-electrode made of acid-resistant stainless steel is situated in the electrolyte container.
After immersing the implant in the electrolyte, the implant is connected to the cathode and the specified current density is applied. The effects taking place at the interface between the aqueous electrolyte and the implant surface result in an increased dissociation of the aqueous electrolyte, which is associated with an increased evolution of hydrogen. Because of the cathodic connection, a large portion of the hydrogen begins to diffuse into the implant. Depending on the diffusion flow of hydrogen in the implant body material, which is adjustable through the process parameters, depending on the applied potential, the treatment time and the structural status of the material of the implant body, which results from the deformation of the alloy, for example, the grain size and the composition of the material at the surface and/or in the immediate vicinity of the surface, this results in an incorporation of hydrogen into the structural areas of the implant body near the surface, which proceeds differently with regard to the rate and depth of penetration and determines the duration of the degradation achieved. In addition, this incorporation also depends on the lattice structure of the material of the implant body. For example, the hydrogen diffusion coefficient in an iron alloy containing 20 wt % Mn with a face-centered cubic lattice is lower than that with the body-centered cubic lattice of pure iron. The grain boundaries in particular serve as thermodynamically preferred diffusion pathways of hydrogen. The degradation properties of the treated implant also depend on the composition of the galvanic electrolyte and the electric parameters. Hydrogen loading of the implant body is also accompanied by a roughening of the surface of the implant.
Another advantage of the inventive method according to the above exemplary embodiment is that the cathodically-supported surface treatment requires a plant technology that is not very cost-intensive. The surface treatment may be conducted in galvanic installations for the deposition of gold. For the cathodically-supported surface treatment, such an installation need only have an acid-resistant container and counter-electrodes of chemically-resistant materials, e.g., a perforated plate of platinum-plated titanium.
The aqueous electrolyte system preferably has contains between 20 and 30 vol % of an 85% phosphoric acid.
In another preferred exemplary embodiment, the electrolyte system into which the implant body is dipped contains at least one phosphate. In particular when the implant surface contains iron, the surface of the implant body becomes enriched with biocompatible iron phosphate compounds due to the presence of phosphate in the electrolyte. Since the biocompatible iron phosphate compounds are deposited on the surface and incorporated into areas of the implant near the surface, irritation of cells is reduced or prevented. Direct contact between the material of the implant body, preferably containing iron, and the surrounding cellular tissue is thus postponed until a time which is farther from the point in time than is the case with traditional implants.
Another advantage is that after the hydrogen has been incorporated, the implant body is coated with magnesium stearate and/or parylene and/or an active pharmaceutical substance over at least a portion of its surface, the active pharmaceutical substance in particular being embedded in a polymer, e.g., a polylactide, a polyglycoside or a copolymer thereof, especially preferably PLLA or PLGA or a blend of the aforementioned polymers.
The phrase “active pharmaceutical substance” (or active therapeutic substance or therapeutically active substance) in the sense of the present invention is understood to be a plant-based, animal-based or synthetic active ingredient, i.e., a drug (medication) or hormone used in a suitable dosage as a therapeutic agent for influencing states or functions of the body, as a replacement for active ingredients synthesized by the human or animal body, e.g. insulin, and to eliminate disease pathogens, tumors, cancer cells or exogenous substances or to render them harmless. The release of the substance in the environment of the implant has a positive effect on the course of healing or counteracts pathological changes in the tissue as a result of the surgical procedure and in oncology serves to render malignant cells harmless.
Such active pharmaceutical substances have an anti-inflammatory and/or antiproliferative and/or spasmolytic effect, for example, so that restenoses, inflammations or (vascular) spasms, for example, can be prevented. Such substances may include, for example, one or more substances from the group of active agents such as calcium channel blockers, lipid regulators (e.g., fibrates), immunosuppressants, calcineurin inhibitors (e.g. tacrolimus), antiphlogistics (e.g., cortisone or diclofenac), anti-inflammatories (e.g. imidazoles), antiallergics, oligonucleotides (e.g. dODN), estrogens (e.g., genistein), endothelializing agents (e.g., fibrin), steroids, proteins, hormones, insulins, cytostatics, peptides, vasodilators (e.g., sartans) and substances having an antiproliferative effect, namely taxols or taxans, preferably paclitaxel or sirolimus here.
A coating by means of a polymer, e.g., a polylactide, a polyglycoside or a copolymer thereof, especially preferably PLLA or PLGA or a blend of the aforementioned polymers containing the active pharmaceutical substance is especially advantageous because the reduction in pH achieved in degradation of the polymer in the area of the implant surface constitutes an additional acceleration factor for corrosion, in particular in the case of an implant with an iron alloy.
Coating of the surface of the implant with parylene and/or magnesium stearate after incorporation of hydrogen is advantageous because the surface properties of the implant are to a certain extent “frozen” in this form after incorporation of hydrogen due to the coating above it. In this way, the surface properties, which would otherwise depend on the duration of storage or shipping of the implant until it is introduced into the body to be treated and thus also the degradation, time can be adjusted reproducibly and in a defined manner.
The great ability of parylene to penetrate into gaps has an advantageous effect, so there is deep penetration of parylene into rough surfaces created by the hydrogen treatment, down to the base of the gaps. The permeation properties for water, chloride solutions and hydrogen that are characteristic of parylene ensure an especially well-controlled degradation behavior of the implant in combination with the underlying hydrogen-loaded boundary layer near the surface.
This is characterized by a uniform slow corrosion process over the cross section of the implant.
Parylene is a completely linear, partially crystalline, uncrosslinked aromatic polymer. The various polymers have different properties and can be divided into four basic types, namely parylene C, parylene D, parylene H and parylene F. Parylene C is preferred for use as an additional coating after hydrogen loading.
By means of the inventive method, in coating with magnesium stearate, an implant characterized by a defect-free body surface due to subsequent sealing can be manufactured. Local defects and/or pores present on the surface of the implant body and roughened areas are effectively protected from contact with body fluids having a corrosive action. The hydrophobic surface property and the low water of crystallization content of magnesium stearate, which is also achieved through a subsequent drying step, which is preferably is performed after the application of the magnesium stearate coating, result in extremely low diffusion of water to the basic material of the implant body during subsequent shipping and storage of the implant. The local contamination present at the surface of the implant due to the production process as well as the precipitates at the surface due to the alloy composition of the implant body are embedded here in an inert form due to the magnesium stearate and therefore can no longer react under ambient conditions. Likewise, the release of particles with a low tendency to binding tendency from the surface of the implant body during dilatation can be prevented. These particles remain in the viscous magnesium stearate layer, which is highly flexible. This yields an increased hemocompatibility and/or biocompatibility.
Because of the magnesium stearate coating on the implant body, the coefficient of friction of the implant is lowered in an advantageous manner. As a result, lower forces may be applied in displacement of a stent as an implant in a catheter for example. Therefore, in the case of a stent, a more accurate fixation of the stent is made possible. Furthermore, crimping and the subsequent release of the implant at the site for treatment are simplified.
In a preferred exemplary embodiment of the inventive method, the magnesium stearate coating is applied by dipping in a solution containing magnesium stearate and a solvent, preferably acetone and/or isopropanol, and preferably at a temperature between approx. 10° C. and 40° C. Alternatively, the magnesium stearate layer may also be applied in such a way that said solution containing magnesium stearate is sprayed onto the body of the implant (spray coating). To do so, the part is suspended on a thin wire in a chamber and is sprayed on all sides by means of a rotating disk (batch holder).
In a preferred exemplary embodiment, the efficacy of the dipping process can be accomplished to by applying a pressure lower than the ambient pressure, preferably lower than approx. 90% of the ambient pressure, i.e. atmospheric pressure, at the site where the dipping process is performed. The resulting degassing effect leads to rapid filling of the filigree surface structure of the implant with magnesium stearate. After a retention time of a few minutes in the solution, preferably at least approx. 2 minutes, the implant body coated with magnesium stearate is removed from the immersion bath and is dried in a drying oven at a temperature above room temperature, preferably greater than approx. 30° C. It is especially preferable here if the drying temperature is as low as possible, i.e. between approx. 40° C. and approx. 70° C., because this leads to a slow release/evaporation of the at least one solvent, so that a pore-free first layer containing magnesium stearate is created.
The above statement of object is also achieved by an implant obtainable by an inventive method as described above. Such an implant has the advantages indicated above in conjunction with the inventive production process. The surface morphologies and surface compositions obtained due to the incorporation of hydrogen are characteristic of this treatment and are discernible on the finished manufactured implant.
Furthermore, the object as formulated above is achieved by an implant in which hydrogen is incorporated into at least a portion of the structure near the surface in a concentration of approx. 50 ppm to approx. 150 ppm. As explained above, a concentration of hydrogen in the concentration range indicated leads to especially effective acceleration of degradation.
In another exemplary embodiment, hydrogen is incorporated into the structure of a boundary layer of the implant body arranged near the surface, where the boundary layer has a thickness of max. approx. 15 μm. The stated thickness of the boundary layer with hydrogen is optimal with regard to the degradation behavior on the one hand and the risk of brittle fracture on the other hand.
It is also preferable that the implant has a roughened surface. An increased roughness of the surface of the implant body, which is advantageous for the application of an additional cover layer (e.g., magnesium stearate) or the degradation behavior, is achieved due to the hydrogen incorporation processes described above.
As already explained, it is also advantageous if the implant body has a phosphate in the boundary layer arranged near the surface. In this way, the biocompatibility of the implant is improved at least at the start of degradation in particular when using an iron alloy for the implant body.
It is also preferable if the surface of the implant body has at least partially a coating containing magnesium stearate and/or parylene and/or an active pharmaceutical substance. Preferred layer thicknesses of the parylene coating here are between approx. 0.5 μm and approx. 10 μm.
The preferred thickness of the magnesium stearate coating is approx. 0.5 μm to approx. 10 μm, preferably approx. 1.0 μm to approx. 5.0 μm. The concentration of the magnesium stearate in the additional coating is approx. between 80 wt % and 100 wt %.
Due to the incorporation of hydrogen into a boundary layer near the surface and the subsequent additional coating by means of magnesium stearate and/or parylene, the degradation time of the implant can be varied and adjusted within wide limits in a defined manner according to the respective intended purpose of the implant.
In a preferred exemplary embodiment, the body of the implant preferably contains a degradable metallic material, preferably predominantly iron, in particular more than 80 wt % iron, especially preferably at least 99 wt % iron, in particular in an alloy. Alternatively or additionally, manganese, zinc and/or tungsten may also be used as additional metallic materials. Since these implants can be manufactured inexpensively, they are especially popular for use for treatment of diseases of the human or animal body. In particular in the case of implants containing iron, the incorporation of hydrogen leads to a reduced degradation time. This closes a gap between the degradable and nondegradable alloys for implants.
EXAMPLES
The inventive method and/or the inventive implant is/are explained in the following examples. All the features described constitute the subject of the invention, regardless of how they are combined in the claims or their references back to preceding claims.
Example 1
An implant produced by laser cutting, deburring and electropolishing in the form of a stent consists of an iron-based alloy and is pickled for 10 minutes at room temperature in 30% HCl and then rinsed in distilled water. Depending on the alloy composition, the stent then losses mass in the amount of 3 to 8%. The roughness of the stent surface increases. An increase in the integral hydrogen content in a boundary layer from 15 ppm to 30 ppm is observed. The hydrogen can be detected in the carrier-gas hot-extraction method. The stated hydrogen concentration in the boundary layer is still not within the optimum concentration range given, but accelerated degradation is achieved already at the stated hydrogen concentration, in particular when the treated part of the boundary layer has an increased degree of conversion.
Example 2
A stent made of an iron-based alloy prepared by analogy with the first example is pickled for 10 minutes in a 20% HNO 3 solution at room temperature and then rinsed in distilled water. This is followed by a cathodic treatment in an alkaline phosphate solution containing at least one compound from the group of sodium phosphate, potassium phosphate, calcium dihydrogen phosphate, disodium phosphate, dipotassium phosphate and calcium hydrogen phosphate. Disodium phosphate, dipotassium phosphate and calcium hydrogen phosphate are less water-soluble here than the other compounds of the group.
For example, a stent is brought in contact with a stainless steel wire in an aqueous solution with 80 g/L KH 2 PO 4 and is connected to the anode. The pH of the solution is approx. 9. At a bath voltage between 2 V and 8 V and a current density of 0.5 A/dm 2 to 1.5 A/dm 2 , the stent surface is loaded with negatively charged phosphate ions over a period of 1 to 5 minutes at room temperature. These phosphate ions form a thin layer of sparingly water-soluble iron phosphates (Fe(II) or Fe(III) phosphates) on the surface of the stent. Likewise, the formation of iron diphosphate is also possible. The max. layer thickness is approx. 0.5 μm. It should be noted that no higher current density and no increase in treatment time are allowed, because otherwise the hydrogen content in the boundary layer would be minimized too much.
This surface, which now consists of Fe phosphates, has a higher biocompatibility than a pure iron surface. Furthermore, this surface provides temporary surface protection, which means that the iron stent does not corrode further during its storage time and therefore it is not necessary to shorten the minimum stability of the catheter. On the other hand, the iron phosphate surface is not corrosion-resistant enough to present a greater resistance to corrosive attack in the blood vessel. The surface containing iron phosphate thus functions as an inhibitor with an increased biocompatibility which acts temporarily (over the storage time).
Example 3
Like Example 2, but cathodic treatment of the implant is performed in an acidic solution containing phosphoric acid. For example, the phosphates listed in Example 2 are dissolved in the solution containing phosphoric acid.
The solution consists in particular of an aqueous 10-30% phosphoric acid in which the iron stent is brought in contact with a stainless steel wire and is connected as the anode as in Example 2 using the identical current and voltage parameters. The acid medium here produces further fissuring of the stent surface. Various iron phosphates are again formed.
Example 4
As in examples 1 to 3, with additional sealing of the rough surface of implant body with magnesium stearate or parylene C.
Coating with parylene C is performed from the gas phase. After a coating time of approx. one-half hour, a layer thickness of approx. 0.5 μm is achieved.
Alternatively, a magnesium stearate coating is applied to the implant surface. After performing one of Exemplary Embodiments 1 to 3 and then drying, the endoprosthesis is suspended from a plastic string (e.g., polyamide) and then immersed in the solution to apply the magnesium stearate. The solution consists of 9 parts high-purity acetone or isopropanol and 1 part magnesium stearate, for example. The immersion process takes place at room temperature in an evacuable desiccator in which a vacuum of approx. 100 mbar is created by means of a pump. In this way, the filigree microporous surface structures and/or undercuts and structures of a complex shape formed by the prior plasma-chemical pretreatment are effectively freed of residual gas. Complete coverage of the stent surface by the magnesium stearate in the solution may be accomplished in this way, such that it also penetrates into the surface structures and undercuts. After a retention time of approx. 3 minutes in the immersion bath, the desiccator is aerated, the implant is removed from the immersion body and then dried in a circulating air cabinet at a temperature of 60° C. while still suspended from the plastic string. The layer thickness of the magnesium stearate coating obtained in this way is in the range of approx. 0.5 to approx. 10 μm.
Due to the vacuum prevailing in the desiccator, the magnesium stearate is deposited very uniformly on the surface. A low drying temperature advantageously produces a slow release/evaporation of the solvent of the dipping solution, resulting in a pore-free magnesium stearate layer. If the implant produced in this way is a stent, then the body provided with the first layer and the intermediate layer may then be completed with a catheter and subjected to a radiation sterilization.
The magnesium stearate produces an additional sealing effect on the implant surface. This means that an implant treated in this way can either be stored for a longer period of time (e.g., until assembly of the catheter system) or may have a longer lifetime/functionality in the case of an orthopedic implant. This yields the possibility of maintaining mechanical stability for a longer period of time until resorption of the magnesium stearate. This leads to the possibility of use for an absorbable intramedullary nail in orthopedics, for example. Such a nail is resorbed by the osteoclasts of the spongiosa after a few months when its supporting effect is no longer needed. The magnesium stearate treatment also offers the advantage that the complex electropolishing of the implant (in particular in the case of stents) may be omitted or may be performed with much less effort.
As in the production of the parylene or magnesium stearate coating, the fissured surface of the implant may alternatively or additionally be coated with an active pharmaceutical substance. Preferred substances are indicated above in the description.
Detection of increased degradation of implants which are loaded with hydrogen can be performed by storage in PBS (phosphate buffered solution) or in SBF (simulated body fluid), for example. In the case of suitably treated stents with an implant body comprising an iron alloy with a composition of >50 wt % up to 99.99 wt % iron, with alloy elements such as Mn, Si, Pd, Pt, N, C, S and optionally additional alloy constituents, an increase in Fe elution up to a factor of 1.5 has been found after storage in SBF. Furthermore, due to the roughening effect, an increase in the size of the real surface area by a factor of 1.5 has been achieved after storage in PBS.
In the dimensioning of the inventive hydrogen loading of the implant body, the respective dimensions of the implant must also be taken into account. This will be demonstrated below on the basis of a stern as an example.
On the whole, the diameter of the internal structural area of a stent web loaded with an increased hydrogen content should amount to at least 50% of the total diameter of the stent web. Otherwise, there is the risk that the cracks emanating from the edge zone can no longer be stopped at the middle of the component. In this case, the respective stent can no longer perform its supporting function.
It may be estimated that at a thickness of the boundary layer with an increased hydrogen concentration of 5 μm, cracks run down to a depth of 10 μm into the matrix and the lifetime of the web of a stent 100 μm wide therefore drops to 80%. With a boundary layer thickness of 15 μm, the cracks are stopped by the structure of the stent body after approx. 25 μm. Thus, at a boundary layer thickness of 15 μm, the web cross section of a stent or of any other implant must amount to at least 170 μm×170 μm (=0.289 mm 2 ). The remaining crack-free cross-sectional area would then have edge lengths of 120 μm×120 μm (=0.144 mm 2 ) and would guarantee a degradation time within the desired time range.
It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teaching. The disclosed examples and embodiments are presented for purposes of illustration only. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention. | The present invention relates to a method for manufacturing an implant, in particular an intraluminal endoprosthesis, with a body containing metallic material, preferably iron. To control the degradation of the implant, the method comprises the following steps: a) preparing the body of the implant, and b) incorporating hydrogen into at least a portion of the structure of the implant body near the surface. Furthermore, such an implant is described. | 2 |
BACKGROUND
1. Technical Field
The present disclosure relates to controlling circuits, and more particularly to a circuit for controlling rotation speed of a fan of an electronic device.
2. Description of Related Art
Various electronic devices, such as computers, game players, etc., generate heat when operating. These electronic devices may be damaged if the heat is not dissipated in a timely fashion. Generally, fans are used to facilitate removal of heat to keep the temperature of the electronic devices within safe temperature ranges. The temperatures of the electronic devices may be changeable. It is not energy efficient if the fans speed cannot be adjusted according to the temperatures of the electronic device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a first embodiment of a circuit for controlling a rotation speed of a fan of an electronic device.
FIG. 2 is a second embodiment of a circuit for controlling the rotation speed of the fan of the electronic device.
DETAILED DESCRIPTION
Referring to FIG. 1 , a first embodiment of a circuit 1 is to control a rotation speed of a fan 10 of an electronic device. The circuit 1 includes a temperature sensor 100 , and a rotation speed adjusting circuit 200 .
The temperature sensor 100 includes a thermistor RT, and a voltage divider connected between the thermistor RT and ground. The voltage divider includes two resisters R 1 and R 2 connected in series between the thermistor RT and ground. The thermistor RT is a negative temperature coefficient (NTC) thermistor.
The rotation speed adjusting circuit 200 includes an electronic switch Q 1 , a resistor R 3 , and a zenzer diode ZD 1 . In this embodiment, the electronic switch Q 1 is a bipolar junction transistor (BJT) having a base connected to a node between the two resistors R 1 and R 2 , a collector connected to a negative terminal of the fan 10 , and an emitter grounded. A positive terminal of the fan is connected to a power supply Vcc. An anode of the zenzer diode ZD 1 is grounded. A cathode of the zenzer diode ZD 1 is connected to the collector of the electronic switch Q 1 via the resistor R 3 . In other embodiments, the electronic switch Q 1 may be a metal oxide semiconductor field effect transistor (MOSFET).
The thermistor RT senses a temperature of the electronic device. The base of the electronic switch Q 1 receives a first voltage Vb from the voltage divider. The first voltage Vb is determined according to the equation: Vb=Vcc*r 2 /(rt+r 1 +r 2 ), wherein rt, r 1 , and r 2 are resistances of the thermistor RT, the resistor R 1 , and the resistor R 2 respectively. The resistance rt of the thermistor RT decreases with increasing temperature of the electronic device. When the resistance rt of the thermistor RT decreases, the first voltage Vb increases, which makes a base current of the electronic switch Q 1 increase. It can be determined from the output characteristic of BJTs that a collector current of the electronic switch Q 1 increases with increasing of the base current. Current flowing through the fan 10 increases since the current flowing through the fan 10 is equal to the collector current of the electronic switch Q 1 . Therefore, the fan 10 is driven to rotate faster.
On the contrary, when the temperature of the electronic device decreases, the resistance rt of the thermistor RT increases. The first voltage Vb decreases to decrease the base current of the electronic switch Q 1 . The current flowing through the fan 10 decreases to slow down the rotation speed of the fan 10 .
Referring to FIG. 2 , a second embodiment of a circuit 2 is to detect and control the rotation speed of the fan 10 of the electronic device. The circuit 2 includes the temperature sensor 100 , the rotation speed adjusting circuit 200 , and further includes a rotation speed detector 300 , and a processor 400 .
The rotation speed detector 300 includes a rotation speed sensor 20 , a resistor R 4 , an electronic switch Q 2 , and a zener diode ZD 2 . A first input of the rotation speed sensor 20 is connected to the positive terminal of the fan 10 . A second input of the rotation speed sensor 20 is connected to the negative terminal of the fan 10 . The electronic switch Q 2 is a BJT having a base connected to an output of the rotation speed sensor 20 , a collector connected to the first input of the rotation speed sensor 20 via the resistor R 4 , and an emitter grounded. An anode of the zener diode ZD 2 is connected to the emitter of the electronic switch Q 2 , and a cathode of the zener diode ZD 2 is connected to the collector of the electronic switch Q 2 . The collector of the electronic device Q 2 is connected to the processor 400 . In other embodiments, the electronic switch Q 2 may be a MOSFET.
The rotation speed detector 20 monitors the rotation speed of the fan 10 by detecting the current flowing through the fan 10 , and outputs a second voltage to the base of the electronic switch Q 2 . The electronic switch Q 2 outputs a monitoring signal according to the second voltage. The monitoring signal indicates changes in the rotation speed of the fan 10 . For example, when the rotation speed of the fan 10 increases, the second voltage increases. A base current of the electronic switch Q 2 increases. The collector of the electronic switch Q 2 then outputs the monitoring signal to the processor 400 , indicating that the rotation speed of the fan 10 increases. In this embodiment, the zener diode ZD 2 is used to protect the electronic switch Q 2 from being damaged by an over voltage between the collector and the emitter of the electronic switch Q 2 .
The processor 400 receives and processes the monitoring signal. For example, the processor 400 may convert the monitoring signal to a display signal to indicate the changes in the rotation speed of the fan 10 on a monitor of the electronic device.
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 the above everything. 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 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 the foregoing description and the exemplary embodiments described therein. | A circuit for controlling a rotation speed of a fan of an electronic device according to a temperature of the electronic device. The circuit senses the temperature of the electronic device, and outputs a voltage changing with the sensed temperature. The rotation speed of the fan changes with the voltage. The circuit slows the rotation speed of the fan down when the sensed temperature of the electronic device is decreased. | 5 |
TECHNICAL FIELD
[0001] This invention pertains to adhesive bonding of vehicle body panels having visible surfaces. More specifically, this invention pertains to adhesives and adhesive application practices for making strong adhesive bonds that reduce or eliminate the “read-out” of the adhesive bond line in the visible surface.
BACKGROUND OF THE INVENTION
[0002] Automotive vehicle body structures often include closure members, such as, doors, hoods, deck lids, tailgates, and the like that have complementary inner and outer panels that are joined at peripheral surfaces. Sometimes the manufacture of the body includes the attachment of a body panel like a vehicle top to a body frame structure. Where the panel members are both made of stamped metal alloys the pieces are often hemmed and welded at their edges. However, when one or both of the panel members are formed of a fiber reinforced polymer material, a bead of adhesive is applied to flange surfaces of one or both panels. The panels are positioned with overlying joining surfaces and pressed together and the assembly is heated to cure the adhesive bond. A continuing difficulty arises in that a surface deformation along the adhesive bond line is visible in outer (un-bonded) surfaces of the exterior panel. This bond-line read-out effect is usually viewed as a defect in the surface of the door or panel assembly when it is visible to the user of the vehicle. The avoidance or repair of such defects has been a continuing problem for automotive manufacturers.
[0003] Many polymeric vehicle body panels are made of sheet molding compound (SMC). SMC is a glass fiber reinforced thermosetting composition in which the polymer precursor material typically comprises styrene, an unsaturated polyester, filler, maturation agent, and catalyst. The reinforcing material comprises glass mat and chopped glass roving. The material is prepared in sheet form enclosed in sheets of polyethylene film. These sheets are laid in molds for forming thermoset body panels and other parts. Like panels may also be made from carbon composite materials which are thermosetting polymers reinforced with carbon fibers, often in the form of cloth layers.
[0004] Epoxy based adhesives are widely used for bonding SMC panels or other reinforced polymer panels. The epoxy precursor materials are often relatively low molecular weight addition polymers of bisphenol A and/or bisphenol F and epichlorohydrin. Amine-group terminated compounds may be used as catalysts. Urethane adhesives are also used in bonding reinforced polymer panels. These adhesives provide good bond strength in joining complementary panels or in attaching panels to metal frame members. But they have higher coefficients of thermal expansion than those of the polymeric or metal panels or frame members. Due to the difference in coefficient of thermal expansion, the adhesive and the polymer panels experience different degrees of expansion or shrinkage during thermal cycling for adhesive curing, paint baking, or other processing or environmental temperature cycling. The differential in thermal expansion/shrinkage of panel and the adhesive creates differential residual stresses at the joint that deforms the exterior panel yielding the visible bond-line.
[0005] Unsuccessful attempts have been made to eliminate the bond-line read-out by adding ten to forty percent by volume of glass and/or steel microspheres (of 75 to 150 micrometer diameters). The use of such fillers reduces the bond-line effect by reducing the difference in thermal expansion between the parts and adhesive. But the excessive filler content affects the strength of the adhesive bond. There remains a need to address the adhesive bonding of polymeric panels or other parts having surface appearance requirements.
SUMMARY OF THE INVENTION
[0006] In accordance with an embodiment of this invention, polymer panels and reinforced polymer panels may be adhesively bonded with little or no bond-line read-out using a polymeric adhesive containing nanometer-thick platelets of clay particles as the principal reinforcing filler material. As an example, montmorillonite particles that are about one nanometer in thickness and about one hundred to about six hundred nanometers in nominal diameter may be used. Since such clay particles are hydrophilic, it may be preferred to chemically modify the particles for dispersion in the polymeric precursor materials of the uncured adhesive. For example, an organically modified montmorillonite such as dimethyl dehydrogenated tallow montmorillonite may be used. Preferably, the nanometer size clay particles are used in amounts of up to about five volume percent of the adhesive.
[0007] Montmorillonite clays are hydrated silicates with hydroxide groups and containing calcium, aluminum, and magnesium. The crystal structure of the clay is characterized by alternating alumina and silica layers so that the clay particles may be used in the form of platelets with a very high ratio of diameter to thickness (aspect ratio). In the above example, the aspect ratio was in the range of about one hundred to six hundred. It is preferred to use filler particles in this bonding process that have an aspect ratio of at least 50. Preferably, these filler particles are used in place of other filler particles because the coefficient of thermal (CTE) of nanometer size, high aspect ratio filler-reinforced adhesives approaches that of the joined parts at very low volume percent (less than five volume percent) of added fillers. Further, since only a small volume fraction of fillers are added, the bond-line read-out on a visible surface of a bonded assembly can be eliminated or reduced without compromising the strength of the adhesive.
[0008] In many embodiments of the invention the adhesive will be a thermosetting material. But the practice of the invention is not limited to thermosetting adhesive formulations because differences in CTE values of adhesive and polymeric workpiece can lead to bond-line read-out due to other temperature cycling of the adhesive bonded parts. For example, room temperature chemically cured or moisture cured adhesive formulations using manometer size high aspect ration filler-reinforced clay filler may be used in the practice of the invention.
[0009] In a practice of the invention, an SMC body panel or other polymeric workpiece is positioned for adhesive bonding to another panel or to a body frame structure. The other member may be a polymer panel or a metal panel or frame member. One or more of such body panels or other workpieces have bonding areas with a thickness of about one to ten millimeters are susceptible to bond-line read-out after thermal curing of an adhesive and/or paint baking. A bead of thermosetting polymer adhesive with up to about five volume percent nanometer thick filler particles dispersed in the mobile adhesive mixture is applied to a predetermined bonding surface area of at least one of the parts to be joined.
[0010] An SMC body panel may typically have a peripheral flange region to which the nanoclay particle filled adhesive is applied. There may be other designated bonding regions on a part. Adhesive is typically transported from a one-part or two-part storage container, mixed into one-part, if necessary, and applied as a bead or strip onto the bonding regions of at least one of the workpieces. Often a computer-controlled robot device is used to carefully apply a bead or strip of the adhesive in a predetermined pattern on bonding surfaces of one or both parts to be joined. It is also found that the pattern of application of the adhesive strip may be important in managing the bonding of the parts without a visible surface deformity. Masking of the bonding surface may be used to better define the application of the adhesive material. As stated, the limited content, by volume, of nanometer-thick, high aspect ratio clay platelets in the adhesive is important to reduce the CTE difference, and therefore the differential shrinkage, between the adhesive and the joined parts around the adhesive interface.
[0011] Often a peripheral flange portion of an SMC panel has a bonding surface width in which a bead of adhesive is to be applied. The intent of the bonding process is to form an adhesive bond of a specified width along its pathway on or around an SMC panel. In one embodiment of this invention, it is found that bond-line read-out is minimized when the adhesive is applied, so that when the parts are pressed together, the lateral edges of the adhesive bond lie exactly on the intended edges of the bonding surface. In another embodiment of the invention, two adhesive beads are applied with a gap between them so that their respective outer edges lie exactly on the intended edges of the bonding surface.
[0012] Thus, the use of nanometer thick, high aspect ratio filler particles in a suitable adhesive composition permits the bonding of reinforced polymer parts with minimal bond-line read-out. And, as stated above, careful placement of strips of the adhesive with respect to the edges of the bonding area also reduces bond-line read-out.
[0013] The practice of the invention is particularly applicable where the adhesive bond joins workpieces that are up to about five to ten millimeters in thickness because it is in such relatively thin pieces with an interfacial adhesive layer that heating and cooling of the adhesive joint leads to bond-line read-out.
[0014] Other objects and advantages of the invention will be apparent from a detailed description of preferred embodiments of the practice of the invention. But these descriptions of embodiments are illustrative and not limiting of the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 illustrates representative shapes of a molded glass fiber reinforced polymer inner door panel and a reinforced polymer outer door panel that are in a juxtaposed position just prior to being brought together for adhesive bonding. A bead of adhesive has been applied to the attachment surface of the inner reinforced polymer panel.
[0016] FIG. 2 is a cross-sectional view at 2 - 2 of the outer and inner reinforced polymer panels of FIG. 1 , now in a pressed-together position for adhesive bonding, illustrating a platelet-filled adhesive where the lateral edges of the adhesive strip precisely overlie the edges of the local bonding surfaces of the panels.
[0017] FIG. 3 is a cross-sectional view at 2 - 2 of the outer and inner reinforced polymer panels of FIG. 1 in a different adhesive application embodiment of the invention. The panel sections are shown in a pressed-together position for adhesive bonding illustrating a platelet-filled adhesive where two spaced apart beads of adhesive have been applied such that the outer edges of the two adhesive strips precisely overlie the edges of the bonding surfaces of the panels.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] A practice of the invention will be illustrated where molded SMC inner and outer automotive vehicle door panels are adhesively bonded. However, it is to be understood that the invention is also applicable to adhesive bonding of other combinations of polymeric and metal parts and to the binding of other reinforced polymer parts.
[0019] In FIG. 1 , a glass fiber reinforced sheet molding compound (SMC) polymer matrix outer panel 10 is seen positioned with its inner side (not visible in the figure) facing the inner side 14 of a SMC inner panel 12 . Reinforced polymer outer panel 10 has been molded to have the top to bottom curvature of the side of a vehicle, a formed region 16 for a handle for opening and closing the door, and a framed-in window opening 18 . Inner panel 12 has been molded from SMC material to complement the shape of outer panel 10 . Inner panel 12 is shaped to define its corresponding window opening 20 and to provide a compartment (indicated generally at 22 ) for containing a mechanism for opening and closing a window and other components to be fitted within the bonded door panel assembly.
[0020] As best seen on the inner side 14 of inner panel 12 each molding has peripheral surfaces 24 (on inner panel 12 ) and a belt line surface 26 for bonding to the facing side of the mating panel. Outer panel 10 likewise has peripheral flange edges 28 . These generally level, relatively thin, generally uniformly thick (e.g., five millimeters thick) peripheral flange surfaces 24 , 26 , 28 provide complementary engaging bonding surfaces for the facing panels 10 , 12 that are to be attached with an adhesive bond.
[0021] In the adhesive bonding of these complementary inner and outer panels 10 , 12 strips or bands of adhesive 30 are applied in a suitable pattern to surfaces 24 and 26 on inner surface 14 of inner panel 12 . The panel is placed in a suitable fixture or workholding device in a position for careful application of the adhesive to predetermined locations. The strips or bands of adhesive composition are often carefully applied in a predetermined pattern to the bonding surface(s) of one of the pieces to be joined using, for example, a computer controlled robot arm or other adhesive applicator. The adhesive is applied in a bead, strip, or band on a bonding surface to achieve a suitably thick layer of adhesive covering a desired bonding surface area and pattern between the workpieces to be joined. Masking of the bonding surface with, for example, Teflon® tape or a mold release material may be practiced in defining the adhesive application pattern. After the adhesive is applied to at least one of the panels, the panels are pressed together against the adhesive in a door assembly and the assembly is, for example, heated to polymerize or cure the thermosetting composition to form a strong bond between the door panels or other workpieces.
[0022] The adhesive is applied to at least one of the panels 10 , 12 so that when the panels (or other workpieces) are pressed together against the applied adhesive a compressed adhesive interface of desired thickness and cross-section is formed. By way of example, a compacted adhesive interface layer uniformly about one millimeter in thickness may be formed. One such layer is illustrated at 32 (between panels 10 , 12 in the cross-sectional view of FIG. 2 and two parallel, spaced apart adhesive layers 34 , 36 are illustrated between panels 10 , 12 in the cross-sectional view of FIG. 3 . The thicknesses of the adhesive layers are exaggerated in these figures for purposes of illustration.
[0023] Adhesive 30 may be of a known adhesive composition such as an epoxy adhesive material or a urethane adhesive material. The adhesive composition may be initially prepared in one-part or two-part formulations depending on a desired shelf life of the material before it is used in a bonding operation. Such formulations typically contain viscous but mobile liquid constituents that are curable to a strong adherent interfacial bond layer between surfaces of panels to be joined. The formulations may contain solid particles as catalysts or polymerization aids, or as additives for prolonging storage time. The formulations may contain solid particles or materials for coloring. And the uncured adhesive formulations may contain solid fillers. But, in accordance with this invention, an essential filler constituent is employed for reducing the CTE of the adhesive for the purpose of reducing or eliminating adhesive bond-line read-out on a surface of a bonded panel. The essential filler particles may be used as the sole solid filler constituent or, less preferred, in combination with other filler particles. As described above, the required filler component is characterized as being in the form of very thin platelets (of the order of a nanometer in thickness) with a very high aspect ratio (for example, platelet diameters of 100 to 600 nanometers). The platelet filler particles are used in amounts up to about five volume percent of the adhesive formulation to avoid an image of the adhesive bond on a visible surface of the bonded article. Montmorillonite clay particles are preferred, especially clay particles that have been treated for dispersion in the organic adhesive constituents.
[0024] The platelet filler material and its content in the adhesive are of primary importance in avoiding bond-line read-out, but the pattern of the adhesive interfacial layer also contributes to the reduction of bond line defects. This practice will be illustrated with further reference to FIGS. 2 and 3 .
[0025] FIGS. 2 and 3 are like cross-sectional views taken at location 2 - 2 of window frame portions of outer panel 10 and inner panel 12 . While panels 10 and 12 are illustrated in a juxtaposed, but spaced apart, position in FIG. 1 , the panels are shown in their assembled position in FIGS. 2 and 3 , pressed against the applied adhesive material. The illustrated window frame portions of the panels serve to illustrate bonding surfaces having bonding widths and the relationship of the compacted adhesive interface with respect to the width of the bonding area. It is to be understood that the peripheral bonding surfaces of panels 10 , 12 may have a length in meters and the adhesive is applied over the totality of the length of the bonding surfaces. But as illustrated in single cross-sections in FIGS. 2 and 3 , there is a preferred relationship between the width of the bonding surfaces and the width of the interfacial adhesive layer.
[0026] In FIG. 2 , it is seen that the width of adhesive layer 32 substantially coincides with the width of the bonding surface at the illustrated portion of the panels 10 , 12 . Applied, compacted, and cured adhesive layer 32 , with its essential platelet filler particles 40 , extends precisely to the edges 42 , 44 of window frame portions of panels 10 , 12 . And adhesive layer 32 is of substantially uniform thickness across the facing bonding surfaces of panels 10 , 12 . This coincidence of the adhesive bonding layer 32 with the width of the bonding surfaces of the SMC panels is found to distribute the differential residual stress in the bonded parts in such a way that minimizes bond-line read-out after thermal cycling experienced in curing the adhesive.
[0027] In FIG. 3 the platelet filler particle-containing adhesive 30 was initially applied as two beads. Both adhesive beads may be applied to one panel or one bead to each panel. After the panels have been assembled and pressed together two adhesive interfacial layers 34 , 36 are formed as illustrated in FIG. 3 . The interfacial adhesive layers 34 , 36 are equi-width and spaced apart with a gap between them. The overall width of the adhesive layer, 34 along with 36 , is determined based on the structural strength required by the adhesive joint. As long as the total width of the adhesive layer is lower than the flange width ( 42 or 44 ), splitting the adhesive layer into two equal width beads and placing them at the two ends of the flange would help reducing bond-line read-out. The outer edge of interfacial adhesive layer 34 coincides with the left outer edges 42 , 44 of panels 10 , 12 (as viewed in FIG. 3 ) and the outer edge of interfacial adhesive layer 36 coincides with the right outer edges 42 , 44 of panels 10 , 12 . Again this adhesive interfacial relationship of spaced layers with outer edges at the boundaries of the bonding surfaces is found to reduce bond-line read-out after curing of the thermosetting adhesive and any other subsequent thermal processing of the panels.
[0028] Practices of the invention have been illustrated in terms of some preferred embodiments. But the illustrations are not intended to be limiting of the practice of the invention. | The bonding of polymeric panels with thermosetting adhesive compositions may lead to an unsightly image of the adhesive bond line on an external surface of the joined articles. This bond-line read-out is reduced or eliminated using an adhesive material with filler particles characterized by nanometer size clay platelets when the content of the filler particles does not exceed about five percent by volume of the uncured adhesive. Selective placement of the adhesive extending to the edges of the bonding surfaces of the polymeric members also reduces bond-line read-out. | 1 |
CLAIM OF PRIORITY
[0001] This patent application claims priority to provisional patent application No. 60/939,530 entitled “Improved Method and Device for Testing Telephone Communication Lines”, filed by Charles Wissman on May 22, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to devices and methods for testing communication circuits.
BACKGROUND
[0003] In spite of more fiber being deployed in the telecommunications industry, communication lines consisting of a twisted pair are still the most common for delivering signals to customer's premises. This is true for both voice and high speed data.
[0004] One common measure of the quality of the twisted pair line is the longitudinal balance of the line. The longitudinal balance is a measure of how well the line rejects external noise. Such noise may come from several sources such as power influence from external power sources, cross talk from adjacent pairs in the cable, and external radio interference (which is more important with high speed data communication).
[0005] To understand how longitudinal balance is measured, a short bit of background is necessary. The twisted pair line is a 3 terminal device: (1) the “Tip” is one wire in the pair, (2) the “Ring” is the other wire in the pair, and (3) the “Shield” surrounding the cable. The longitudinal balance is how well matched the impedance between Tip and Shield is compared to the impedance between Ring and Shield.
[0006] The basic method of measuring the balance of a line is outlined in the Institute of Electrical and Electronics Engineers (IEEE) Standard 455. FIG. 1 is from the IEEE Standard 455. A balanced circuit ( 102 ) internal to a test instrument ( 104 ) is connected to twisted pair line in a bridge configuration—i.e., one terminal is connected to the Tip ( 105 ) and one to the Ring ( 110 ). The test equipment then sends an AC signal ( 115 ) onto the Shield of the cable (i.e., a common mode signal in generic engineering terms or a longitudinal signal in industry terms). Any impedance mismatch between the Tip side of the line and the Ring side will result in a signal appearing between Tip and Ring ( 120 ) (i.e., a differential signal in generic engineering term or a metallic signal in industry terms). The longitudinal balance is given by the following equation:
[0000]
V
m
/
V
s
or
(
V
t
-
V
r
)
/
V
s
[0007] In more generic engineering terms (known as the common mode rejection ratio), this equation can be expressed as:
[0000]
V
differential
/
V
common
mode
usually
measured
in
dB
[0008] It is known that achieving the best balance on the circuit under test (i.e., the lowest longitudinal balance or the lowest common mode rejection ratio) is limited by the test equipment—specifically by the test equipment's internal balanced circuit. Ideally, the internal balanced circuit is perfectly balanced, that is the impedance presented to the Tip is exactly the same as the impedance presented to the Ring. Said another way with reference to FIG. 1 , Z 1 =Z 2 .
[0009] In practice, however, the internal balanced circuit is not perfectly balanced. Rather, it is a network of resistor, capacitors, and sometimes inductors that have impedance. The internal balanced circuit of most practical instruments includes series capacitors to block any DC current flow, which allows for the testing of lines that are connected to central office equipment. Making the series capacitance as large a possible reduces the impedance of the capacitors, and therefore minimizes their effect on the balance of the internal balanced circuit. There is a practical limit to this however; physical size, expense, and ability to withstand high voltage that sometimes occurs on lines in service limit the amount of capacitance that can be used in a practical device.
[0010] Currently in most instruments the series capacitors are hand matched and trimmed, which is labor intensive and time consuming. An example of one instrument that requires hand matching of the series capacitors is U.S. Pat. No. 5,157,336 at 6:5-6 where the capacitors “ . . . are selected in a manner know to one skilled in the art . . . ” Even after hand-matching and trimming the capacitors, their capacitance will drift over time and temperature. Also, each capacitor usually drifts at different rates than the others used in the internal circuit such that it may be impossible to maintain an acceptable level of balance in the internal balanced circuit.
[0011] U.S. Pat. No. 5,436,953 by Nilson discusses some of the problems with trying to maintain the precision of an internal balanced circuit. Nilson teaches a method of mathematically correcting for the imbalance of the internal balanced circuit by measuring the balance of the cable in “at least two different connection profiles.” Because the Nilson method requires a relay switch for every measurement, the method works best when only a few measurements must be taken daily—e.g., central office equipment. However it is not well suited to a portable test instrument intended for trouble-shooting which needs to make continuous measurements at rates at least several times per second. Relays would slow down the measurement and wear out quickly. The typical lifespan of a relay is 100,000 operations, which is less than 28 hours of operation at one switch per second.
[0012] What is needed therefore is a circuit and method that quickly and efficiently compensates for the internal imbalance and has a long operational lifetime.
SUMMARY OF THE INVENTION
[0013] A novel method for testing a communications circuit is disclosed. The method includes the following steps: (a) connecting an internal balanced circuit to a well-balanced resistor network; (b) measuring a first plurality of real and imaginary components of the voltages with the internal balanced circuit connected to the well-balanced resistor network; (c) calculating an error for the internal balanced circuit based on the first plurality of voltages; (d) connecting the internal balanced circuit to the communications circuit; (e) measuring a second plurality of real and imaginary components of the voltages with the internal balanced circuit connected to the communications circuit; and (f) calculating a corrected balance for the communications circuit based on the second plurality of voltages and the error for the internal balanced resistor network. In one embodiment, the method further comprises repeating steps (a) through (c) at a predetermined interval, such as when the internal balanced circuit is powered-on
[0014] The method may also include the steps of communicating the calculated corrected balance to a user, and that may be accomplished by a visual and/or audio device. The method at step (c) may calculate the error using the following equation (labeled Eq. 10 in the detailed description):
[0000]
Error
=
dZb
Zb
=
MeasuredV
bal
Vt
Vs
(
1
-
Vr
Vs
)
[0015] The method may calculate the correct balance of step (f) using the following equation (labeled Eq. 8 in the detailed description):
[0000]
CorrectedBalance
=
MeasuredV
bal
-
dZb
Zb
Vt
Vs
(
1
-
Vr
Vs
)
[0016] The method may also accommodate for errors associated with a differential amplifier by calculating a corrected V bal . The corrected V bal may be used in the calculation steps (c) and (f). This calculation may be performed using the following equation (labeled Eq. 11 in the detailed description):
[0000]
CorrectedV
bal
=
MeasuredV
bal
-
V
t
V
s
V
bal
short
[0017] A novel device for testing a communications circuit is also disclosed. The device comprising a circuit board connected to a central processing unit. The circuit board further includes a switch, an internal balanced circuit, a well-balanced resistor network, and a plurality of leads adapted to connect to the communications circuit. The switch can selectively connect the internal balanced circuit to the well-balanced resistor network or to the plurality of leads. The central processing unit is programmed to perform the steps of the novel method described above. The device can also include a signaling device connected to the central processing unit. Non-limiting examples of the signaling device may include a monitor, display, touch screen display, speaker, light, LED, visual signaling device, audio signaling device and combination thereof. The device may also include a control device connected to the central processing unit. Non-limiting examples of the control device may include a mouse, pointing device, keyboard, a touch screen display and combination thereof.
[0018] Finally, a computer readable medium having stored thereon one or more sequences of instructions for causing one or more microprocessors to perform the steps for testing a communications circuit, wherein the steps comprise those of the novel method described above.
BRIEF DESCRIPTION OF THE DRAWINGS AND ATTACHMENT
[0019] FIG. 1 illustrates the circuit/testing diagram from IEEE Standard 455.
[0020] FIG. 2 illustrates a reconfiguration of the circuit/testing diagram from IEEE Standard 455 ( FIG. 1 ).
[0021] FIG. 3 presents a schematic of a novel testing device with a Resistor Calibrator Network (R cal ).
[0022] FIG. 4 illustrates a schematic of a novel testing device when the relay is in the POS 2 position.
[0023] FIG. 5 presents a detailed schematic of a novel testing device, including the differential amplifier, the internal balanced circuit, Resistor Calibrator Network (R cal ) and the oscillator drive.
[0024] FIG. 6 is a flowchart that illustrates a novel method for testing communication circuits.
[0025] FIG. 7 illustrates a novel device incorporating the method and circuits described herein.
[0026] The appendix is an example of the source code used to implement the novel method described herein.
DETAILED DESCRIPTION
[0027] What is described below is a novel device and method for testing communication circuits. The device implementing the mathematical method compensates for the imbalance of the internally balance circuits currently found in conventional testing equipment. This results in a device that is more robust, accurate and sensitive.
[0028] FIG. 2 is essentially the same circuit as represented by FIG. 1 from IEEE 455, but some components have been reconfigured to simplify the equations. The internal balanced circuit ( 205 ) is now modeled as two identical lumped impedances (Z b ) shown as part 210 , with any difference in the impedances presented to Tip and Ring represented by dZ b ( 215 ). The Z 1 of FIG. 1 is now Z b +dZ b in FIG. 2 , while the Z 2 of FIG. 1 is now Z b in FIG. 2 . In perfectly balanced internal balanced circuit dZ b =0. By measuring the imbalance (i.e., dZ b ) of the internal balance circuit ( 205 ), a mathematical method can be used to compensate for the imbalance.
[0029] Referring back to FIG. 1 and using voltage divider equations,
[0000]
Balance
=
V
bal
V
s
=
V
t
-
V
r
V
s
=
Zb
+
dZb
Zb
+
dZb
+
Zt
-
Zb
Zb
+
Zr
(
Eq
.
1
)
[0030] As long as the impedance in the two branches (i.e., branches 220 and 225 ) are reasonably matched such that dZ b <<Z b , then using the result of Eq. 1:
[0000]
Zb
+
dZb
Zb
+
dZb
+
Zt
≈
Zb
+
dZb
Zb
+
Zt
(
Eq
.
2
)
[0031] Combining the simplification of Eq. 2 back into Eq. 1, yields:
[0000]
Balance
≈
Zb
(
Zr
-
Zt
)
+
dZbZr
(
Zb
+
Zr
)
(
Zb
+
Zr
)
or
Zb
(
Zr
-
Zt
)
(
Zb
+
Zr
)
(
Zb
+
Zr
)
+
dZbZr
(
Zb
+
Zr
)
(
Zb
+
Zr
)
(
Eq
.
3
)
[0032] The error created by dZ b is just the right hand component of Eq. 3:
[0000]
Error
≈
dZbZr
(
Zb
+
Zr
)
(
Zb
+
Zr
)
(
Eq
.
4
)
[0033] Again referring to FIG. 2 and using voltage divider equations:
[0000]
Zr
=
Zb
(
Vs
Vr
-
1
)
(
Eq
.
5
)
Zt
=
(
Zb
+
dZb
)
(
Vs
Vt
-
1
)
≈
Zb
(
Vs
Vt
-
1
)
(
Eq
.
6
)
[0034] Substituting Eqs. 5 and 6 into Eq. 4 yields:
[0000]
Error
=
dZb
Zb
(
Vs
Vr
-
1
)
Vs
Vt
Vs
Vr
=
dZb
Zb
Vt
Vs
(
1
-
Vr
Vs
)
(
Eq
.
7
)
[0035] The corrected balance is equal to the error (Eq. 7) subtracted from the measured balance. Or stated as an equation:
[0000]
CorrectedBalance
=
MeasuredBalance
-
dZb
Zb
Vt
Vs
(
1
-
Vr
Vs
)
(
Eq
.
8
)
[0036] All the terms of Eq. 8 can be measured in real-time by the instrument, except for dZ b /Z b . The lower dZ b /Z b is, the better the improvement correction from the mathematical method works. For example, even with dZ b /Z b =0.1, which represents a fairly poor match, Eq. 8 gives a nearly 40 dB improvement in balance sensitivity. And for a dZ b /Z b =0.05, Eq. 8 yields a 45 dB improvement.
[0037] Referring now to FIG. 3 , a schematic of an embodiment of the novel device is presented. The device contains a relay ( 305 ) (or other switching mechanism) that switches the device between two states. When relay ( 305 ) switched to POS 1 ( 310 ) then the internal balanced circuit of the device is connected to the circuit under test (also referred to herein as a communications circuit) and the entire network (instrument and circuit under test) is represented by FIG. 2 . When the relay ( 305 ) switched to POS 2 ( 315 ) the internal balanced circuit is connected to Resistor Calibrator Network (R cal ), and the network is represented by FIG. 4 .
[0038] Returning to Eq. 8, the only term that is not measured real time by the instrument is dZ b /Z b . To measure this term, the relay ( 305 ) of FIG. 3 is positioned so that the internal balanced circuit is placed in POS 2 ( 320 ) such that the internal balanced circuit is connected to R cal . The network in POS 2 is represented by FIG. 4 . R cal is a well matched resistor network that may be internal to the test instrument. Resistors have a significant advantage over capacitors in that resistors are very easy to accurately match. Also, resistors are much more stable than capacitors, so they do not drift as dramatically from their initial performance characteristics. An example of commercially available matched resistor networks is T912-1K-010-02 from Caddock Electronics. Also the resistor network can be hand trimmed with relatively inexpensive and stable trim potentiometers.
[0039] R cal can be chosen or trimmed to be so well balanced that its balance approaches 0. One such embodiment is illustrated in schematic of FIG. 5 . This schematic details the differential amplifier ( 505 ), the internal balanced circuit ( 510 ), the R cal ( 515 ) and the oscillator drive ( 520 ). Also, the inputs to the system are the BAL_TRGA ( 525 ) which is connected to the Tip wire, and the BAL_TRGB ( 530 ) which is connected to the Ring wire. The output of the system is BALOUT_S ( 535 ) that outputs an AC signal ( 115 ) onto the Shield of the cable (i.e., a common mode signal in generic engineering terms or a longitudinal signal in industry terms).
[0040] When a well balanced R cal is used, as in FIG. 5 , Eq. 8 becomes:
[0000]
0
=
MeasuredV
bal
-
dZb
Zb
Vt
Vs
(
1
-
Vr
Vs
)
(
Eq
.
9
)
dZb
Zb
=
MeasuredV
bal
Vt
Vs
(
1
-
Vr
Vs
)
(
Eq
.
10
)
[0041] Now that the error created by dZ b has been quantified it can be compensated for mathematically using Eq. 8. It should be noted that the terms in the above equations are vector (complex) quantities, with real and imaginary components. Thus, calculations should be made using vector algebra. U.S. Pat. No. 5,436,953 from Nilson teaches a form of synchronous detection for measuring the real and imaginary components of the different voltages, and there are other methods that are well know to those of skill in the art. Also, if any of the components that comprise the internal balanced circuit drift, it generally occurs over days, not seconds. So dZ b /Z b need only be measured periodically. One possible period may be each time the instrument is turned on, which is convenient and, more importantly, adequate for reliable measurement.
[0042] Though not nearly as significant as the error created by the internal balanced circuit, non-ideal behavior of the differential amplifier can also cause an error in balance measurement. This can be caused by operational amplifiers with lower common-mode rejection ratios and parasitic impedances on the circuit board. To compensate for the errors from the differential amplifier, shorting the Tip, Ring and Ground terminals of the instrument together yields the equivalent to FIG. 4 with R cal =0. So, V t =V r =V s , and any errors have been isolated to differential amplifier. At this point, the value of V bal is measured and stored (which will be referred to herein as V bal — short ). Measurement of V bal — short usually needs to be done only once—typically as part of a final test and calibration before shipping. To compensate for differential amplifier error:
[0000]
CorrectedV
bal
=
MeasuredV
bal
-
V
t
V
s
V
bal_short
(
Eq
.
11
)
[0043] The corrected V bal from Eq. 11 may be used in the place of the measured V bal in the balance equations outlined above, including Eq. 8 and Eq. 10.
[0044] Now turning to FIG. 6 , a novel method using the equations and devices described above is presented:
A. In steps 605 and 610 , the instrument is set to POS 2 (see FIG. 3 ) so that the internal balanced circuit is connected to R cal (a well-balanced resistor network that may be internal to the test instrument). This may be done, for example, with a relay or other switching mechanism. (see part 517 in FIG. 5 and part 305 in FIG. 3 ) This operation can be performed at any preprogrammed interval, which may include upon power up or at some other predetermined interval. B. At step 615 , the instrument measures the real and imaginary parts of V t , V r , V s , and measured V bal when the internal balanced circuit is connected to the well-balanced resistor network. C. At step 620 , dZ b /Z b (the error) is calculated from V t , V r , V s and measured V bal ; (see Eq. 10), the calculated value of dZ b /Z b is stored for later use. D. At step 625 , the instrument is set to POS 1 (see FIG. 3 ) so that the internal balanced circuit is connected to the circuit under test—typically a twisted pair line. This may be done, for example, with a relay or other switching mechanism. (see part 517 in FIG. 5 and part 305 in FIG. 3 ) E. At step 630 , the instrument measures the real and imaginary parts of V t , V r , V s , and measured V bal when the internal balanced circuit is connected to the circuit under test. F. At step 635 , using the measured voltages from step 630 along with the previously stored value of dZ b /Z b , the corrected balance for the circuit under test is calculated. (See Eq. 8) G. At step 640 , the corrected balance may be displayed to the user. H. At step 645 , the method may determine with the predetermined interval has elapsed such that dZ b /Z b , needs to be recalculated. If so, then the system continues to step 605 . Otherwise, the method continues back to step 630 . This method may continue this loop, giving the user real-time calculations of the corrected balance.
[0053] Finally, FIG. 7 illustrates a device ( 705 ) incorporating the method and circuits described herein. The device ( 705 ) contains a CPU ( 710 ) that controls the circuit board ( 715 ). This control could include switching the relay (or other switching mechanism) from POS 1 to POS 2 as described above. The circuit board ( 715 ) includes a plurality of test leads ( 720 ) that can both measure the circuit under test (not shown) and may also provide a signal to the circuit under test. The circuit board ( 715 ) provides the CPU ( 710 ) data regarding the circuit under test, which may include the measured voltages (i.e., V t , V r , V s , and measured V bal ). And the CPU ( 710 ) can then make the appropriate calculations, according to the method described herein. (Attached as Appendix A below is an example of computer source code that can be used with the CPU). The CPU ( 710 ) may output the results of its calculations to the display ( 725 ) or other visual signaling device. Optionally, the display may include a touch screen, which may send control signals to the CPU ( 710 ), hence the bi-directional control lines between the CPU ( 710 ) and the display ( 725 ). The device ( 705 ) may also include a speaker ( 730 ) or other audio signaling device, which can communicate the output of the CPU ( 710 ) to a user of the device. The user may control the device ( 705 ) through the control device ( 735 ), which may include a mouse, pointing device, keyboard or a touch screen display. If a touch screen display is used, then it may perform both the function of a display ( 725 ) and control device ( 735 ). Because it may be desirable to make this device portable, a housing (shown as dashed line 740 ) may be used to house the circuit board ( 715 ), the CPU ( 710 ), the control device ( 735 ), the display ( 725 ) and the speaker ( 730 ). The plurality of test leads ( 720 ) may exit the housing to allow the user to easily connect the device ( 705 ) to the circuit under test.
[0054] While the description above refers to particular embodiments of the present invention, it should be readily apparent to people of ordinary skill in the art that a number of modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true spirit and scope of the invention. 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 rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein. Moreover, the applicants expressly do not intend that the following claims “and the embodiments in the specification to be strictly coextensive.” Phillips v. AHWCorp., 415 F.3d 1303, 1323 (Fed. Cir. 2005) (en banc).
[0000]
APPENDIX
/***********************************************************************
//Calculate_Corrected_Balance( )
Gets Vbal, Vt, Vr, Vs while internal balanced circuit is connected to line under test and
calculates corrected balance using equation corrected_balance = Vbal − dZb*Vt/Vs*(1−
Vr/Vs) (eq. 8)
***********************************************************************/
unsigned int Calculate_Corrected_Balance( float scale_factor, char *result_string, int
decimals)
{
int input_array[10];
float real_float, imag_float, error_real_float, error_imag_float;
float corrected_balance_real_float, corrected_balance_imag_float, mag_float,
log_mag_float;
get_complex_a2d(BAL_HI_AND_TRS_COMMAND, input_array, 8, 2000);
/*
At this point:
i
input array[i]
0
Vbal real
1
Vbal imaginary
2
Vt real
3
Vt imaginary
4
Vr real
5
Vr imaginary
6
Vs real
7
Vs imaginary
*/
//Correct diffamp null. Use cal constants stored in user block
//Corrected Vbal = Measure Vbal − (Vt/Vs)*Vbal_short
Correct_DiffAmp(input_array);
//Vt/Vs*(1−Vr/Vs)
real_float = RealBalScaleFactor((float) input_array[2], (float) input_array[3], (float)
input_array[4], (float) input_array[5], (float) input_array[6], (float) input_array[7]);
imag_float = ImagBalScaleFactor((float) input_array[2], (float) input_array[3],
(float) input_array[4], (float) input_array[5], (float) input_array[6], (float)
input_array[7]);
//dZb/Zb*Vt/Vs*(1−Vr/Vs) //dZb/Zb was measused, calculated and stored at start up.
Now stored in g_bal_cor_flt_xxxx
error_real_float = RealMult(g_bal_cor_flt_real, g_bal_cor_flt_imag, real_float,
imag_float);
error_imag_float = ImagMult(g_bal_cor_flt_real, g_bal_cor_flt_imag, real_float,
imag_float);
//corrected_balance = Vbal − dZb*Vt/Vs*(1−Vr/Vs) (eq. 1)
corrected_balance_real_float = (float)input_array[0] − error_real_float;
corrected_balance_imag_float = (float)input_array[1] − error_imag_float;
//Now calculate magnitude and express in dB
mag_float = sqrt(corrected_balance_real_float*corrected_balance_real_float +
corrected_balance_imag_float*corrected_balance_imag_float);
if(mag_float < 10)
{
strcpy(result_string, “---”);
return 1;
}
log_mag_float = 20 * log10(mag_float) + scale_factor;
float_to_string(log_mag_float, result_string, decimals);
return (unsigned int) mag_float;
}
/***********************************************************************
Get_Bal_Cal_and_TRS_Readings( )
Gets Vbal, Vt, Vr, Vs while internal balanced circuit is connected to Rcal (well-balance
resistor network) and calculates dZb/Zb using dZb/Zb = Vbal/((Vt/Vs*(1−Vr/Vs)) (Eq
10) Stores dZb/Zb the global variables g_bal_cor_flt_real, g_bal_cor_flt_imag
***********************************************************************
void Get_Bal_Cal_and_TRS_Readings(void)
{
int input_array[10], i;
float real_float, imag_float;
get_complex_a2d(BAL_CAL_AND_TRS_COMMAND, input_array, 8, 2000);
/*
At this point:
i
input array[i]
0
Vbal real
1
Vbal imaginary
2
Vt real
3
Vt imaginary
4
Vr real
5
Vr imaginary
6
Vs real
7
Vs imaginary
*/
//for diagnostics. Not used in calculations
g_bal_cal_real = input_array[0];
g_bal_cal_imag = input_array[1];
//Correct diffamp null. Use cal constants stored in user block
Correct_DiffAmp(input_array);
//Vt/Vs*(1−Vr/Vs)
real_float = RealBalScaleFactor((float) input_array[2], (float) input_array[3], (float)
input_array[4], (float) input_array[5], (float) input_array[6], (float) input_array[7]);
imag_float = ImagBalScaleFactor((float) input_array[2], (float) input_array[3],
(float) input_array[4], (float) input_array[5], (float) input_array[6], (float)
input_array[7]);
g_bal_cor_flt_real = RealDiv((float)input_array[0], (float)input_array[1], real_float,
imag_float);
g_bal_cor_flt_imag = ImagDiv((float)input_array[0], (float)input_array[1],
real_float, imag_float);
}
/***********************************************************************
Vector Algebra Functions
***********************************************************************
//Returns real part of multiplication of 2 complex numbers
float RealMult(float RealIn1, float ImaginaryIn1, float RealIn2, float ImaginaryIn2)
{
return(RealIn1 * RealIn2) − (ImaginaryIn1 * ImaginaryIn2);
}
//Returns imaginary part of multiplication of 2 complex numbers
float ImagMult(float RealIn1, float ImaginaryIn1, float RealIn2, float ImaginaryIn2)
{
return(RealIn1 * ImaginaryIn2) + (RealIn2 * ImaginaryIn1);
}
//Returns real part of division of 2 complex numbers
float RealDiv(float RealIn1, float ImaginaryIn1, float RealIn2, float ImaginaryIn2)
{
return((RealIn1 * RealIn2) + (ImaginaryIn1 * ImaginaryIn2)) / ((RealIn2 *
RealIn2) + (ImaginaryIn2 * ImaginaryIn2));
}
//Returns imaginary part of division of 2 complex numbers
float ImagDiv(float RealIn1, float Imagin* aryIn1, float RealIn2, float ImaginaryIn2)
{
return((ImaginaryIn1 * RealIn2) − (RealIn1 * ImaginaryIn2)) / ((RealIn2 *
RealIn2) + (ImaginaryIn2 * ImaginaryIn2));
}
//Returns real part of Vt/Vs*(1−Vr/Vs)
float RealBalScaleFactor(float TipR, float TipI, float RingR, float RingI, float ShieldR,
float ShieldI)
{
float RealTemp1;
float RealTemp2;
float ImagTemp1;
float ImagTemp2;
// VTip/VShield
RealTemp1 = RealDiv(TipR, TipI, ShieldR, ShieldI);
ImagTemp1 = ImagDiv(TipR, TipI, ShieldR, ShieldI);
// VRing/VShield
RealTemp2 = RealDiv(RingR, RingI, ShieldR, ShieldI);
ImagTemp2 = ImagDiv(RingR, RingI, ShieldR, ShieldI);
// 1 − VRing/VShield
RealTemp2 = 1 − RealTemp2;
ImagTemp2 = −ImagTemp2;
// VTip/VShield * (1 − VRing/VShield)
RealTemp1 = RealMult(RealTemp1, ImagTemp1, RealTemp2, ImagTemp2);
ImagTemp1 = ImagMult(RealTemp1, ImagTemp1, RealTemp2, ImagTemp2);
return RealTemp1;
}
//Returns imaginary part of Vt/Vs*(1−Vr/Vs)
float ImagBalScaleFactor(float TipR, float TipI, float RingR, float RingI, float ShieldR,
float ShieldI)
{
float RealTemp1;
float RealTemp2;
float ImagTemp1;
float ImagTemp2;
// VTip/VShield
RealTemp1 = RealDiv(TipR, TipI, ShieldR, ShieldI);
ImagTemp1 = ImagDiv(TipR, TipI, ShieldR, ShieldI);
// VRing/VShield
RealTemp2 = RealDiv(RingR, RingI, ShieldR, ShieldI);
ImagTemp2 = ImagDiv(RingR, RingI, ShieldR, ShieldI);
// 1 − VRing/VShield
RealTemp2 = 1 − RealTemp2;
ImagTemp2 = −ImagTemp2;
// VTip/VShield * (1 − VRing/VShield)
// don't corrupt RealTemp1 = RealMult(RealTemp1, ImagTemp1, RealTemp2,
ImagTemp2);
ImagTemp1 = ImagMult(RealTemp1, ImagTemp1, RealTemp2, ImagTemp2);
return ImagTemp1;
}
/***********************************************************************
* //Correct diffamp null. Use cal constants stored in user block
Uses the formula Corrected Vbal = Measure Vbal − (Vt/Vs)*Vbal_short (Eq 11) Assumes
Vbal with the Tip and Ring leads shorted to Shield is stored in g_bal_diffamp_null_xxxx
***********************************************************************/
void Correct_DiffAmp(int *DataArray)
{
float VTipNormal_Real, VTipNormal_Imag, DiffError_Real, DiffError_Imag;
int i;
//Vtip/Vshield
VTipNormal_Real = RealDiv((float)DataArray[2], (float)DataArray[3],
(float)DataArray[6], (float)DataArray[7]);
VTipNormal_Imag = ImagDiv((float)DataArray[2], (float)DataArray[3],
(float)DataArray[6], (float)DataArray[7]);
DiffError_Real = RealMult((float)g_bal_diffamp_null_real,
(float)g_bal_diffamp_null_imag,VTipNormal_Real, VTipNormal_Imag);
DiffError_Imag = ImagMult((float)g_bal_diffamp_null_real,
(float)g_bal_diffamp_null_imag,VTipNormal_Real, VTipNormal_Imag);
DataArray[0] = DataArray[0] − (int) DiffError_Real;
//g_corrected_diff_real = DataArray[0];
DataArray[1] = DataArray[1] − (int) DiffError_Imag;
//g_corrected_diff_imag = DataArray[1];
} | A novel method for testing a communications circuit is disclosed. The method includes the following steps: (a) connecting an internal balanced circuit to a well-balanced resistor network; (b) measuring a first plurality of real and imaginary components of the voltages with the internal balanced circuit connected to the well-balanced resistor network; (c) calculating an error for the internal balanced circuit based on the first plurality of voltages; (d) connecting the internal balanced circuit to the communications circuit; (e) measuring a second plurality of real and imaginary components of the voltages with the internal balanced circuit connected to the communications circuit; and (f) calculating a corrected balance for the communications circuit based on the second plurality of voltages and the error for the internal balanced resistor network. A novel device and software program that incorporates this novel method are also disclosed. | 7 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to sewing machines and in particular to a new and useful stitch group sewing machine which includes means for varying the stitch length of each stitch group.
A stitch group sewing machine wherein the length of the stitches in the group is controlled by gearing is shown in German Pat. No. 824,738 (U.S. Pat. No. 2,411,493). This known stitch group sewing machine is a buttonhole sewing machine with a work holder gripping the work in the region of the buttonhole to be formed. The work holder is driven by a first gearing controlled cam plate which makes one complete revolution during the formation of a buttonhole. A first cam slot moves the work holder parallel to the longitudinal axis of the sewing machine, and hence in lengthwise direction of the buttonhole to be formed. A second cam slot moves the work holder crosswise to the longitudinal axis of the sewing machine in connection with a second gearing. The needle bar is mounted in a pivotably mounted frame and executes swinging movements transverse to the longitudinal axis of the sewing machine for the formation of zig-zag stiches.
The first gearing contains an angle lever, whose one leg carries a sensor engaging in the cam slot and whose other leg comprises a link guide. In the link guide a sliding block of a pitman connected with the work holder engages in the link guide. By displacement of the sliding block in the link guide the transmission of the bearing and hence the amount of forward movement of the work holder parallel to the longitudinal axis of the sewing machine, can be varied and in this way the length of the buttonhole to be formed can be adjusted.
The cam plate is intermittently set into rotation by a one way clutch which is in drive connection with the main shaft of the sewing machine via a drive mechanism. The transmission ratio of the drive mechanism can be adjusted similary as for the first gearing, whereby the speed of rotation of the cam plate can be varied at constant rotational speed of the main shaft. In this manner the number of stitches which form the buttonhole can be varied.
If when changing the buttonhole length the number of stitches is to be varied as well to obtain a constant stitch length, the transmission ratio of the drive mechanism must be matched very exactly to the transmission ratio of the first gearing. This mutual adaptation or adjustment is time consuming and requires a certain skill and experience, so that generally it must be effected by a mechanic rather than by the seamstress.
To eliminate the danger of follow-up or continued running that exists in the operation of a one way clutch due to inertia, the known sewing machine is provided with an intermittently active brake device acting at the circumference of the cam plate. Since such a brake is subject to wear, and since the braking depends on the surface quality or the degree of soiling of the friction surfaces so that no assurance for smooth operation of the cam plate is given especially at high speeds, such a drive system is not suitable for modern sewing machines, for which generally high speeds are required, to reduce the sewing time.
SUMMARY OF THE INVENTION
The invention provides a stitch group sewing machine wherein the ratio of speed of rotation of the cam plate to the speed of rotation of the sewing machine required for obtaining the desired number or length of stitches of the group to be sewn can be adjusted in a simple and yet exact manner and is maintained at the set value during sewing even at high rotational speeds of the sewing machine.
It is possible by electrical means and hence in an especially simple manner in terms of operation to adjust or vary the speed ratio between the sewing machine and the cam plate executing the forward movement of the work holder. Thus, while the length of the stitch group remains unchanged, the number of stitches and hence the basic adjustment of the stitch length can be set or changed. If, however, only the length of the stitch group is changed, then, as a function of the set transmission ratio of the gearing, the rotation speed of the motor for the cam plate and hence the number of stitches is automatically varied as well, so that the stitch length, one set, is preserved unchanged. Further it is possible to vary the length of the stitch group and the stitch length simultaneously, so that the basic data contained in a cam plate can be varied in many ways.
When using a sufficiently strong motor for the cam plate, where fluctuations of the load moment, caused e.g. by variations of the pitch angle of the control cam, do not bring about any appreciable variations of the motor speed, the ratio of cam plate speed to sewing machine speed required for obtaining a certain stitch group is maintained comparatively exactly during the entire sewing process.
The high accuracy is obtained in maintaining the required speed ratio by having an amplifier connected to the control device which is a variable gain amplifier arranged in a control circuit whose control variable is the rotational speed of the cam plate driving motor and whose command variable is formed by the control device.
A certain type of stitch group referred to as bar seam consists of one or more rows of straight, so-called tension stitches and a plurality of zig-zag stitches covering the tension stitches. The tension stitches have the purpose to give the bar seam a high tensile rigidity. This is best achieved with long stitch lengths. If however, the work holders is driven by the cam plate continuously rather than intermittently, the desire for great stitch lengths conflicts with the then occurring danger of needle breakage and damage to the work. Under these circumstances the tension stitches are advantageously formed with an average stitch length of 2.5 mm, and this for short as well as for long bar seams.
The possibility exists, at an unchanged length of the bar seam, to leave the number and hence the length of the tension stitches unchanged whereas the number and hence the length of the zig-zag stitches is varied, owing to which bar seams adapted to the particular purpose of use and type of cloth and having always an optimum tension stitch length of 2.5 mm and selectively narrow or wide zig-zag stitches can be formed. When changing the length of the bar seam, the number of tension stitches is varied as a function of the particular length of the bar seam by a corresponding variation of the speed of the cam plate, in such a way that also in this case, the optimum tension stitch length of 2.5 mm is maintained. With the invention it is possible to vary the basic data of a stitch group contained in a control cam plate relatively to each other also sectionwise, so that with a single cam plate a plurality of stitch group type modifications not previously attainable in the prior art can be achieved.
The control device advantageously comprises two potentiometers fed by the output voltage of a tachogenerator driven by the sewing machine. The output voltage of the potentiometers is alternately suppliable as a dividend by a switch which is actuable by the path dependent seitch to a dividing element. The control device comprises an additional potentiometer which is mechanically coupled with a displaceable element determining the transmission ratio of the gearing. It has an output voltage as a divisor which is supplied to the dividing element whose voltage forms forms the command variable of the control circuit.
Accordingly, it is an object of the invention to provide a stitch group sewing machine which includes a control device connected to the sewing machine into gearing which is variable for varying the swing and reciprocation of the needle so as to control the desired stitch length.
A further object of the invention is to provide a sewing machine 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 drawings:
FIG. 1 shows a partial side elevational and sectional view of a stitch group sewing machine construction in accordance with the invention;
FIG. 2 is a sectional view along line II--II of FIG. 1;
FIG. 3 is a sectional view along line III--III of FIG. 2;
FIG. 4 is a block diagram of the regulating and control circuit of the motor for the control cam plate;
FIG. 5 is a plan view of a bar seam.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular the invention embodied therein comprises a stitch group sewing machine which comprises a housing generally designated 1 which contains a sewing machine drive including a drive arm shaft 8 which effects both the upward and downward movement of a needle 12 and the swinging of the needle in a swinging plane. A separate cam plate drive motor 41 drives a control cam plate 38 which drives a gearing generally designated 91 which has an adjustable transmission ratio and which drives stitch length control means at selective speeds. The cam plate is thus connected through a connecting mechanism for varying the desired stitch length of each stitch group.
The sewing machine comprises a housing 1 comprising a support plate 2, a pedestal 3, a supporting arm 4, a standard 5, and an arm 6 which terminates in a head 7. In arm 6 an arm shaft 8 is mounted which drives a needle bar 11 by way of a crank 9 and a pitman 10. In the needle bar 11 a thread carrying needle 12 is fastened, which cooperates with a shuttle or looper not shown for the formation of stitches.
The needle bar 11 is received in a frame 13 which is mounted for displacement on a bolt 14 running parallel to the longitudinal axis of arm 6 and is connected with a connecting rod 15 running parallel to it. Connecting rod 15 forms the output element of a zig-zag stitch setter 16 with which the overstitch width of zig-zag stitches is controlled. The zig-zag stitch setter 16 is a known hinged stitch setter. It comprises a lever 17, whose one end is connected with the connecting rod 15.
On lever 17 an eccentric rod 18 is articulated, which engages around an eccentric 19. Eccentric 19 is driven by the arm shaft 8 via a gearing (not shown). The other end of lever 17 is connected with one end of a pitman 20. At the other end of pitman 20, a crank 22 fastened on a shaft 23 and extending substantially parallel to pitman 20 engages via a bolt 21. Shaft 23 is passed through the wall of arm 6 and carries on the outer side of arm 6 a crank 24. Crank 24 is connected via a link 25 with one arm of a two-arm crank 26. At crank 26 there engages an extension spring 227 which exerts on crank 26 an upwardly directed tensile force. At the other arm of crank 26 a tie rod 28 is articulated.
On tie rod 28 a holder 29 is clamped, which carries, spaced to one side, a freely rotatable roller 30. Under the action of an extension spring 27, roller 30 takes support on the generated surface of a spiral cam plate 31. Cam plate 31 is secured on the hub of a handwheel 32 rotatably mounted on stand 5 and is adjustable in fine degrees in connection with a known lock means (not shown). The lower end of tie rod 28 is articulated via a hingepiece 33 to a split lever 34 which is mounted in a lug 35 of pedestal 3. In lever 34 a sensing roller 36 is mounted.
In pedestal 3 a vertically extending shaft 37 is mounted which carries at its lower end a cam plate 38. Shaft 37 is in drive connection with the output shaft 40 of a motor 41 via a bevel gearing 39. A tachogenerator 42 driven by shaft 40 is flanged to motor 41.
Cam plate 38 carries on the bottom side a concentic cam track 43 provided with axially offset sections 43a, 43b, which cam track is associated with the sensing roller 36 and thus controls the setting of the zig-zag stitch setter 16 within the limits established by the manually adjustable cam plate 31 as cam plate 38 revolves.
In its top side, cam plate 38 has a slot 44. In slot 44 engages a sensing pin 45 which is fastened to the free end of a lever 46. Lever 46 is fastened to the lower end of a shaft 47 mounted vertically in pedestal 3. At the upper end of shaft 47 a widened shoulder 48 is formed. By screws 49 a supporting arm 50 is fastened on shoulder 48, and on it a slide 51 of U-shaped cross-section is slidably arranged. On the underside of slide 51, two holding strips 52, 53 which partially engage the supporting arm 50 from below are fastened by screws 54. In a recess of slide 51 (not shown) cup springs also not shown, are arranged which press on the supporting arm 50 and bring about that slide 51 is secured by friction against automatic shifting. On the top side of slide 51 a flat cylindrical shoulder 55 is formed. On shoulder 55 a driver 56 is rotatably mounted which itself has a cylindrical projection 57 and a flat straight recess 58. Projection 57 is embraced by one flat end of a link 59 whose other end is connected with a setting lever 60. Setting lever 60 is passed through a cutout 61 in pedestal 3.
Driver 56 protrudes through a cutout 62 in the supporting arm 4. In recess 58 of driver 57 a flat, plate type arm 63 is received which rests on the top side of supporting arm 4. One end of arm 63 is rotatably arranged on a sliding block 64, which is displaceably mounted in a guideway 65 of pedestal 3 parallel to the longitudinal axis of supporting arm 4. The other end of arm 63 is connected with an exchangeable work carrying plate 66, which has a rectangular opening 67 for needle 12 corresponding to the maximum size of the bar seam to be produced. The slot type stitch hole in supporting arm 4 is marked 68. On the underside of arm 63, near the work carrying plate 66, a sliding block 69 is rotatably arranged. The sliding block 69 is displaceably received in a guiding groove 70 formed in an insert 71 disposed in the supporting arm 4. In its lengthwise direction the guiding groove 70 has a form such that it imposes on the pivoting motion of arm 63 a longitudinal displacement as arm 63 pivots about the axis of rotation of sliding block 64, so that arm 63 carries out in the region of the opening 67 a straight movement crosswise to the longitudinal axis of supporting arm 4.
Arm 63 and work carrying plate 66 form a lower clamping jaw 72 of a work holder 73 which holds the work in plier fashion. On arm 63 an upper clamping jaw 74 is fastened. Clamping jaw 74 contains a spring loaded holding plate 75 provided with a matching opening (not shown) for passage of needle 12. Holding plate 75 can be listed off the work carrying plate 66 in known manner through a roller lever 76 nd a vertically movable pressure plate 77.
The holding strip 52 fastened on slide 51 is formed as a rack which laterally projects over slide 51; it meshes with a pinion 79 arranged in a recess of shoulder 48. Pinion 79 is secured on a shaft 80 which is disposed in a centered bore 81 of shaft 47. At the lower end of shaft 80 is clamped the setting shaft 82 of a continuously adjustable potentiometer 83. The housing 84 of potentiometer 83 is fastened to lever 46 by a bracket 85.
An upper segmental disc 86 is secured at the upper end of the shaft 37 carrying cam plate 38, and on a U-shaped holder 87 a lower segmental disc 88. The upper segmental disc 86 cooperates with an inductive slot switch 89. The lower segmental disc 88 cooperates with a second inductive slot switch 90. On the part of pedestal 3 which projects laterally over supporting arm 4, a cap, (not shown) is arranged which rests against stand 5 and covers the slot switches 89,90 and the cam plate 38.
Lever 46 with the supporting arm 50 and slide 51, displaceable by lever 60 on supporting arm 50, form together with driver 56 a gearing 91 for the work holder 73.
The sewing machine motor 92 shown symbolically in FIG. 4 is operated through a known control circuit (not shown). Associated with the control circuit is a switch 93 with delayed automatic cutoff for turning motor 92 on, as well as a switching contact 94 of a relay 95. Switch 93 and contact 94 are in parallel. Motor 92 drives the arm shaft 8 of the sewing machine through a belt drive (not shown).
On arm shaft 8 a tachogenerator 96 is secured. The output voltage of tachogenerator 96 is supplied simultaneously to two manually adjustable potentiometers 97, 98 of which one 97 serves to set the stitch length l SP of tension stitches SP and the other 98 to set the stitch length l ZZ of zig-zag stitches ZZ. The output voltage B1,B2 of the two potentiometers 97,98 is supplied via a two-position contact 99 of a relay 100 alternately to a first input of a dividing element 101 as a dividend. Potentiometer 83, coupled mechanically with gearing 91, serves to set the bar length l R . The output voltage C of potentiometer 83 is supplied as divisor to a second input of the dividing element 101.
The dividing element 101 is a four-quadrant analog multiplier ICL 8013 of Intersil with the function ##EQU1## operated as a division circuit. The factor 10 results from the internal construction of the dividing element 101.
The output voltage A of dividing element 101 is supplied as command variable W to a variable gain amplifier 102, which operates in four quadrants and therefore is able to deliver current for both directions of rotation of the connected motor 41, but also drain current in both polarities for braking motor 41. The variable gain amplifier 102 is the clocked power amplifier BN 6441 of the firm ESR. Variable gain amplifier 102 contains a comparator circuit for the comparison between the command variable W representing the instantaneous desired value and the controlled variable X representing the instantaneous actual value. The variable gain amplifier 102 further contains a power stage for the direct operation of motor 41, which is a permanently energized d-c motor. The tachogenerator 42 connected with motor 41 reproduces the speed n K of this motor as d-c voltage in analogous manner. The output voltage of tachogenerator 42 is supplied to the variable gain amplifier 102 as controlled variable X representing the actual value.
Variable gain amplifier 102, motor 41, and tachogenerator 42 jointly form a control circuit 103. Tachogenerator 96, the potentiometers 83, 97, 98 and the dividing element 101 form together a control device portion 104 for the formation of the command variable W for the control circuit 103.
The slot switch 89 acting as path dependent switch is connected with the relay 100, which upon release of slot switch 89 switches the make-and-break contact 99 in such a way that the potentiometer 97 which serves to set the tension stitch length l SP is connected with the dividing element 101. The slot switch 90 which also acts as path dependent switch is connected with relay 95, which upon release of the slot switch 90 switches contact 94 to open position, thus interrupting the circuit of the sewing machine motor 92.
The stitch group sewing machine operates as follows: The mode of operation of the sewing machine will be explained with reference to the formation of a type of stitch group referred to as bar seam. The bar seam illustrated in FIG. 5 comprises a series of straight tension stitches SP, which toward the end of the bar seam gradually change over to zig-zag stitches. The stitch length of the tension stitches SP is designated l SP . At the end of the tension stitch seam lie one or more stitches designated as transverse stitches QS of zero stitch length. Then follows a number of zig-zag stitches ZZ of stitch length l ZZ , covering the tension stitch seam. At the end of the zig-zag seam are again one or more transverse stitches QS and one or more finishing stitches VS, which are formed at the site of the last transverse stitch QS.
The bar seam illustrated in FIG. 5 comprises a total of 48 stitches and has a bar length l R of 40 mm. The 48 stitches are grouped in 16 tension stitches SP, 4 transverse stitches QS, 1 finishing stitch VS and 27 zig-zag stitches ZZ. The tension stitches SP have a stitch length 1 SP =40/16 mm=2.5 mm, and the zig-zag stitches ZZ a stitch length l ZZ =40/27 mm=1.48 mm.
For the formation of the bar seam according to FIG. 5, the cam plate 38 rotates at constant speed during the entire sewing process, that is both in the tension stitch and in the zig-zag region. For the formation of the tension stitches SP an angle of ##EQU2## of the cam slot 44 is available. The transverse stitches QS, the zig-zag stitches ZZ, and the finishing stitch VS are distributed over the remaining 240°. In the tension stitch region the cam slot 44 has per stitch a greater radial rise than in the zig-zag region. The radial cam rise Δr SP in the tension stitch region is 1.285 mm, the radial cam rise Δr ZZ in the zig-zag region, 0.74 mm.
For the formation of the tension stitches SP the speed n K of the motor 41 which drives the cam plate 38 must be in a certain ratio to the speed n A of the arm shaft 8, to the bar length l R , and to the stitch length l SP . These various factors are in the following functon relations: n K approx. ##EQU3## For the formation of the bar seam according to FIG. 5, the slide 51 on supporting arm 50 is shifted to the left according to FIG. 2, through the setting lever 60, upo to the limit of the setting range. In this position of slide 51 the driver 56 has the maximum possible distance from the axis of rotation of shaft 47, so that at gearing 91 the maximum transmission ratio is set. Upon displacement of slide 51, the holding strip 52 connected therewith and formed as a rack rotates the pinion 79 and adjusts the potentiometer 83 via shaft 80 to a value analagous to the transmission ratio of gearing 91. The potentiometer 97 for setting the stitch length l SP is always set to the stitch length 2.5 mm. The potentiometer 98 for setting the stitch length l ZZ is set to the value of the desired stitch length l ZZ , that is, for the bar seam according to FIG. 5, to 1.48 mm.
The sewing machine is switched on by actuating switch 93, whereupon motor 92 drives the arm shaft 8 during the first stitches at a speed of 1000 min -1 . With the switching on, voltage is applied to potentiometer 83 and to amplifier 102. The output voltage C of potentiometer 83, which is dependent on the transmission ratio of gearing 91 and hence reproduces the bar length l R in analogous form, is continuously applied to the dividing element 101. The speed n A of the arm shaft 8 is reproduced by the tachogenerator 96 as dc voltage in analogous manner. The output voltage of tachogenerator 96 is supplied simultaneously to the two potentiometers 97, 98. As motor 92 is being turned on, the segmental disc 86 is outside the slot switch 89. In this position of the slot switch 89 the relay 100 is switched so that contact 99 connects the potentiometer 97 for adjustment of the switch length l SP with the dividing element 101 and the output voltage B1 thereof is connected to the dividing element 101. The voltages B1 and C are divided in the divison element 101 according to the formula ##EQU4## B1 being the mathematical product of the analogous voltage values for the input variables l SP and n A , and C analagous voltage value for the input variable l R .
The output voltage A of the dividing element 101 is supplied as command variable W of the control circuit 103 to the amplifier 102. The output voltage or amplifier 102 is supplied as armature voltage to motor 41, the speed n K of motor 41 being proportional to the magniture of the applied voltage. When sewing the bar seam according to FIG. 5, at a speed n A of the arm shaft 8 of 1000 min -1 there results for the motor 41 driving the cam plate 38 a speed n K of 17.8 min -1 .
The tachogenerator 42 in drive connection with motor 41 reproduces the speed n K of motor 41 representing the controlled variable X in analogous manner as d-c voltage. For a variance comparison, the output voltage is tachogenerator 42 is supplied to one input of the variable gain amplifiier 102, whereby the desired speed value given by the command variable W is maintained very exactly.
After a few stitches the speed n A of the sewing machine is increased to 4000 min -1 . The output voltage of tachogenerator 96 thus increasing proportionally immediately brings about a corresponding increase of the output voltage B1 of potentiometer 97 and hence of the output voltage A of the dividing element 101 or respectively of the command variable W. The increase of the command variable W leads directly to a corresponding increase of the speed n K of motor 41 to a value of 71 min -1 .
At the time the sewing machine is switched on, the segmental disc 88 is outside the slot switch 90. Owing to this, relay 95 is switched so that contact 94 is open. After a short time motor 41 has rotated shaft 37 so that the segmental disc 88 enters into the slot switch 90, and as a result relay 95 is switched and contact 94 is closed. It is only then that switch 93, which operates with delayed automatic switch-off, opens, so that from that time on motor 92 is connected with its control circuit via the closed switching contact 94.
During the sewing of the tension stitches SP, the seady drive of cam plate 38 and the continuous motion of cam slot 44 bring about a steady pivoting of lever 46. The pivoting movement of lever 46 is transmitted via supporting arm 50 and via slide 51 adjusted thereon and via driver 56. Driver 56 pivots arm 63 about the axis of rotation on sliding block 64.
The transmission ratio of gearing 91 determined by the position of slide 51 and the speed n K of motor 41 controlled as a function of the transmission ratio as well as of the speed n A and of the adjusted tension stitch length l SP bring about that the work holder 73 is pivoted by an amount of 2.5 mm in the region of the opening 67 during each stitch formation so that correspondingly long tension stitches SP result. The continuous pivoting of the work holder 73 does indeed lead to a deflection of the needle 12 inserted in the work, but at a stitch length of 2.5 mm the deflection is still so small that neither needle breakage nor impairment of the thread linkage nor a visible impairment of the work occur.
During the sewing of the tension stitches SP, lever 34 is pushed down by the lower section 43a of the cam track 43 far enough for the tie rod 28 to hold the pitman 20 of the zig-zag stitch setter 16 is a substantially horizontal position parallel to lever 17. In this position of pitman 20 the vibratory movements created by eccentric 19 at lever 17 have no influence on the positon of the connecting rod 15, so that frame 13 and needle bar 11 execute no lateral movements.
Toward the end of the tension stitch region, the section 43b of cam track 43 gets into the zone of the sensing roller 36. By the action of extension spring 27 the sensing roller 36 is pulled upward, with crank 24 pivoting pitman 20 with bolt 21 upward via crank 26, link 25, crank 24, and the crank 22 rigidly connected with it. As lever 17 is connected with the end of pitman 20 opposite bolt 21, the swinging motion created by eccentric 19 at lever 17 causes at the same time a swinging motion of pitman 20. Due to the displacement of bolt 21, the swinging motion of pitman 20 now has at the hinge point with lever 17 a horizontal component, which brings about that lever 17 and hence connecting rod 15 and the needle bar 11 execute lateral swinging movements in the rhythm of the stitch formation. These will, toward the end of the tension stitch region, create a gradual transition from the straight tension stitches SP to the transverse stitches QS, which have the same overstitch width b as the following zig-zag stitches ZZ.
The overstitch width b is determined by the set position of cam plate 31. Cam plate 31 limits the upward movement of tie rod 28 caused by spring 27 in that it serves as a stop for roller 30.
After the control cam plate 38 has run through the angle of 120° provided for the formation of the tension stitches SP, the segmental disc 86 enters into the slot switch 89 and switches relay 100, whereby contact 99 is switched and potentiometer 98 for setting the stitch length l ZZ of the zig-zag stitches ZZ is connected with the dividing element 101. Now the speed n K of motor 41 is approx. ##EQU5##
Since for the formation of the bar seam according to FIG. 5 the ratio of stitch length l SP to stitch length l ZZ corresponds to the ratio of the radial rise Δr SP of cam slot 44 to the radial rise Δr ZZ and therefore the speed of motor 41 in the region of the zig-zag stitches ZZ is the same as in the region of the tension stitches SP, the output voltage B2 of potentiometer 98 has in this case the same value as the output voltage B1 of potentiometer 97, so that the command variable W remains unchanged.
Toward the end of the sewing process, the control circuit of motor 92 reduces the speed n A of arm shaft 8 from 4000 min -1 to 1000 min -1 . Immediately thereafter, the speed n K of motor 41 is reduced in the same ratio via the control device 104 and the control circuit 103.
After one complete revolution of control cam plate 38, the finishing stitch VS is formed and the bar seam is completed. At this moment the two segmental discs 86 and 88 move out of the slot switches 89, 90, whereby through the two relays 95 and 100, for one thing contact 94 is opened and hence motor 92 turned off and, for another, contact 99 is switched again and thereby potentiometer 97 is connected with the dividing element 101. Motor 92 is braked almost instantly from the reduced speed to zero, owing to which also the output voltage of the tachogenerator 96 is reduced to zero just as quickly. As a result, the command variable W becomes zero almost without delay and with equal rapidity motor 41 is braked, so that no appreciable follow-up motion of cam plate 38 takes place.
If, starting with the bar seam according to FIG. 5, the bar length l R is to be shortened, then, via lever 60, the transmission ratio of gearing 91 is reduced while at the same time the potentiometer 83 is adjusted to a value proportional thereto. Since now the reduced output voltage C is supplied to the dividing element 101 as divisor, the output voltage A and the command variable W increase. As a result, motor 41 is now operated at a higher speed n K . At a bar length l R =25 mm, the speed n K increased both for the tension stitch and for the zig-zag stitch range at a speed n A from 1000 min -1 to 28.5 min -1 and at a speed n A from 4000 min -1 to 114 min -1 . In connection with the smaller transmission ratio of gearing 91, the higher speed n K again results in a stitch length l SP of 2.5 mm in the tension stitch region and a stitch length l ZZ of 1.48 mm in the zig-zag stitch region. Now, however, the bar seam consists of fewer stitches.
If at constant stitch length l SP of 2.5 mm the stitch length l ZZ in the zig-zag stitch region is to be reduced for example to 0.6 mm, the desired stitch length l ZZ is set on the potentiometer 98. Since the output voltage B2, now reduced in value, is supplied to the dividing element 101 as dividend, during sewing in the zig-zag region the value of the output voltage A and of the command variable W diminshes. The result is that, after contact 99 has been switched, motor 41 is now operated in the zig-zag stitch region at a lower speed n K as compared with the speed n K in the tension stitch region. While at a bar length l R of 40 mm and a speed n A of 1000 min-1 the speed n K in the tension stitch region is again 17.8 min -1 , in the zig-zag stitch region the speed n K diminishes to 9 min -1 . At a speed n A of 4000 min -1 there results for the tension stitch region a speed n K =71 min -1 and for the zig-zag stitch region n K =36 min -1 . The diminished speed n K in the zig-zag stitch region therefore shortens the stitch length l ZZ and brings about that the number of zig-zag stitches is correspondingly greater than in the bar seam according to FIG. 5.
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 feed drive for a stitch group sewing machine includes a cam plate serving to drive a cloth clamp and it is connected with a separate motor. In order to keep the stitch length constant at varying length of the stitch group, the motor speed is controllable by a control device as a function of the rotational speed of the sewing machine, of the transmission ratio of a gearing between cam plate and cloth clamp which determines the length of the stitch group, and of the adjusted stitch length. The stitch group to be sewn can be divided into two sections with a stitch length variable independently of each other, in that a path-dependent switch operable after a partial revolution of the cam plate corresponding to the length of the first section alternately connects one of two potentiometers which determine the stitch length, with the motor control circuit. | 3 |
DESCRIPTION
[0001] 1. This invention relates to a food-stirring device for use with microwave ovens (hereafter referred to as a Microwave Oven Food-Stirrer).
BACKGROUND
[0002] 2. It has been known for some time that the distribution of energy within a microwave oven is not uniform. There have been several developments in microwave technology to try to overcome the inconvenience this causes with microwave cooking (a rotary plate being one of them). However, it is still a fact today that when heating or cooking a dish that requires an even distribution of heat, the cooking period must be interrupted regularly in order to disperse the energy by manual means (ie dishes need a good stir every now and then!).
[0003] 3. The idea of a Microwave Oven Food-Stirrer was born from the fact that while cooking or re-heating any of several food types in a microwave oven, there is a need to return to the oven periodically to stir the food in order to ensure that it is cooked/re-heated evenly. A microwave oven capable of stirring the food itself would give a far more even distribution of energy throughout the food during the cooking/re-heating period, reduce the cooking time required and allow the cooking period to be continuous (a procedure recommended for best results in most dishes). Other benefits of the incorporation of such a device may include the energy saving realized by the uninterrupted microwave function, the saving on the ware of microwave components realized by the same and the reduced tendency to destroy health-giving nutrients within food stuffs through over cooking.
[0004] 4. A Microwave Oven Food-Stirrer is one method to facilitate this function. While this invention would be easy to incorporate into the design of a new oven, to be included during manufacture, it is designed primarily as an accessory (a separate stand-alone enhancement) to any existing microwave oven which incorporates a rotary plate.
PURPOSES
[0005] 5. Primary. The primary purpose of this invention is to enhance the distribution of heat through food which being cooked or heated in a microwave oven.
[0006] 6. Secondary. A secondary purpose is to provide a stirring or whisking capability during the process of microwave cooking.
METHOD
[0007] 7. The method by which the purposes of this invention are met is through use of the internal rotary plate (Item 6 ) of a microwave oven to provide rotation of the food/beverage, while a stationary stirring implement placed into the food/beverage creates a relative stirring/mixing action through it.
DETAILS
[0008] 8. Specific details of the invention are as follows:
[0009] a. All constituent parts of the invention would need to be manufactured in a microwave-proof material.
[0010] b. The main constituent parts of the invention are:
[0011] (1) Roof-Rail.
[0012] (2) Roof-Fittings.
[0013] (3) Stirring Implement.
[0014] (4) Adhesive.
[0015] 9. Roof-Rail (FIG. 1, Item 1 ). The Roof-Rail is an “l” sectioned strip which is secured to the roof (Item 14 ) of the microwave oven on a radial from its centre using adhesive. Ideally Roof Rails would be positioned on the roof along the radial running perpendicular to the back wall of the oven, from the back wall to just beyond the centre. Along the Roof-Rail would slide a Roof-Fitting (FIG. 1, Item 2 ). While the Roof-Rail could be fitted retrospectively to any microwave oven using suitable adhesive, ideally, it would be incorporated into the microwave oven design during manufacture. (The Roof-Rail and Roof-fitting are shown in clear detail at FIG. 2).
[0016] 10. Roof-Fitting (FIG. 1, Item 2 ). Roof-fittings are designed to ride snugly along the Roof-Rail (Item 1 ) and incorporate a female ‘bayonet’ type fitting to receive Stirring Implements (Item 3 ). The bayonet fitting would be position to be facing the front of the oven for case of insertion of Stirring Implements. Roof fittings would vary in length to cater for different sized ovens and to vary the depth of a Stirring Implement within the food/receptacle (Item 4 ). The varied position of a Roof-Fitting along the Roof-Rail would allow the Microwave Oven Food-Stirrer to be located in a position to provide an optimum stirring capability within different sized receptacles. (The Roof-Rail and Roof-Fitting are shown in clear detail at FIG. 2).
[0017] 12. Stirring Implement (FIG. 1, Item 3 (FIGS. 4 & 5 Items 6 , 7 , 8 , 9 , 10 & 11 ). Stirring Implements have a male ‘bayonet’ type fitting incorporated into their design for attachment to Roof Fittings. Male bayonet fittings would be positioned so that on connection to the female, the Stirring Implement is angled within the food/receptacle for optimum stirring capability. Stirring Implements are designed for different mixing/stirring functions and different sized receptacles/bowls. Generally, they are contoured to the walls of different receptacle types in order to provide optimum stirring capability and bring the hotter food toward the centre—see FIG. 3. Of the numerous Stirring Implement design options, some are a ‘Whisk-type’ (FIG. 4, Item 6 ). ‘Fork-type’ (FIG. 4, Item 7 ), ‘Wave-type’ (FIG. 4, Item 8 ), and ‘Concave-type’ implements (FIG. 4, Item 9 ). More complex ‘aerodynamic’ type designs, such as those shown in FIG. 5, Items 10 and 11 , are other options for achieving a more even distribution of heat through the food/beverage.
[0018] 13. Optional Constituent Parts/Design Features. To further enhance the effectiveness of the Microwave Oven Food-Stirrer, a number of optional constituent parts/design features may be considered as additions to its fundamental design. These are:
[0019] a. Rotary Plate Non-Slip Mat (not shown). To ensure that the food receptacle maintains its rotation with the rotary plate while using the Microwave Oven Food Stirrer, a Non-Slip Mat may be placed between the food receptacle and rotary plate.
[0020] b. Secure Bowl and Rotary Plate (FIG. 6, Items 12 and 13 ). To further ensure that the food receptacle maintains its rotation with the rotary plate while using the Microwave oven Food Stirrer, a rotary plate and bowl with interlocking troughs and studs (tines) as shown at FIG. 7 may be used.
[0021] c. Variable-Speed Rotary Plate. Designing the rotary plate so that it could rotate at various speed would permit varying speeds of stirring action. Different speeds may be optimised for different food/beverage types. (For a fast rotation, it would be necessary to incorporate a receptacle securing method such as either of those described in paragraphs 13a and 13b above).
[0022] d. Secondary Rotation. To enhance the stirring/whisking effect, the Microwave Oven Food Stirrer, as an integral part of a microwave oven, could be designed to rotate through its ‘point of contact’ with the oven roof. (In this case, the Roof-Rail would not feature as part of the item).
[0023] 14. The complete assembly is shown at FIG. 7. | A devise which makes use of the relative motion of a rotary plate inside a microwave oven for stirring food stuffs in a microwave oven so that an even heat distribution throughout the food is facilitated. The device consists of a Roof-Rail, a Roof-Fitting, and Stirring Implements and where necessary may employ a food receptacle securing method. The device is shown at FIG. 7 of the attached drawings. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application 60/824,398, filed Sep. 1, 2006, which application is incorporated herein to the extent there is no inconsistency with the present disclosure.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] The invention relates generally to recombinant single chain antibodies with utility in combinations with other techniques for detection of serum markers characteristic of diseased cells, specifically cell surface NADH:protein disulfide reductase (ECTO-NOX) isoforms, to nucleic acid molecules encoding single chain antibodies specific for the cell surface marker characteristic of neoplastic and certain other diseased cells, to recombinant cells producing those neoplastic marker-specific monoclonal antibodies and single chain antibodies of similar or different specificity,
[0004] There is a unique, growth-related family of cell surface hydroquinone or NADH oxidases with protein disulfide-thiol interchange activity referred to as ECTO-NOX proteins (for cell surface NADH oxidases) (1,2). One member of the ECTO-NOX family, designated tNOX (for tumor associated) is specific to the surfaces of cancer cells and the sera of cancer patients (3, 4). The presence of the tNOX protein has been demonstrated for several human tumor tissues (mammary carcinoma, prostate cancer, neuroblastoma, colon carcinoma and melanoma) (5), and serum analysis suggest a much broader association with human cancer (6, 7).
[0005] NOX proteins are ectoproteins anchored in the outer leaflet of the plasma membrane (8). As is characteristic of other examples of ectoproteins (sialyl and galactosyl transferase, dipeptidylamino peptidase IV, etc.), the NOX proteins are shed. They appear in soluble form in conditioned media of cultured cells (5) and in patient sera (6, 7). The serum form of tNOX from cancer patients exhibits the same degree of drug responsiveness as does the membrane-associated form. Drug-responsive tNOX activities are seen in sera of a variety of human cancer patients, including patients with leukemia, lymphomas or solid tumors (prostate, breast, colon, lung, pancreas, ovarian, liver) (6, 7). An extreme stability and protease resistance of the tNOX protein (9) may help explain its ability to accumulate in sera of cancer patients to readily detectable levels. In contrast, no drug-responsive NOX activities have been found in the sera of healthy volunteers (6, 7) or in the sera of patients with disorders other than neoplasia.
[0006] While the basis for the cancer specificity of cell surface tNOX has not been determined, the concept is strongly supported by several lines of evidence. A drug responsive tNOX activity has been rigorously determined to be absent from plasma membranes of non-transformed human and animal cells and tissues (3). The tNOX proteins lack a transmembrane binding domain (10) and are released from the cell surface by brief treatment at low pH (9). A drug-responsive tNOX activity has not been detected in sera from healthy volunteers or patients with diseases other than cancer (6, 7). Several tNOX antisera have identified the immunoreactive band at 34 kDa (the processed molecular weight of one of the cell surface forms of tNOX) with Western blot analysis or immunoprecipitation when using transformed cells and tissues or sera from patients with cancers as antigen source (5, 10, 11). No immunoreactive 34 kDa band was observed with Western blot analysis or immunoprecipitation when using non-transformed cells or tissue or sera from healthy volunteers or patients with disorders other than cancers as antigen source (5, 10, 11). Those antisera include a monoclonal antibody (5), single-chain variable region fragment (ScFv) which reacts with a cell surface NADH oxidase from neoplastic cells, polyclonal antisera made in response to expressed tNOX (11) and polyclonal peptide antisera to the conserved adenine nucleotide binding region of tNOX (11).
[0007] tNOX cDNA has been cloned (GenBank Accession No. AF207881; 11; US Patent Publication 2003-0207340 A1). The derived molecular weight from the open reading frame was 70.1 kDa. Functional motifs include a quinone binding site, an adenine nucleotide binding site, and a CXXXXC cysteine pair as a potential protein disulfide-thiol interchange site based on site-directed mutagenesis (11). Based on available genomic information (12) the tNOX gene is located on chromosome X, and it is comprised of multiple exons (thirteen). It is known that there are a number of splice variant mRNAs and proteins expressed.
[0008] The hybridoma cell line which produces the tumor NADH oxidase-specific monoclonal antibody MAB 12.1 was deposited with the American Type Culture Collection, Manassas, Va., 20108 on Apr. 4, 2002, under the terms of the Budapest Treaty. This deposit is identified by Accession No. ATCC PTA-4206. The deposit will be maintained with restriction in the ATCC depository for a period of 30 years from the deposit date, or 5 years after the most recent request, or for the effective life of the patent, which ever is longer, and will be replaced if the deposit becomes non-viable during that period. This monoclonal antibody is described in U.S. Pat. No. 7,053,188, issued May 30, 2006, incorporated by reference herein.
[0009] The light and heavy chain variable regions of DNA upon which ScFv production is based are from the monoclonal antibody produced by the hybridoma on deposit with the American Type Culture Collection as Accession No. PTA-4206. See also U.S. Pat. No. 7,053,188.
[0010] Because cancer poses a significant threat to human health and because cancer results in significant economic costs, there is a long-felt need in the art for an effective, economical and technically simple system in which to assay for the presence of cancer, and for use in such an assay, an conveniently replenished source of the specific antibody can identify proteins characteristic of neoplastic conditions.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides a recombinant single chain antibody specific for Ecto-NOX, coding sequences therefore and methods for recombinant production of this single chain antibody. This recombinant antibody is useful for the analysis of a biological sample for the presence of particular isoforms of the pan-cancer antigen known as tNOX (for tumor-specific NADH oxidase) and other members of the ECTO-NOX family of proteins in Western blots. The amino acid sequence of the single chain antibody specific for Ecto-NOX proteins, including tNOX, is presented in FIG. 4B , and a specifically exemplified coding sequence is given in FIG. 4A ; it is understood that synonymous coding sequences are within the scope of the present invention, and functionally equivalent single chain antibodies with the same binding specificity are also within the scope of the present invention.
[0012] The single chain variable region antibody (ScFv) allows for identification of ECTO-NOX isoforms on Western blots was demonstrated to have utility in cancer detection, diagnosis and monitoring of disease progression. The detection of tNOX isoforms on Western blots of 2-D gels of patient sera, is described in US provisional patent application 60/824,333, filed September 1, 2006. “Neoplasia Specific tNOX Isoforms and Methods” which is incorporated by reference herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A and SEQ ID NO:1 provide the sequence encoding the Ecto-NOX specific heavy chain ScFv (V H ), and FIG. 1B and SEQ ID NO:2 provide the DNA sequence encoding the Ecto-NOX specific light chain ScFv (V L ).
[0014] FIG. 2 presents the strategy for the synthesis of the ScFv gene.
[0015] FIG. 3 is a diagram of the pET-11a expression vector (available from Stratagene, La Jolla, Calif.). The sequence of the multiple cloning site portion is also shown (SEQ ID NO:17), as is the N-terminal sequence of the T7 gene 10 leader peptide (SEQ ID NO:18).
[0016] FIGS. 4A and 4B provide the DNA coding sequence and the deduced amino acid sequences of ScFv(S), respectively. See also SEQ ID NO:3 and SEQ ID NO:4, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention provides a recombinant single chain antibody which specifically binds all Ecto-NOX proteins, including the tumor specific form associated with tumor and other neoplastic cells (tNOX), when these proteins are resolved by gel electrophoresis and blotted to a solid support (such as a nylon support) (Western blot, immunoblot analysis).
[0018] The expression and function of the single chain antibody of the present invention for use in Western blots has been found to be dependent on the particular linker which joins the variable heavy and variable light portions. As specifically exemplified, the sequence of the linker is GGGGSGGGGSGGGGS (SEQ ID NO:5). The specifically exemplified single chain antibody also contains, at its C-terminus, a so-called S-tag, an amino acid sequence which allows for the use of a second antibody which specifically binds to this S-protein sequence, thus facilitating detection of the binding of the single chain antibody to an immunoblot.
[0019] As an alternative to the specifically exemplified S-tag, it is understood that other tag sequences which serve as binding sites for detectable second antibodies or other detectable molecule (with binding specificity for the single chain antibody of the present invention) or to facilitate purification over an affinity column or an immunoaffinity column can be substituted for the S tag. These tags, and expression vectors containing them include without limitation, the GST (glutathione S-transferase), flagellar antigen, Myc, Nus, among others. Other oligopeptide “tags” which can be fused to a protein of interest by molecular biological techniques include, without limitation, strep-tag (Sigma-Genosys, The Woodlands, Tex.) which directs binding to streptavidin or its derivative streptactin (Sigma-Genosys); a glutathione-S-transferase gene fusion system which directs binding to glutathione coupled to a solid support (Amersham Pharmacia Biotech, Uppsala, Sweden); a calmodulin-binding peptide fusion system which allows purification using a calmodulin resin (Stratagene, La Jolla, Calif.); a maltose binding protein fusion system allowing binding to an amylose resin (New England Biolabs, Beverly, Mass.); and an oligo-histidine fusion peptide system which allows purification using a Ni2+-NTA column (Qiagen, Valencia, Calif.).
[0020] The amino acids which occur in the various amino acid sequences referred to in the specification have their usual three- and one-letter abbreviations routinely used in the art: A, Ala, Alanine; C, Cys, Cysteine; D, Asp, Aspartic Acid; E, Glu, Glutamic Acid; F, Phe, Phenylalanine; G, Gly, Glycine; H, His, Histidine; I, Ile, Isoleucine; K, Lys, Lysine; L, Leu, Leucine; M, Met, Methionine; N, Asn, Asparagine; P, Pro, Proline; Q, Gln, Glutamine; R, Arg, Arginine; S, Ser, Serine; T, Thr, Threonine; V, Val, Valine; W, Try, Tryptophan; Y, Tyr, Tyrosine.
[0021] A protein is considered an isolated protein if it is a protein isolated from a host cell in which it is recombinantly produced. It can be purified or it can simply be free of other proteins and biological materials with which it is associated in nature.
[0022] An isolated nucleic acid is a nucleic acid the structure of which is not identical to that of any naturally occurring nucleic acid or to that of any fragment of a naturally occurring genomic nucleic acid spanning more than three separate genes. The term therefore covers, for example, (a) a DNA which has the sequence of part of a naturally occurring genomic DNA molecule but is not flanked by both of the coding or noncoding sequences that flank that part of the molecule in the genome of the organism in which it naturally occurs; (b) a nucleic acid incorporated into a vector or into the genomic DNA of a prokaryote or eukaryote in a manner such that the resulting molecule is not identical to any naturally occurring vector or genomic DNA; (c) a separate molecule such as a cDNA, a genomic fragment, a fragment produced by polymerase chain reaction (PCR), or a restriction fragment; and (d) a recombinant nucleotide sequence that is part of a hybrid gene, i.e., a gene encoding a fusion protein. Specifically excluded from this definition are nucleic acids present in mixtures of (i) DNA molecules, (ii) transformed or transfected cells, and (iii) cell clones, e.g., as these occur in a DNA library such as a cDNA or genomic DNA library.
[0023] As used herein expression directed by a particular sequence is the transcription and translation of an associated downstream sequence.
[0024] In the present context, a promoter is a DNA region which includes sequences sufficient to cause transcription of an associated (downstream) sequence. The promoter may be regulated, i.e., not constitutively acting to cause transcription of the associated sequence. If inducible, there are sequences present which mediate regulation of expression so that the associated sequence is transcribed only when an inducer molecule is present in the medium in or on which the organism is cultivated.
[0025] In the present context, a transcription regulatory sequence includes a promoter sequence and can further include cis-active sequences for regulated expression of an associated sequence in response to environmental signals.
[0026] One DNA portion or sequence is downstream of second DNA portion or sequence when it is located 3′ of the second sequence. One DNA portion or sequence is upstream of a second DNA portion or sequence when it is located 5′ of that sequence.
[0027] One DNA molecule or sequence and another are heterologous to another if the two are not derived from the same ultimate natural source. The sequences may be natural sequences, or at least one sequence can be designed by man, as in the case of a multiple cloning site region. The two sequences can be derived from two different species or one sequence can be produced by chemical synthesis provided that the nucleotide sequence of the synthesized portion was not derived from the same organism as the other sequence.
[0028] An isolated or substantially pure nucleic acid molecule or polynucleotide is a polynucleotide which is substantially separated from other polynucleotide sequences which naturally accompany a native transcription regulatory sequence. The term embraces a polynucleotide sequence which has been removed from its naturally occurring environment, and includes recombinant or cloned DNA isolates, chemically synthesized analogues and analogues biologically synthesized by heterologous systems.
[0029] A polynucleotide is said to encode a polypeptide if, when manipulated by methods known to those skilled in the art, it can be transcribed and/or translated to produce the polypeptide or a fragment thereof.
[0030] A nucleotide sequence is operably linked when it is placed into a functional relationship with another nucleotide sequence. For instance, a promoter is operably linked to a coding sequence if the promoter effects its transcription or expression. Generally, operably linked means that the sequences being linked are contiguous and, where necessary to join two protein coding regions, contiguous and in reading frame. However, it is well known that certain genetic elements, such as enhancers, may be operably linked even at a distance, i.e., even if not contiguous.
[0031] The term recombinant polynucleotide refers to a polynucleotide which is made by the combination of two otherwise separated segments of sequence accomplished by the artificial manipulation of isolated segments of polynucleotides by genetic engineering techniques or by chemical synthesis. In so doing one may join together polynucleotide segments of desired functions to generate a desired combination of functions.
[0032] Large amounts of the polynucleotides may be produced by replication in a suitable host cell. Natural or synthetic DNA fragments coding for a protein of interest are incorporated into recombinant polynucleotide constructs, typically DNA constructs, capable of introduction into and replication in a prokaryotic or eukaryotic cell, especially a mammalian cell in culture, e.g., Vero cells, CHO cells, among others, or Aspergillus pullulans or Aspergillus nidulans, Trichoderma reesei, Saccharomyces cerevisiae or Pichia pastoris, where protein expression is desired. Usually the construct is suitable for replication in a unicellular host, such as a bacterium, but a multicellular eukaryotic host may also be appropriate, with or without integration within the genome of the host cell. Commonly used prokaryotic hosts include strains of Escherichia coli, although other prokaryotes, such as Bacillus subtilis or a pseudomonad, may also be used. Such factors as ease of manipulation, ability to appropriately glycosylate expressed proteins, degree and control of protein expression, ease of purification of expressed proteins away from cellular contaminants or other factors influence the choice of the host cell.
[0033] The polynucleotides may also be produced by chemical synthesis, e.g., by the phosphoramidite method described by Beaucage and Caruthers (1981) Tetra. Letts. 22: 1859-1862 or the triester method according to Matteuci et al. (1981) J. Am. Chem. Soc. 103: 3185, and may be performed on commercially available, automated oligonucleotide synthesizers. A double-stranded fragment may be obtained from the single stranded product of chemical synthesis either by synthesizing the complementary strand and annealing the strand together under appropriate conditions or by adding the complementary strand using DNA polymerase with an appropriate primer sequence.
[0034] DNA constructs prepared for introduction into a prokaryotic or eukaryotic host will typically comprise a replication system (i.e. vector) recognized by the host, including the intended DNA fragment encoding the desired polypeptide, and will preferably also include transcription and translational initiation regulatory sequences operably linked to the polypeptide-encoding segment. Expression systems (expression vectors) may include, for example, an origin of replication or autonomously replicating sequence (ARS) and expression control sequences, a promoter, an enhancer and necessary processing information sites, such as ribosome-binding sites, RNA splice sites, polyadenylation sites, transcriptional terminator sequences, and mRNA stabilizing sequences. Signal peptides may also be included where appropriate from secreted polypeptides of the same or related species, which allow the protein to cross and/or lodge in cell membranes or be secreted from the cell.
[0035] An appropriate promoter and other necessary vector sequences will be selected so as to be functional in the host. Examples of workable combinations of cell lines and expression vectors are described in Sambrook et al. (1989) vide infra; Ausubel et al. (Eds.) (1995) Current Protocols in Molecular Biology, Greene Publishing and Wiley Interscience, New York; and Metzger et al. (1988) Nature, 334: 31-36. Many useful vectors for expression in bacteria, yeast, fungal, mammalian, insect, plant or other cells are well known in the art and may be obtained such vendors as Stratagene, New England Biolabs, Promega Biotech, and others. In addition, the construct may be joined to an amplifiable gene (e.g., DHFR) so that multiple copies of the gene may be made. For appropriate enhancer and other expression control sequences, see also Enhancers and Eukaryotic Gene Expression, Cold Spring Harbor Press, N.Y. (1983). While such expression vectors may replicate autonomously, they may less preferably replicate by being inserted into the genome of the host cell.
[0036] Expression and cloning vectors advantageously contain a selectable marker, that is, a gene encoding a protein necessary for the survival or growth of a host cell transformed with the vector. Although such a marker gene may be carried on another polynucleotide sequence co-introduced into the host cell, it is most often contained on the cloning vector. Only those host cells into which the marker gene has been introduced will survive and/or grow under selective conditions. Typical selection genes encode proteins that confer resistance to antibiotics or other toxic substances, e.g., ampicillin, neomycin, methotrexate, etc.; complement auxotrophic deficiencies; or supply critical nutrients not available from complex media. The choice of the proper selectable marker will depend on the host cell; appropriate markers for different hosts are known in the art.
[0037] Recombinant host cells, in the present context, are those which have been genetically modified to contain an isolated DNA molecule of the instant invention. The DNA can be introduced by any means known to the art which is appropriate for the particular type of cell, including without limitation, transformation, lipofection or electroporation.
[0038] It is recognized by those skilled in the art that the DNA sequences may vary due to the degeneracy of the genetic code and codon usage. All DNA sequences which code for the polypeptide or protein of interest are included in this invention.
[0039] Additionally, it will be recognized by those skilled in the art that variations may occur in the coding sequence specifically exemplified herein which will not significantly change activity of the amino acid sequence of the encoded polypeptide. All such equivalent DNA sequences are included within the scope of this invention and the definition of the regulated promoter region. The skilled artisan will understand that the sequence of the exemplified sequence can be used to identify and prepare additional, nonexemplified nucleotide sequences which are functionally equivalent to the sequences given.
[0040] Thus, mutational, insertional, and deletional variants of the disclosed nucleotide sequence can be readily prepared by methods which are well known to those skilled in the art. These variants can be used in the same manner as the exemplified primer sequences so long as the variants have substantial sequence homology with the original sequence. As used herein, substantial sequence identity refers to identity which is sufficient to enable the variant polynucleotide to function in the same capacity as the specifically exemplified Ecto-NOX specific single chain antibody. Preferably, this identity is greater than 85%, even more preferably this identity is greater than 90%, and most preferably, this identity is greater than 95%. It is well within the skill of a person trained in this art to make mutational, insertional, and deletional mutations which are equivalent in function or are designed to improve the function of the sequence or otherwise provide a methodological advantage. Substitutions, insertions or deletions of from 1 to 5 amino acids which do not affect the binding specificity are within the scope of the present invention. Methods for confirming antigen (Ecto-NOX tNOX) binding specificity are well known in the art.
[0041] Polymerase Chain Reaction (PCR) is a repetitive, enzymatic, primed amplification of a nucleic acid sequence. This procedure is well known and commonly used by those skilled in this art (see Mullis, U.S. Pat. Nos. 4,683,195, 4,683,202, and 4,800,159; Saiki et al. (1985) Science 230:1350-1354). By using a thermostable DNA polymerase such as the Taq polymerase, which is isolated from the thermophilic bacterium Thermus aquaticus, the amplification process can be completely automated. Other enzymes which can be used are known to those skilled in the art. It is understood that PCR can also be used to join fragments of DNA and/or to introduce defined mutations into a sequence of interest. Standard techniques for cloning, DNA isolation, amplification and purification, for enzymatic reactions involving DNA ligase, DNA polymerase, restriction endonucleases and the like, and various separation techniques are those known and commonly employed by those skilled in the art. A number of standard techniques are described in Sambrook et al. (1989) Molecular Cloning, Second Edition, Cold Spring Harbor Laboratory, Plainview, N.Y.; Maniatis et al. (1982) Molecular Cloning, Cold Spring Harbor Laboratory, Plainview, N.Y.; Wu (ed.) (1993) Meth. Enzymol. 218, Part I; Wu (ed.) (1979) Meth. Enzymol. 68; Wu et al. (eds.) (1983) Meth. Enzymol. 100 and 101; Grossman and Moldave (eds.) Meth. Enzymol. 65; Miller (ed.) (1972) Experiments in Molecular Genetics, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.; Old and Primrose (1981) Principles of Gene Manipulation, University of California Press, Berkeley; Schleif and Wensink (1982) Practical Methods in Molecular Biology; Glover (ed.) (1985) DNA Cloning Vol. I and II, IRL Press, Oxford, UK; Hames and Higgins (eds.) (1985) Nucleic Acid Hybridization, IRL Press, Oxford, UK; Setlow and Hollaender (1979) Genetic Engineering: Principles and Methods, Vols. 1-4, Plenum Press, New York; Fitchen, et al. (1993) Annu. Rev. Microbiol. 47:739-764; Tolstoshev, et al. (1993) in Genomic Research in Molecular Medicine and Virology, Academic Press; and Ausubel et al. (1992) Current Protocols in Molecular Biology, Greene/Wiley, New York, N.Y. Abbreviations and nomenclature, where employed, are deemed standard in the field and commonly used in professional journals such as those cited herein. Antiobody vaccines are described in Dillman R. O. (2001) Cancer Invest. 19(8):833-841. Durrant L. G. et al. (2001) Int. J. Cancer 1; 92(3):414-420 and Bhattacharya-Chatterjee M. (2001) Curr. Opin. Mol. Ther. Feb. 3(1):63-69 describe anti-idiotype antibodies. Many of the procedures useful for practicing the present invention whether or not described herein in detail, are well known to those skilled in the arts of molecular biology, biochemistry, immunology, and medicine.
[0042] All references cited in the present application are incorporated by reference herein to the extent that there is no inconsistency with the present disclosure. Such references reflect the skill in the arts relevant to the present invention.
[0043] The following examples are provided for illustrative purposes, and are not intended to limit the scope of the invention as claimed herein. Any variations in the exemplified single chain antibodies, coding and amino acid sequences, epitopes, purification methods, diagnostic methods, preventative methods, treatment methods, and other methods which occur to the skilled artisan are intended to fall within the scope of the present invention.
EXAMPLES
Example 1
Recombinant tNOX-Specific Single Chain Antibody
[0044] Monoclonal antibody generated against tNOX NADH oxidase tumor cell specific was produced in sp-2 myeloma cells, however, the monoclonal antibody slowed the growth of sp-2 myeloma cells that were used for fusion with spleen cells after 72 h. This phenomenon made it difficult to produce antibody in quantity. tNOX-specific monoclonal antibody-producing cells are described in U.S. Pat. No. 7,053,188, and they are on deposit with the American Type Culture Collection as PTA-4206. To overcome this problem, the coding sequences of the antigen-binding variable region of the heavy chain and the light chain (Fv region) of the antibody cDNA were cloned and linked into one chimeric gene, upstream of the S-tag coding sequence. The Fv portion of an antibody, consisting of variable heavy (V H ) and variable light (V L ) domains, can maintain the binding specificity and affinity of the original antibody (Glockshuber et al. 1990. Biochemistry 29:1262-1367).
Example 2
Cloning cDNAs Encoding the Variable Regions of Immunoglobulin Heavy Chain and Light Chain
[0045] For a recombinant antibody, cDNAs encoding the variable regions of immunoglobulin heavy chain (V H ) and light chain (V I ), are cloned by using degenerate primers. Mammalian immunoglobulins of light and heavy chain contain conserved regions adjacent to the hypervariable complementary defining regions (CDRs). Degenerate oligoprimer sets allow these regions to be amplified using PCR (Jones et al. 1991. Bio/Technology 9:88-89; Daugherty et al. 1991. Nucleic Acids Research 19:2471-2476). Recombinant DNA techniques have facilitated the stabilization of variable fragments by covalently linking the two fragments by a polypeptide linker (Huston et al. 1988. Proc. Natl. Acad. Sci. USA 85:5879-5883). Either V L or V H can provide the NH 2 -terminal domain of the single chain variable fragment (ScFv). The linker should be designed to resist proteolysis and to minimize protein aggregation. Linker length and sequences contribute and control flexibility and interaction with ScFv and antigen. The most widely used linkers have sequences consisting of glycine (Gly) and serine (Ser) residues for flexibility, with charged residues as glutamic acid (Glu) and lysine (Lys) for solubility (Bird et al. 1988. Science 242:423-426; Huston et al. 1988. supra).
Example 3
Isolation of RNA
[0046] Total RNA was isolated from the hybridoma cells (ATCC Accession No. PTA-4206) producing tNOX-specific monoclonal antibodies by the following procedure modified from Chomczynski et al. (1987) Anal. Biochem. 162:156-159 and Gough (1988) Anal. Biochem 176:93-95. Cells were harvested from medium and pelleted by centrifugation at 450×g for 10 min. Pellets were gently resuspended with 10 volumes of ice cold PBS and centrifuged again. The supernatant was discarded and cells were resuspended with an equal volume of PBS. Denaturing solution (0.36 ml of 2-mercaptoethanol/50 ml of guanidinium stock solution-4M guanidinium thiocyanate, 25 mM sodium citrate, pH 7.0, 0.5% sarkosyl) 10 ml per 1 g of cell pellet was added prior to use and mixed gently. Sodium acetate (pH 4.0,1 ml of 2M), 10 ml of phenol saturated water and 2 ml of chloroform:isoamyl alcohol (24:1) mixtures were sequentially added after each addition. The solution was mixed thoroughly by inversion. The solution was vigorously shaken for 10 sec, chilled on ice for 15 min and then centrifuged 12,000×g for 30 min. The supernatant was transferred and an equal volume of 2-propanol was added and placed at −20° C. overnight to precipitate the RNA. The RNA was pelleted for 15 min at 12,000×g, and the pellet was resuspended with 2-3ml of denaturing solution and 2 volumes of ethanol. The solution was placed at −20° C. for 2 h, and then centrifuged at 12,000×g for 15 min. The RNA pellet was washed with 70% ethanol and then 100% ethanol. The pellet was resuspended with RNase-free water (DEPC-treated water) after centrifugation at 12,000×g for 5 min. The amount of isolated RNA was measured spectrophotometrically and calculated from the absorbance at 280 nm and 260 nm.
[0047] The poly(A)mRNA isolation kit was purchased from Stratagene. Total RNA was applied to an oligo(dT) cellulose column after heating the total RNA at 65° C. for 5 min. Before applying, the RNA samples were mixed with 500 μl of 10×sample buffer (10 mM Tris-HCl, pH 7.5,1 mM EDTA, 5 M NaCl). The RNA samples were pushed through the column at a rate of 1 drop every 2 sec. The eluates were pooled and reapplied to the column and purified again. Preheated elution buffer (65° C.) was applied, and mRNA was eluted and collected in 1.5 ml of centrifuge tubes on ice. The amount of mRNA was determined at OD 260 (1 OD unit=40 μg of RNA). The amounts of total RNA and mRNA obtained from 4×10 8 cells were 1328 μg and 28 μg, respectively.
[0048] mRNA (1-2 μg) dissolved in DEPC-treated water was used for cDNA synthesis. mRNA isolated on three different dates was pooled for first-strand cDNA synthesis. The cDNA synthesis kit was purchased from Pharmacia Biotech. mRNA (1.5 μg/5 μl of DEPC-treated water) was heated at 65° C. for 10 min. and cooled immediately on ice. The primed first strand mix containing MuLV reverse transcriptase (11 μl) and appropriate buffers for the reaction were mixed with mRNA sample. DTT solution (1 μl of 0.1 M) and RNase-free water (16 μl) also were added to the solution. The mixture was incubated for 1 h at 37° C.
Example 4
ScFv Primer Design
[0049] Degenerate primers for light chain and heavy chain (Novagen, Madison, Wis.) were used for PCR. PCR synthesis was carried out in 100 μl reaction volumes in 0.5 ml microcentrifuge tubes by using Robocycler (Stratagene, La Jolla, Calif.). All PCR syntheses included 2 μl of sense and anti-sense primers (20 pmoles/μl ), 1 μl of first-strand cDNA as a template, 2 μl of 10 mM of dNTPs, 1 μl of Vent polymerase (2 units/μl), 10 μl of 10×PCR buffer (100 mM Tris-HCl, pH 8.8 at 25° C., 500 mM KCl, 15 mM MgCl 2 , 1% Triton X-100), 82 μl of H 2 O. Triton X-100 is t-octylphenoxypolyethoxyethanol. All PCR profiles consisted of 1 min of denaturation at 94° C., 1 min of annealing at 55° C., and 1 min of extension at 72° C. This sequence was repeated 30 times with a 6-min extension at 72° C. in the final cycle. PCR products were purified with QIAEX II gel extraction kit from Qiagen, Valencia, Calif. PCR amplification products for heavy and light chain coding sequences were analyzed by agarose gel electrophoresis and were about 340 base pair (bp) long and 325 bp long, respectively.
[0050] Total RNA or DNA was analyzed by agarose gel electrophoresis (1% agarose gels). Agarose (0.5 g in 50 ml of TAE buffer, 40 mM Tris-acetate, 1 mM EDTA) was heated for 2 min in a microwave to melt and evenly disperse the agarose. The solution was cooled at room temperature, and ethidium bromide (0.5 μg/ml) was added and poured into the apparatus. Each sample was mixed with 6×gel loading buffer (0.25% bromophenol blue, 0.25% xylene cyanol FF, 40% (w/v) sucrose in water). TAE buffer was used as the running buffer. Voltage (10 v.cm) was applied for 60-90 min.
Example 5
PCR Amplification
[0051] According to the proper size for heavy and light chain cDNAs, the bands were excised from the gels under UV illumination, and excised gels were placed in 1 ml syringes fitted with 18-gauge needles. Gels were crushed to a 1.5 ml Eppendorf tube. The barrel of each syringe was washed with 200 μl of buffer-saturated phenol (pH 7.9±0.2). The mixture was thoroughly centrifuged and frozen at −70° C. for 10 min. The mixture was centrifuged for 5 min, and the top aqueous phase was transferred to a new tube. The aqueous phase was extracted again with phenol/chloroform (1:1). After centrifuging for 5 min, the top aqueous phase was transferred to a clean tube, and chloroform extraction was performed. Sodium acetate (10 volumes of 3 M) and 2.5 volumes of ice-cold ethanol were added to the top aqueous phase to precipitate DNA at −20° C. overnight.
[0052] Purified heavy and light chain cDNAs were ligated into plasmid pSTBlue-1 vector and transfected into NovaBlue competent cells (Stratagene). Colonies containing heavy and light chain DNAs were screened by blue and white colony selection and confirmed by PCR analysis. Heavy and light chain DNAs were isolated and sequenced using standard techniques. FIGS. 1A and 1B show the DNA sequences of heavy and light chain DNAs of ScFv.
[0053] PCR amplification and the assembly of single ScFv gene was according to Davis et al. (1991) Bio/Technology 9:165-169 ( FIG. 2 ). Plasmid pSTBlue-1 carrying V H and V L genes were combined with all four oligonucleotide primers in a single PCR synthesis ( FIG. 3 ). Following first PCR synthesis, one tenth of the first PCR product was removed and added to a second PCR reaction mixture containing only the primer a (V H sense primer) and primer d (V L Antisense primer). The product of the second PCR synthesis yielded single ScFv gene. The single ScFv gene was ligated to plasmid pT-Adv (Clontech, Palo Alto, Calif.). pT-Adv carrying ScFv gene was used for DNA sequencing.
Example 6
Linker Design
[0054] The complete ScFv gene was assembled from the V H , V L and linker genes to yield a single ScFv gene by PCR ( FIG. 4 ). The DNA sequence encoding the linker was 45 nucleotides long (GGAGGCGGTGGATCGGGCGGTGGCGGCTCGGGTGGCGGCGGCTCT; SEQ ID NO:6), which translates to a peptide of 15 amino acids (GlyGlyGlyGlySerGlyGlyGlyGlySerGlyGlyGlyGlySer; SEQ ID NO:5). Primers for PCR amplification are shown in Table 3. S-peptide was linked to the C-terminus of ScFv[ScFv(S)]. S-peptide binds to S-protein conjugated to alkaline phosphatase for Western blot analysis. The DNA sequence of the S-peptide is AAAGAAACCGCTGCTGCTAAATTCGAACGCCAGCACATGGACAGC (SEQ ID NO:7) which translates to S-peptide (LysGluThrAlaAlaAlaLysPheGluArgGlnHisMetAspSer; SEQ ID NO:8).
Example 7
Expression of Recombinant ScFv
[0055] Recombinant ScFv(S) was expressed in E. coli. First, oligo nucleotides encoding S-peptide were linked to the 3′ end of the open reading frame (ORF) of ScFv DNA by PCR amplification. Incorporation of S-peptide enables to detect expressed ScFv protein by S-protein conjugated to alkaline phosphatase. The tNOX-specific ScFv(S) coding sequence was then subcloned to plasmid pET-11a, a plasmid designed for protein expression in E. coli (Stratagene, Calif.). For PCR amplification, two primers were designed to amplify ORF of ScFv(S) containing endonuclease restriction sites (NdeI and NheI) and S-peptide residues.
[0056] Plasmid pET-11a and ORF of ScFv(S) were digested with restriction enzymes NdeI and NhI and ligated to produce plasmid pET11-ScFv(S). E. coli BL21 (DE3) was transformed with pET11-ScFv(S) and grown at 37° C. for 12 h in LB medium containing ampicillin (100 μg/ml). ScFv was expressed by addition of 0.5 mM IPTG and incubation for 4 h. Cells were harvested and lysed using a French Pressure Cell (French Pressure Cell Press, SLM Instruments, Inc.) (three passages at 20,000 psi). Cell extracts were centrifuged at 10,000×g for 20 min. Pellets containing denatured inclusion bodies of ScFv were collected. Renaturation of the inclusion bodies containing the ScFv was according to Goldberg et al. 1995. Folding & Design 1:21-27.
[0000]
TABLE 1
Primers for PCR amplification of ScFv(s) gene
1.
Primers for cloning of variable regions of
heavy chain and light chain of antibody
(A)
Primers for heavy chain (V H )
Forward primer:
5′-GGCCCAGCCGGCCGAGGTCAAGCTGCAGGAGTCAGGA-3′
(SEQ ID NO: 9)
Reverse primer:
5′-CTCGGAACCTGAGGAGACGGTGACCGTGGTCCC-3′
(SEQ ID NO: 10)
(B)
Primers for light chain (V L )
Forward primer:
5′-TCCAAAGTCGACGAAAATGTGCTCACCCAGTCTCCA-3′
(SEQ ID NO: 11)
Reverse primer:
5′-AGCGGCCGCTTTCAGCTCCAGCTTGGTCCCCCC-3′
(SEQ ID NO: 12)
2.
Primers for subcloning of ScFv(s) gene into
pET-11a expression vector
(A)
Primers for heavy chain (V H ) and linker
amplification
Forward primer:
5′-GTCAAGCTGCAGGAGTCAGGA-3′
(SEQ ID NO: 13)
Reverse primer:
5′-AGAGCCGCCGCCACCCGAGCCGCCACCGCCCGATCCACCGCCTC
CTGAGGAGACGGTGACCGTGGT-3′
(SEQ ID NO: 14)
(B)
Primers for light chain (V L ), linker and S-tag
amplification
Forward primer:
5′-GGAGGCGGTGGATCGGGCGGTGGCGGCTCGGGTGGCGGCGGCTC
TGAAAATGTGCTCACCCAGTCT-3′
(SEQ ID NO: 15)
Reverse primer:
5′-AGTCAGGCTAGCTTAGCTGTCCATGTGCTGGCGTTCGAATTTAG
CAGCAGCGGTTTCTTTCGCTTTCAGCTCCAGCTT-3′
(SEQ ID NO: 16)
BIBLIOGRAPHY
[0000]
1. Morré, D. J. (1998) in Plasma Membrane Redox Systems and Their Role in Biological Stress and Disease (Asard, H., Bérczi, A. and Caubergs, R. J., Eds) pp. 121-156, Kluwer Academic Publishers, Dordrecht, Netherlands.
2. Morré, D. J. and Morré, D. M. (2003) Free Radical Res. 37: 795-808
3. Morré, D. J., Chueh, P.-J. and Morré, D. M. (1995) Proc. Natl. Acad. Sci. USA 92:1831-1835.
4. Bruno, M., Brightman, A. O., Lawrence, J., Werderitsh, D., Morré, D. M. and Morré, D. J. (1992) Biochem. J. 284: 625-628.
5. Cho, N., Chueh, P.-J., Kim, C., Caldwell, S., Morré, D. M. and Morré, D. J. (2002) Cancer Immunol. Immunother. 51: 121-129.
6. Morré, D. J., Caldwell, S., Mayorga, A., Wu, L-Y. and Morré, D. M. (1997) Arch. Biochem. Biophys. 342: 224-230.
7. Morré, D. J. and Reust, T. (1997) J. Bioenerg. Biomemb. 29, 281-289.
8. Morré, D. J. (1995) Biochim. Biophys. Acta 1240: 201-208.
9. del Castillo-Olivares, A., Chueh, P.-J., Wang, S., Sweeting, M., Yantiri, F., Sedlak, D., Morré, D. J. and Morré, D. M. (1998) Arch. Biochem. Biophys. 358: 125-140.
10. Morré, D. J., Sedlak, D., Tang, X., Chueh, P. J., Geng, T. and Morré, D. M. (2001) Arch. Biochem. Biophys. 392: 251-256.
11. Chueh, P. J., Kim, C., Cho, N., Morré, D. M. and Morré, D. J. (2002) Biochemistry 41: 3732-3741.
12. Bird, C. (1999) Direct submission of human DNA sequence from clone 875H3 (part of APK1 antigen) to GenBank database at NCBI. (Accession no. AL049733). | The present Specification describes compositions and methods for production of a recombinant single chain variable region (ScFv) antibody useful for the detection of members of the ECTO-NOX family of cell surface proteins on Western blots. This single chain antibody is especially useful in the detection, diagnosis and monitoring of neoplastic disorders. A linker sequence required to appropriately combine the light and heavy chain variable region fragments to form the functional recombinant single chain antibodies is also provided. The resultant ScFv is a pan ECTO-NOX antibody for detection on Western blots of most if not all tNOX isoforms. | 2 |
TECHNICAL FIELD
The present invention is directed to decking and fencing products, and in particular to spindles and balusters for decking and fencing.
BACKGROUND OF THE INVENTION
Outdoor decks and fences are extremely popular in residential home construction. Homes and apartments, as well as a variety of other buildings, often incorporate exterior decks and fences into their design. Additionally, decks and fences are commonly added onto existing structures and landscapes. These decks and fences provide convenient spaces for a variety of outdoor activities, including cookouts, dining and sunbathing, as well as other leisure activities. Moreover, decks typically are provided with a railing or perimeter fence to keep people from falling over the edge of the deck.
Wood products have traditionally been the primary source of materials for use in decking construction. However, wood products are becoming increasingly scarce due to the harvesting of trees at ever faster rates and the rather limited rate at which timber resources can be replenished. Also, environmental concerns and regulations directed to conservation or preservation of forests tend to restrict the availability of wood products. With the diminishing availability of timber resources, wood products are becoming increasingly expensive. There is, therefore, a substantial need for long lasting substitute construction materials that can lessen the need to harvest timber resources.
One potential approach to addressing the above need is to provide substitute decking and fencing products made of plastic, rather than wood. However, because the deck and fencing products must be capable of sustaining certain roads, the replacement products need to be stable and rigid. The material should also be capable of economical manufacture, and be relatively inexpensive. It also needs to be easily fabricated and used in the field.
A variety of plastic building products are known. For example, U.S. Pat. No. 4,045,603 describes a three-layer synthetic construction material made from recycled waste thermoplastic synthetic resin material and cellulose fiber aggregate. This material includes face surfaces consisting essentially of re-hardened fused and rolled thermoplastic synthetic resin material bits, and an intervening core material consisting essentially of a compressed non-homogenous mixture of cellulose aggregate material bits and re-hardened fused thermoplastic synthetic resin material bits.
U.S. Pat. No. 3,764,245 describes an apparatus for producing a light structural board of thermoplastic resin.
U.S. Pat. No. 5,253,458 describes a simulated log made from a cast polyvinylchloride (PVC) pipe, selectively filled with a hard cast foam or bead type foam. This patent further describes that the cast PVC pipe is first manufactured and then subsequently filled with the foam filler.
Accordingly, it can be seen there is a need yet in the art for replacement decking and fence components as a replacement for traditional wood products, which provide a strong finished product at minimal cost, which are weather resistant and which can be produced easily. It to the provision of such decking and fence components that the present invention is primarily directed.
SUMMARY OF THE INVENTION
Briefly described, in a preferred form the present invention comprises a spindle or baluster for use in a fence or deck railing. The spindle comprises a plastic outer shell having a first end section, a second end section opposite the first end section, and a middle section intermediate the first and second end sections. An elongate metal reinforcing element is disposed within the outer shell and extends from the first end section to the second end section. Rigid plastic foam is disposed within at least a portion of the first and second end sections of the shell and at least substantially surrounds portions of the metal reinforcing element. Preferably, the plastic foam is injected into the end sections as a liquid and expands to substantially fill the entire end sections of the shell. Also preferably, the metal reinforcing element is hollow and has an outside transverse dimension which is closely matched to an internal transverse dimension of the intermediate section of the shell.
With this construction, a composite spindle or baluster is provided which is very easy to manufacture, which provides excellent appearance, and which provides good strength (both in terms of bending resistance and compression load carrying capability). This composite material represents a good alternative to the use of traditional wood spindles and balusters.
Accordingly, it is an object of the present invention to provide a composite spindle or baluster which is economical in manufacture and application, durable in construction, and simple.
It is another object of the invention to provide a composite spindle or baluster which has good strength and rigidity for use in fencing and deck railings.
It is yet another object of the present invention to provide a composite spindle or baluster which, while having the general appearance of a traditional wood spindle or baluster, does not rely on scarce timber resources and which is highly resistant to weathering.
These and other objects, advantages, and features of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a perspective illustration of a spindle or baluster according to a preferred form of the invention.
FIG. 2 is a sectional illustration of the spindle or baluster of FIG. 1.
FIG. 3A is a partially cut-away illustration of a portion of the spindle or baluster of FIG. 1.
FIG. 3B is a partially cut-away illustration of a portion of the spindle or baluster of FIG. 1 in a second preferred form of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing figures, wherein like reference numerals depict like parts throughout the several views, FIGS. 1 and 2 show a composite spindle 10 according to a preferred form of the invention. The composite spindle 10 generally comprises a rigid plastic outer shell 11, a steel tubular reinforcing element 12, and high density polyurethane foam 13 and 14 for securing the steel tubular reinforcing element 12 within the PVC outer shell 11.
The PVC outer shell 11 includes a first end section 16, a second end section 17 opposite the first end section 16, and an intermediate section 18 between the first and second end sections. Each of the end sections 16, 17 is square in cross-section over substantially their entire lengths, with a transition region 22, 23 easing the transition between the square cross-section of the end sections 16, 17 and the "turned" profile of the intermediate section 18. In this regard, the overall visual effect of the spindle is that of a traditional, wooden spindle which, while initially square in cross-section along its entire length, is formed by turning it on a lathe to produce the rounded shapes in the intermediate section, such as the rounded shapes depicted in FIGS. 1 and 2.
For illustration purposes, FIGS. 1 and 2 depict an intermediate section having certain design elements common to turned wooden posts or spindles. For example, as depicted in FIGS. 1 and 2, the intermediate section includes three bulbous transition elements 26, 27 and 28. A pair of club shaped or bat shaped surfaces 31 and 32 extend between the bulbous transition elements 26 and 27 and 27 and 28, respectively. Of course, other shapes are possible.
As can be seen in FIGS. 1 and 2, the outside diameter of the steel tubular reinforcing element 12 is closely matched to the internal transverse dimension or inside diameter of the PVC outer shell 11 at certain locations, namely at the places where the bulbous transition elements 26 and 28 meet the transition regions 22 and 23, respectively. Also, at the edges of the bulbous transition element 27 the internal transverse dimension or internal diameter of the PVC outer shell 11 is closely matched to the outside diameter of the steel tubular reinforcing element 12.
Preferably, the steel tubular reinforcing element 12 has a 0.625" outside diameter and wall thickness of 16 guage. Also preferably, the high density polyurethane foam 13, 14 in the end sections 16, 17 is of a 6 to 16 lbs. density.
To manufacture and assemble the composite spindle, the PVC outer shell is first blow molded and then the steel tubular reinforcing element 12 is inserted in through one end of the PVC shell towards the other end thereof. With the steel tubing in place, liquid polyurethane foam is then injected into the end sections 16, 17 and allowed to cure. Alternatively, the steel tubular reinforcing element 12 can be placed in the mold prior to forming the PVC outer shell. A third manufacturing option would be to make the empty shell 11 first, then fill it with foam in the ends 16 and 17 thereof, and then to force the tubular reinforcing element through the foam at one end of the composite spindle and ram it into the other end thereof.
As depicted in FIG. 2 and FIG. 3A, the polyurethane foam injected into the end sections 16 and 17 of the PVC outer shell 11 can be injected at a controlled rate and in a controlled amount to control or limit the amount or extent of the filling of the end sections 16 and 17 with polyurethane foam. A depicted in FIGS. 2 and 3A, sufficient amounts of high density polyurethane foam can be injected into the interior of the end sections 16 and 17 to ensure adequate securement of the steel tubular reinforcing element within the PVC outer shell. Alternatively, as depicted in FIG. 3B, additional liquid polyurethane foam can be added to the end sections 16 and 17 to fill the end sections 16 and 17 substantially completely with polyurethane foam. Indeed, as depicted in FIG. 3B, a small amount of the polyurethane foam can be allowed to escape beyond the end sections 16 and 17 and into the intermediate section 18. FIGS. 3A and 3B depict that the high density foam can be used to fill the end sections only half way (FIG. 3A) or entirely (FIG. 3B).
The resulting composite spindle has the appearance of a turned wooden spindle, without the attendant demand on timber resources for producing such. Moreover, the cost of manufacturing such a composite spindle is quite reasonable. Also, by the combination of the plastic outer shell, the shell reinforcing element, and the high density polyurethane foam, a strong, stiff spindle is achieved. The composite spindle constructed this way meets typical building code requirements for strength. Such building code requirement typically are not met by producing a hollow spindle of a similar shape made out of PVC, for example. This composite spindle is quite weather resistant, owing to the external surfaces being made of PVC, while the less weatherable element (the steel) is concealed therewithin.
While the invention has been disclosed in preferred forms, it will be apparent to those skilled in the art that certain modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as set forth in the appended claims. For example, other plastic materials can be used for the shell besides PVC. Likewise, instead of using a polyurethane foam, some other foam could be used to provide additional rigidity and stiffness and to secure the steel reinforcing element within the end sections of the outer shell. Also, the intermediate section or center section of the spindle can take various shapes, as desired. Also, the steel reinforcing tube can be replaced with a solid steel reinforcing rod. These and other modifications, nonetheless, fall within the scope of the invention as set forth in the following claims. | A spindle or baluster for use in a fence or deck railing which comprises a plastic outer shell having a first end section, a second end section opposite the first end section, and a middle section intermediate the first and second end sections. An elongate metal reinforcing element is positioned within the outer shell and extends from the first end section to the second end section. A rigid plastic foam is disposed within at least a portion of the first and second end sections and substantially surrounds portions of the metal reinforcing element. | 4 |
CONTRACTUAL ORIGIN OF THE INVENTION
The United States of America has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the United States Department of Energy and the University of Chicago, the operator of Argonne National Laboratory.
BACKGROUND OF THE INVENTION
This inention relates to a combustor for fine particulate coal, a plentiful fuel in the United States. Coal can be used as a fuel to provide a stream of clean, hot gas for a prime mover such as a gas turbine in, for example, a peaking station for generation of electricity or a locomotive. However, because coal is a solid, its use as a fuel creates ash and soot as well as the usual pollutants resulting from combustion. Turbine blades are quite vulnerable to erosion by particulates in the gas stream, and can also be corroded by chemical reactions occurring between matter in the gas stream and the blade metal at the high temperature at which the turbine is operating. These processes together can destroy a turbine blade in a very short time. Thus, it is important that the gas stream be free of particulate matter.
Using finely ground coal allows a combustion process resulting in a clean stream of hot gas. However, while combustion of fine particulate reduces ash, the combustion process can be difficult to control. Combustion must occur in a manner which insures good control of the temperature and the local and overall stoichiometric ratio (the ratio of air to fuel in the mixture) to insure complete combustion, and avoid formation of nitrogen oxide, a pollutant, as well as soot, which is extremely difficult to burn. If the temperature is too high, the formation of nitrogen oxides is encouraged; if it is too low, combustion is incomplete and soot will be formed. A local excess of air per unit of fuel likewise leads to formation of nitrogen oxides; a deficiency results in localized incomplete combustion and production of soot. Of course, both are undesirable since nitrogen oxides pollute the atmosphere, and soot prevents the delivery of clean gas.
SUMMARY OF THE INVENTION
It is an object of the present invention to combust particulate coal and provide a stream of hot gas to a prime mover.
It is another object of the present invention to provide a stream of hot gas which is free of ash, soot, or other particulate matter.
It is another object of the present invention to control the stoichiometric ratio and temperature of combustion to minimize the production of pollutants and soot.
In accordance with the present invention, the combustor is comprised of two concentric truncated cones. At the upper ends of the cones, the annular space between them is sharply expanded to form a torus constituting a primary combustion chamber. The distance between the cones in the annular space below the primary combustion chamber gradually increases toward the lower ends of the cones, and forms a secondary combustion chamber. Air and fuel are introduced to the primary combustion chamber through tangential injectors to induce circular movement of the air-fuel mixture in the primary combustion chamber around the inner cone. Secondary air is introduced through slanted injectors at the top of the ring near the inner cone to induce a circular movement of air in the primary chamber between the inner cone and the fuel-air mixture.
The primary combustion chamber communicates with the secondary chamber. The partially-burned fuel-air mixture and secondary air move to the secondary chamber, where combustion is completed. Because the secondary chamber expands as distance from the primary chamber increases, the gas expands and mixes with secondary air, thereby moderating the combustion temperature. Because the mixture is rotating around the inner cone, molten ash is driven by centrifugal force to the inside surface of the outer cone. The ash flows downwardly by gravity into a hemispherical collector attached to the bottom of the outer cone. Combustion gas reverses its flow direction to travel through the center of the inner cone and exhaust through an exit at the top, from which it travels to the prime mover.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated in the accompanying drawings wherein FIG. 1 is a cross-sectional view of a particulate coal combustor.
FIG. 2 is a graph depicting selected points in the combustion process.
FIG. 3 is a cross-section of the coal combustor along line 3--3 of FIG. 1.
FIG. 4 is a detail view of one primary combustion chamber secondary air injection port.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a particulate coal combustor 10 having a primary combustion chamber 12 and a secondary combustion chamber 14. Primary combustion chamber 12 surrounds combustion gas exhaust trunk 16, through which hot gas passes from combustor 10 to a prime mover, which is not shown. An outer wall 20 of primary chamber 12 has a plurality of primary injection ports 22 through which finely-ground coal, air, or both are admitted to primary chamber 12. As shown in FIG. 3, the angular spacing between adjacent injectors 22 is constant. Furthermore, the axis of each port 22 is tangential to circular primary combustion chamber 12 so that air is injected in the direction of arrow "A" to induce circular motion of the fuel-air mixture.
Secondary air injection ports 24 are located in an upper surface 21 of the primary chamber. As with the primary injection ports 22, the angular spacing between adjacent secondary air injection ports 24 is constant. The axis of each is slanted as shown in FIG. 3 so that secondary air is injected in the direction of arrow "B" to induce circular motion of the secondary air mass.
The bottom of primary chamber 12 is open to secondary combustion chamber 14. Secondary chamber 14 is formed by outer conical section 26 and inner conical section 28. Inner conical section 28 depends from exhaust trunk 16. Outer conical section 26 surrounds inner section 28; the diameter of outer section 26 increases at a rate which is greater than the rate at which the diameter of inner section 28 increases. Thus, the cross-sectional area of secondary chamber 14 steadily increases toward the bottom of combustor 10.
A hemispherical combustor base 30 is attached to the lower end of outer conical section 26. Base 30 separates the combustion region from atmosphere and also collects molten ash which is withdrawn through a drain 32.
Primary air is provided to injection ports 22 through manifold 34, which surrounds combustor 10 near the lower end of outer conical section 26. The air passes from manifold 34 through a plurality of holes 36 into a space formed by outer conical section 26 and insulating jacket 38. The air travels upward around outer conical section 26, absorbing energy by heat transfer from secondary combustion chamber 14. Thus, the primary air is preheated, and the temperature in secondary combustion chamber 14 is moderated. Jacket 38 also surrounds primary combustion chamber 12, thus providing a plenum 39 through which the preheated air can travel to injection ports 22 and 24. Particulate coal is also delivered by any conventional means, not shown here, to alternate injection ports 22.
Exhaust trunk 16 also contains tertiary air injection ports 42. Unlike primary and secondary ports 22 and 24, however, these tertiary ports 42 are not tangential; instead, their axes point toward the central axis of combustor 10 so that air is injected in the direction of arrow "C" to reduce rotation of the hot gas.
The operation of combustor 10 will now be briefly described. Primary air, preheated by heat exchange with secondary combustion chamber 14, is distributed through plenum 39 to half of the primary injector ports 22. Fuel is mixed with primary air for injection into the other half of primary injection ports 22. Because ports 22 are tangential, the air-fuel mixture moves circularly within primary chamber 12 around exhaust trunk 16. The stoichiometric ratio is maintained at about 0.6, where 1.0 represents the amount of air just sufficient to completely combust a unit amount of a given type of coal. A ratio of 0.6 avoids formation of soot (occurring at lower ratios) and incompatible high temperatures (occurring at higher ratios). Preheated secondary air is introduced to the primay chamber via ports 24. Since these ports are slanted, this flow also contributes to the circular motion. Using multiple and tangential injector ports insures thorough and even mixing of the fuel and air. However, since the secondary air contains no fuel, the concentration of fuel is higher in the periphery of primary chamber 12 and lower toward the center of combustor 10, that is, nearer inner conical section 28 and exhaust trunk 16. Because of the circular flow in primary chamber 12, centrifugal force causes larger particles of fuel to remain near the periphery of chamber 12 for the longer period of time necessary for combustion. As the mass of the particles are reduced by combustion, the particles tend to move away from the periphery because centrifugal force is reduced, and because secondary air induces movement of the fuel-air mixture from primary chamber 12 to secondary chamber 14. The secondary air allows combustion to continue but also limits the maximum temperture, thus limiting the formation of nitrogen oxides.
The stoichiometric ratio of 0.6 is achieved by adjusting the relative quantities of fuel and air; FIG. 2 shows in range 1 the stoichiometric ratio and tempertures maintained in primary chamber 12. Thus, the formation of soot and nitrogen oxides are avoided. The even mixture of fuel and air also assures that the stoichiometric ratio is maintained within limits on a local as well as an overall basis.
The injection of secondary air allows combustion to continue. Because secondary air is, as shown in FIGS. 3 and 4, introduced in very nearly the same direction as the fuel-air mixture is already flowing, the circular flow is enhanced. Secondary air injection also provides a component of motion toward secondary chamber 14.
As the fuel-air mixture continues into secondary combustion chamber 14, combustion and the circular movement of the mixture continues. However, the temperature in secondary chamber 14 tends to decrease for two reasons. First, the gas in secondary chamber 14 is cooled by the upward flow of air between conical section 26 and jacket 38. Second, the volume of chamber 14 steadily increases in the downward direction; secondary air mixing with hot primary combustion products in this expansion region tends to limit the maximum temperature. Thus, excessive temperatures which can enhance the formation of pollutants, or harm the components of the prime mover are avoided. Range 2 in FIG. 2 represents the approximate conditions in the inner region of primary chamber 12 and upper region of secondary chamber 14. The relative amounts of primary and secondary air are adjusted to allow combustion to continue and to prevent formation of nitrogen oxides. Ash is carried by centrifugal force to the inner surface of outer conical section 26, and flows downward to drain 32. Finally, as the hot gas leaves secondary chamber 14, it must turn sharply to pass through inner conical section 28 and exhaust trunk 16; the sharply curving path tends to throw any remaining particulate material into base 30. Range 3 in FIG. 2 represents the conditions in the secondary combustion chamber. Tertiary air may be injected through ports 42 to deswirl the hot gas before it enters the prime mover. | A particulate coal combustor with two combustion chambers is provided. The first combustion chamber is toroidal; air and fuel are injected, mixed, circulated and partially combusted. The air to fuel ratio is controlled to avoid production of soot or nitrogen oxides. The mixture is then moved to a second combustion chamber by injection of additional air where combustion is completed and ash removed. Temperature in the second chamber is controlled by cooling and gas mixing. The clean stream of hot gas is then delivered to a prime mover. | 5 |
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/032,907 filed Aug. 4, 2014 by the same inventor and incorporates its entire contents by reference.
BACKGROUND
[0002] People are becoming more concerned about the environmental impact of the products and services they purchase. As a result, sellers are using many Environmental Certificates (Eco Labels) that, in theory, are sustainability measurements of their products or services.
[0003] Since sellers have found that Eco Labels greatly increase sales, bogus labels are rampant. Anyone can setup an “Eco” Label and many labels are like junk bonds—worthless. Because each Eco Label issuer has their own criteria, consumers are left wondering which Ecolabel is valid. The Wall Street Journal states that 98% of consumer products use some type of deceptive eco claims. Other studies show that more than 95% of consumer products examined committed at least one offense of “greenwashing,” a term use to describe unproven environmental claims.
[0004] Because of these misleading claims some governments are cracking down. In the United States, the Federal Trade Commission (FTC) and in Europe the European Union are either enforcing existing consumer laws or proposing new legislation.
[0005] This growing issue has led to confusion and fatigue among consumers. To address the demand for standards, they have undertaken efforts to standardize the principles, practices and key characteristics relating to three major voluntary environmental labeling types—Type I—environmental labeling (i.e. EcoLables), Type II—self-declaration claims and Type III—environmental declarations (e.ge. report cards/information labels).
[0006] The rating groups have taken these ISO standards along with various other laws, regulations and best practices to develop the various criteria for a company's products or services that they must meet to receive one of their labels and/or certificates.
SUMMARY OF THE INVENTION
[0007] To address this problem, the present invention will set up a Five Star Rating Process to rate Eco Labels and compare them with the criteria of the Internal Organization for Standardization (ISO) standards for environmental labeling. The criteria used in the present invention includes ISO 14020 Environmental Labels and Declarations—General Principles, ISO 14021 (Type II environmental labeling, self-declared environmental claims), ISO 14024 (Type I environmental labeling—environmental labels and declarations), and ISO 14025 (Type III environmental declarations i.e. “report cards” and information labels.) The result will allow shoppers to see where a particular label falls in a five star range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a graphical overview of the data entry configuration of the present invention.
[0009] FIG. 2 is a flowchart showing how the present invention obtains criteria for an Eco Label on a product, compares it with the international standards, employs teams to evaluate and sort the criteria and provide quality control and expert review for Eco Label evaluation.
[0010] FIG. 3 is a flowchart depicting the algorithm for providing a final score for an Eco Label, and a summary of the entire rating process.
[0011] FIG. 4 is a graphical overview of the architectural components of a client-server database supporting indexing, search and retrieval according to one embodiment using multiple search engines.
[0012] FIG. 5 is a diagram showing an example of the computer system of a sophisticated mobile device, with camera, global positioning system and other components not shown.
DETAILED DESCRIPTION
[0013] The Five Star rating process is the present invention's Expert System to convert all Eco Labels to single universal scale. FIG. 1 is a diagram depicting how Eco Label criteria rating data may be acquired and stored in the present invention's servers 3 . In one embodiment, clients may use mobile devices 1 ( a ), 1 ( b ), 1 ( c ) equipped with cameras to scan an environmental label and retrieve a rating of the product from the system's servers 3 if such information is available on the servers. Mobile devices can include any portable intelligent device including, for example, phones, tablets, laptops, smart watches. If the environmental label has not yet been entered into the system with a rating stored on the servers 3 , information about the label may stored on the servers 3 and the system may initiate a search as depicted in FIG. 4 to obtain the criteria for the label from the website of the organization that issued the criteria. If the label and criteria information is documented on the server 3 but the expert rating is still in progress, the system may notify the users that a rating is pending. New labels and criteria information 2 ( a ), 2 ( b ), 2 ( c ) may be automatically saved to the servers 3 and sent to teams of experts 4 , 5 , 6 who will follow the algorithms depicted in FIG. 2 and FIG. 3 to evaluate the criteria provided for an environmental label, compare it with international standards, and store their evaluations of the criteria on the system's servers 3 . The system may then calculate a final score for a product based on the information on its environmental labels and the expert scoring of the environmental label criteria. The final score and related information is stored on the server and can be retrieved by users who scan. labels with their mobile devices 1 ( a ), 1 ( b ), 1 ( c ).
[0014] FIGS. 2 and 3 show the Expert System's Rating Process Flow. This rating process involves multiple steps that initially begin with a group of environmental experts performing a detailed evaluation of the ISO 14020 standard. This group will look at each of the labeling types; Type I—environmental labeling (i.e. ecolabels), Type II self-declarations claims, and Type III—environmental declarations (e.g. report cards/information labels) and based on their expertise create an Evaluation Criteria Template consisting of no more than 12 sections. Within each section will be additional measures within a section that are used to determine if a rating group's criterion is valid.
[0015] Once the Evaluation Criteria Template is completed the actual process of performing an evaluation of a rating group's criteria can be started. This process consists of the following stages:
[0016] Based upon the product or service environmental ecolabel and/or certificate the issuer's rating group website is accessed. A search is performed to locate the associated certification criteria documents. If the documents are available these are than downloaded and made available to the Criteria Team. If the documents cannot be located the issuing organization is contacted and a request is made for a copy of the documents. If the issuing organization provides the documents than these are made available to the Criteria Team, if the documents are not provided than this is documented along with any supporting documents into the EcoCaliber Expert System (ECRS) and the next product or service issuer's criteria. documents are search for.
[0017] The Criteria Team Manager than selects 3 or more Criteria Evaluation Team members who will work independently during the evaluation process. These individuals will then perform a detailed review of the issuer's criteria and extract relevant sections and association them within the Evaluation. Criteria Template. This process will continue until each applicable section has been completed by all of the team members before the template moves on to the Scoring Team. If any team member identifies a problem the problem is discussed with a Resolution Manager who resolves the issue so that the evaluation can continue.
[0018] Once the Scoring Team Manager is notified that the Criteria Evaluation Team has completed their work the Scoring Team Manager selects 3 or more Scoring Team members who cannot be part of the Criteria Team who did the evaluation. Each member scores the template independently and secretly as they do this the relative importance of the criteria sections are weighted in ECRS. Starting with the first Section, the score is entered before proceeding to the next section. Once each section has been scored the final score is calculated by ECRS and is the weighted mean of all the scores. Once the scoring has completed the QA/QC Team Manager is notified. If any of the team members encounters or identifies a problem the Resolution Manager resolves the issue and the Evaluation Criteria Template is returned to the Criteria Team for reevaluation and the process starts again.
[0019] When the QA/QC Team Manager receives notification that the scoring is completed the QA/AC Team members are selected consisting of 3 or more members. The team members perform a though check of the Evaluation Criteria Template and results. During this result checking process if any problems or issues are identified the Resolution Manager is notified and resolves the issue if it cannot he resolved the template is returned to the Criteria Team and the process begins again. If there are no problems and the QA/QC Team members pass the Evaluation Criteria Template and Score the Expert Review Manager is notified.
[0020] Based on the product or service being rated the Expert Review Manager will select the Review Experts who will participate in the final review process. Based upon their expertise this group will review the Evaluation Criteria Template, any associated documents, scoring, and any notes or comments. Once the review is completed they will approve or reject the final score calculated by the ECRS system. If the Experts Approve the results/score the ECRS system is update and all associated documents will be archived in the ECRS system. If there are any problems these are identified and the Resolution Manager is notified. Based upon the comments/remarks from the Expert Review group the Evaluation Criteria Template is return for reevaluation and the process starts again.
[0021] This multistage process is designed to provide an impartial, expert review of the various rating group criteria against an international standard which is constant and applicable across all products and services. Using this as its base and then applying weighted mathematical algorithms to each of the sections the final score/rating will be an accurate reflection of the product or services environmental impact.
[0022] Based on this score the consumer can then determine, given similar products or services, which one to purchase no matter what ecolabel or certificate is put there by the company.
[0023] In one embodiment, users may automatically search the system to locate information about an environmental label and if no rating is available, automatically request an expert review of the environmental label and begin the process by prompting a search engine to search the internet for the issuing organization and the label's criteria. FIG. 4 provides a graphical overview of the primary architectural components of a client-server database supporting similarity-based indexing, search and retrieval using multiple search engines (Google, Yahoo and Bing, for example) and, for example, sql database queries. Referring to FIG. 4 , a client 230 ( 1 ), 230 ( 2 ) to 230 (m) may be a laptop, intelligent mobile device, pad or other personal intelligent device equipped, for example, with near field communication and by WiFi or wireless telecommunications link to a search manager 220 and servers 200 which may be cloud-based servers. The database (or preferably a collection of databases) 200 utilizes a local client-cloud server architecture that provides simultaneous services to multiple clients, networks of clients and multiple users (such as a household of users) of those clients. Architectures have been implemented that leverage the advantages of parallel computation, using both clusters of computer nodes and single nodes with multiple processors and cores. A commercial off-the-shelf (COTS) database 200 or a computer or network file system (referred. to herein as a “COTS Database”) can be utilized for persistent storage, while the high-performance in-memory indexing and search technologies are implemented in Search Engines 210 ( 1 ) to 210 (n) that operate as cooperating threads or tasks within the overall architecture (for example, searching for competitor data for a given product, jurisdictional sales tax data, service, product provider or service provider data from one or more cloud-based servers supporting the client networks). A Search Manager 220 provides coordination between the Clients 230 ( 1 ) to 230 (m), a COTS Database 200 , and Search Engines 210 ( 1 ) to 210 (n), as well as the initial connection protocol for the Clients 230 ( 1 ) to 230 (m). The application can be parallelized by allocating separate computational resources to each component, such as a Search Engine 210 ( 1 ) to 210 (n), by allocating multiple computational resources to any component, as occurs in a Search Engine 210 that utilizes multiple threads, or using a combination of these methods. Communications among components in a parallel implementation may be effected using a communications medium such as a computer network or using shared memory. The NFC communication is short distance between tag or transaction terminal and NFC client but an intelligent telephone client 230 may communicate with a COTS database 200 and search manager 220 that are cloud-based and that database 200 and search manager 220 in turn refer to a search engine 210 ( 1 ) to 210 (n) to collect to data applicable to an environmental label.
[0024] In another embodiment, the invention is directed toward one or more computer systems such as mobile devices capable of carrying out the functionality described herein having associated memory and databases. An example of a computer system 1700 of a sophisticated intelligent mobile device is shown in FIG. 5 . The example does not show all aspects of a mobile device such as the camera, a clock, a time of day and date calendar, a GPS unit, an accelerometer and other features of a typical mobile device. However, such features of an ever improving digital camera are typically found in mobile devices known in the art and even comprise video cameras for capturing sequences of images if selected by a user.
[0025] Computer system 1700 includes one or more processors, such as processor 1704 . The processor 1700 is programmed as a special purpose processor to authenticate a user using biometric (for example, facial structure) and a personal identification code entered by the user each time a mobile device is turned on and prepared for use by an individual user. The processor 1704 is connected to a communication infrastructure 1706 (e.g., a communications bus or network). Various software aspects are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant art(s) how to implement the invention using other computer systems and/or architectures.
[0026] Users of mobile devices (not shown) communicate with computer system 1700 by means of communications interface 1706 , typically a touchscreen having a reprogrammable display or other interface known in the art. A typical mobile device computer used by a user may have a similar structure to computer system 1700 , the difference being that computer system 1700 may comprise databases and memory. A mobile device, on the other hand, provides a user with access to any of these for creating new images or doing any of the creation of the images and image portions such as face, eye region and pupil as discussed above.
[0027] Computer system 1700 can include a display interface 1702 that forwards graphics, text and other data from the communication infrastructure 1706 for display on the display unit 1730 . A display, as will be described herein, may provide a touch screen for, for example, entering data.
[0028] Computer system 1700 also includes a main memory 1708 for maintaining the authentication and image processing algorithms described above, preferably random access memory (RAM) for temporary data storage and may also include a secondary memory 1710 . The secondary memory 1710 may or may not include, for example, a hard disk drive 1712 and/or a removable storage drive 1714 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 1714 reads from and/or writes to a removable storage unit 1718 in a well known manner. Removable storage unit 1718 represents a floppy disk, magnetic tape, optical disk, micro SD card, etc. which is read by and written to by removable storage drive 1714 . As will be appreciated, the removable storage unit 1718 includes a computer usable storage medium having stored therein computer software and/or data.
[0029] In alternative aspects, secondary memory 1710 may include other similar devices for allowing computer programs or other code or instructions to be loaded into computer system 1700 (for example, downloaded upon user selection from a server). Such memory devices may include, for example, a removable storage unit 1722 and an interface 1720 . Examples of such may include a program cartridge and cartridge interface (such as that found in some video game devices), a removable memory chip (such as an erasable programmable read only memory (EPROM), or programmable read only memory (PROM)) and associated socket and other removable storage units 1722 and interfaces 1720 , which allow software and data to be transferred from the removable storage unit 1722 to computer system 1700 .
[0030] Computer system 170 also includes a communications interface 1724 which may be a cellular radio transceiver known in the cellular arts. Mobile communications interface 1724 allows software and data to be transferred between computer system 1700 and external devices and may comprise access to telecommunications, texting, the internet, social networks, movies via NetFlix, games and the like but only after authentication. As discussed above, a biometric and personal identification code multi-factor gaze authentication is presented for use with obtaining access to such device features. Examples of communications interface 1724 may include a modern, a network interface (such as an Ethernet card), an RF communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface. 1724 are in the form of non-transitory signals 1728 which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 1724 . These signals 1728 are provided to communications interface 1724 via a telecommunications path (e.g., channel) 1726 . This channel 1726 carries signals 1728 and may be implemented using wire or cable, fiber optics, a telephone line, a cellular link, an radio frequency (RF) link and other communications channels.
[0031] In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as removable storage drive 1714 , a hard disk installed in hard disk drive 1712 and signals 1728 . Not all intelligent mobile devices have all these features. These computer program products provide software to computer system 1700 . The invention is directed to computer authentication methods and apparatus.
[0032] Computer programs (also referred to as computer control logic) are typically stored in main memory 1708 and/or secondary memory 1710 . Computer programs may also be received via communications interface 1724 . Such computer programs, when executed, enable the computer system 1700 to perform — the features of the present invention, as discussed herein. In particular, the authentication computer programs of the present invention, when executed, enable the processor 1704 to perform the features of the present invention and provide access to further features that are virtually unlimited (but importantly, personal to a user individual and should not be accessed by others without permission from the user). Accordingly, such computer programs represent controllers of the computer system 1700 .
[0033] In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 1700 using removable storage drive 1714 , hard drive 1712 or communications interface 1724 . The control logic (software), when executed by the processor 1704 , causes the processor 1704 to perform the functions of the invention as described herein. The present authentication method and apparatus may be downloadable to a mobile device from an applications store.
[0034] In another embodiment, the invention is implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s).
[0035] As will be apparent to one skilled in the relevant art(s) after reading the description herein, the computer architecture shown in FIG. 17 may be configured as any number of computing devices such as a system manager, a work station, a game console, a portable media player, a desktop, a laptop, a server, a tablet computer, a PDA, a mobile computer, a smart telephone, a mobile telephone, an intelligent communications device or the like.
[0036] While various aspects of the present invention have been described above, it should be understood that they have been presented by way of example and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the present invention. Thus, the present invention should not be limited by any of the above described exemplary aspects, but should be defined only in accordance with the following claims and their equivalents. | An expert system for evaluating the criteria of environmental labels on consumer products is presented. The system employs a special purpose computer for receiving information about environmental labels, obtaining the criteria used these environmental labels, and sending information to teams of experts who independently evaluate each criteria section against the ISO standards for environmental labels. The system then stores the criteria and the expert evaluations of the criteria and calculates an overall rating for a product based on its environmental labels. The experts work independently on different aspects of rating criteria before a final to assure a reliable final rating. Users may access information about an environmental label, for example, through a mobile device with a camera and interact access. The present invention allows consumers to purchase products based on an impartial rating and avoid being misled by unreliable environmental labels. | 6 |
CROSS-REFERENCE APPLICATION
The present application is a continuation application of U.S. application Ser. 10/240,549, filed on Apr. 17, 2003. U.S. application Ser. No. 10/240,549 is a national stage of PCT/SE2001/000728, filed on Apr. 3, 2001, which claims priority from Sweden application 0001202-1, filed Apr. 4, 2000. The entire contents of these applications are fully incorporated herein by reference.
BACKGROUND
The present invention relates to an implant provided with attachment and hole-insert parts which have surfaces with different degrees of finishing and/or degrees of roughness and/or porosities. It also relates to a method for establishing different degrees of finishing and/or degrees of machining and/or porosities on outer surfaces of an implant with attachment and hole-insert parts. The invention also relates to an arrangement for providing a range of implants which are optimized for different dental situations.
It is already known to use implants which have upper parts for attachment of spacer elements or other superstructures and, below said upper parts, lower parts which are intended to be inserted in a hole in the bone, for example in the jaw bone or tooth bone. The attachment part in question is arranged on the jaw bone which, after the implant has become incorporated, is exposed for connection of the spacer or superstructure in question. Said lower parts can be designed with threads and it is possible to use straight cylindrical thread portions which at the bottom merge into a cone-shaped threaded portion at the tip of the implant.
For examples of implants, reference may be made inter alia to WO 97/43976 and WO 97/03621.
It is, also already known to provide the different surfaces of the implant with different finishes and/or machine treatments and/or porosities. In this connection reference may be made to, inter alia, the Swedish applications 9901971-3, 9901973-9 and 9901974-7 filed by the same applicant as the present application. Reference may also be made to U.S. Pat. Nos. 5,571,017, 5,829,978, 5,842,865, 5,885,079, 5,947,735 and 5,989,027.
From the above references it is already known to use different degrees of porosity on the surfaces in question. There are different opinions concerning the sizes of the pores and their applications. Thus, it has previously been proposed that the surface of the attachment part be made of a machined smooth surface, while the threads on the lower parts of the implant can be made with porosities of different sizes, i.e. different degrees of roughness. From the above references it is also already known to provide different parts along the longitudinal extent of the implant with different degrees of porosity. It is known that one zone with a first degree of porosity on the surface changes abruptly into a second or adjacent zone having a second degree of porosity.
SUMMARY
In the case of implants, for example in dentistry, it is preferable to avoid abrupt changes between different zones with different degrees of porosity and instead provide one or more marked or extended zones in which the change of porosity is continuously modified. Thus, in a marked or extended zone, a first porosity can be present at one end of the zone and can condense or decrease towards the other end of the zone. In one embodiment, the zone in question will be able to extend along at least the greater part of the longitudinal extent of the implant. Thus, for example, a porosity of zero, or close to zero, will be present on the surface at the attachment part of the implant, i.e. the degree of finishing and/or degree of machining is high on this surface. Thereafter, i.e. on the surface of the thread(s) of the implant, the porosity will start with a low value and will increase gradually in the longitudinal direction of the implant towards the tip of the implant, or vice versa. The increase in the porosity of the implant along the longitudinal extent of the implant can be made linear or progressive. Implants will alternatively be able to be provided with two or more such marked zones where the porosity is linearly or progressively increasing or decreasing from one end of the respective zone to the other end of the zone. In a further alternative embodiment, the porosity or the porosities will be able to increase linearly or progressively in the circumferential directions of the implant. In a further alternative, the porosities will be able to form marked islands on the outer surfaces of the implant, which islands are thus situated on finished and/or machined surfaces.
The variations in the degrees of finishing and/or machining and/or the porosities will be able to meet different requirements of dental situations, for example, where implants must be able to be applied in different types of bone, for example tooth bone and jaw bone in the upper jaw, tooth bone and jaw bone in the front and inner areas of the lower jaw, etc. The porosities must be able to provide different possibilities of introducing or anchoring the implant in tooth bones or jaw bones of different degrees of softness or hardness. In some cases the porosities are also intended to be used as depots for bone-growth-stimulating or bone-growth-promoting agents, and the movement of these agents from the depots to the surrounding bone must be controlled and varied according to the different dental situations. The porosities must therefore be able to mirror the tooth bone structure and provide optimum insertion and anchoring functions for the implant in the respective bone and optimum functions concerning the release of the bone-growth-stimulating agents.
There is therefore a need to be able to provide implants with optimum porosities, and the continuous or soft transitions in the marked zones are dictated by the fact that the changes or differences in the different bone types or bone conditions consist of indistinct transitions or changes, i.e. the hardness or softness of a bone's structure often represents a soft or continuous change in the patient's jaw bone or tooth bone. From the purely technical aspect, there are great problems in providing said continuously decreasing or increasing changes in the degrees of porosity in marked zones of the implant. The main object of the present invention is to solve this problem.
There is a need to be able to make available a range of implants which have different decreasing porosity functions in marked zones, i.e. there is a need for differently structured porosity arrangements on different implants. The invention also solves this problem. By virtue of having a range of implants with different porosity changes in one or more zones, an optimum implant can be used for the respective dental situation. It is known that the porosity affords a greater surface for union with surrounding bone. In the case of especially soft bone structures, it is of interest to be able to offer the large surfaces for union which high porosities afford. In some situations it may be of interest also to provide the outer surface of the attachment part with porosity.
The feature which can principally be regarded as characterizing an implant according to the invention is that the surfaces are provided with at least one zone in which the degree of finishing and/or the degree of roughness and/or the porosity is continuously changed.
In embodiments of the inventive concept, the implant has a single zone with continuously decreasing or increasing porosity. Some of the surface or surfaces, for example the surface of the attachment part, can be formed with a low, minimal porosity. In further illustrative embodiments, two or more zones can be arranged along the longitudinal and/or circumferential directions of the implant. In a preferred embodiment, each zone will take up a longitudinal or circumferential value which is 5% or more of the respective extent. The invention is preferably used in connection with implants having an outer thread or threads.
The feature which can principally be regarded as characterizing a method according to the invention is that the implant is applied wholly or partially in or near an electrolyte, and that the implant is subjected to cooling which is preferably substantial and that voltage is applied to an anode and cathode arrangement where the implant is arranged so that a current produced by the voltage is passed through the implant to establish said porosity. Liquid nitrogen can be used for cooling, and the implant can be connected to an anode included in the anode and cathode arrangement at a boundary surface in the container. The anode is situated in the nitrogen in the container and the cooling of the anode effected by the nitrogen is transmitted to the implant by means of its mechanical contact with the anode. The implant is immersed wholly or partially in electrolyte and a continuous transition zone is obtained by the fact that, in parts of the implant not immersed, the electrolyte is taken up in a decreasing amount along the height of the implant and by the fact that the decreasing amount gives rise to the continuous change in the porosity. In alternative embodiments, parts of the implant can be masked so that the electrolyte is prevented from gaining access to the masked portions and is thus prevented from forming porosities. Different sizes of porosities are determined inter alia by means of the electrolyte composition and/or changes in voltage and/or current.
The novel arrangement is characterized mainly by the fact that a number of implants are provided with different continuously decreasing changes in porosity in one or more zones and by the fact that the different implants in the range can be used to achieve optimum solutions to different dental situations.
Further embodiments of the implant, method and arrangement according to the above will be evident from the attached subclaims relating to the independent claims for the implant, method and arrangement, respectively.
By means of what has been proposed above it is possible to offer new types of implants which open up new approaches to and optimum solutions for dental situations. By means of the invention it is also possible, in an economically advantageous manner, to manufacture implants with porosities of the type in question in marked zones. It is therefore not necessary to use the abruptly changing zones in the known arrangements, with the different degrees of roughness/porosity which characterize the prior art. There are a great many possible variations for producing implants of this type and the novel method makes available a production technique which permits said variations in an advantageous manner. The invention also permits greater or lesser porosity on the surface of the attachment part if the priority is to eliminate risks of infection on the surface and to promote bone union (greater surfaces for incorporation of bone).
BRIEF DESCRIPTION OF THE DRAWINGS
The main characteristics of an implant, a method and an arrangement according to the invention will be described below with reference to the attached drawings, in which:
FIG. 1 is a diagram showing the porosity or roughness as a function of the implant length L, and a curve indicating a porosity continuously increasing towards one end of the implant,
FIG. 2 is a side view showing an implant related to the diagram in FIG. 1 , and where the implant has a certain degree of finishing on its left part (attachment part) and where the porosity or roughness increases as the curve rises in FIG. 1 towards the free end of the implant,
FIG. 3 is a diagram showing voltage and current parameters in an applied electrochemical process,
FIG. 4 is a side view and schematic representation showing an electrolyte used in the electrochemical process, and an anode and cathode arrangement arranged in this,
FIG. 5 is a schematic representation, enlarged in relation to FIG. 4 , showing the application of the implant in relation to a suitable cooling unit and electrolyte, and where the implant has been masked on parts of its length,
FIG. 6 is a side view showing another masking in relation to the example in FIG. 5 ,
FIG. 7 is a side view showing the implant with a number of different zones with continuously decreasing porosity and zones of very low porosity,
FIG. 8 is a vertical section showing decreasing zones in the circumferential direction of the implant,
FIG. 9 is a vertical section showing the application of the implant to an anode part which extends into the cooling unit/container unit according to FIG. 4 , and where the porosity increases towards the free or lower end of the implant,
FIG. 10 is a vertical section/vertical view showing a further design of the connection of the implant to the cooling unit and maskings for establishing substantial porosity-free zones,
FIG. 11 is a vertical section/vertical view showing a reverse application to the cooling unit compared to the embodiment according to FIG. 10 ,
FIG. 12 is a vertical section/vertical view showing the application of the implant to the cooling unit with the implant lying in such a way that a varied porosity is obtained in the circumferential direction of the implant, and
FIG. 13 shows an example of a dental implant produced according to the invention.
DETAILED DESCRIPTION
The varying or continuously modified porosity in the zone or zones concerned can be obtained in different ways. In the present case, an electrochemical method is preferably used which can be of a type known per se. As the electrochemical method which is described in the Swedish patent applications 9901971-3 and 9901974-7 is highly suitable for use in this context, reference is made to these patent applications which were filed by the same applicant as that of the present patent application. As will be evident from the electrochemical method already described, the oxide layer on the surface of the implant can be formed and varied by adjusting various parameters in the process, which parameters can include the composition of the electrolyte, the voltage and current in the anode and cathode arrangement used, the electrode geometry, the treatment time, etc. To obtain the features according to the present invention, the implant requires to be applied to and acted on by the electrolyte in the manner described below. However, the electrochemical process will not be described in detail here, and instead reference is made to said patent applications.
In FIG. 1 , a curve 1 indicates a continuously modified roughness/porosity along the length of an implant. The change here is assumed to be obtained along a zone or zones of the implant. In the present case, a low degree of roughness/porosity is used at one end of the implant, which low degree of roughness can have a value of 0.7 μm. After a predetermined extent along the implant, the roughness in this case changes distinctly to a value of 1.0 μm, for example. Thereafter, the roughness increases in the zone or zones in question up to a value of 1.5 μm. This increase represents a continuous change and can be linear and can have a progressiveness in accordance with the line of the curve 1 .
The implant shown diagrammatically in FIG. 2 is related to the diagram according to FIG. 1 such that a distance A on the implant corresponds to the distance 1 in the diagram. The length or distance B corresponds to the curve length 1 to 1 ′. As will be seen from FIG. 2 , the distance A represents an attachment part 2 for a spacer element, and the distance B represents a hole-insert part 3 of an implant 4 . The implant 4 has a design characteristic to the invention. In this case, the distances A and B form two different zones in which there is a continuous or progressive roughness/porosity. For example, the attachment part 2 can have less roughness/porosity along its length or a roughness/porosity which is lowest at an end surface 2 a and increases gradually towards the bottom surface 2 a ′. The lower degree of roughness/porosity established at the end surface 2 a is indicated by 2 b , while the gently increasing roughness/porosity at the bottom surface 2 a ′ is indicated by 2 c . Thus, the outer surface 2 d can be considered to have a low and gently increasing roughness/porosity viewed from the end surface 2 a . According to the invention, the degree of roughness/porosity can be varied, and in one illustrative embodiment the outer surface 2 d can be entirely without porosity markings or can have extremely low porosity, i.e. the outer surface 2 d is very finely machined. In the illustrative embodiment, the extent B of the implant is arranged such that there is a single zone, in which zone therefore a low roughness/porosity is present at the upper end 3 a of the hole-insert part 3 and a relatively high (cf. FIG. 1 ) roughness/porosity is present at the end 3 b of the hole-insert part.
FIG. 3 shows typical current and voltage values in the electrochemical process (see also said Swedish patent applications). To establish high degrees of roughness and porosity, a current value of 0.2 ampere is used in this case, and the voltage value can extend up to a level of 300 volts, for example. The current curve is indicated by I and the voltage curve by U. The horizontal axis represents a time axis t. In accordance with the previously known method according to said Swedish patent applications, a certain spark formation occurs in the area 5 on the voltage curve U. The spark formation occurs along the whole of the implant surface and gives rise to pore formation and increased surface roughness.
FIG. 4 is a diagrammatic representation showing an electrolyte 15 used in the electrochemical process, and an anode and cathode arrangement applied in the latter. The anode 8 which can be formed by the implant itself or can consist of a part which is mechanically coupled to the implant 9 is connected to the positive potential 10 of an energy source 11 . The positive connection of the anode and cathode arrangement is indicated by 13 . The negative potential 12 of the energy source is correspondingly connected to the cathode 14 of the anode and cathode arrangement. As has been indicated in the figure, the lower parts 9 a of the implant are dipped in the electrolyte 15 . Capillary and other suction and evaporation phenomena mean that electrolyte is taken up in decreasing quantity-upwards and along the outer surface parts 9 b of the implant which are situated above the immersed parts 9 a of the implant. The effect of this is that the immersed parts 9 a are exposed to a chemical treatment which gives a greater porosity than the porosity of those parts 9 b which are situated above the parts 9 a . This has the effect that a zone is obtained on the parts 9 b where the porosity is continuously modified or decreases in the upward direction.
The kinetics of the electrochemical process can be controlled by varying the temperature of the implant. The porosity and surface roughness of the parts 9 b can thus be regulated by cooling the implant. FIG. 4 shows a cooling arrangement 6 which in this case consists of a container 6 a for liquid nitrogen 1 . In the illustrative embodiment shown, the anode 8 of the anode and cathode arrangement is arranged in or extends through the interior 8 of the container and is in this way subjected to a cooling function exerted by the liquid nitrogen.
It will be appreciated from the above and from FIG. 5 that the position of the zone can be changed with the aid of the degree of immersion of the implant in the electrolyte 15 . In FIG. 5 , the degree of immersion can be adjusted in the directions of the arrows 16 . It will also be appreciated that the suction forces along the surface 9 c of the implant mean greater electrolyte accumulation 15 a at the lower parts 9 d of the implant than the electrolyte accumulation 15 b at parts 9 b which are situated higher up. The electrolyte can thus influence the implant with a greater amount of electrolyte at said lower parts 9 d to than at the parts 9 c situated higher up, which also indicates said continuous or progressive change or reduction of the porosity towards the upper parts of the implant. In accordance with the embodiment according to FIG. 5 , masking functions are also used which correspond to those indicated in said Swedish applications. The maskings can consist of tube-shaped parts 17 , 18 of Teflon, latex, etc.
Alternatively, lacquers can be used. The maskings are intended to prevent porosity occurring on the masked parts during the electrochemical process. In the present case, the tube part 17 or the like masks an area 9 f which is situated under the spacer attachment part 2 d . The last-mentioned part is in turn masked by the tube or the lacquer 18 . Said areas 9 f and 2 d therefore have a very low porosity or no porosity at all, depending on previous treatment or working
According to FIG. 6 , it is also possible to use the masking function to form islands or areas 9 g , 9 b which extend across parts of the surfaces of the implant. In these areas 9 g , 9 h , the porosity continuously changes from the lower parts of the implant in the direction towards the upper parts of the implant. In this case the masking has been done with a tube, a lacquer, etc. 19 leaving the surface open for said areas. In the present case, the implant 9 d is thus given a porosity which continuously increases or changes from the lower part up towards the masking 19 , which increase or change merges into said areas 9 g , 9 h.
According to the invention, masking functions can thus be used, and during the total process of coating the implant 4 with one or more zones of decreasing or increasing porosity, the positions of the maskings can be rearranged or changed. According to FIG. 7 , several zones C, D and E can be established along the longitudinal extent or height of the implant.
According to FIG. 8 , different zones C′, D′ and E′ can also be established in the circumferential direction where each zone, for example the zone 19 , has a greater porosity at the end 19 a than at the end 19 b and the porosity continuously decreases within the zone.
It is also possible to influence the degree of roughness/porosity by mechanical working after the electrochemical treatment has been carried out.
FIG. 9 shows in more detail the mechanical connection between the implant 4 and the anode part 8 according to FIG. 4 . The anode part 8 can have a recess for the spacer attachment part 2 d of the implant, which recess is indicated by 8 a . The size of the recess is adapted to the spacer attachment part so that the implant is secured in the anode part 8 . This arrangement also provides masking for the outer surface 2 d of the part 2 . It will be evident from this embodiment that a large mechanical contact surface is present between the implant and the anode 8 , which contact surface is established by means of the top surface 2 a of the implant and the bottom surface 8 a ′ of the recess 8 a . The implant and the anode must be pressed against each other with forces F and F′ respectively. Upon connection of the anode and cathode arrangement 13 , 14 with a voltage according to the above, said porosity is established at the lower parts of the implant, while at the same time the implant is exposed to a very great cooling effect from the liquid nitrogen in the container 6 a . The cooling function is thus established via the bottom part 6 b of the cooling arrangement. The anode part 8 and the bottom part 6 b can be sealed by means of a sealing ring 21 or the like.
FIG. 10 shows another means of connection of the implant 4 to the anode part 8 which in this case does not have the recess (cf. 8 a ) indicated in FIG. 9 . In this case, the top surface 2 a of the spacer attachment member 2 is secured to the bottom surface 8 a ″ of the anode by securing means of a suitable type. In this case, the anode part 8 is sealed off by sealing means or members 21 ′ from the inner wall 6 a ′ of the container 6 a . The arrangement can be provided with guides 22 or equivalent acted on in the direction 23 , for example by means of actuating members 24 which can consist of or comprise mechanical drive wheels (for example gear wheels). In this case, the implant 4 is provided with masks 25 , 26 of the type indicated above. A characteristic of the zones is that the porosity is greatest at the bottom of each zone and decreases upwards to the spacer attachment part 2 .
In FIG. 11 , the implant is turned around compared to the case in FIG. 10 . The free end surface 9 d ′ of the implant is in this case secured in the recess 8 a of the anode in the same way as in FIG. 10 . Alternatively, the anode in this case can comprise a recess in the same way as in FIG. 9 , which recess is adapted to the tip (free end) of the implant 4 . In this case too, the implant, the anode, etc. are displaceable in the direction of the arrows 25 in order to provide for immersion in the electrolyte 15 to a greater or lesser extent. In this case, the coarse porosity is established at the end surface 2 a of the spacer attachment part 2 and decreases towards the free end 9 d ′ of the implant. In this case there is therefore only one zone.
In the embodiment according to FIG. 12 , the implant is in principle arranged horizontally in relation to the surface of the electrolyte 15 . In this case too, the anode 8 has a recess 8 a in which the spacer attachment part 2 is connected. The thus horizontally arranged implant can be immersed to a greater or lesser extent in the electrolyte 15 in the directions of the arrows 26 . In this way, porosity of different sizes is present about the circumferential direction of the implant, cf. FIG. 8 .
In accordance with the above, the implant itself can only form the anode in said anode and cathode arrangement. The implant extends through the bottom part 6 b of the container 6 according to the example above. In FIG. 2 , the outer surfaces of the hole-insert part have been indicated by 3 a ′ and 3 b ′. The degrees of porosity have been symbolized by 2 f and 2 g , respectively. In FIG. 7 , the length or height of the implant is indicated by H. A marked or extended zone, for example one of zones C, D or E, means that the extent of the zone in the direction H of the implant must be at least 5% of the value of H. Correspondingly, the decreasing porosity or porosities in the circumferential direction, for example the circumferential direction C′ in FIG. 8 , will assume a value of at least 5% of the total circumference 2 h in said extended or marked zone. In FIG. 10 , a first thread of a cylindrical portion is indicated by 4 ′ and a thread on the tipped part of the implant is indicated by 4 ″. The degree of immersion of the implant in the electrolyte 15 depends on where and how long the marked or extended zone for the continuously changed porosity is to be and/or on the degree of masking of the implant. According to the invention, it is also possible to provide a range of implants which are basically the same, but with different porosity changes within one or more marked zones, different zones, etc. Reference is made here to the different embodiments according to the above, where it is clear that implants can have different numbers of marked zones with different porosity changes, i.e. changes with different sizes of the porosities and different changes of these porosities. With such a range, it is possible to choose the implant which in the given dental situation is considered to give the best result or the most optimum result in said dental situation. The choice can be made on the basis of practical experience or by assigning different dental situations to different implants.
FIG. 13 shows an example of a dental implant of a type known per se (Branemark System®) which has been provided with a surface structure according to the invention. The implant is made of titanium and has a machined surface. The machined surface remains on the spacer attachment part 2 , the flange, while the threaded part, the hole-insert part 3 , has a roughness/porosity produced according to the above method and continuously decreasing along the length of the implant from the flange.
The figure also shows two enlargements taken on the threaded part, and on the curved part at the spacer attachment part, where the machined main surface has been acted on to a lesser extent by the electrolyte treatment.
The invention is not limited to the embodiment shown above by way of example, and instead it can be modified within the scope of the attached patent claims and the inventive concept. | An implant ( 4 ) is provided with attachment and hole-insert parts ( 2, 3 ) with surfaces which have different degrees of finishing and/or degrees of roughness and/or porosities ( 2 f , 2 g ). Arranged on the surfaces there is at least one dozen (A-B) in which the degree of finishing and/or the degree of roughness and/or the porosity is continuously changed. The changes in porosity in said zones can mirror continuous or discontinuous changes in the bone in question, for example the jaw bone or tooth bone. The continuously changed zones can be obtained with the aid of electrolyte ( 15 ) and, connected to the latter, an anode and cathode arrangement ( 13, 14 ). When establishing the porosity, it is possible to mask different portions of the respective implant and to control the temperature of the implant. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a supercharger and, more specifically, to a mechanically driven screw supercharger for supercharging internal-combustion engines such as automotive engines, marine engines and industrial engines.
2. Description of the Prior Art
Japanese Patent Provisional Publication (Kokai) No. 51-37316 discloses a mechanically driven screw supercharger 10 shown in FIG. 6.
The mechanically driven screw supercharger 10 has a set of male and female screw rotors 3 and 4 which are driven for rotation through a driving pulley 5, a belt 6 and a driven pulley 7 by a crankshaft 2 to such air through a suction filter 8 and to supercharge an internal-combustion engine (hereinafter referred to simply as "engine") 1. The screw supercharger 10 employing the screw rotors 3 and 4 is of a displacement type, and the rotating speed of the screw rotors 3 and 4 is proportional to the rotating speed of the crankshaft 2 of the engine 1. Therefore, the screw supercharger 10 has an advantage in that the engine 1 can be supercharged at the start and during acceleration without any time lag, which is impossible when using an exhaust turbine supercharger (turbo supercharger) driven by the exhaust gas.
Furthermore, having an internal compressing mechanism, the screw supercharger 10 operates at a lower compression loss and at a higher adiabatic efficiency as compared with the mechanically driven Roots supercharger.
FIG. 7 shows a conventional screw compressor applicable to the supercharger for the aforesaid application. This screw compressor is provided with a set of meshing female and male screw rotors (hereinafter referred to simply as "rotors") 3 and 4 rotatably supported in a casing 9. The rotative power of a prime mover 101 is transmitted through a driving pulley 5, belts 6 and a driven pulley 7 to the rotors 3 and 4. The driven pulley 7 is mounted fixedly on an input shaft 35, i.e., the rotor shaft of the female rotor 4, projecting outside through the casing 9. In this compressor employing the pulleys 5 and 7 and the belts 6 for transmitting the rotative power of the prime mover 101 to the rotors 3 and 4, the power is transmitted through the frictional engagement of the belts 6 and the pulleys 5 and 7. Therefore, a considerably high tension is applied to the belts 6 to produce a frictional force of a necessary magnitude between the belts 6 and the pulley 5 and 7. Accordingly, the input shaft 13 is subjected to a bending stress applied thereto by the belts 6 in addition to a torsional stress, and hence the input shaft 13 must have a considerably large diameter to withstand such stresses. However, an increase in the size of the rotor shaft, and hence the size of the bearings, entails an increase in the size and weight of the compressor, an increase in mechanical power loss attributable to the use of large bearings, and a lowering of the upper limit of the rotating speed of the rotors.
Furthermore, in the compressor of an oil-free type having synchronizing gears 11 and 12 as shown in FIG. 7, the bending of the input shaft 13 spoils the setting of the compressor and is liable to cause the rotors 3, 4 to interfere with each other. Still further, it is difficult to combine this known screw compressor with an engine to use the same as a supercharger, because this screw compressor is intended for use as a compressor and not as a supercharger and, when used as a supercharger, the characteristics of the screw compressor need to match those of the engine.
As is obvious from the air demand characteristics of an engine 1 as shown in FIG. 8, air demand Q2 per combustion cycle, namely, the quantity of air to be sucked into the combustion chamber for one combustion cycle to maintain the output torque of the engine 1 at a fixed level, is substantially constant regardless of the engine speed, and hence air demand Q1 per unit time, namely, the quantity of air to be supplied into the combustion chamber per unit time, increases in proportion to the engine speed. However, supercharging pressure needs to be increased with engine speed to maintain the air demand Q2 per unit time, because rheological resistance and the resistance of the suction valve against the flow of air increase with engine speed.
The supercharger 10 has the above-mentioned excellent characteristics, while the inherent internal pressure ratio of the supercharger is invariable. Accordingly, when the pressure downstream of the supercharger 10, namely, the supercharging pressure, varies, there arise unavoidably in the supercharger of the prior art two problems, namely, a problem in that compression loss increases thus entailing an increase in the power consumption rate, and a problem in that the pulsative flow of air due to a the sharp pressure variation of the discharged air attributable to pressure difference between the inside and outside of the discharge port increases the noise of the supercharger 10.
SUMMARY OF THE INVENTION
Accordingly, it is a first object of the present invention to provide a mechanically driven screw supercharger eliminating the former problem in the conventional screw supercharger.
It is a second object of the present invention to provide a mechanically driven screw supercharger eliminating the latter problem in the conventional screw supercharger.
To solve the former problem in the supercharger of the prior art, the present invention provides a screw supercharger having a set of male and female screw rotors rotatably supported in a casing and driven through a wrapping transmission means including belts and pulleys by a prime mover, characterized in that a through hole is formed in the wall of the casing at a position through which the input shaft of the screw rotor or the extension of the axis of the input shaft of the screw rotor extends, in that a cylindrical bearing supporting part is formed around the through hole so as to project outside from the casing, and in that a driven pulley is supported through bearings on the bearing supporting part and is fixedly mounted on the input shaft.
To solve the latter problem in the supercharger of the prior art, the present invention provides a screw supercharger having, in addition to a main discharge port directly communicating with the suction passage of the engine, at least one auxiliary discharge port provided on the side of the suction port at an appropriate distance from the main discharge port, and a bypass passage connecting the auxiliary discharge port to the suction passage at a position downstream of the main discharge port through a switching valve capable of discharging air into the atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become fully apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a longitudinal sectional view of a mechanically driven screw supercharger, in a first embodiment, according to the present invention;
FIG. 2 is a diagrammatic illustration of the mixture feed system of an internal-combustion engine equipped with the mechanically driven screw supercharger of FIG. 1;
FIG. 3 is a fragmentary sectional view of assistance in explaining an auxiliary discharge port formed in the mechanically driven screw supercharger of FIG. 1 included in the mixture feed system of Fig. 2;
FIG. 4 is a graph showing the relation between internal pressure ratio and confined air volume in a supercharger;
FIG. 5 is a diagrammatic illustration of the mixture feed system of an internal-combustion engine equipped with a mechanically driven screw supercharger, in a second embodiment, according to the present invention;
FIG. 6 is a diagrammatic illustration of the mixture feed system of an internal-combustion engine equipped with a conventional mechanically driven screw supercharger;
FIG. 7 is a longitudinal sectional view of a conventional engine-driven screw compressor applicable to an internal-combustion engine as a mechanically driven screw supercharger; and
FIG. 8 is a graph showing the variation of supercharging pressure, air demand per unit time, and air demand per one combustion cycle of an internal-combustion engine with engine speed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a first embodiment of the present invention, a mechanically driven screw supercharger (hereinafter referred to simply as "screw supercharger") 20 of the present invention shown in FIG. 1 is substantially the same in construction as the conventional screw supercharger shown in FIG. 7, except in the construction of the power transmission system. In FIGS. 1 and 7 corresponding parts are denoted by the same reference numerals, and the description thereof will be omitted.
Referring to FIG. 1, a through hole 14 is formed in the wall of the casing 9, and a bearing supporting boss 15 is formed around the through hole 14 so as to project outside from the wall of the casing 9. The input shaft 13 (namely, the shaft of the female screw rotor 4) projects outside the casing 9 through the through hole 14 and the bearing supporting boss 15. The driven pulley 7 is supported on bearings 16 mounted on the bearing supporting boss 15. The driven pulley 7 is provided integrally with a central boss 17 projecting toward the casing 9. The extremity of the input shaft 13 is splined to the central boss 17 of the driven pulley 7.
In this embodiment, the screw supercharger 20 is driven through a power transmission system including belts and pulleys, but the present invention is not limited thereto, and the screw supercharger 20 may be driven through any other suitable wrapping power transmission system.
The through hole 14 need not necessarily be formed so as to receive the input shaft 13 therethrough, but may be formed at a position on the extension of the axis of the input shaft 13.
In the screw supercharger 20 thus constructed, the input shaft 13 is not exposed to a bending moment of the tension applied to the belts 6. Therefore, the input shaft 13 (namely, the shaft of the female screw rotor 4), need not have an increased diameter in order to withstand the bending moment, and hence the bearings 16 may be of a smaller capacity as compared with those of the conventional screw supercharger. Accordingly, the screw supercharger 20 can be formed so as to be of smaller weight and able to operate at a higher speed as compared with the equivalent conventional screw supercharger as shown in FIG. 7. Furthermore, employment of smaller bearings improves the adiabatic efficiency through the reduction of power loss. When the screw supcharger 20 is applied to an automobile, where the pressure ratio is in the range of 1.2 to 3.0, the reduction of power loss owing to the reduction in size of the bearings and the reduction in weight of the screw supercharger improves the fuel economy of the automobile.
Furthermore, since the bending, moment of the tension applied to the belts is not applied to the rotor shaft, the rotor shaft is not bent, and hence the setting of the synchronizing gears is not spoiled.
In a second embodiment, a screw supercharger 20 according to the present invention is substantially the same in construction as the screw supercharger 20 in the first embodiment, except that the screw supercharger 20 in the second embodiment is provided, in addition to a main discharge port 22 (see FIG. 3) directly connected to a suction passage 21 (see FIG. 2), with an auxiliary discharge port 24 formed in the casing 23 surrounding the screw rotors 3, 4 at the suitable distance from the main discharge port 22 as shown in FIG. 3, and hence parts corresponding to those previously described with reference to FIG. 1 are denoted by the same reference numerals and the description thereof will be omitted.
An arrangement of the mixture feed system including the screw supercharger in the second embodiment will be described hereinafter with reference to FIGS. 2 and 3.
The auxiliary discharge port 24 is connected to a bypass passage 26 connected through a three-way switching valve 25 to the suction passage 21 at a position downstream of the main discharge port 22. The three-way switching valve 25 has a port A connected to the auxiliary discharge port 24, a port B connected to the suction passage 21, and a port C communicating through a relief valve 27 with the atmosphere. One of the ports of the pilot valve unit of the relief valve 27 is connected to the port C, and the other port of the pilot valve unit is connected to the suction passage 21 at a position downstream of the main discharge port 22. The relief valve 27 opens when the pressure in the suction passage 21 downstream of the main discharge port 22 becomes higher than the pressure at the port C.
After the engine 1 has been started, a suitable control means determines whether the engine 1 is in a high-load operating mode requiring increased air supply on the basis of signals representing the degree of movement of the accelerator pedal, the engine speed, the internal pressure of the engine, and the fuel supply rate.
When the engine 1 is in the high-load operating mode, determination is made as to whether the engine 1 is operating in a high-speed operating mode. When the engine 1 is operating in a low-speed operating mode, the three-way switching valve 25 is operated to make the port A communicate with the port B to discharge air through the auxiliary discharge port 24 to reduce the internal pressure ratio, for example, to 1.5. When the engine 1 is operating in the high-speed operating mode, the three-way switching valve 25 is operated to disconnect the port A from both the ports B and C so that the internal pressure ratio is raised, for example, to 2.0. Thus, in the high-load and low-speed operating mode, air compressed at a low internal pressure ratio, for example, 1.5, is discharged into the engine 1 and, in the high-load and high-speed operating mode, air compressed at a high internal pressure ratio, for example, 2.0, to deal with an increase in the resistance to the flow of suction air attributable to increase in the engine speed. Although the internal pressure ratio is varied according to the engine speed, the quantity of air discharged for every combustion cycle by the screw supercharger 20 remains constant regardless of the engine speed.
In a low-load or moderate-load operating mode where the air demand per unit time is small, the port A is connected to the port C and, when the discharge rate of the screw supercharger is excessively greater than the air demand per unit time and the pressure in the suction passage downstream of the main discharge port 22 is higher than the pressure at the port C (namely, the pressure at the auxiliary discharge port 24), the relief valve 27 opens to discharge air into the atmosphere.
The variation of the required power of the screw supercharger resulting from the change of the internal pressure ratio of the screw supercharger according to the operating mode of the engine (for example, the reduction of the internal pressure ratio from 2.0 to 1.5 for the high-load and low-speed operating mode of the engine), will be described with reference to FIG. 4.
When the port A is disconnected from the port B to stop the discharge of air from the auxiliary discharge port 24 in the high-load and low-speed operating mode, the state of the air confinement space within the screw supercharger 20 varies along a path a→b→f→c→d→e→a. The required power per cycle is represented by an area a-b-f-c-d-e.
When the port A is connected to the port B to allow the discharge of air from the auxiliary discharge port 24 in the same operating mode of the engine, the state varies along a path a→b→f→d→e→a. In this case, the required power per cycle is represented by an area a-b-f-d-e.
Since the power represented by an area a-g-d-e is recovered by the engine in either case, a net required power per cycle is represented by an area g-b-c when the internal pressure ratio is 2.0. However, the net required power per cycle is reduced at least a decrement represented by an area d-f-c when the internal pressure ratio is reduced to 1.5. Theoretically, this decrement is as large as 22% of the required power per cycle when the internal pressure ratio is 2.0.
Another arrangement of the mixture feed system including the screw supercharger 20 of the present invention will be described hereinafter with reference to FIG. 5. The arrangement of the mixture feed system shown in FIG. 5 is substantially the same as that shown in Fig. 2, except that the arrangement of the mixture feed system of FIG. 5 is provided additionally with a tank 28 and a check valve 29. Therefore, parts corresponding to those previously described with reference to Fig. 2 are denoted by the same reference numerals, and the description thereof will be omitted.
Referring to FIG. 5, air discharged from the auxiliary discharge port 24 is accumulated temporarily in the tank 28 without discharging directly into the atmosphere through the port C. The air accumulated in the tank 28 is used for supercharging the engine 1 in starting the engine 1 and during the high-load and low-speed operating mode. When the tank 28 is filled with air to its full capacity, the excessive air is discharged through the relief valve 27.
As is apparent from the foregoing description, according to the present invention, the screw supercharger is provided, in addition to the main discharge port, with at least one auxiliary discharge port formed at a distance toward the suction side from the main discharge port, and the auxiliary discharge port is connected through a switching valve capable of connecting the auxiliary discharge port to the atmosphere by a bypass passage to the suction passage at a position downstream of the main discharge port. Accordingly, the internal pressure ratio of the screw supercharger can be regulated according to load on the engine and engine speed to reduce the power consumption of the screw supercharger by eliminating the unnecessary air compressing operation of the screw supercharger, and to reduce the noise of the screw supercharger by reducing the pressure difference between the suction passage, and the main discharge port and auxiliary discharge port of the screw supercharger.
Although the invention has been described in its preferred form with a certain degree of particularity, many changes and variations are possible therein. It is therefore to be understood that the present invention may be practiced otherwise than specifically described herein without departing from the scope and spirit thereof. | A screw supercharger is provided having a set of male and female screw rotors rotatably supported in a casing and driven through a wrapping transmission including belts and pulleys by a prime mover, wherein a through hole is formed in the wall of the causing at a position through which the input shaft of the screw rotor or the extension of the axis of the input shaft of the screw rotor extends, in that a cylindrical bearing supporting part is formed around the through hole so as to project outside from the casing, and in that a driven pulley is supported through bearings on the bearing supporting part and is fixedly mounted on the input shaft. | 5 |
BACKGROUND OF INVENTION
[0001] The present invention is directed to methods and apparatus for logging and permanently monitoring subsea oil, gas, and injection wells; specifically to deploying photonic, electromagnetic or hydraulic conduits in an alternative path adjacent the production tubing in said wells.
[0002] Subsea wells are broadly defined as wells that do not provide fixed access from the surface of the sea. Subsea wells have wellheads located at or very near the sea floor and produce into subsea pipelines or provide access only through long subsea umbilical cables to distant locations. Traditional offshore wells located on offshore platforms have wellheads located on the a platform at or above the sea surface.
[0003] Fluid flowing from subsea wells proceeds out of the wellbore from one or more producing zones, through a system of continuous conduits, subsea wellheads, subsea flow lines and subsea pipelines to a surface production and storage facilities. Often, the well products have to travel many miles from the location of the subsea well head to such storage facilities.
[0004] As oil and gas becomes more and more difficult to find on land or in shallow coastal waters, the oil and gas industry has commenced exploration and development in deeper waters, miles from production and storage facilities. Prior to oil and gas being discovered in deep waters, the preferred method of producing the wells was to place the wellheads and the subsequent control devices for the wells at the sea surface on a platform. The access to these wells for the purpose of placing monitoring devices or performing intervention logging services was easily performed from the off-shore platform with the many well known methods of wireline logging, continuous coiled tubing, or even hydraulically pump down logging and monitoring systems.
[0005] Obtaining access to subsea wells for logging, monitoring or control purposes generally requires a costly submersible connection from the sea surface to the wellhead. Current methods, for example, to repair permanently disposed monitoring equipment, or to insert a suite of well logging tools into subsea wells, require the mobilization of a surface vessel which contains an off shore rig known to those in the industry as a semi-submersible rig or a drill ship. In all cases, the entry into the subsea well of the logging tools or tools to replace and dispose permanent monitoring equipment is performed through the production tubing. Because such wells are very expensive to drill and bring on line, most oil and gas producers prefer to not reenter the well unless absolutely necessary.
[0006] Hence, subsea wells are difficult to log or access for the placement of monitoring equipment. Further, visual inspections of these subsea wells are impossible because of the depths and distances of the wellhead from the nearest maintenance and production platform facility. Abnormal subsea well conditions cannot be observed in the manner of offshore platform wells or land wells, where pressureu gauges and visual leak detection may be maintained.
[0007] Monitoring of the subsea wells for safety, reservoir evaluation, and environmental reasons requires the instrumentation monitoring of the subsea well to be done remotely. This requires the transmission of the data from subterranean sensors in the well and subsea monitoring sensors over large distances to a receiving and processing node. This transmission of data is normally done over copper or optic fiber transmission umbilicals connecting the subsea wells back to surface data receiving stations. Because of the long distances and depths, considerable expense must be incurred to utilize these subsea umbilicals.
[0008] Furthermore, the current monitoring methods to monitor subsea wells are further compromised by the frequent failure of various subterranean gauges and instruments used to monitor oil and gas wells. Because of the remoteness of subsea wells from the surface of the sea and the need for rig interventions to access the subsea and subterranean monitoring devices, they require well maintenance to be performed from intervention rigs which are not always immediately available to perform such maintenance. The result of these failures and the difficulty of quickly repairing them generally results in the decision to continue producing deep-water wells without any subsea monitoring information for leaks and pressure anomalies and without subterranean monitoring of reservoir parameters. Such shortcuts are undesirable because they can lead to catastrophic failures of wells, hydrocarbon releases into the sea, and less than optimal reserve recovery.
[0009] The logging of wells has traditionally been done from platforms and on land wells to obtain additional information about a well's reservoir condition and the integrity of the well's structure. In subsea wells, logging is rarely done, as it requires the mobilization of very large and expensive semi-submersible rigs or drill ships. Furthermore, these subsea logging interventions introduce the possibility of losing wireline equipment in the well and compromising the well's ability to produce. Also, subsea logging operations normally require the production of the well be reduced or curtailed during process of rigging up of the logging equipment.
[0010] Because of the above-mentioned difficulties of logging and maintaining unreliable subterranean monitoring equipment and very long umbilical transmission lines, many subsea wells are produced while monitoring the produced fluid back at the process or storage facility many miles away. This method of monitoring does not yield any indication of where the fluids are coming from in the well (i.e. which portion of the formation may be producing) which may be desired where production may be resulting from large perforated intervals in the well. Additionally, flow rate information monitored at the surface does not identify possible cross flow of fluids between reservoir intervals, changes in water, oil, and gas quantities as function of the depth of the well, the presence of leaks in well tubular conduits, and whether the reservoir is depleting in pressure.
[0011] It is desirable from both a reservoir engineering perspective as well as from a safety and environmental perspective to obtain real-time information from subsea wells relating to dynamic subterranean environment, fluid production parameters, and subsea well equipment integrity. Examples of parameters which are desirable to monitor on a real-time basis are fluid flow rates, water cut, resistivity of subterranean formations, spontaneous potential of subterranean reservoirs, pressure, temperature, sand production, steel wall thickness of tubulars, seismic energy from the reservoir or other sources, and other variables known to those familiar with oil and gas production. This information is currently gathered from either permanently disposed monitoring devices attached to the production tubing or from well intervention methods that insert the devices concentrically through the production tubing in the subsea well.
[0012] The commonly disposed permanent monitoring devices include pressure sensors, flow meters, temperature sensors, geophones, accelerometers, seismic source broadcasters, and other sensors and instruments. These devices are inserted in subsea wells concentrically through the well's production tubing either using wireline, coiled tubing, and slickline, from a rig placed at the surface of the sea and connecting to the subsea well through the water by risers. Alternatively, these permanently disposed devices are inserted in a well with the production tubing. The production tubing is also inserted into the well via the use a rig on the surface of the sea where again a large riser is run from the subsea wellhead at the sea floor up through the water to the rig. Therefore, when permanently disposed monitoring equipment is inserted in a well either with production tubing or the other forms of insertion of the devices concentrically through the production tubing, a surface rig is required.
[0013] All of these parameters are obtained traditionally on land or offshore platform wells using offshore platform wells via the art of well logging. However, in the case of subsea wells the methods have to date not been developed to allow for safe, simple, and rapid log intervention into wells. Likewise, the retrieval of down hole pressure gauges or other instruments on land or offshore platform wells is often achieved by a well intervention with commonly known methods of wire line operations thereby not requiring a rig to be mobilized to the land or offshore platform location. Failure and need for retrieval of subterranean pressure gauges or other subterranean instruments in subsea wells can not be performed by wire line or logging interventions unless a semi-submersible rig or drill ship is deployed to the subsea well location. The present invention provides a rigless intervention method to access subsea wells.
[0014] Several subterranean data gathering systems are currently used to obtain data from the wells. This is commonly done using down hole permanent pressure gauges, and flow meters, that have long umbilical from the subsea well to a platform or floating production facility. The umbilical have electrical or optical cable to transmit data from the different permanently deployed instruments and devices in the well. The current method of gathering data from subsea wells practiced by the oil and gas industry requires the pressure gauges and pressure gauge electrical or optical data transmission line be disposed in the subsea well during the initial well construction, known to those familiar with the art as the well completions. It also requires that all down hole instruments be connected to data transmission lines, either electrical or optical lines, by a subsea wet connection. This connection then connects the subterranean data transmission lines to the subsea umbilical transmission lines.
[0015] These connections are difficult to do at deep-water depths, which often have large currents, high hydrostatic pressures, and are at depths where only a very limited number of Remotely Operated Vehicles (ROVs) can operate and make such wet connections.
[0016] The deep-water wells are being placed further from land, platforms, or floating process facilities to which the umbilicals are connected. This results in very long umbilicals with large weights and costs. Therefore, each additional instrument data transmission requirement from the subsea well requires an additional line in the umbilical going from the subsea wellhead back to the host facility at the sea surface often many miles away.
[0017] When the pressure gauge fails or when the data transmission line fails, or when the data transmission's wetmateable connection fails, the only recourse for repair of the data gathering system is an intervention into the well, using either a drill ship or a semi-submersible drilling rig resulting in the pulling of the well completion, and a significant number of days of lost production during the recompletion of the well, all as previously described.
[0018] The present invention provides a method and apparatus to intervene into these deepwater subsea wells without deploying a deepwater rig to hydraulically connect to the subsea wellhead and thereafter deploy logging instruments into the well has long been sought by the oil and gas industry. Another feature of the present invention permits the entry of subsea wells for the purpose of obtaining data without placing logging tools and wire line cable into the production tubing fluid flow stream of these subsea wells. The intrusion of logging tools into the flow stream of such wells presents a significant risk of losing the logging equipment in the well and obstructing fluid production. The present invention obviates the need for such interventions.
SUMMARY OF INVENTION
[0019] A new method of logging, monitoring and controlling subsea oil and gas wells is provided. This invention describes a method and apparatus to obtain continuous or periodic data (if desired) from reservoirs producing through subsea wells. This invention further describes the method and apparatus used to process, transmit, and archive said data into information for reservoir and well management. The present invention relates to a new method and apparatus for constructing subsea wells using an alternative path conduit to connect the subterranean conduit to a submersible conduit proceeding from the wellhead to the surface of the sea.
[0020] The preferred embodiment of this invention consists of a dual conduit system with the dual conduits connected at the bottom in the well providing a U-connection at the ends of the dual conduit and the other ends proceeding through the well head terminating outside the well head in a pair of hydraulic wet connection devices. This then forms a continuous conduit starting at the sea floor near the sub-well down the well and then back up to the subsea surface outside the well terminating in the two sea floor hydraulic wetmate devices.
[0021] This invention further teaches the method of constructing a well by placing the alternative path conduits into one of the subsea wells casing conduits. This invention teaches the insertion of logging tools, instruments, wireline, optic fibers, electrical cable, and other tools and instruments through the inventions alternative path conduits. This alternative path tube is deployed in the well, proceeds upwards through the wellhead, subsea safety valves, through subsea hydraulic disconnects, and to the sea surface, where it can be accessed by surface service vessels which can deploy logging tools and other instruments into the alternative path. The invention further teaches the method of inserting permanent subsea and subterranean monitoring devices through the alternative path conduits of this invention.
[0022] This invention further teaches the connection of the alternative path conduits to a surface instrument pod by connecting continuous conduit from the conduit proceed forth from the sub sea well and wellhead terminating at the hydraulic wet connects, where the inventions surface instrument pod remains on station above the subsea well at the sea surface. The invention further teaches that the instrument pod can have recording, processing and transmission devices inside the pod where the devices record, processes, and transmits the data and information to receiving locations on land or offshore. The use of an umbilical connected back to a remote surface instrument pod from the alternative path conduit disposed in the subsea well avoids the need for long umbilical cables back along the sea floor to the host production facility miles from the subsea well. An additional feature of this invention permits remote data transmission and well interaction. Commands can be transmitted from a remote station to the surface instrument pod, and then down the umbilical disposed in the sea, and into to the subsea well for the purpose of operating downhole devices, such as valves, gauges, sensors and the like in response to these remote commands.
BRIEF DESCRIPTION OF DRAWINGS
[0023] [0023]FIG. 1 is a partial schematic representation of the invention as disposed in several subsea wells.
[0024] [0024]FIG. 2 is a cross-sectional schematic view of the invention showing the apparatus of the present invention disposed into a subsea well.
[0025] [0025]FIG. 3 is a partial schematic view of a U-connection in a producing well.
DETAILED DESCRIPTION
[0026] Referring now to FIG. 1 of the drawings, a plurality of wells W are shown located on the sea floor 5 . The well is drilled from the surface of the sea 7 using a semi-submersible 100 or drillship drilling rig (not shown). One or more wells W are bored by the action of rotating a drill bit on the end of a drill pipe from the surface rig where the drill bit is inserted inside of risers pipes and the drill cuttings are flushed out of the well bore with a drilling fluid using method and apparatus well known to those in the oil and gas industry.
[0027] As more clearly shown in FIG. 2, a subsea well is constructed by drilling a borehole 1 down into the earth to intersect subterranean fluid production intervals 2 located in the earth. The well is constructed with at least one diameter of casing 3 disposed into the annulus of the borehole 1 and grouted into place from the surface rig, using cement 4 placed between the annular space formed between the bore hole 1 and casing 3 . This process can be repeated with at least one additional casing 13 . The final casing, in this figure casing 13 , is explosively penetrated using explosive charges forming perforation tunnels 10 connecting the borehole hydraulically with the subterranean fluids in the earth. A production tubing string 8 is inserted inside the casing 13 and deployed from a surface rig. The production tubing 8 can provide adjacent its lower end, a sealing element known as a packer 6 . The packer 6 is inserted in the annulus of casing 13 with the production tubing and set in the casing 13 above the perforation tunnels 10 to form a seal between the production tubing 8 and the casing 13 using any of the methods known to those familiar with oil and gas well completion technology. The upper end of the production tubing 8 is terminated and retained in a wellhead 9 forming a sealed hydraulic conduit between the production tubing and the casing with hydraulic communication with the reservoir or production zone 2 through the perforations 10 .
[0028] Preferred embodiments of Tthe present invention teaches include the insertion of at least one parallel tubing string 11 of a smaller diameter disposed parallel, but exterior, to the production string 8 , forming an alternative path through the well head and into the well.
[0029] In one preferred embodiment, the parallel tubing string 11 is connected to the outer diameter of casing 13 and inserted in the well from the surface rig while the casing 13 is deployed into the annulus of the wellbore 1 . In another embodiment, a parallel tubing string (not shown) may be attached to the production tubing Sand inserted into the well as the production tubing 8 is deployed from the surface rig. In either embodiment, the parallel tubing string 11 is connected through the wellhead 9 and sealed therein forming a sealed alternative path conduit into the subsea well without communication with the production fluid from the production interval 2 . In both embodiments, at least one parallel path-tubing conduit 14 is connected above the wellhead 9 to a hydraulic quick connection 12 . This connection can be made either at the wellhead or several hundred feet away from the wellhead to avoid the possibility of ROV collisions with the wellhead structure.
[0030] In yet another embodiment more fully shown schematically in FIG. 3, the well is constructed with a parallel alternative conduit path formed by inserting in the well two parallel conduits in the well attached at the bottom in the well with a U-tube connection. These parallel conduits form an alternative path to the production tubing 8 that goes down the well and then back through the subsea wellhead 9 , with each end hydraulically connected above the well head with a hydraulic disconnect device 12 . Each parallel conduit string 11 in each embodiment can provide a fluid control safety valve 15 disposed either above or below the wellhead 9 . As may be readily seen from FIG. 3, the return conduit need not be of the same internal diameter as the ingress conduit. The continuous path of 14 to 11 through the wellhead 9 communicates through the egress side 11 a and conduit 16 a . In each manner of installation, the fluid control safety valve 15 is used to control the unwanted escape of fluids through the alternative path conduit system. Other hydraulic check valves may be placed at 12 a as need to prevent escape of fluids upon disconnection of the conduit during operations.
[0031] This invention further teaches includes the construction of at least one continuous hydraulic conduit path from below the subsea floor 5 into and through the subsea wellhead 9 to the surface of the sea 7 by connecting alternative path conduit 14 above the well head proceeding from the well to a submersible conduit 16 , such that one end of the continuous path has one end at the surface of the sea 7 . Referring back to FIG. 1, conduit 16 can be partially supported by subsurface buoys 51 .
[0032] Referring still to FIG. 1, the present invention further includes the connection of the submersible conduit 16 from the subsea wellhead 9 to a surface instrument pod 17 . This surface instrument pod can be moored to the sea floor by a system of cables and anchors 18 to keep instrument pod 17 on station above the subsea wells. Alternatively, instrument pod 17 can be tethered by a single line providing resilient means to hold the pod in a set position while permitting the pod to move with the movement of the waves. So far as is known to applicant, no alternative path subsea conduit path has ever been used to provide a means of communicating with or controlling a subsea producing well.
[0033] The present invention requires that the alternative path conduit be installed during completion of the well. Consequently, the installation of the alternative path conduit must be coordinated with the setting and grouting of the well structure. Accordingly, the well profile must be planned with the alternative path conduit. If the alternative path conduit is to provide a path for optic fiber cabling only, a ¼ inch tubing or similar can be installed and strapped to the final casing upon setting of the casing string from the drilling platform or ship. If the alternative path conduit is to provide a means for wireline logging tools, chemical injection lines or hydraulic control lines, larger diameter conduit can be used to permit subsequent use as a combination pathway for one or more of these methods. If the preferred U-shaped alternative path conduit is set in the completed well, a memory-tool (i.e. one having a means of sensing and preserve the information as it passes through the pipe at a fixed velocity) may also be pumped into and out of the well to log the well without any wireline connection. Since the alternative path conduit is set in the wellhead of each subsea well, the wellhead must be designed for the alternative path conduit as well. Once set in the wellhead, the alternative path conduit provides a useful and easy diagnostic tool for monitoring, controlling and logging the well. The casing and wellhead are set in a manner well known to those in the industry. The connection of the alternative path conduit to the wetmate connection may be made either at the surface and installed with the wellhead or installed later. It is anticipated that most installations will be made after the installation of the wellhead is accomplished and flanged up on the sea floor.
[0034] For installation, instrument pod 17 is connected to conduit 16 aboard a surface vessel, like a semi-submersible drilling rig, or other vessel that allows for the connection of the conduit 16 aboard the vessel having the same relative motion as the instrument pod 17 and the conduit 16 proceeding up from the sub sea well. The preferred embodiment disposes one or more instrument packages within the instrument pod 17 that permit the gathering of data coming various data transmission lines disposed inside the alternative path conduit 16 proceeding up from the well. These data lines are any of the well known lines that are used for data transmission including but not limited to optical fiber, electrical conductors, and hydraulic fluids. The optical fiber can be connected to a light source. The electrical conductor can be connected to a logging system. In the case of hydraulic fluids, a pressure monitoring system can be connected to the conduit.
[0035] Optical fibers may be inserted in the alternative path conduit by connecting a pump to the provided port on the instrument pod 17 . Silicon gel or another fluid can be pumped into the annulus of the alternative path conduit and fiber optic cabling is fed into the pumping silicon gel (or other fluid) which carries the line into the well bore due to the frictional force of the silicon (or other fluid) against the fiber optic line. Upon reaching total depth, the pumped fiber is fully deployed in the wellbore. Fluids that may be used for deployment include liquids such as water as well as gases, such as air or nitrogen.
[0036] If the alternative path conduit has been connected with a U-connection within the wellbore, the fiber optic cabling will be transported through the tubing and either egress the well at the wellhead or be transported back to the instrument pod by the pumping. The disposition of the optic fiber in the wellbore permits the instrument pod 17 to sense with the use of the optical time domain reflectometry apparatus described in U.S. Pat. No. 5,592,282 to Hartog which is incorporated herein by reference and made a part hereof for all purposes, the thermal profile (distributed temperature measurement) of each well into which the line is disposed providing inflow conformance. The disposed fiber optic line also permits monitoring of production or well conduit integrity thereby permitting detection of leaks in the casing or production string. The fiber optic line also permits the monitoring of gas lift valves from the thermal profile of the well.
[0037] In other embodiments, the fiber optic line may include one or multiple sensors or sensor locations. The sensors or sensor locations are adapted to measure a parameter of interest, such as temperature, distributed temperature, pressure, acoustic energy, electric current, magnetic field, electric field, flow, chemical properties, or a combination thereof. The sensors may be fiber optic sensors, electrical sensors, or other types.
[0038] Further, the alternative path conduit can be used to pump both multi-mode and single mode optic fiber into the same well bore thereby permitting calibration and correlation of backscattering signals to improve the resolution of the optical time domain reflectometry analysis of deep subsea wells.
[0039] In an alternative embodiment, an electrical cable can be disposed in the alternative path conduit instead of the optical fiber. The electrical cable may include one or more sensors or sensor locations, as in the case of the optical fiber. The optical fiber and the electrical cable are generally referred to herein as a “cable”.
[0040] Well logging is often accomplished by disposing a tool down a wellbore with a variety of tools located thereon. These tools may be inserted into the well bore, adjacent the production flow line, and therefore never risk causing obstruction or damage to these very expensive deep water well projects. Any cased hole logging tool can be disposed and run from a tubular member adjacent the production tubing. These include, without limitation, neutron decay detector scanning, gamma ray logging, magnetic resonance logging, seismic sensing, and the like. For example, referring now to FIG. 3, if conduit 16 was 2 inches in diameter, normal well logging tools could be easily inserted in the well bore to the full extent of the well bore. These tools could be easily pumped down the annulus of conduit 16 through wellhead 9 and into the larger diameter side of the U-shaped subsea conduit 11 . The logging techniques could be accomplished from the buoy, or the tools could be permanently deployed to allow all varieties of common logging techniques to be accomplished with the deployed tools. These tools could be inserted to the total well depth either from the moon pool of the drilling rig as it completes the well or from the instrument pod 17 after placement on the deck of a service vessel.
[0041] The alternative path conduit and instrument pod allows an extension of the wellhead to the sea surface for control, logging and sampling lines. The instrument buoy would be deployed after connection with the submersible conduit from a regular buoy tender vessel. Since the buoy is much closer to the subsea wellhead than the remote production platform, control lines may be easily used to log well inflow conformance by real-time temperature profiles. If more than one well in a field is provided with the alternative path conduit and buoy system, a real time reservoir profile may be developed by combining the information received from each alternative path instrument pod. This information may be transferred from each instrument pod to either a production platform or land based radio station and processed and provided over modern communication channels to knowledge workers interested in well production and characteristics.
[0042] The instrument pod may also be used as a staging area for remotely activated well shutoff controls which would shut-in a well as required by reservoir engineers for the reasons well known to those having skill in this industry. A command could be issued to the instrument pod which would thereafter executed either an acoustic, electrical, or photonic signal to a subsurface valve to shut in the well.
[0043] Service of the alternative path pod and lines can be readily accomplished from regular surface vessels and remotely operated subsea vehicles (ROVs) presently used to service subsea wells. As required, the service vessel would be called to service each buoy with fuel (if required to run generators), glycol or other chemicals (if need to pump into the well zone), or replace or service cabling or conduit run into the alternative path. The pod would be lifted onto the work vessel by crane or other lifting means. The rise and fall of the vessel would not prevent the servicing of the conduit. A pump would be connected to the conduit and the optic fiber line could be washed from the conduit. Alternatively, new lines may be inserted into the alternative path conduit by pumping in a manner well known to those providing current well service.
[0044] Since the conduit is continuous from the surface into the well bore and back to the surface in the preferred embodiment. The introduction of cabling, or conductors into the well bore can be enhanced by filing the conduit with a low-denisity hydraulic medium, such as nitrogen gas, and then pumping in the lines one side while bleeding off the gas from the other side of the continuous looped circuit.
[0045] It is noted that the alternative path conduit, through its different methods of communication as previously disclosed (such as optical fiber, electrical cable, and hydraulic fluid) can act as a means to send commands from the pod to devices located in the wellbore. For instance, a command to set the packer 6 may be sent from a remote location to the pod and from the pod down the alternative path conduit to the packer. Provided the command sent is the “set packer” command, the packer is then set. Besides a packer, devices that can be controlled include but are not limited to valves (such as flow control valves), perforating guns, and tubing hangers.
[0046] The preceeding are examples of deploying permanent or temporary monitoring devices D within the alternative path conduit, including the deployment of cables, logging tools, memory tools, seismic arrays, and sensors. FIG. 3 schematically illustrates a device D being deployed within the alternative path conduit.
[0047] While particular embodiments of the invention have been described herein, this application is not limited thereto. It is intended that the invention be as broad in scope as the art may allow and that the specification and claims be interpreted as accordingly. | A method for logging, controlling, or monitoring a subsea well or group of wells through a path not within production tubing is disclosed. Preferred embodiments of the present invention allow logging tools, wire rope, optic fibers, electrical cables, monitoring and measuring instruments and other items known to those skilled in the art of oil and gas production to be disposed into the well without interfering with the flow path through the production string. In another aspect of the invention, a preferred embodiment includes the mooring or tethering of an instrument pod over the subsea well. The instrument pod is designed provide on-board data storage, data processing, data receiving, and data transmission equipment, such that data from the well can be transmitted back to a receiving network where said data may be stored and processed into useful information for reservoir operators. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of the earlier filing date of copending provisional application Serial No. 60/348,189, filed Oct. 18, 2001, by Majeed A. Foad, titled “Technique for Growing Single Crystal Si on Top of an Insulator”, and incorporated herein by reference.
FIELD
[0002] The invention relates to semiconductor material processing and more particularly to the formation of thin films of crystallized semiconductor material.
BACKGROUND
[0003] Modern integrated circuits are typically formed adjacent (in and/or on) a semiconductor substrate, such as a silicon substrate. Typically, at least many hundreds of devices are integrated surface are formed on a wafer (e.g., an 8-inch diameter substantially circular wafer). After formation of the individual devices or integrated circuits, the wafer is diced to form the discrete devices or integrated circuits.
[0004] According to current technology, a silicon wafer has a thickness on the order of about 600-750 microns. The wafer is usually formed from electronic grade polysilicon (EGS) that is used to grow single crystal silicon by Czochralski (CZ) crystal growth or float zone (FZ) growth. The single crystal silicon is typically commercially available in either {100}- or {111}-orientations though other orientations are possible. Steps are taken in either the CZ growth or FZ growth to minimize impurities in the bulk silicon, particularly at the wafer surface. Nevertheless, impurities do exist in the bulk silicon. These impurities can introduce effects on device or integrated circuit performance, including effects on device leakage current, capacitance of junctions, etc.
[0005] One way to improve device performance and to minimize the deleterious effects attributed to the bulk semiconductor material (e.g., bulk silicon material) is by separating the device layer from the bulk. One popular approach is the introduction of an insulating layer such as sapphire or silicon dioxide (e.g., SiO 2 ) over the surface of a wafer then forming a thin film of sapphire single crystal semiconductor material (e.g., single crystal silicon material) over the insulating layer (e.g., an epitaxial layer of, for example, silicon formed on top of the oxide). One common terminology given to such a structure is a sapphire on silicon (SOS) or silicon on insulator (SOI) structure. An SOI structure isolates the device layer from the bulk semiconductor by forming a thin layer of silicon, on the order of 0.05 to 0.2 micron thick silicon layer over a similarly thick layer of SiO 2 .
[0006] One method of forming an SOI is referred to as a SIMOX process. In this process, the top layer of a wafer is subjected to a large dosage oxygen implant. A subsequent substrate anneal causes the implanted oxygen to convert to a sub-surface, stoichiometric SiO 2 from the bulk outward until all the oxygen is consumed. The process is called Oswald ripening and the thickness and position of the SiO 2 layer depends, inter alia, on the dose of the implanted oxygen and implantation energy, respectively.
[0007] A second method of forming an SOI structure is through a bonded wafer approach. In one such approach, two wafers are separately fabricated. On the first wafer, a thin layer of SiO 2 is thermally grown. The second wafer is implanted with a high dosage of hydrogen (H 2 ). The implanted hydrogen produces a damage layer in the bulk of the wafer. The wafers are then bonded together, with the second wafer bonded over the SiO 2 layer of the first wafer. The bonded structure is subjected to an anneal and then sheared at the damage layer to form the SOI structure.
[0008] In both the SIMOX process and the bonded wafer process, the process to form the SOI structure can be time consuming. What is needed is an alternative approach of forming an SOI structure.
SUMMARY
[0009] A method is disclosed. In one aspect, the method includes introducing over a wafer a material having a crystalline form. In this material, a crystal (e.g., crystallite) is identified of a desired lattice orientation. The remaining material is then configured to the lattice orientation of the identified crystal.
[0010] The method finds use in the formation of SOI and SOS structures in that a semiconductor material such as a silicon material may be introduced in a polycrystalline form over an insulator such as SiO 2 or sapphire and a desired crystal orientation may be identified in the polycrystalline material and the remaining material configured to the lattice orientation of the identified crystal. Thus, a single crystal layer (e.g., epitaxial layer) of silicon may be formed over the SiO 2 or sapphire layer.
[0011] In one aspect, the method identifies, e.g., by x-ray difraction, a crystal in a material such as semiconductor material having a desired lattice orientation, e.g., Si{100}, and the remaining crystals of the material are configured to the lattice orientation of the crystal. In another aspect, the crystal is identified in an area corresponding with a center axis of the wafer and the remaining crystals of the material are configured to the orientation of the identified crystal by transforming the remaining crystals from a crystalline form to an amorphous form and re-crystallizing the amorphisized polycrystalline material to a single crystalline material throughout the layer over the wafer. One way this is accomplished is by exposing the crystals desired to be configured to a particular lattice orientation to a high energy light source, such as a laser, and re-crystallizing through epitaxial re-growth. The light source transforms the material from a crystalline form to an amorphous form, for example, by melting. The wafer is rotated in concentric revolutions about an axis of the wafer to expose additional crystals to the laser light. As the melted crystals cool, they re-crystallize to the orientation of the identified crystal.
[0012] A machine-readable medium comprising executable program instructions is also disclosed. The instructions when executed cause a digital processing system to perform a method including identifying a crystal of a desired lattice orientation in a material introduced over a wafer, the material having a polycrystalline form and configuring the material to a lattice orientation of the identified crystal. A system is also disclosed. The system includes a chamber, a laser light source coupled to the chamber and configured to direct a laser light into the chamber, and a processor comprising a machine-readable medium with executable program instructions to identify a crystal of a desired lattice orientation in a material introduced over a wafer, the material having a polycrystalline form over a wafer and configuring the material to a lattice orientation of the identified crystal.
[0013] Additional features, embodiments, and benefits will be evident in view of the figures and detailed description presented herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The features, aspects, and advantages of the invention will become more thoroughly apparent from the following detailed description, appended claims, and accompanying drawings in which:
[0015] [0015]FIG. 1 is a schematic, cross-sectional side view of a system according to the invention including a chamber for fabricating a wafer according to the invention.
[0016] [0016]FIG. 2 illustrates a schematic planar top view of a wafer having a material of a crystalline form of random orientation formed over the illustrated surface of a wafer and a crystal in the material of a desired lattice orientation according to an embodiment of the invention.
[0017] [0017]FIG. 3 shows the wafer of FIG. 2 with concentric circles formed over the surface of the wafer by a high energy light in accordance with an embodiment of the invention.
[0018] [0018]FIG. 4 shows a schematic side view of the structure of FIG. 2 after configuring the crystalline material to the lattice orientation of the identified crystal in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0019] A method relating to configuring a material having a crystalline form over a wafer to a desired lattice orientation of a crystal of the material. One application of the method is in the formation of an SOI or SOS structure. In this manner, a semiconductor material such as silicon may be introduced over an insulating layer such as SiO 2 or sapphire on a wafer. The semiconductor material such as silicon may be introduced in polycrystalline form as a thin film made up of many crystallites (i.e., crystals). A crystal of the semiconductor material having a desired lattice orientation is identified and the remaining crystals are configured to adapt to the orientation of the identified crystal. In this manner, a single crystal layer of, for example, silicon may be fabricated over an insulating material to form the SOI or SOS structure. In this respect, the invention offers a method of efficiently forming SOI or SOS structures.
[0020] A system for configuring a material introduced over a wafer to a desired orientation is also disclosed. FIG. 1 illustrates an embodiment of such a system. FIG. 1 shows a cross-sectional side view of a wafer processing chamber 150 included as part of system 100 . Disposed within chamber 150 is stage 160 that supports a wafer, such as an eight-inch diameter, essentially cylindrical wafer having a thickness on the order of 600-750 microns. In this illustration, wafer 110 is seated on a superior (e.g., top) surface of stage 160 inside processing chamber 150 . Stage 160 is supported in chamber 150 by shaft 165 extending through a base of processing chamber 150 . The base of shaft 165 is coupled to shaft pulley ring 168 . Motor 170 , in this instance, outside processing chamber 150 , is coupled to pulley ring 168 to rotate shaft 165 and stage 160 . Motor pulley ring 169 is coupled to a shaft of motor 170 and motor pulley ring 169 is aligned in the same plane with shaft pulley ring 168 . Belt 175 extends around shaft pulley ring 168 and motor pulley ring 169 to rotate shaft 165 and stage 160 in response to a rotation of motor 170 through, for example, a gear head assembly. Details about the gear-head assembly and rotation of motor 170 and motor pulley ring 169 and shaft pulley ring 168 are not provided so as not to obscure the invention. Similarly, additional components, such as components to maintain, for example, where necessary a desired temperature or pressure within processing chamber 150 are not described as such are unnecessary for an understanding of the invention.
[0021] Referring to wafer 110 , seated on a superior surface of stage 160 in system 100 of FIG. 1, wafer 110 includes a thin film of the insulating material 120 formed on an exposed surface. Insulating material 120 is, for example, SiO 2 grown through a thermal growth process to a thickness of approximately 0.05-0.2 micron thickness to act as the insulating material for an SOI structure. The growth of insulating material 120 of SiO 2 follows conventional processing techniques. A sapphire material may alternatively be grown for an SOS structure as can other materials as desired.
[0022] Introduced over insulating material 120 is a thin layer of silicon material 130 in polycrystalline form to a thickness of approximately, in this embodiment, 0.05-0.2 microns. Silicon material 130 may be introduced by way of a plasma enhanced chemical vapor deposition (PECVD) process as known in the art. Silicon material 130 is, in this embodiment, of polycrystalline form and thus is composed of a myriad of small single crystallites, i.e., crystals of random orientation. In one embodiment, the chamber temperature is optimized during silicon introduction to produce large silicon crystallites. Although a silicon material is described, it is to be appreciated that other semiconductor materials, or other crystalline materials for that matter, may be alternatively introduced depending on the desired process. It is also to be appreciated that the introduction of silicon material 130 may occur in a chamber other than processing chamber 150 and then wafer 110 may be transferred to processing chamber 150 for further processing.
[0023] [0023]FIG. 2 shows a top surface of wafer 110 having silicon material 130 introduced over the surface. As illustrated in FIG. 2, silicon material 130 is made up of a myriad of single crystals or crystallites of random orientation. These different orientations are illustrated schematically as 130 A, 130 B, 130 C, 130 D, and 130 E and representatively described as {100}-, {110}, and {111}-orientation, although other orientations are likely also present. In the representation shown in FIG. 2, the different orientations are represented adjacent an area corresponding with central axis 105 of wafer 110 .
[0024] In one embodiment, the crystalline structure of silicon material 130 is analyzed in situ at an area adjacent central axis 105 for the orientation of crystals adjacent the axis. Such analysis may be conducted through, for example, x-ray or electron beam diffraction techniques so that the orientation of the crystals may be identified. To facilitate the identification of the orientation of crystals in silicon material 130 , the structure may be subjected to a heat treatment (e.g., on the order of 300 to 700° C. for up to 30 minutes) to grow larger crystals. The analysis permits the selection of a crystal of a desired lattice orientation in silicon material 130 adjacent central axis 105 . In this case, crystal 130 A ({110}) is selected as having the desired crystal orientation. Due to the myriad of crystals present in a polycrystalline layer or film, it is appreciated that a crystal having the desired orientation can be identified near central axis 105 . Where such crystal is not present adjacent central axis 105 , the area for the search may be expanded as necessary.
[0025] Returning to FIG. 1, one way of configuring the crystals of silicon material 130 to the lattice orientation of crystal 130 A is by melting the crystals and re-growing such crystals with the orientation of crystal 130 A. It is generally recognized that an amorphourized crystal material will seek reorder in crystalline form as a lower energy state and similarly will have an affinity for the crystal orientation of adjacent crystals in the material. The method described herein capitalizes on this property of crystal material to form a single crystal film of a desired lattice orientation.
[0026] [0026]FIG. 1 shows high energy beam source 180 coupled to a top surface of processing chamber 150 . High energy beam source 180 is, for example, an excimer laser. High energy beam source 180 directs high energy light 192 onto a top surface of wafer 110 inside processing chamber 150 . In one embodiment, high energy beam source 180 produces beam 192 of laser light having a beam diameter similar or smaller in size to that of a crystal diameter of silicon material 130 . A representative beam diameter for such an embodiment is one to three microns. In this manner, beam 192 from high energy beam source 180 can be directed at the individual crystals of silicon material 130 . In one example, high energy light source 180 is an excimer laser that applies light beam 192 in 10 nanosecond pulses to melt the crystals of silicon material 130 .
[0027] Referring to FIG. 1, system 100 includes motor 170 to rotate shaft 155 and stage 160 and consequently wafer 110 . The rotation allows beam 192 to be directed in revolutions about central axis 105 of wafer 110 . FIG. 3 shows a series of revolutions about central axis 105 of wafer 110 , starting adjacent identified crystal 130 A and moving outward in circles or revolutions of increasingly greater radius. Beam 192 is emitted from high energy beam source 180 in the form of pulses, such as laser pulses, directed at crystals that make up silicon material 130 to melt such crystals in a counter-clockwise direction.
[0028] [0028]FIG. 3 also shows, in an insert, a magnified view of a portion of the pulse pattern of light beam 192 . The insert shows that wafer 110 is rotated, in this example, at a speed whereby the individual pulses of light 192 overlap one another. Such overlap insures that each crystal of silicon material 130 is melted as wafer 110 is rotated. It is to be appreciated that, given a sufficient intensity of light and a sufficient pulse time, such an overlap is not necessary.
[0029] Referring to FIG. 1, one way of forming concentric revolutions about wafer 110 , each revolution having a different radius than its predecessor, is by controlling the location of light beam 192 from high energy light source 180 as wafer 110 is rotated. One way this is accomplished is through mounting high energy light source 180 on radial position track 185 . Radial transfer arm 185 is mounted on processing chamber 150 and provides a track for movement of high energy light source 180 in a radial direction over wafer 110 .
[0030] [0030]FIG. 3 shows the radial movement 200 of high energy light source 180 and light beam 192 in a radial direction across the top surface of wafer 110 . In one example, wafer 110 is rotated in continuous revolutions allowing a movement of high energy light source 180 along a radius to expose the surface of wafer 110 associated with the circumference of each revolution to beam 192 from high energy light source 180 . At the completion of each revolution, high energy light source 180 is adjusted radially (e.g., from a first radius to a second greater radius) and a subsequent revolution is traced by high energy light source 180 . In one example, radial transfer arm 185 comprises track 187 extending the length of a radius of a wafer on stage 166 . Pin 190 coupled to and extending laterally from light pipe 191 of high energy light source 180 , is positioned in track 187 . High energy light source 180 is moved radially by positioning pin 190 within track 187 . Such positioning may be done manually or more preferably electrically and with the aid of motor assembly (not shown). Such motor assembly may be controlled by controller 195 . Information about the location of pin 190 may also be stored and monitored by controller 195 . Processor or controller 195 controls the radial movement of high energy light source 180 in radial transfer arm 185 .
[0031] [0031]FIG. 1 illustrates system controller or processor 195 coupled to a high energy light source 180 and motor 170 . Controller 195 is configured to monitor the position of high energy light source 180 and control the power supplied to motor 170 , and thus the revolution velocity based, for example, on an algorithm that determines a circumference of each revolution and the pulse duration of high energy light source 180 and adjusts motor 170 accordingly. Controller 195 may also be configured to control the mixture and flow of film forming agents to chamber 150 . In an LPCVD reaction process, the controller may further be coupled to a pressure indicator that measures the pressure in the chamber as well as a vacuum source to adjust the pressure in the chamber.
[0032] Controller or processor 195 is supplied with software instruction logic that is a computer program stored in a computer readable medium such as memory in the system controller. The memory is, for example, a portion of a hard disk drive. The controller may also be coupled to a user interface that allows an operator to enter the process parameters, such as the desired pulse duration, the light pulse diameter, and the desired number of revolutions to melt substantially all the grains of silicon material 130 . Alternatively, certain values may be calculated by algorithm(s) stored in controller 195 .
[0033] As noted above, controller 195 may also control the positioning of high energy light source 180 . In one example, controller stores information about the location of pin 190 and extrapolates, for this information, information about the position of beam 192 over wafer 110 . Controller 195 also stores information about beam diameter and wafer diameter. An algorithm supplied to controller 195 determines the number of radial positions necessary for all the material on wafer 110 to be exposed to beam 192 (wafer radius from crystal 130 A divided by beam 192 diameter). With this information, controller 195 positions high energy light source 180 . A signal from motor 170 or a sensor coupled to motor pulley ring 169 or shaft pulley ring 168 alerts controller 195 to a complete revolution and controller 195 in turn adjusts high energy light source 180 .
[0034] [0034]FIG. 4 shows the structure of FIG. 2 after the transformation of silicon material 130 to single crystal material 1300 using the process described above. In one example, silicon material 1300 is an epitaxial film of single crystal silicon, with substantially all of the crystals configured with an orientation of crystal 130 A-{100}. According to the invention, an efficient method of orienting a material on a substrate is illustrated. Since the process relies on directly transforming discrete crystals or small amounts of crystals at any one time, the process can more accurately transform such crystals to a desired orientation than prior art methods that rely on thermal processing to transform all the material at once. Further, since the process described reorients the film on a surface, the general characteristics of the film, such as film thickness may more accurately be characterized than prior art processes that, for example, rely on wafer shear techniques to produce the film.
[0035] In the preceding detailed description, the invention is described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A method including introducing over a wafer a material having a crystalline form, identifying a crystal in the material of a desired lattice orientation, and configuring the material to the lattice orientation of the crystal. A system for growing a film on a substrate including a chamber, a laser light source coupled to the chamber and configured to direct a laser light into the chamber, and a processor coupled to the chamber comprising a machine readable medium including executable program instructions that when executed cause the processor to perform a method including identifying a crystal of a desired lattice orientation in a crystalline material introduced over a wafer, and configuring, the material to a lattice orientation of the identified crystal. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved closure for sealing retortable containers and more particularly for a closure for sealing cans and wide mouth containers including barrier plastic containers and for retaining the seal during and after the retorting of the sealed package.
There is a type of container for foods and similar products which whether molded or otherwise formed from plastic or metal has a relatively thin rim. Some such containers are molded wide mouth barrier plastic containers which are used for food packaging with a retorting operation.
The composite closure comprises a metal disc cover having a clamp-like or grooved edge containing a sealant for sealing the container and a molded plastic ring for holding the cover on the container. A portion of the sealant on the closure groove is clamped against the container rim in a broad annular band with the seal being relatively insensitive to container size changes during the heating of a retorting process.
Accordingly, an object of the present invention is to provide an improved composite closure for retortable containers.
Another object of the present invention is to provide an improved composite closure for barrier plastic containers.
Another object of the present invention is to provide an improved resealable composite closure for containers which has an improved seal after retorting.
Another object of the invention is to provide an improved tamper evident composite closure.
Other and further objects of the present invention will become apparent upon an understanding of the illustrative embodiments about to be described, or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention has been chosen for purposes of illustration and description and is shown in the accompanying drawings, forming a part of the specification, wherein:
FIG. 1 is a perspective view of a sealed package in accordance with the present invention.
FIG. 2 is an exploded perspective view of the package of FIG. 1.
FIG. 3 is a vertical cross-sectional view of a preferred embodiment of the retortable closure in accordance with the present invention.
FIG. 4 is a fragmentary horizontal sectional view illustrating the tear band and container ratchets.
FIGS. 5 thru 8 are enlarged vertical sectional views of the package before and after sealing.
FIG. 9 is an enlarged vertical sectional view of the package after opening.
FIG. 10 is a vertical sectional view of the closure cap of the invention after molding.
FIG. 11 is a fragmentary vertical sectional view of a blow or vacuum formed container finish for sealing with a closure cap in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This is an improved composite closure for sealing retortable containers including plastic containers including those known as barrier plastic containers which are impervious to oxygen penetration and thereby extremely spoil resistant. Such plastic containers are often in the form of large mouth containers and there is a need for an inexpensive and efficient sealing closure. In addition to the requirements of low cost and an excellent seal, the closure must also retain its seal through the retorting or heat treating steps used in food packaging.
The figures illustrate a preferred embodiment of such a composite closure 1. It comprises a sealing cover or disc 2 which is held in sealing position on the container 3 at an outer channel or groove 7 by a molded plastic ring 4. A preferred cover 2 is illustrated in FIG. 3 which is formed from sheet metal into the illustrated shape comprising the disc-like inner portion 6 and an annular sealing groove 7 with a generally C-shaped cross section.
The plastic ring 4 has a skirt portion 9 and a generally inwardly and upwardly curved clamping portion 10 for engaging the cover 2 at the sealing groove 7. Container engaging threads 11 are provided on the inner surface of the ring 4 skirt 9 and preferably a tamper indicating band 12 is provided at the lower edge of the skirt 9. A line of weakness 16 is cut or molded between the tamper indicating strip 12 and the upper portion of the skirt 9.
The radially outer edge of the disc 2 includes the groove as illustrated at 7.
The groove 7 contains a plastisol or other sealant material 8 to form a vacuum tight seal with the container 3. The sealant 8 may be molded with a forming tool or applied as a spray or coating to the groove 7. The diameter C of the container 3 at its rim 17 is made smaller than the diameter D of the center line of the cover groove 7. This is done because the container 3 diameter increases more than the diameter of the groove 7 when the package is heated in the sealing or retorting operation. This means that the closure 1 as applied toot the hot container (FIG. 7) seals tightly and with the desired fit for the higher retorting temperature. When the sealed package cools (FIG. 8), the greater shrinkage of the container 3 rim 17 causes its radial diameter to become smaller than that of the groove 7 resulting in the creation of an inward radial sealing pressure between the inner edge of the sealant 8 and the container rim 17.
The container threads 15 and closure threads 11 have the preferred shape illustrated in which the bottom of the container threads 15 and the top of the closure threads 11 are made relatively flat and horizontal. The result is that any relative movement between the threads 11 and 15 during the retorting operation caused by the unequal expansion of the closure 1 and container 3 causes an insignificant relative vertical movement between the threads 11 and 15 so that the threads retain their vertical tension for both the heated and the cooled packages.
FIG. 11 illustrates a container 25 which comprises a similar barrier type finish which is blow molded or vacuum formed. This plastic container has the generally hollow form at the finish with the space between the inside and outside wall about three times the thickness of the barrier plastic. Otherwise the threads and beads and other features of the container finish are similar to these described for the container 3 of FIGS. 1-10.
DESCRIPTION OF THE TAMPER EVIDENT BAND
The composite closure takes advantage of its metal cover 2 to provide the usual flexible vacuum indicating button 20 which is held down after the container sealing to show the package vacuum and which pops up with an audible click when the package is opened to indicate to the user that the desired vacuum was present.
Additionally for most packages it is desirable to have a visual indicator in the form of a breakaway or tamper evident band provided on the lower edge of the plastic ring. The preferred band 12 is molded with spaced ratchets 21 with one or more ratchet teeth 22 thereon. The ratchets 21 are molded integrally with the ring 4 in a downward position as illustrated in FIG. 10 and are then bent upwardly, with or without heat, as illustrated in FIG. 5 to engage cooperating spaced molded ratchets 23 on the container 3.
The line of weakness 16 defines the band 12 from the upper portion of the ring 4. The ratchets 21 easily snap over the bead 24 in their hot and expanded and softened condition during sealing but are not easily moved once the sealed package cools.
When the closure 1 is first turned for removal, the engagement of the ratchets 21 on the band 12 and ratchets 23 on the container 3 cause the band 12 to be broken free at the line 16 from the ring 4 and to fall down to the container step 24. Additionally, the ratchets 21 and 23 interact to prevent premature unscrewing of the closure 1 while the ring 4 is soft and pliable during retorting.
The band 12 when broken away from the closure 1 and as the rest of the closure 1 rises on the container 3, remains positioned between the ratchets 23 and the container bead on step 24 so that it is not easily removed from the container.
The flexible ratchets 21 on the closure 1 bend outwardly should they happen to stop on a container ratchet 23 peak so that there is not distortion of the closure 1 skirt portion 9.
It has been found desirable to employ a closure cap such as described above for sealing containers having a top or finish generally similar to that for the container 3 but which are formed with a blowing or vacuum forming process. Such a container will have the hollow form illustrated in FIG. 11, but will operate otherwise in the manner already described.
It will be seen that an improved composite closure has been provided for sealing containers including plastic containers, which is capable of maintaining a tight seal through and after retorting.
As various changes may be made in the form, construction and arrangement of the parts herein without departing from the spirit and scope of the invention and without sacrificing any of its advantages, it is to be understood that all matter herein is to be interpreted as illustrative and not in a limiting sense. | A closure is described for sealing retortable containers. The closure has a disc shaped metal cover with a grooved sealing portion at its outer edge containing a sealant and a plastic ring for engaging the container. A clamping action holds sealant in the cover groove against a rim of the container and the relative dimensions of the closure groove and the container are chosen for providing a tight seal particularly after retorting. | 1 |
This application claims the benefit of U.S. Provisional Application No. 60/219,188, filed Jul. 19, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to apparatus using metal hydrides as a means to store and operate with hydrogen, and, more specifically, to the use of such hydrogen and in operation in which the hydrogen gas is purified during storage or operation.
2. Background Art
Inexpensive but essentially pure sources and storage of hydrogen gas (H 2 ) is increasingly important to the production of energy as economic and environmental factors compels a shift away from dirty petrochemical fuels. Unless efforts are made to retain the purity of hydrogen gas, impurities, such as oxygen, water vapor and carbon monoxide, inevitably become entrained within a stream of hydrogen gas. These impurities impede the operation and/or efficiency of any device which stores the hydrogen gas, or which utilizes the hydrogen gas in its operation.
Purification of a hydrogen gas stream was an elaborate procedure that, in most cases, involved a net energy input into the hydrogen utilization system. For example, commonly assigned U.S. Pat. No. 5,250,368, drawn to a metal hydride battery and metal hydride hydrogen storage system, teaches a combination molecular sieve dryer and electrical resistance heating wire to remove water vapor when the hydrogen stream is directed in one direction, and by heating, re-introduces the water vapor back into the hydrogen stream when it is directed in the opposite direction. This system is capable of inhibiting entry of the water vapor into the hydrogen storage chamber, where it can cause the metal hydride hydrogen storage material to deteriorate and lose storage capacity.
Later modifications of such systems that purified hydrogen when passing in a stream from one part of a metal hydride battery system to another part included a passive hydrogen purification for hydrogen gas delivery, for example, as described in commonly assigned U.S. Pat. No. 5,688,611. In the metal hydride battery described in that patent, a formulation of a metal hydride material is dispersed within a matrix of a silica gel powder. The silica gel powder provides for absorption of water vapor before the hydrogen is absorbed in the metal hydride. The metal hydride storage medium itself may include corrosion resistant elements, and an optional surface film which is water vapor and carbon-oxide repellant. Such a film is taught in commonly assigned U.S. Pat. No. 5,532,074.
Other modifications to such metal hydride battery systems are taught in commonly assigned U.S. Pat. No. 4,781,246, drawn to a thermally reversible heat exchange unit for use in any of a number of devices utilizing the cycling of hydrogen gas in a heat transfer or hydrogen storage operations. Examples of the apparatus or systems in which heat exchange units described in U.S. Pat. No. 4,781,246 may be utilized are refrigerators, heat pumps, air conditioners, compressors and hydrogen storage devices, including hydrogen purifiers. All of these systems require an efficient method to isolate the water vapor from the metal hydride storage medium.
An automatic system is taught in commonly assigned U.S. Pat. No. 6,042,960 which inhibits transfer of water vapor in the absence of the pressurized flow of hydrogen in the context of a battery system.
Hydrogen gas streams utilized in other than metal hydride battery systems require modifications to these systems toward providing greater efficiencies. For example, in commonly assigned U.S. Pat. Nos. 5,450,721 and 5,623,987, an air conditioning system, and a modular manifold hydrogen gas delivery system are described and claimed. Those systems utilize the different hydrogen absorption characteristics of specified metal hydride alloys to provide a sudden heat energy transfer from or to a desired location. Because the system is closed, and does not introduce new hydrogen gas or other elements into the system which can affect the sorption characteristics of the metal hydrides therein, thus a filter for removing water vapor and other gas impurities was not considered necessary. However, it is now known that even in “hermetically sealed” systems, gaseous impurities may be introduced at the initial start-up and may even enter into such a system during operations conducted at high pressures or from outgassing from the internal wall surfaces and cracks, or from diffusion through the walls.
When a repeating cycle of hydrogen absorption and desorption is used in a heat exchange cycle, impurities in the gas stream can result in the deterioration of hydriding capacity. Hydrogen absorption in a metal hydride alloy as used in heat exchange units is accompanied by a heat of formation which is exothermic. In order to continuously absorb hydrogen to an alloy's maximum capacity, heat must be removed from the bed. The rate at which a hydride alloy can absorb or release hydrogen is dependent upon the rate at which heat can be transferred into or out of the alloy. Increasing the heat transfer rate will allow the processing of higher flow rates, or alternatively, the same flow rate can be processed by a proportionately smaller amount of alloy. Therefore, small containers capable of rapid heat transfer can handle high flow rates.
With each thermal cycle, the metal hydride alloy in a container is first filled to capacity and then emptied. Gaseous impurities can react with the hydride alloy causing a reduction in its hydrogen storage capacity and may inhibit the further absorption of hydrogen gas. The net result causes a decline in hydrogen throughput with each thermal cycle. For this reason, thermal compression of hydrogen using metal hydrides has been restricted to relatively pure hydrogen streams (99.995%) that have less than 50 ppm of active gas impurities. Although hydrogen purification systems can be used to remove impurities, the purification systems themselves are often complex, expensive to maintain, and, for hydrogen produced at atmospheric pressure, would require their own motive force in the form of a mechanical compressor or blower. These disadvantages offset benefits that could be derived from thermal compression.
The need for a filter to remove gaseous impurities from a hydrogen gas stream has been found in a variety of applications. Many of the applications in which such filters are utilizable differ in essential respects from the applications in which such filters have been utilized heretofore. For example, an application in which metal hydride combinations re utilized to compress hydrogen gas is described in commonly assigned U.S. Pat. Nos. 4,402,187 and 4,505,120. One major difference is that a hydrogen gas stream enters the compressor at an inlet and exits at an outlet at much higher pressure. The continual addition of new hydrogen into such a system introduces a continua stream of impurities that are entrained in the hydrogen. Although most hydrogen compression systems are capable of self-cleansing of a certain amount of impurities in the hydrogen gas stream, the continual addition without a purge of the impurities can overwhelm a system so that it becomes non-operational. Other applications of hydrogen gas also utilize a purification device, as will be more fully described in the detailed description below. To avoid unnecessary repetition, the description and teachings of the above mentioned commonly assigned U.S. Pat. Nos. 4,402,187; 5,450,721; 4,505,120; 4,781,246; 5,250,368; 5,532,074; 5,623,987; 5,688,611 and 6,042,960 are each incorporated herein by reference where appropriate as if fully set forth herein, for purposes of enablement of this application. A need in the operational transfer function of a hydrogen gas stream exists for removing impurities in applications beyond those heretofore known. A need is also apparent for a purification device for a hydrogen gas stream that is capable of removing not only water vapor, but also minute quantities of other types of gas impurities, such as oxygen (O 2 ), carbon monoxide (CO) and carbon dioxide (CO 2 ).
SUMMARY OF THE INVENTION
Accordingly, what is disclosed and claimed herein is a passive purification device that is usable within a hydrogen gas transport stream, preferably in line with a conduit, that is standard for a number of hydrogen gas storage and utilization applications.
In one embodiment, such a passive purification device in a thermal hydrogen compressor may comprise a metal hydride material for retaining and storing a concentrated volume of hydrogen gas, that material being capable of repeatedly absorbing and discharging gaseous hydrogen, the material comprising a mixture of water vapor absorbing particles, metal hydride particles and a noble metal in powder form. The material may further comprise a metallic powder selected from the group consisting of: Platinum black, Palladium black and Ruthenium black. In a second embodiment, a hydrogen compressor comprising an inlet for hydrogen gas fed at a low inlet pressure and an outlet for hydrogen gas at high pressure, therebetween at least two sets of connected units A, C and E and at least two sets of units serving the unit functions B, D and F said A through F being a first chamber in communication with said inlet through a one-way valve adapted to admit hydrogen gas into said first chamber at said low inlet pressure containing a first hydridable material having an adsorption pressure below said low inlet pressure at a first temperature, heat exchange means associated with said first chamber adapted to operate alternately to maintain said first chamber at or below said first temperature and to raise the temperature of said first chamber to a second temperature higher than said first temperature, a second chamber in communication with said first chamber through a one-way valve adapted to prevent flow of hydrogen from said second chamber to said first chamber and containing a second hydridable material forming a less stable hydride than said first hydridable material and having a plateau pressure at a temperature below said second temperature less than the plateau pressure of said first hydridable material at said second temperature, heat exchange means associated with said second chamber adapted to operate alternately to maintain said second chamber at a temperature lower than said second temperature and at a third temperature higher than said first temperature, a third chamber in communication with said second chamber through a one-way valve adapted to prevent flow of hydrogen from said third chamber to said second chamber and in communication with said outlet and containing a third hydridable material forming a less stable hydride the said second hydridable material having a plateau pressure at a temperature below said third temperature less than the plateau pressure of said second hydridable material at said third temperature, heat exchange means associated with said third chamber adapted to operate alternately to maintain said third chamber at a temperature lower than said third temperature and at a fourth temperature higher than said first temperature and control means for alternating the temperature capacity of heat exchange means B, D and F to maintain the lower of the two specified temperatures when hydrogen is being absorbed by the hydridable material in the associated chambers and at the higher of the two specified temperatures when hydrogen is present in and being desorbed from the hydridable material in the associated chambers, and said first chamber further including a hydrogen vent that is controlled by said control means for venting hydrogen gas from said first chamber at predetermined intervals and for a predetermined amount of time.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a prior art system schematic diagram of a hydrogen compressor.
FIG. 2 illustrates in a schematic diagram the configuration of a thermal hydrogen compressor utilizing the hydrogen purification device according to this invention.
FIG. 3 is a graph showing the effects of hydride cycling using a dry hydrogen gas stream against a wet hydrogen gas stream.
FIG. 4 illustrates in graphical form the effects of hydride cycling and the difference between dry hydrogen and wet hydrogen passing through a device according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a hydrogen gas compressor 10 is schematically illustrated, comprising a known hydrogen gas heat exchanger unit 12 , connected to a low pressure hydrogen gas source 14 through an inlet pipe 16 and through an outlet pipe 18 to a high pressure hydrogen gas storage receptacle 20 . Hydrogen source 14 and receptacle 18 may comprise conventional regulated gas tanks suitable for safely transporting and offering for commercial sale the high-pressure hydrogen.
The hydrogen heat exchange units 12 comprise known hydrogen compressors, such as the one shown in FIG. 1 and include an inlet 22 and outlet 24 for a cold water stream, and an inlet 26 and outlet 28 for a hot water stream. The apparatus 10 provides for heating of the hot water by any appropriate means, such as an electrical resistance heater 30 energized by an electrical source 32 , or by a gas burner, as shall be explained below with reference to the inventive embodiments. The hot water inlet 26 , outlet 28 and heater 30 may comprise a closed hot water loop which circulates the hot water by means of a pump 34 .
The hydrogen compressor apparatus 10 may include optional sensing equipment, such as a hydrogen mass flow meter 36 , a pressure transducer 38 and thermocouple temperature sensors 40 electrically connected to various portions of the system by means of leads 42 and communicating with a central processing unit (CPU) 44 . The CPU 44 further includes plural connections 46 to the heat exchanger units 12 for providing control functions to the various elements comprising the heat exchange units 12 , as will be explained below with reference to the inventive embodiments.
Optional connections 48 from the CPU 44 to a printer or stripchart recorder 50 may be utilized to maintain a permanent record of the operation of the hydrogen compressor system 10 , which may be a conventional operation as disclosed and taught in the aforementioned U.S. Pat. Nos. 4,402,187 and 4,505,120.
The inventive embodiments of an improved hydrogen gas thermal compressor apparatus 60 is shown in FIG. 2 . The improvements provide a number of benefits, which include not only the compression of hydrogen gas, for example, by a tenfold increase in hydrogen gas pressure, but also a purification of the hydrogen gas to over 99.99% pure hydrogen. These benefits derive from utilizing the invention described and claimed herein, resulting in more efficient, less expensive operation for providing an economical and commercially viable source of pure hydrogen gas at high pressure.
Referring now to FIG. 2, a hydrogen compressor system 60 according to the present invention, the structure of an inventive hydrogen gas compressor, utilizing the present invention, is described relative to its principles of operation. A thermal compressor system 60 , as shown in FIG. 2, comprises three essential subsystems. A first subsystem comprises at least two sets of hydride beds, an A set, namely 62 A, 64 A, 66 A, 68 A and 70 A, and a B set, namely 62 B, 64 B, 66 B, 68 B and 70 B, including piping between them, as will be described below. Another essential subsystem is the hot and cold water circulation subsystems 72 , 74 , and the control subsystem CPU 76 shown in FIG. 2 . Each of these known subsystems will be briefly described in greater detail below, but for a fuller, more elaborate description of the hydride heat exchange units, reference is made to the teaching of the aforementioned U.S. Pat. Nos. 4,402,187 and 4,505,120.
Each similarly numbered hydride bed pair, for example, hydride bed containers 62 A, 62 B and connecting pipes 82 A, 82 B comprise a heat exchange unit 62 ; and similarly the remaining hydride bed container pairs 64 A, 64 B together with pipes 84 A, 84 B comprise a second hydride heat exchange unit, and so on. The piping 82 A, 82 B, 84 A, 84 B etc. is interconnected, as will be described below. The first set of pipes 82 A, 82 B is connected to the hydrogen inlet 16 (FIG. 1) by means of the internal inlet pipe 116 . Inlet pipe 116 has disposed along it a low pressure switch 100 and a safety pressure, relief valve 102 . The low pressure switch 100 will close off the inlet if pressure goes below a certain valve, i.e., 15 p.s.i. and the pressure relief switch 102 will release incoming hydrogen gas if it exceeds a predetermined pressure value, e.g. 200 p.s.i.a. Exposure of the piping 16 , 116 to pressures below atmospheric pressure are to be avoided in that a negative pressure will lead to undesirably attract gaseous impurities from the ambient environment into the system 60 . Likewise, if for some accidental reason the hydrogen gas pressure within the inlet pipe exceeds a safe or expected pressure, the pressure relieve valve will vent the hydrogen to a vent stack for the processing, as will be described below.
Further along the inlet pipe 116 , there is disposed a hydrogen cut off valve 104 such as a solenoid valve, which is controlled by the CPU 76 through electrical control connections 46 (FIG. 1 ). The valve 104 opens and closes in accordance with the cycle timing of the remainder of the system 60 to introduce an additional aliquot of hydrogen gas into the system for compression, which provides for continual additions of hydrogen gas, thus supplying product to be throughput into the compressor 10 .
The above description of the hydrogen compressor system 60 is mostly conventional. Within each of the piping 82 A, 82 B, each connected to the inlet pipe 11 6 , is a one-way check valve 106 , that opens only when the hydrogen gas pressure on the side of inlet pipe 116 is greater than that of the piping 82 A, 82 B. Thus, as the hydrogen is delivered downstream, i.e., from heat exchange unit 62 toward unit 64 and on wards, the pressure of the hydrogen within the first heat exchange unit 62 will fall below the normal gas pressure present in the inlet pipe 116 . For the most part, each hydride bed pair 64 A, 64 B; 66 A, 66 B; 68 A, 68 B, etc. has as a hydrogen source the immediately adjacent upstream bed, and a connection provided by, for example, hydrogen inlet pipes 82 A, 82 B; 84 A, 84 B; etc. The inlet pipes 82 A, 82 B provide a path for the hydrogen 85 to the hydride bed within each of the containers, 64 A, 64 B, 66 A, 66 B, etc. As the cold water and hot water are cycled from one series of beds, e.g., from the A series to the B series, the hydrogen is compressed at each stage until it reaches the internal outlet pipe 118 , connected to outlet pipe 18 (FIG. 1 ). The process of hydrogen gas compression is described in aforementioned U.S. Pat. Nos. 4,402,187 and 4,505,120, incorporated by reference, and review of those patents and others set forth above is recommended for a more detailed description.
An optional feature utilizable in the embodiment of hydrogen compressor 60 shown in FIG. 2 is a hydrogen 108 vent, the opening and closing of which is controlled by the CPU 76 , through an electrical connection 110 extending there between. The timing of the opening and closing of hydrogen vents 108 is most conveniently and efficiently done during the periods immediately prior to the switch over of the hot and cold water streams, that is, at the time that the bed which was in contact with the cold water is switched to hot water. At this time, the hydrogen absorption/desorption occurring in the first two metal hydride beds 62 A, 62 B, approaches equilibrium, and so the hydrogen pressure of the pipes 82 A, 82 B is not at a maximum. Venting is directed by the controller CPU 76 as it receives a signal of the pressure differential within the piping 82 A, 82 B. The CPU signals the hydrogen vents 108 which is opened for at most one to two seconds. Any impurities entrained within the hydrogen gas, pressurized at about 30-40 p.s.i., are ejected into the exit vent pipe 114 , which connects to a central vent stack 120 . Vent stack itself may be connected to a disposal site for the “impulse” hydrogen gas, where it may be burned off, for example, in a hot water heater for providing otherwise waste heat for the useful purpose of heating the hot water utilized in the compressor 60 .
In the period when the maximum hydrogen is absorbed in the metal hydride beds 62 A, 62 B, the hydrogen therein is almost pure, whereas the hydrogen in the piping 82 A, 82 B is relatively impure. Makeup hydrogen is available from the source 14 , and in expelling the “impure” hydrogen gas during each throughput cycle, a larger relative proportion of the impurity gases is expelled than of the hydrogen gas within the system. That is, after the vents 108 are closed and the hydrogen gas is desorbed, the remaining hydrogen in pipes 82 A, 82 B includes fewer impurities than before the venting process because the makeup hydrogen in the next aliquot received from the source 14 will have relatively less impurities than the hydrogen gas vented through vents 108 . As the venting process occurs during every cycle, or V 2 cycle, if desired, impurity gases do not build up in the system and ultimate saturation of the desiccant material is avoided.
In systems where ultra pure hydrogen gas may be desired, for example, in a hydrogen purifier device, more than one vent cycle may be utilized, beyond the vents 108 , shown in FIG. 1 . For example, vents (not shown) may be inserted in pipes 84 A, 84 B, and may be controlled by the CPU 44 to vent a second aliquot of hydrogen gas that may have included some minor level of impurities. The vented hydrogen gas does not necessarily translate into waste, however, because of the transformation of hydrogen gas that may have impurities to a pure hydrogen gas stream, which is more valuable commercially than wet or impure hydrogen. Moreover, burning of vented hydrogen in a stack to heat water or for other use, for example, in the device 60 , also produces a fuel savings and provides to the system, a self-generating energy source.
In the thermal compressor 60 , hydrogen gas is absorbed in a reversible metal hydride alloy in the hydride bed 62 A at low pressure in a water-cooled container. The container is subsequently heated with hot water which releases the hydrogen gas at a higher pressure.
Continuous compression is achieved with two identical containers in a parallel configuration; one container cooled by water absorbs hydrogen while the other is heated with hot water to release hydrogen at the same rate. The cool and hot water streams in pipes are periodically switched by ball valve switches 78 so that water flowing through one set of pipes 77 switches to the other set of pipes 79 , and vice versa and the simple check valves 106 keep hydrogen gas moving through the compressor. In a second embodiment, hydrogen gas purification is a feature which may be used in any of a number of applications, such as ring manifold type heat exchangers, as described in aforementioned U.S. Pat. No. 5,623,987, in air conditioners utilizing metal hydrides, described in U.S. Pat. No. 5,450,721, and in other heat exchange devices, such as described in U.S. Pat. No. 4,781,246, used in refrigerators, heat pumps, and low pressure hydrogen storage devices.
This improvement comprises in the use of an additive to the metal hydride material that includes both a powder desiccant and a corrosion resistant additive to the metal hydride material. Although such additives are taught in aforementioned U.S. Pat. No. 5,688,611, the additives have not been in apparatus such as those described above, such as in hydrogen gas purifiers, refrigeration systems, air conditioners, and hydrogen storage systems. It has been determined that adding desiccant and using a corrosion resistant metal hydride alloys increases the capability of these apparatus to utilize hydrogen that cannot be guaranteed pure, and thus greatly increasing the cost-effectiveness of the operation of these types of systems. Even when utilized in closed systems, where the same hydrogen is cycled between a storage metal hydride bed and a device which utilizes the hydrogen gas for its operation or between two or more separate hydride beds, as in the case of a hydrogen compressor, it has been noted that impurities such as oxygen, carbon monoxide, carbon dioxide, water vapor, and even inert gas impurities, such as nitrogen, ammonia, helium and argon, find their ways into the closed system. Once removed from the hydrogen, these impurities can be either permanently stored within the desiccant material, or may be vented as in the case of the hydrogen compressor device described above.
In yet another embodiment, the additives can also be utilized within the desiccant material that cause even inert gaseous impurities to combine with other elements so as to form a compound that is absorbable by the desiccant additive. It has been found that adding some small amount, less than one percent (1%) of a noble or similar metal, such as platinum or palladium, causes otherwise relatively inert gaseous impurities to be catalyzed and recombine to form a desiccant absorbable gas. For example, beneficial use has been found in a powdered form of a platinum black or palladium black, when completely mixed in with the metal hydride and desiccant material taught in aforementioned U.S. Pat. No. 5,688,611. The powdered catalyst powder acts to dissociate, for example, an oxygen molecule (O 2 ) to its constituent atoms and then to combine with the hydrogen in the system to form a water molecule. Similarly, a nitrogen molecule (N 2 ) may be catalyzed at high heats to form ammonia since both oxygen and nitrogen impurities would be harmful to the operation of the metal hydride material, catalytic formation of water or ammonia are beneficial because these impurities are absorbed by the desiccant material. Thus, one embodiment of this invention encompasses the use of a noble metal in powder form to act as a catalyst. This improved additive material can be utilized together with any metal hydride material, whether utilized in compressors, air conditioners, hydrogen gas purifiers, and other apparatus utilizing repeated metal hydride absorption/desorption cycling.
Referring now to FIGS. 3 and 4, the efficacy of utilizing a catalyst comprising a noble metal powder is shown. FIG. 3 shows the Hydrogen gas heat transfer rate as a function of time, in two separate instances, one in which the hydrogen gas is essentially pure Hydrogen and a second in which the hydrogen gas is completely saturated in water vapor, i.e. 1.8% by weight H 2 O. As can be seen from the graph line 180 , the pure hydrogen gas is immediately absorbed by the metal hydride, and after 2 minutes, reaches an equilibrium point where the hydrogen pressure in the chamber and the amount of absorbed hydrogen remain relatively constant.
On the other hand, the water vapor laden hydrogen gas also has a marked absorption, but this lasts for only about 10 seconds. Soon thereafter, there is a gradual increase in the amount of hydrogen absorbed, confirming the theory that the water vapor acts at the surface of the metal hydride to inhibit additional hydrogen absorption.
Referring now to FIG. 4, a hydrogen gas stream of pure hydrogen is absorbed by a mixture of metal hydride, a water absorbing material, such as desiccant, and a metal powder of a noble metal. Alternatively, the noble metal may be melted into the metal hydride alloy so as to form a thin surface film, thereby providing the catalytic operation before the hydrogen is absorbed within the metal hydride material.
As can be seen by the graph line 184 in FIG. 4, the pure hydrogen gas is absorbed to an equilibrium very quickly, with 95% of the gas being absorbed within the first two minutes. As can be seen from the valves, where graph line 184 levels off, there is slightly less, about 10% less, hydrogen absorbed by weight percent in the weight of hydrogen relative to the absorption material mixture. This is attributable to the added weight of the desiccant and noble metal, about 3% by weight. 1% by weight of the total weight of the absorbing material. Neither the desiccant nor the noble metal are absorbers of hydrogen gas, and so there is relatively less hydrogen absorbed when measured against the total weight of the absorbing mixture.
The efficacy of using the noble metal additive, together with the desiccant and metal hydride mixture is shown by graph line 186 , representing the hydrogen absorption of a water saturated hydrogen gas. As can be readily seen by the coincidence of graph lines 184 and 186 , the water vapor fails to inhibit absorption of the hydrogen gas by the metal hydride, which hydrogen gas is absorbed as quickly by the metal hydride as if the water vapor were not present in the hydrogen. It is evident that the water vapor is absorbed in the desiccant, and any dissociated oxygen molecules are effectively catalyzed to reform as water molecules by the noble metal catalyst. Thus free, dissociated oxygen molecules which may result from water molecules.
The addition of water absorbing desiccant restores the absorption kinetics, but capacity degrades as a result of poisoning, whether by water vapor disassociating into oxygen molecules or because of other impurities in the hydrogen. In a Nickel Lanthanide metal hydride, the nickel content of the metal hydride alloy particles acts as a dissociation catalyst for hydrogen prior to absorption. The nickel can also act as a weak catalyst for dissociating water molecules. The resulting hydrogen may be absorbed into the alloy, but oxygen tends to react with the rare earth element (lanthanum or mischmetal) forming a stable oxide that is no longer available to hold hydrogen. Thus, a noble metal catalyst which reunites the oxygen molecules with ambient hydrogen molecules is an important addition to any water absorbing mixture which includes a metal hydride.
The invention has been described in connection with preferred embodiments. It will be understood that modifications may be made to the invention while retaining the general scope and teaching of the invention herein. The invention is thus understood to be limited only by the elements and limitations of the following claims. | Heat exchangers, hydrogen gas compressors, hydrogen gas storage devices, hydrogen gas purifiers and metal hydride air conditioners utilizing a flow of a hydrogen gas stream which is absorbed and desorbed by a metal hydride causes disproportionation and “poisoning” of the metal hydrides by introduction of impurities such as water vapor, oxygen and carbon monoxide. Use of a noble metal in powder form, when introduced in the metal hydride particles has been found to act as a catalyst and to delay absorption of the impurities in the metal hydride, and further permits the more efficient and longer use of such devices by inhibiting the undesirable disproportionation and poisoning. In another embodiment, a vent is provided in the initial stage of a hydrogen compressor to vent out the impurities before these result in decreasing efficiency of the devices due to disproportionation, poisoning and increased vapor pressure. | 8 |
PRIORITY CLAIM
[0001] This application claims priority form U.S. Provisional Application Ser. No. 60/272,372 filed Feb. 27, 2001 and U.S. Provisional Application Ser. No. 60/275,587 filed Mar. 12, 2001.
FIELD OF THE INVENTION
[0002] This invention relates generally to lubricating systems.
BACKGROUND OF THE INVENTION
[0003] Two-cycle engines were developed as a lower cost, lightweight alternative to four-cycle engines. Two-cycle engines are commonly employed to power outboard engines, chainsaws, lawn mowers, motorcycles, weed eaters, hedge trimmers, portable blowers, power generators, hydraulic power units, or any other application where lightweight, high RPM power is required. Two-cycle gasoline engines, unlike four-cycle gasoline engines, do not have oil filled crankcases as a means of lubricating the moving parts of the engine. Rather, two-cycle engines use a blended mixture of fuel and lubricating oil as a means of powering the engine and simultaneously lubricating various parts of the engine. This blended fuel mixture requires one of two engine setups. One setup pre-blends the fuel and oil before putting it in the engine. Also, a more current trend in two-cycle engine design keeps the fuel and oil separate in their own reservoirs, and blends the fuel and oil during operation. In this second setup, the ratio of fuel to oil may depend upon power requirements. Both of these technologies have created a variety of problems common to any engine.
[0004] In the instance where an engine design does not employ pre-blended fuel, rather employing separate fuel and oil reservoirs, additional problems have developed. First, the oil reservoir must be independently checked to make sure that it contains an adequate amount of oil. As the viewing area for checking the oil level is often located in an undesirable location, an operator is required to contort themselves in awkward positions to accomplish this task. Often times, this inconvenience means that the oil level goes unchecked, which potentially leads to running the engine on no oil.
[0005] The filling of the oil reservoir requires additional tools, more specifically, funnels, spouts, rags or other such devices used to aid in filling the oil reservoir. The use of funnels to fill the oil reservoir creates a couple of problems. First, the portion of the funnel located within the reservoir at the time of filling displaces a significant volume of oil. Consequently, when the funnel is removed, the oil volume is reduced by a volume equivalent to the funnel, thus a true full reservoir is not attained. Further, the funnel's bulky shape makes it difficult to determine when the oil reservoir is nearing full, often yielding in overfilling the oil reservoir. Regardless of whether an under-filled or over-filled reservoir is attained, additional problems result from the current oil reservoir technology.
[0006] An additional problem with current engine lubrication technology is the potential of harm to the engine itself. More specifically, in instances where a reservoir is over-filled, oil residue is left upon the surface of the engine around the entrance to the reservoir. Consequently, dust and other foreign material, hazardous to internal engine components, collects around the opening to the reservoir. This combination of foreign material and oil can be introduced into the oil reservoir upon opening the reservoir or working around an open reservoir. Likewise, funnels and other such devices employed in filling the reservoir also collect dust that is potentially passed into the oil reservoir during a subsequent use. Thus, the state of current lubrication technology actually serves to increase the potential for engine harm. This problem is magnified when the environment in which these engines are employed is considered. For example, chain saws being used in forests produce vast quantities of sawdust, or motorcycles traveling along dusty roads.
[0007] Aside from the ease of use and potential damage to the engine, current engine lubrication technology is also potentially damaging to other assets around the engine. Primarily, any spilled oil or blended fuel/oil not only attaches itself to the engine, but also to anything else it happens to contact. The fuel/oil has a tendency to undesirably attach itself to other assets in the area of the engine. For example, in a marine environment oil may attach itself to fishing gear, water-skiing equipment, SCUBA gear or other such assets. The oil is often detrimental to the other assets in that it causes fouling or actual deterioration of the assets itself.
[0008] Aside from just the physical or tangible assets in the area of which the engine is employed, there are environmental concerns as well. Spillage or oil remnants are often deposited in the environment. This oil spillage in a marine application creates oil slicks on the surface of the water, damaging both surface and subsurface marine plants and animals. Further, oil spillage on dry land is absorbed into the soil potentially harming both plants and animals. Further, oil spillage is potentially damaging to water reservoirs and aquifers.
[0009] The various problems of lubrication discussed above are not limited to internal combustion engines. Rather, all machine parts or elements have similar lubrication problems or considerations. More specifically, machine parts, including milling machines, presses, drills, fabrication units, lathes, agricultural equipment, construction equipment, earth moving equipment and other mechanical devices all require sufficient lubrication in order to function properly, and all are subject to the above discussed lubrication concerns and problems.
[0010] Therefore, there exists a need to provide a clean lubricating oil or machine element lubricating system.
SUMMARY OF THE INVENTION
[0011] The present invention comprises a disposable or reusable lubricating oil container system wherein the disposable/reusable oil container functions as the primary oil reservoir for engines or other machine parts. The container snaps, plugs into or attaches to a self-tapping repository chamber connected to a lubrication system of an engine or other machine part. The container has a neck portion defining an opening for transferring lubricating oil. The oil is transferred from the container to an engine or other machine part via a sealing unit attached to the neck. Additionally, the container can be an existing retail container for motor and engine lubricants or can be specifically designed for a given purpose.
[0012] In accordance with further aspects of the invention, a safety seal and cap are employed over the neck.
[0013] In accordance with other aspects of the invention, the container includes a graduated section or a viewing section at its surface.
[0014] In accordance with still further aspects of the invention, a strap employed secures the container to the carrier.
[0015] In accordance with yet other aspects of the invention, the sealing unit attaches to the container by a male or female coupling unit.
[0016] In accordance with other aspects of the invention, an attachment ring secures the sealing unit to the container.
[0017] In accordance with still further aspects of the invention, carrier attachments secure the carrier to an engine or machine part for damping vibration.
[0018] In accordance with yet other aspects of the invention, the carrier is a heat shield for the container.
[0019] As will be readily appreciated from the foregoing summary, the invention provides a unique disposable lubricating cartridge system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
[0021] [0021]FIG. 1 is a cross-sectional view of a disposable lubricating container and reservoir formed in accordance with the present invention;
[0022] [0022]FIG. 2 is a top view of a carrier for the container shown in FIG. 2; and
[0023] [0023]FIGS. 3 and 4 are cross-sectional side views of sealing units formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] This invention preferably functions with engines employing either premixed fuel/oil or separate fuel and oil reservoir engine arrangements. However, this invention is employable with any machine part. For clarity, only the internal combustion engine with a separate reservoir arrangement is illustrated here. More specifically, FIG. 1 shows a disposable lubricating container system 20 that includes a disposable lubricating container 24 with a sealing unit 44 that is used in conjunction with an oil reservoir 70 of an internal combustion engine 22 .
[0025] The overall size, shape, and design of the container system 20 is a function of the environment in which the system is employed. The container 24 can be an existing retail container for motor or engine lubricants or can be designed for a specific purpose. For example, a small container is likely to be employed with devices where space and weight are a factor, e.g., chainsaws and hand-held lawn equipment. Further, where the employment environment permits, larger, more typical container geometries may be implemented. Additionally, the container 24 can have a graduated section and/or a viewing section located on a surface of the container 24 . In this manner, a visual inspection of the container 24 gives an oil level reading.
[0026] In the embodiment shown in FIG. 1, the container 24 includes a reducing area 36 , a neck 38 , and locking recesses 62 . In the preferred embodiment, the reducing area 36 and the neck 38 are located at one end of the container 24 . However, other geometries for the disposable lubricating container 24 are considered within the scope of this invention. For example, the oil container 24 may be cylindrical, rectangular, trapezoidal, square, circular or any other shape. In each physical arrangement, the location and shape of the reducing area 36 and neck 38 are controlled by the spatial limitations of the container's deployment. The neck 38 and reducing area 36 are typically employed at the lowest elevation point of the container 24 as it is oriented on the machine element. In this manner all of the lubricating oil is allowed to drain from the container 24 prior to removal of the container 24 .
[0027] The neck 38 provides an opening to the inside of the container 24 . The neck 38 is capped by a seal 52 prior to operation. Also, the neck 38 is designed to receive the mated sealing unit 44 a. The sealing unit 44 a houses a penetrating tube 42 a and a vent 40 acting as a self-tapping fluid transfer system. The penetrating tube 42 a is designed such that upon insertion of the sealing unit 44 a into the container 24 , the seal 52 is broken. The penetrating tube 42 a further serves as the transfer structure for passing the lubricating oil from the container 24 to the reservoir 70 , directly into a fuel/oil blending structure (not shown) if no reservoir is employed, or lubrication site of another machine element. In the preferred embodiment, the sealing unit 44 a is preferably constructed from hardened rubber. However, other materials, such as polymer-based plastic and resin, are considered within the scope of this invention. When the sealing unit 44 a is inserted into the neck 38 , the vent 40 is in fluid communication with a cartridge vent tube 30 located on the inside of the container 24 . The cartridge vent tube 30 provides air to enter the container 24 in order to equalize pressure within the container 24 as the lubricating oil is used up.
[0028] The container system 20 also includes a carrier 48 for securing the container 24 to the engine 22 . However, the container system 20 can also be attached to a device employing the engine 22 or any other machine part without a carrier if desired. The carrier 48 includes locking arms 32 , each with a locking arm point 60 a. The locking arm points 60 are received by respective locking recesses 62 in a manner that keeps the container 24 from moving excessively. The locking arm points 60 a are located on longitudinally disposed ends of the carrier 48 . For example, the container can slide, snap or plug into or otherwise attach itself to the carrier. The locking arm points 60 are located on longitudinally disposed ends of the carrier 48 . For example, the locking recesses 62 may run longitudinally along the sides of container 24 , in a direction parallel to the central access of the container 24 . The carrier 48 is designed to mate with the locking recesses 62 of the container 24 such that the carrier 48 securely holds the container 24 .
[0029] Material choice for the carrier is variable. The carrier is constructed of material allowing the locking arms 32 to elastically deform while inserting the container 24 into the carrier 48 while maintaining substantially rigid characteristics. Additionally, as the carrier acts as a heat shield for the container, the material choice for the carrier preferably is thermally resistant. The carrier 48 , in the preferred embodiment, is constructed of a thermal-resistant, polymer-based material, such as a thermo-set plastic. However, any other material capable of elastic deformation while maintaining substantial rigidity and thermal resistance is considered within the scope of this invention. For example, metallic, nonmetallic, or carbon-based materials, ceramics, alloys or composites thereof are employable as carrier 48 material. However, other container-attaching methods are considered within the scope of this invention.
[0030] The carrier 48 includes carrier attachments 34 for affixing the carrier 48 to another rigid body, for example, an engine 22 or a housing. The attachments 34 serve the additional purpose of damping any vibration. As such, any combination of frictional fastening devices such as bolts, screws, rivets, pins, or the like with any known damping structure such as rubber bushings, plastic bumpers, or spring dampers are examples of attachments 34 .
[0031] The transfer tube 42 a is connected to the reservoir 70 or other machine element and is in fluid communication with reservoir tubes 72 . The reservoir 70 is illustrative of the remaining lubrication system of an engine. For clarity purposes, the specifics of any engine components have been left out of the illustration. This invention is employable with any engine arrangement or lubrication system structure.
[0032] The safety seal 52 and a cap (not shown) are located at the end of the neck 38 . The cap is typically threaded on the neck and serves as a primary containment device for the lubricating oil. The seal 52 serves a secondary containment device for the oil. Typically the seal is a metallic foil that adheres to the terminal end of the neck 38 . However, other seal 52 materials can be used, for example, rubber or polymer based substances.
[0033] [0033]FIG. 2 is a top view of the carrier 48 . The carrier 48 includes a tie strap 78 as an additional securing device for the container 24 (see FIG. 1). The tie strap 78 is preferably an elastic member designed to extend over the container 24 and further assist in securing the container 24 to the carrier 48 . One end of the strap 78 is secured to a first side of the carrier 48 . The tie strap 78 contains a fastener 80 attached to the end of the strap 78 not secured to the carrier 48 . In the preferred embodiment, the fastener 80 is a hook. The hook of the fastener 80 attaches to a loop 82 that is secured to a side of the carrier 48 opposite the first side. Other fasteners are considered within the scope of this invention, for example, clamps, hook and loop arrangements, snaps, buckles, or clasps. Further, only one tie strap 78 is illustrated, however any number of straps, applied in any arrangement is within the scope of this invention.
[0034] [0034]FIG. 3 depicts an alternate embodiment sealing mechanism. A sealing unit 44 b is designed as male insert that fits inside the neck 38 (see FIG. 1). The unit 44 b includes a penetrating tube 42 b. The tube 42 b is hollow with a funnel-like shape capable of puncturing the safety seal 52 . Further, the unit 44 b includes a sealing ring 56 a that is annularly located around the outer surface of the sealing unit 44 b. The sealing ring 56 a increases the internal biasing force of sealing unit 44 b against the internal surface of neck 38 and further helps to maintain the sealing unit's positive connection with the container 24 . The sealing ring 56 a also serves to prevent leakage of the lubricating oil inside the container 24 to the outside environment. Additionally, an attachment ring 84 is used to further maintain the connection between the sealing unit 44 and the container 24 . The attachment ring 84 is designed to threadably, or otherwise attach itself to the container 24 /neck 38 .
[0035] [0035]FIG. 4 shows an alternative embodiment sealing mechanism. A sealing unit 44 c serves as a female counterpart for the neck 38 . In this embodiment, the internal diameter of the sealing unit 44 c is slightly larger then the external diameter of the neck 38 . When sealing unit 44 c is connected to the neck 38 , neck 38 is encompassed by the sealing unit 44 c and is biased by a sealing ring 56 b located on the inner wall of the unit 44 c. The unit 44 c includes a penetrating tube 42 c for puncturing the foil seal 52 and for transferring the lubricating oil within the container 24 to the reservoir 70 .
[0036] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow. | A disposable lubricating container system including a disposable container, a carrier, a sealing unit and transfer tubes. The carrier rigidly attaches itself to an engine or other machine part and the container attaches to the carrier. The container mates with the carrier to securely hold the container while being easily removed or inserted into the carrier. The sealing unit attaches to a neck portion of the container and serves to provide a fluid transfer system for the lubricating oil or fuel/oil mixture from the container to the engine. Lubricating oil in the container is transfered to an existing oil reservoir, directly to engine components or other machine parts. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/243,092, filed Oct. 4, 2005, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a limb protection apparatus having a torsion spring assembly. Further, the present invention relates to a limb protection apparatus having a torsion spring assembly having a preload.
BACKGROUND OF THE INVENTION
[0003] Torsion springs, which are used in many devices, including knee braces, hinges, etc., are designed to be activated rotationally and provide an angular return force. A typical torsion spring has no preload. That is, the typical torsion spring does not have an angular return force being applied when the spring is at rest or not being used. Those torsion springs that do have a preload require an adjustment mechanism in order to create the preload. There is a need in the art for a torsion spring having a preload.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention, in one embodiment, is a spring assembly having a first substantially cylindrical component, a second substantially cylindrical component coupled with the first substantially cylindrical component, a coupling component configured to prevent full 360 degree rotation of the first and second substantially cylindrical components in relation to each other, and a spring encircling at least a portion of the first and second components. The spring has a preload created by the first and second component and is operably coupled to a limb protection apparatus.
[0005] The present invention, in another embodiment, is a limb protection apparatus having a spring assembly and a limb guard component. The spring assembly has a first substantially cylindrical component, a second substantially cylindrical component coupled with the first component, and a coupling component configured to prevent full 360 degree rotation of the first and second substantially cylindrical components in relation to each other. Further spring assembly has a spring encircling at least a portion of the first and second components, a first connection component associated with a second end of the first substantially cylindrical component, and a second connection component associated with a second end of the second substantially cylindrical component. The spring has a pre-load tension created by the first and second components. The limb guard is operably coupled with the first and second connection components.
[0006] In another embodiment, the present invention is a limb protection apparatus having a torsion spring assembly having a preload, a first member, a second member, and a limb guard component operably coupled to the first and second members. The spring assembly has a first substantially cylindrical component, a second substantially cylindrical component, and a spring disposed substantially around the first and second substantially cylindrical components. The first substantially cylindrical component has a first connection component and a first coupling component and the second substantially cylindrical component has a second connection component and a second coupling component. The second coupling component is rotatably coupled with the first coupling component, whereby the first substantially cylindrical component rotates less than 360 degrees. The spring is connected at a first end to the first substantially cylindrical component and at a second end to the second substantially cylindrical component. The first member is operably coupled to the first connection component and the second member is operably coupled to the second connection component.
[0007] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a spring assembly, according to one embodiment of the present invention.
[0009] FIG. 2 is a perspective view of a spring and two cylindrical components, according to one embodiment of the present invention.
[0010] FIG. 3 is a perspective view of two coupled cylindrical components, according to one embodiment of the present invention.
[0011] FIG. 4 is a perspective view of a spring assembly, according to another embodiment of the present invention.
[0012] FIG. 5 is a schematic drawing of a spring assembly, according to a further embodiment of the present invention.
[0013] FIG. 6 is a schematic drawing of a spring assembly coupled with a limb protection apparatus, according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0014] The present invention relates to a limb protection apparatus having a torsion spring assembly, including a torsion spring assembly with a preload. The assembly of the present invention can be used with known limb protection devices such as leg guards, shin guards, and the like. According to one embodiment, the present invention provides both limb protection and benefits provided by limb brace devices.
[0015] FIG. 1 illustrates a torsion spring assembly 10 , according to one embodiment of the present invention. The assembly 10 has a coiled spring 12 encircling two cylindrical components 14 , 16 . Each cylindrical component 14 , 16 has a connection component 18 , 20 configured to engage with any device or component that is to be placed under rotational tension with respect to another different component or device attached at the opposite connection component.
[0016] FIG. 2 depicts a disassembled torsion spring assembly 30 , according to a further aspect of the present invention. The assembly 30 has a spring 32 and two cylindrical components 34 , 36 . The cylindrical component 34 is also referred to herein as a “female component” and the cylindrical component 36 is also referred to herein as a “male component.” The female component 34 , in accordance with one embodiment, has a connection component 38 , a spring receiving channel 40 , a protrusion 42 or “tang”, and an opening 44 in fluid communication with a hollow portion (not shown) in the component 38 .
[0017] The male component 36 , according to one embodiment, has a connection component 46 , a first or “small” portion 48 , a second or “large” portion 50 , and a spring receiving channel 52 . The first portion 48 has a diameter that is smaller than the second portion 50 such that the male component 36 has a shoulder 54 . The shoulder 54 has a protrusion 56 or extending toward the small portion 48 .
[0018] When assembled, the two cylindrical components 34 , 36 according to one embodiment are coupled together such that the small portion 48 of the male component 36 is inserted into the opening 44 of the female component 34 and the tang 42 of the female component 34 contacts the shoulder 56 of the male component 36 . The spring 32 is positioned such that the spring 32 encircles at least a portion of the two cylindrical components 34 , 36 and one end of the spring 32 is inserted into the spring receiving channel 40 and the other end of the spring 32 is inserted into the spring receiving channel 52 , as best shown in the embodiment depicted in FIG. 1 .
[0019] The connection components 38 , 46 depicted in FIG. 2 are “D-shaped” protrusions 38 , 46 , according to one embodiment of the present invention. That is, each protrusion 38 , 46 has a substantially circular profile that includes a flat portion such that the profile of the protrusion 38 , 46 looks somewhat like a “D”. The protrusions 38 , 46 are configured to connect or “mate” snugly with corresponding holes in the components (not shown) intended to be connected to the spring assembly 30 . Alternatively, the connection components 38 , 46 are any known components for connection to devices or components (not shown) of a device intended to be connected to the spring assembly 30 .
[0020] Each spring receiving channel 40 , 52 is configured to receive one end of the spring 32 . According to one embodiment as depicted, each channel 40 , 52 is a channel-shaped opening that is positioned longitudinally on the side of each component 34 , 36 and is almost as long as each component 34 , 36 . This configuration allows for easy assembly and disassembly of the apparatus. Alternatively, each channel 40 , 52 can be any opening of any shape that allows for receiving and retaining an end of the spring 32 .
[0021] FIG. 3 depicts the operable coupling of female 70 and male 72 components of an assembly 68 in which no spring is shown. The components 70 , 72 are coupled such that the protrusion 74 on the male component 72 is in contact with the end 76 of the female component 70 and the tang 78 of the female component 76 is in contact with the shoulder 80 of the male component 72 . In this configuration, the components 70 , 72 can be rotated in relation to each other, but only until the tang 78 and the protrusion 74 , which are positioned along substantially the same axis, come into contact with each other. That is, the tang 78 and the protrusion 74 prevent the components 70 , 72 from rotating a full 360° in relation to each other. As either component 70 , 72 is rotated in relation to the other, the tang 78 and the protrusion 74 eventually come into contact, preventing further rotation.
[0022] The configuration of the spring assembly 68 as depicted in FIGS. 2 and 3 creates a preload, in accordance with one embodiment of the present invention. “Preload” is spring-created tension that exists while the spring is not in use or prior to use. In one aspect of the invention, the coupling of the two components 70 , 72 as discussed above provides the preload. That is, to provide a preload, the assembly 68 is configured such that when a spring is added to the assembly 68 as shown in the embodiment depicted in FIG. 1 , one end of the spring is inserted into the spring receiving channel 82 and the other is inserted into the spring receiving channel 84 such that a tension is created upon insertion of both ends. The tension causes the components 70 , 72 to rotate in relation to one another until the tang 78 and the protrusion 74 come into contact, thereby preventing further rotation and preventing the spring from releasing the tension. Thus, the tension is maintained as preload. In an alternative embodiment, any known coupling that prevents full 360 degree rotation of the male and female components in relation to one another and thereby creates a preload when operably coupled to a spring can be implemented into the spring assembly of the present invention.
[0023] FIG. 4 depicts a spring assembly 100 according to one embodiment that is operably coupled to components 110 , 112 to be placed under torsion tension. In this non-limiting example, the components 110 , 112 are components of a knee brace. The spring assembly 100 has a spring 102 and two cylindrical components 104 , 106 . The cylindrical component 104 has a connection component 108 to which component 112 is coupled. The cylindrical component 106 is coupled to component 110 via a connection component (not shown). As depicted in FIG. 4 solely for exemplary purposes, the preload created by the spring assembly 100 creates sufficient force to cause component 110 to be suspended above the flat surface on which the assembly 100 rests.
[0024] FIG. 5 depicts a schematic representation of a spring assembly 120 that is operably coupled to a knee brace, according to one aspect of the present invention. The spring assembly 120 has a female component 122 , a male component 124 , and a spring 126 . The male component 124 has a first portion (shown schematically with broken lines at 128 ) that is positioned within the female component 122 , a second portion 130 , and a connection component 138 . The male component 124 also has a spring receiving channel shown schematically with broken lines at 134 . The female component 122 has an opening (not shown) in which the first portion 128 has been positioned, a spring receiving channel 140 , and connection component 136 . The spring 126 encircles portions of the male 124 and female 122 components and has a first end 142 engageably positioned in the spring receiving channel 140 in the female component 122 and a second end depicted schematically with broken lines at 144 engageably positioned in the spring receiving channel 134 in the male component 124 . Components 146 , 148 , 150 , 152 of the knee brace are operably coupled at the connection components 136 , 138 to the spring assembly 120 . According to one embodiment, two opposing components (that is, positioned on opposing connection components and also on opposite sides of the spring assembly 120 ) have “D-shaped” apertures that engageably mate with the “D-shaped” connection components 136 , 138 while the other two components have circular apertures that allow for insertion of the connection components 136 , 138 but do not engageably mate with the components 136 , 138 (and thus are not placed under torsion force by the spring assembly 120 ). For example, according to one embodiment, component 148 and component 150 have engaging “D-shaped” apertures such that each of the components 148 , 150 are placed under torsion force by the spring assembly 120 while components 146 , 152 have circular apertures such that neither of the components 146 , 152 is placed under torsion force by the spring assembly 120 . Alternatively, components 146 , 152 can have the “D-shaped” apertures and components 148 , 150 can have the circular apertures.
[0025] In an alternative embodiment of the present invention, FIG. 5 depicts a schematic representation of a spring assembly that is operably coupled to an exercise apparatus. The exercise apparatus, according to one embodiment, is any known exercise device that utilizes or might be able to utilize a spring assembly with a preload. In a further alternative, spring assemblies of the present invention can also be used with any other device or component known to require or be able to utilize a torsional spring.
[0026] In a further embodiment, FIG. 6 depicts a schematic representation of a spring assembly 160 of the present invention that is operably coupled to a limb protection apparatus 162 . The limb protection apparatus 162 , according to one embodiment, is a leg guard or shin guard such as, for example, a leg guard warn by a baseball catcher or a shin guard worn by a soccer player. Alternatively, the apparatus 162 is any known limb protection apparatus that utilizes or might be able to utilize a spring assembly with a preload.
[0027] According to one embodiment, the combination of the spring assembly 160 with a limb protection apparatus 162 in FIG. 6 provides not only limb protection but also some benefits of a leg brace as well. That is, the combination results in both protection and support or bracing benefits for the limb.
[0028] Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | The present invention is a limb protection apparatus having a torsion spring assembly. Further, the present invention is a limb protection apparatus having a torsion spring assembly having a preload. The spring assembly has a spring and two rotatably coupled components disposed within the spring, wherein the two components cannot rotate a full 360 degrees in relation to each other, thereby allowing the assembly to be placed in a preload state. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to electrically variable transmissions having three planetary gear sets, three motor/generators and at least one brake that are controllable to provide continuously variable speed ratio ranges.
BACKGROUND OF THE INVENTION
[0002] Electric hybrid vehicles offer the potential for significant fuel economy improvements over their conventional counterparts; however, their market penetration is limited because of their relatively high cost/benefit ratio. It becomes pertinent to develop hybrid technologies that reduce cost and improve vehicle fuel economy. Two of the contributors to the cost of the hybrid vehicle are the energy storage (battery) power capacity and the size of the electric motor/generators required to realize all-electric reverse in many electric-variable-transmission (EVT)-based hybrid systems. One of the factors that affect the efficiency of the system is the operating efficiency of the motor/generators.
SUMMARY OF THE INVENTION
[0003] This invention describes continuously-variable hybrid transmissions that utilize a combination of planetary gear sets, electric motor/generators and brakes to offer multi-mode EVTs with capability for series hybrid reverse driving, thus reducing the need for massive and expensive energy storage (battery), and to minimize operating the motor/generators under highly inefficient conditions. In the series hybrid reverse driving mode, power from the engine is used to drive at least one of the motor/generators to generate electric power, and the generated electric power is delivered to at least one of the other motor/generators to drive the vehicle in the forward or reverse direction. This capability eliminates the need for significant power from the battery to drive the vehicle in reverse, as is currently the case in known production hybrid vehicles.
[0004] The hybrid transmission family of the present invention provides low-content, low-cost electrically variable transmission mechanisms including first, second and third differential gear sets, a battery (or similar energy storage device), three electric machines serving interchangeably as motors or generators and at least one brake. Preferably, the differential gear sets are planetary gear sets, but other gear arrangements may be implemented, such as bevel gears or differential gearing to an offset axis.
[0005] In this description, the first, second and third planetary gear sets may be counted first to third in any order (i.e., left to right, right to left, etc.).
[0006] Each of the three planetary gear sets has three members. The first, second or third member of each planetary gear set can be any one of a sun gear, ring gear or carrier, or alternatively a pinion.
[0007] Each carrier can be either a single-pinion carrier (simple) or a double-pinion carrier (compound).
[0008] The input shaft is continuously connected with a member of the first, second or third planetary gear set. The output shaft is continuously connected with another member of the first, second or third planetary gear set.
[0009] A first fixed interconnecting member continuously connects the first member of the first planetary gear set with the first member of the second planetary gear set and with the first member of the third planetary gear set.
[0010] A second fixed interconnecting member continuously connects the second member of the first planetary gear set with the second member of the second planetary gear set.
[0011] A first motor/generator is connected to a member of the first or second planetary gear set.
[0012] A second motor/generator is connected to a member of the second or third planetary gear set.
[0013] A third motor/generator is connected to another member of the first or third planetary gear set.
[0014] The motor/generators are connected with the members of the planetary gear sets either directly or through other planetary gear sets, belt/chain or off-set gears with or without torque multiplication.
[0015] A first brake selectively connects at least one member of the first, second or third planetary gear set, preferably via one of the interconnecting members, with a stationary member (transmission housing/casing). This brake is operable to hold the member stationary and enable series hybrid mode operation or to lower the torque requirement of one of the motor/generators. Using the first brake rather than one of the motor/generators to enable the hybrid mode of operation reduces the torque capacity requirement for the motors and improves efficiency. Also, application of the first brake during electric-only drive (forward or reverse) allows the engine to be started without “engine start shock” that is felt in some current EVT hybrid vehicles.
[0016] An optional second brake selectively connects another member of the first, second or third planetary gear set with a stationary member and is operable to hold a member of the first, second or third planetary gear set stationary under certain operating conditions to provide different EVT ranges. The brake may be connected in parallel with one of the motor/generators and be applied under operating conditions that would otherwise require one of the motor/generators to operate at zero or near-zero speeds, thereby improving efficiency by preventing the inefficient use of electric power to maintain zero or near-zero speed.
[0017] An optional third brake selectively connects another member of the first or second planetary gear set with a stationary member and is able to hold the member of the planetary gear set stationary under certain operating conditions to provide different EVT ranges. The brake may be connected in parallel with one of the motor/generators and be applied under operating conditions that would otherwise require one of the motor/generators to operate at zero or near-zero speeds, thereby improving efficiency by preventing the inefficient use of electric power to maintain zero or near-zero speed.
[0018] Additional optional brakes my be added to provide additional EVT ranges or to enhance system efficiency or reduce motor torque requirements.
[0019] The brakes are preferably electromechanically actuated to eliminate the need for high-pressure hydraulic pump and the associated losses; however, other conventional brake actuation methods may be used.
[0020] The three motor/generators are operated in a coordinated fashion to yield continuously variable forward and reverse speed ratios between the input shaft and the output shaft, while minimizing the rotational speeds of the motor-generators and optimizing the overall efficiency of the system. The tooth ratios of the planetary gear sets can be suitably selected to match specific applications.
[0021] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic representation of a powertrain including an electrically variable transmission incorporating a family member of the present invention;
[0023] FIG. 2 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0024] FIG. 3 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0025] FIG. 4 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0026] FIG. 5 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0027] FIG. 6 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0028] FIG. 7 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0029] FIG. 8 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0030] FIG. 9 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0031] FIG. 10 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention;
[0032] FIG. 11 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention; and
[0033] FIG. 12 is a schematic representation of a powertrain including an electrically variable transmission incorporating another family member of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] With reference to FIG. 1 , a powertrain 10 is shown, including an engine 12 connected to one preferred embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 14 . Transmission 14 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 14 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0035] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0036] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 14 .
[0037] An output member 19 of the transmission 14 is connected to a final drive 16 .
[0038] The transmission 14 utilizes three differential gear sets, preferably in the nature of planetary gear sets 20 , 30 and 40 . The planetary gear set 20 employs an outer gear member 24 , typically designated as the ring gear. The ring gear member 24 circumscribes an inner gear member 22 , typically designated as the sun gear. A carrier member 26 rotatably supports a plurality of planet gears 27 such that each planet gear 27 simultaneously, and meshingly engages both the outer, ring gear member 24 and the inner, sun gear member 22 of the first planetary gear set 20 .
[0039] The planetary gear set 30 also employs an outer gear member 34 , typically designated as the ring gear. The ring gear member 34 circumscribes an inner gear member 32 , typically designated as the sun gear. A carrier member 36 rotatably supports a plurality of planet gears 37 such that each planet gear 37 simultaneously, and meshingly engages both the outer, ring gear member 34 and the inner, sun gear member 32 of the planetary gear set 30 .
[0040] The planetary gear set 40 also employs an outer gear member 44 , typically designated as the ring gear. The ring gear member 44 circumscribes an inner gear member 42 , typically designated as the sun gear. A carrier member 46 rotatably supports a plurality of planet gears 47 such that each planet gear 47 simultaneously, and meshingly engages both the outer, ring gear member 44 and the inner, sun gear member 42 of the planetary gear set 40 .
[0041] The input shaft 17 is continuously connected to the carrier member 36 of the planetary gear set 30 . The output shaft 19 is continuously connected to the carrier member 46 of the planetary gear set 40 .
[0042] A first interconnecting member 70 continuously connects the carrier member 26 of the planetary gear set 20 with the ring gear member 34 of the planetary gear set 30 and with the ring gear member 44 of the planetary gear set 40 . A second interconnecting member 72 continuously connects the sun gear member 22 of the planetary gear set 20 with the sun gear member 32 of the planetary gear set 30 .
[0043] A brake 50 selectively connects the ring gear member 44 of the planetary gear set 40 , the ring gear member 34 of the planetary gear set 30 and the carrier member 26 of the planetary gear set 20 via the interconnecting member 70 with the transmission housing 60 . This brake 50 enables series hybrid driving mode wherein power from the engine 12 is used to drive motor/generator 80 to generate electric power, and the generated electric power is delivered to motor/generator 84 to drive the vehicle in forward or reverse.
[0044] The first embodiment 10 also incorporates first, second and third motor/generators 80 , 82 and 84 , respectively. The stator of the first motor/generator 80 is secured to the transmission housing 60 . The rotor of the first motor/generator 80 is secured to the ring gear member 24 of the planetary gear set 20 .
[0045] The stator of the second motor/generator 82 is secured to the transmission housing 60 . The rotor of the second motor/generator 82 is secured to the sun gear member 22 of the planetary gear set 20 .
[0046] The stator of the third motor/generator 84 is secured to the transmission housing 60 . The rotor of the third motor/generator 84 is secured to the sun gear member 42 of the planetary gear set 40 .
[0047] Returning now to the description of the power sources, it should be apparent from the foregoing description, and with particular reference to FIG. 1 , that the transmission 14 selectively receives power from the engine 12 . The hybrid transmission also receives power from an electric power source 86 , which is operably connected to a controller 88 . The electric power source 86 may be one or more batteries. Other electric power sources, such as capacitors or fuel cells, that have the ability to provide, or store, and dispense electric power may be used in place of or in combination with batteries without altering the concepts of the present invention. The speed ratio between the input shaft and output shaft is prescribed by the speeds of the three motor/generators and the ring gear/sun gear tooth ratios of the planetary gear sets. Those with ordinary skill in the transmission art will recognize that desired input/output speed ratios can be realized by suitable selection of the speeds of the three motor/generators.
Description of a Second Exemplary Embodiment
[0048] With reference to FIG. 2 , a powertrain 110 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 114 . Transmission 114 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 114 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0049] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0050] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 114 .
[0051] An output member 19 of the transmission 114 is connected to a final drive 16 .
[0052] The transmission 114 utilizes three differential gear sets, preferably in the nature of planetary gear sets 120 , 130 and 140 . The planetary gear set 120 employs an outer gear member 124 , typically designated as the ring gear. The ring gear member 124 circumscribes an inner gear member 122 , typically designated as the sun gear. A carrier member 126 rotatably supports a plurality of planet gears 127 such that each planet gear 127 simultaneously, and meshingly engages both the outer, ring gear member 124 and the inner, sun gear member 122 of the first planetary gear set 120 .
[0053] The planetary gear set 130 also employs an outer gear member 134 , typically designated as the ring gear. The ring gear member 134 circumscribes an inner gear member 132 , typically designated as the sun gear. A carrier member 136 rotatably supports a plurality of planet gears 137 such that each planet gear 137 simultaneously, and meshingly engages both the outer, ring gear member 134 and the inner, sun gear member 132 of the planetary gear set 130 .
[0054] The planetary gear set 140 also employs an outer gear member 144 , typically designated as the ring gear. The ring gear member 144 circumscribes an inner gear member 142 , typically designated as the sun gear. A carrier member 146 rotatably supports a plurality of planet gears 147 such that each planet gear 147 simultaneously, and meshingly engages both the outer, ring gear member 144 and the inner, sun gear member 142 of the planetary gear set 140 .
[0055] The input shaft 17 is continuously connected to the carrier member 146 of the planetary gear set 140 . The output shaft 19 is continuously connected to the carrier member 136 of the planetary gear set 130 .
[0056] A first interconnecting member 170 continuously connects the carrier member 126 of the planetary gear set 120 with the ring gear member 134 of the planetary gear set 130 and with the ring gear member 144 of the planetary gear set 140 . A second interconnecting member 172 continuously connects the ring gear member 124 of the planetary gear set 120 with the carrier member 136 of the planetary gear set 130 .
[0057] A first brake 150 selectively connects the sun gear member 132 of the planetary gear set 130 with the transmission housing 160 . A second brake 152 selectively connects the ring gear member 144 , ring gear member 134 , and the carrier member 126 via the interconnecting member 170 with the transmission housing 160 . This brake 152 enables series hybrid mode operation in forward and reverse. A third brake 154 selectively connects the sun gear member 142 with the transmission housing 160 .
[0058] The second embodiment 110 also incorporates first, second and third motor/generators 180 , 182 and 184 , respectively. The stator of the first motor/generator 180 is secured to the transmission housing 160 . The rotor of the first motor/generator 180 is secured to the sun gear member 132 of the planetary gear set 130 .
[0059] The stator of the second motor/generator 182 is secured to the transmission housing 160 . The rotor of the second motor/generator 182 is secured to the sun gear member 122 of the planetary gear set 120 .
[0060] The stator of the third motor/generator 184 is secured to the transmission housing 160 . The rotor of the third motor/generator 184 is secured to the sun gear member 142 of the planetary gear set 140 .
[0061] The hybrid transmission 114 receives power from the engine 12 , and also exchanges power with an electric power source 186 , which is operably connected to a controller 188 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and the speeds of the three motor/generators.
Description of a Third Exemplary Embodiment
[0062] With reference to FIG. 3 , a powertrain 210 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 214 . Transmission 214 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 214 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0063] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0064] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 214 .
[0065] An output member 19 of the transmission 214 is connected to a final drive 16 .
[0066] The transmission 214 utilizes three differential gear sets, preferably in the nature of planetary gear sets 220 , 230 and 240 . The planetary gear set 220 employs an outer gear member 224 , typically designated as the ring gear. The ring gear member 224 circumscribes an inner gear member 222 , typically designated as the sun gear. A carrier member 226 rotatably supports a plurality of planet gears 227 such that each planet gear 227 simultaneously, and meshingly engages both the outer, ring gear member 224 and the inner, sun gear member 222 of the first planetary gear set 220 .
[0067] The planetary gear set 230 also employs an outer gear member 234 , typically designated as the ring gear. The ring gear member 234 circumscribes an inner gear member 232 , typically designated as the sun gear. A carrier member 236 rotatably supports a plurality of planet gears 237 such that each planet gear 237 simultaneously, and meshingly engages both the outer, ring gear member 234 and the inner, sun gear member 232 of the planetary gear set 230 .
[0068] The planetary gear set 240 also employs an outer gear member 244 , typically designated as the ring gear. The ring gear member 244 circumscribes an inner gear member 242 , typically designated as the sun gear. A carrier member 246 rotatably supports a plurality of planet gears 247 such that each planet gear 247 simultaneously, and meshingly engages both the outer, ring gear member 244 and the inner, sun gear member 242 of the planetary gear set 240 .
[0069] The input shaft 17 is continuously connected to the carrier member 246 of the planetary gear set 240 . The output shaft 19 is continuously connected to the carrier member 226 of the planetary gear set 220 .
[0070] A first interconnecting member 270 continuously connects the sun gear member 222 with the sun gear member 232 and with the ring gear member 244 . A second interconnecting member 272 continuously connects the ring gear member 224 with the carrier member 236 .
[0071] A first brake 250 selectively connects the ring gear member 224 and the carrier member 236 via interconnecting member 272 with the transmission housing 260 . A second brake 252 selectively connects the sun gear member 222 , the sun gear member 232 and the ring gear member 244 via interconnecting member 270 with the transmission housing 260 . This brake 252 enables series hybrid mode operation in forward and reverse.
[0072] The embodiment 210 also incorporates first, second and third motor/generators 280 , 282 and 284 , respectively. The stator of the first motor/generator 280 is secured to the transmission housing 260 . The rotor of the first motor/generator 280 is secured to the ring gear member 224 of the planetary gear set 220 .
[0073] The stator of the second motor/generator 282 is secured to the transmission housing 260 . The rotor of the second motor/generator 282 is secured to the ring gear member 234 of the planetary gear set 230 .
[0074] The stator of the third motor/generator 284 is secured to the transmission housing 260 . The rotor of the third motor/generator 284 is secured to the sun gear member 242 of the planetary gear set 240 .
[0075] The hybrid transmission 214 receives power from the engine 12 , and also exchanges power with an electric power source 286 , which is operably connected to a controller 288 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Fourth Exemplary Embodiment
[0076] With reference to FIG. 4 , a powertrain 310 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 314 . Transmission 314 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 314 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0077] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0078] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 14 . An output member 19 of the transmission 314 is connected to a final drive 16 .
[0079] The transmission 314 utilizes three differential gear sets, preferably in the nature of planetary gear sets 320 , 330 and 340 . The planetary gear set 320 employs an outer gear member 324 , typically designated as the ring gear. The ring gear member 324 circumscribes an inner gear member 322 , typically designated as the sun gear. A carrier member 326 rotatably supports a plurality of planet gears 327 such that each planet gear 327 simultaneously, and meshingly engages both the outer, ring gear member 324 and the inner, sun gear member 322 of the first planetary gear set 320 .
[0080] The planetary gear set 330 also employs an outer gear member 334 , typically designated as the ring gear. The ring gear member 334 circumscribes an inner gear member 332 , typically designated as the sun gear. A carrier member 336 rotatably supports a plurality of planet gears 337 such that each planet gear 337 simultaneously, and meshingly engages both the outer, ring gear member 334 and the inner, sun gear member 332 of the planetary gear set 330 .
[0081] The planetary gear set 340 also employs an outer gear member 344 , typically designated as the ring gear. The ring gear member 344 circumscribes an inner gear member 342 , typically designated as the sun gear. A carrier member 346 rotatably supports a plurality of planet gears 347 such that each planet gear 347 simultaneously, and meshingly engages both the outer, ring gear member 344 and the inner, sun gear member 342 of the planetary gear set 340 .
[0082] The input shaft 17 is continuously connected to the carrier member 346 of the planetary gear set 340 . The output shaft 19 is continuously connected to the carrier member 336 of the planetary gear set 330 .
[0083] A first interconnecting member 370 continuously connects the ring gear member 324 with the ring gear member 334 and with the ring gear member 344 . A second interconnecting member 372 continuously connects the carrier member 326 with the carrier member 336 .
[0084] A first brake 350 selectively connects the sun gear member 332 with the transmission housing 360 . A second brake 352 selectively connects the ring gear member 324 , the ring gear member 334 and the ring gear member 344 via interconnecting member 370 with the transmission housing 360 . This brake 352 enables series hybrid mode operation in forward and reverse. A third brake 354 selectively connects the sun gear member 342 with the transmission housing 360 .
[0085] The embodiment 310 also incorporates first, second and third motor/generators 380 , 382 and 384 , respectively. The stator of the first motor/generator 380 is secured to the transmission housing 360 . The rotor of the first motor/generator 380 is secured to the sun gear member 332 .
[0086] The stator of the second motor/generator 382 is secured to the transmission housing 360 . The rotor of the second motor/generator 382 is secured to the sun gear member 322 .
[0087] The stator of the third motor/generator 384 is secured to the transmission housing 360 . The rotor of the third motor/generator 384 is secured to the sun gear member 342 .
[0088] The hybrid transmission 314 receives power from the engine 12 , and also exchanges power with an electric power source 386 , which is operably connected to a controller 388 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Fifth Exemplary Embodiment
[0089] With reference to FIG. 5 , a powertrain 410 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 414 . Transmission 414 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 414 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0090] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0091] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 414 . An output member 19 of the transmission 414 is connected to a final drive 16 .
[0092] The transmission 414 utilizes three differential gear sets, preferably in the nature of planetary gear sets 420 , 430 and 440 . The planetary gear set 420 employs an outer gear member 424 , typically designated as the ring gear. The ring gear member 424 circumscribes an inner gear member 422 , typically designated as the sun gear. A carrier member 426 rotatably supports a plurality of planet gears 427 such that each planet gear 427 simultaneously, and meshingly engages both the outer, ring gear member 424 and the inner, sun gear member 422 of the first planetary gear set 420 .
[0093] The planetary gear set 430 also employs an outer gear member 434 , typically designated as the ring gear. The ring gear member 434 circumscribes an inner gear member 432 , typically designated as the sun gear. A carrier member 436 rotatably supports a plurality of planet gears 437 such that each planet gear 437 simultaneously, and meshingly engages both the outer, ring gear member 434 and the inner, sun gear member 432 of the planetary gear set 430 .
[0094] The planetary gear set 440 also employs an outer gear member 444 , typically designated as the ring gear. The ring gear member 444 circumscribes an inner gear member 442 , typically designated as the sun gear. A carrier member 446 rotatably supports a plurality of planet gears 447 such that each planet gear 447 simultaneously, and meshingly engages both the outer, ring gear member 444 and the inner, sun gear member 442 of the planetary gear set 440 .
[0095] The input shaft 17 is continuously connected to the ring gear member 434 . The output shaft 19 is continuously connected to the carrier member 446 .
[0096] A first interconnecting member 470 continuously connects the ring gear member 424 with the carrier member 436 and with the ring gear member 444 . A second interconnecting member 472 continuously connects the carrier member 426 with the sun gear member 432 .
[0097] A first brake 450 selectively connects the ring gear member 424 , carrier member 436 and ring gear member 444 via interconnecting member 470 with the transmission housing 460 . This brake 450 enables series hybrid mode operation in forward and reverse. A second brake 452 selectively connects the sun gear member 442 with the transmission housing 460 .
[0098] The embodiment 410 also incorporates first, second and third motor/generators 480 , 482 and 484 , respectively. The stator of the first motor/generator 480 is secured to the transmission housing 460 . The rotor of the first motor/generator 480 is secured to the sun gear member 422 .
[0099] The stator of the second motor/generator 482 is secured to the transmission housing 460 . The rotor of the second motor/generator 482 is secured to the carrier member 426 .
[0100] The stator of the third motor/generator 484 is secured to the transmission housing 460 . The rotor of the third motor/generator 484 is secured to the sun gear member 442 .
[0101] The hybrid transmission 414 receives power from the engine 12 , and also exchanges power with an electric power source 486 , which is operably connected to a controller 488 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Sixth Exemplary Embodiment
[0102] With reference to FIG. 6 , a powertrain 510 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 514 . Transmission 514 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 514 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0103] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0104] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 514 . An output member 19 of the transmission 514 is connected to a final drive 16 .
[0105] The transmission 514 utilizes three differential gear sets, preferably in the nature of planetary gear sets 520 , 530 and 540 . The planetary gear set 520 employs an outer gear member 524 , typically designated as the ring gear. The ring gear member 524 circumscribes an inner gear member 522 , typically designated as the sun gear. A carrier member 526 rotatably supports a plurality of planet gears 527 such that each planet gear 527 simultaneously, and meshingly engages both the outer, ring gear member 524 and the inner, sun gear member 522 of the planetary gear set 520 .
[0106] The planetary gear set 530 also employs an outer gear member 534 , typically designated as the ring gear. The ring gear member 534 circumscribes an inner gear member 532 , typically designated as the sun gear. A carrier member 536 rotatably supports a plurality of planet gears 537 such that each planet gear 537 simultaneously, and meshingly engages both the outer, ring gear member 534 and the inner, sun gear member 532 of the planetary gear set 530 .
[0107] The planetary gear set 540 also employs an outer gear member 544 , typically designated as the ring gear. The ring gear member 544 circumscribes an inner gear member 542 , typically designated as the sun gear. A carrier member 546 rotatably supports a plurality of planet gears 547 such that each planet gear 547 simultaneously, and meshingly engages both the outer, ring gear member 544 and the inner, sun gear member 542 of the planetary gear set 540 .
[0108] The input shaft 17 is continuously connected to the sun gear member 542 . The output shaft 19 is continuously connected to the ring gear member 524 .
[0109] A first interconnecting member 570 continuously connects the sun gear member 522 with the carrier member 536 and with the carrier member 546 . A second interconnecting member 572 continuously connects the carrier member 526 with the ring gear member 534 .
[0110] A first brake 550 selectively connects the carrier member 526 and the ring gear member 534 via interconnecting member 572 with the transmission housing 560 . A second brake 552 selectively connects the carrier member 546 , the carrier member 536 and the sun gear member 522 via interconnecting member 570 with the transmission housing 560 . This brake 552 enables series hybrid mode operation in forward and reverse.
[0111] The embodiment 510 also incorporates first, second and third motor/generators 580 , 582 and 584 , respectively. The stator of the first motor/generator 580 is secured to the transmission housing 560 . The rotor of the first motor/generator 580 is secured to the carrier member 526 and the ring gear member 534 via interconnecting member 572 .
[0112] The stator of the second motor/generator 582 is secured to the transmission housing 560 . The rotor of the second motor/generator 582 is secured to the sun gear member 532 .
[0113] The stator of the third motor/generator 584 is secured to the transmission housing 560 . The rotor of the third motor/generator 584 is secured to the ring gear member 544 .
[0114] The hybrid transmission 514 receives power from the engine 12 , and also exchanges power with an electric power source 586 , which is operably connected to a controller 588 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Seventh Exemplary Embodiment
[0115] With reference to FIG. 7 , a powertrain 610 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 614 . Transmission 614 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 614 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0116] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0117] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 614 . An output member 19 of the transmission 614 is connected to a final drive 16 .
[0118] The transmission 614 utilizes three differential gear sets, preferably in the nature of planetary gear sets 620 , 630 and 640 . The planetary gear set 620 employs an outer gear member 624 , typically designated as the ring gear. The ring gear member 624 circumscribes an inner gear member 622 , typically designated as the sun gear. A carrier member 626 rotatably supports a plurality of planet gears 627 such that each planet gear 627 simultaneously, and meshingly engages both the outer, ring gear member 624 and the inner, sun gear member 622 of the first planetary gear set 620 .
[0119] The planetary gear set 630 also employs an outer gear member 634 , typically designated as the ring gear. The ring gear member 634 circumscribes an inner gear member 632 , typically designated as the sun gear. A carrier member 636 rotatably supports a plurality of planet gears 637 such that each planet gear 637 simultaneously, and meshingly engages both the outer, ring gear member 634 and the inner, sun gear member 632 of the planetary gear set 630 .
[0120] The planetary gear set 640 also employs an outer gear member 644 , typically designated as the ring gear. The ring gear member 644 circumscribes an inner gear member 642 , typically designated as the sun gear. A carrier member 646 rotatably supports a plurality of planet gears 647 such that each planet gear 647 simultaneously, and meshingly engages both the outer, ring gear member 644 and the inner, sun gear member 642 of the planetary gear set 640 .
[0121] The input shaft 17 is continuously connected to the carrier member 646 . The output shaft 19 is continuously connected to the carrier member 626 .
[0122] A first interconnecting member 670 continuously connects the ring gear member 624 with the carrier member 636 and with the ring gear member 644 . A second interconnecting member 672 continuously connects the sun gear member 622 with the sun gear member 632 .
[0123] A brake 650 selectively connects the ring gear member 644 , the carrier member 636 and the ring gear member 624 via interconnecting member 670 with the transmission housing 660 . This brake 650 enables series hybrid mode operation in forward and reverse.
[0124] The embodiment 610 also incorporates first, second and third motor/generators 680 , 682 and 684 , respectively. The stator of the first motor/generator 680 is secured to the transmission housing 660 . The rotor of the first motor/generator 680 is secured to the ring gear member 624 .
[0125] The stator of the second motor/generator 682 is secured to the transmission housing 660 . The rotor of the second motor/generator 682 is secured to the ring gear member 634 .
[0126] The stator of the third motor/generator 684 is secured to the transmission housing 660 . The rotor of the third motor/generator 684 is secured to the sun gear member 642 .
[0127] The hybrid transmission 614 receives power from the engine 12 , and also exchanges power with an electric power source 686 , which is operably connected to a controller 688 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of an Eighth Exemplary Embodiment
[0128] With reference to FIG. 8 , a powertrain 710 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 714 . Transmission 714 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 714 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0129] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0130] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 714 . An output member 19 of the transmission 714 is connected to a final drive 16 .
[0131] The transmission 714 utilizes three differential gear sets, preferably in the nature of planetary gear sets 720 , 730 and 740 . The planetary gear set 720 employs an outer gear member 724 , typically designated as the ring gear. The ring gear member 724 circumscribes an inner gear member 722 , typically designated as the sun gear. A carrier member 726 rotatably supports a plurality of planet gears 727 such the each planet gear 727 simultaneously, and meshingly engages both the outer, ring gear member 724 and the inner, sun gear member 722 of the planetary gear set 720 .
[0132] The planetary gear set 730 also employs an outer gear member 734 , typically designated as the ring gear. The ring gear member 734 circumscribes an inner gear member 732 , typically designated as the sun gear. A carrier member 736 rotatably supports a plurality of planet gears 737 such that each planet gear 737 simultaneously, and meshingly engages both the outer, ring gear member 734 and the inner, sun gear member 732 of the planetary gear set 730 .
[0133] The planetary gear set 740 also employs an outer gear member 744 , typically designated as the ring gear. The ring gear member 744 circumscribes an inner gear member 742 , typically designated as the sun gear. A carrier member 746 rotatably supports a plurality of planet gears 747 such that each planet gear 747 simultaneously, and meshingly engages both the outer, ring gear member 744 and the inner, sun gear member 742 of the planetary gear set 740 .
[0134] The input shaft 17 is continuously connected to the carrier member 736 . The output shaft 19 is continuously connected to the ring gear member 744 .
[0135] A first interconnecting member 770 continuously connects the ring gear member 724 with the ring gear member 734 and the carrier member 746 . A second interconnecting member 772 continuously connects the sun gear member 722 with the sun gear member 732 .
[0136] A first brake 750 selectively connects the sun gear member 722 and the sun gear member 732 via interconnecting member 772 with the transmission housing 760 . A second brake 752 selectively connects the ring gear member 724 , the ring gear member 734 and the carrier member 746 via interconnecting member 770 with the transmission housing 760 . This brake 752 enables series hybrid mode operation in forward and reverse.
[0137] The embodiment 710 also incorporates first, second and third motor/generators 780 , 782 and 784 , respectively. The stator of the first motor/generator 780 is secured to the transmission housing 760 . The rotor of the first motor/generator 780 is secured to the sun gear member 722 .
[0138] The stator of the second motor/generator 782 is secured to the transmission housing 760 . The rotor of the second motor/generator 782 is secured to the carrier member 726 .
[0139] The stator of the third motor/generator 784 is secured to the transmission housing 760 . The rotor of the third motor/generator 784 is secured to the sun gear member 742 .
[0140] The hybrid transmission 714 receives power from the engine 12 , and also exchanges power with an electric power source 786 , which is operably connected to a controller 788 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Ninth Exemplary Embodiment
[0141] With reference to FIG. 9 , a powertrain 810 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 814 . Transmission 814 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 814 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0142] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0143] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 814 . An output member 19 of the transmission 814 is connected to a final drive 16 .
[0144] The transmission 814 utilizes three differential gear sets, preferably in the nature of planetary gear sets 820 , 830 and 840 . The planetary gear set 820 employs an outer gear member 824 , typically designated as the ring gear. The ring gear member 824 circumscribes an inner gear member 822 , typically designated as the sun gear. A carrier member 826 rotatably supports a plurality of planet gears 827 such that each planet gear 827 simultaneously, and meshingly engages both the outer, ring gear member 824 and the inner, sun gear member 822 of the planetary gear set 820 .
[0145] The planetary gear set 830 also employs an outer gear member 834 , typically designated as the ring gear. The ring gear member 834 circumscribes an inner gear member 832 , typically designated as the sun gear. A carrier member 836 rotatably supports a plurality of planet gears 837 such that each planet gear 837 simultaneously, and meshingly engages both the outer, ring gear member 834 and the inner, sun gear member 832 of the planetary gear set 830 .
[0146] The planetary gear set 840 also employs an outer gear member 844 , typically designated as the ring gear. The ring gear member 844 circumscribes an inner gear member 842 , typically designated as the sun gear. A carrier member 846 rotatably supports a plurality of planet gears 847 such that each planet gear 847 simultaneously, and meshingly engages both the outer, ring gear member 844 and the inner, sun gear member 842 of the planetary gear set 840 .
[0147] The input shaft 17 is continuously connected to the sun gear member 832 . The output shaft 19 is continuously connected to the ring gear member 844 .
[0148] A first interconnecting member 870 continuously connects the carrier member 826 with the ring gear member 834 and with the sun gear member 842 . A second interconnecting member 872 continuously connects the ring gear member 824 with the carrier member 836 .
[0149] A first brake 850 selectively connects the ring gear member 824 and the carrier member 836 via interconnecting member 872 with the transmission housing 860 . A second brake 852 selectively connects the carrier member 826 , ring gear member 834 and sun gear member 842 via interconnecting member 870 with the transmission housing 860 . This brake 852 enables series hybrid operation in forward and reverse.
[0150] The embodiment 810 also incorporates first, second and third motor/generators 880 , 882 and 884 , respectively. The stator of the first motor/generator 880 is secured to the transmission housing 860 . The rotor of the first motor/generator 880 is secured to the sun gear member 822 .
[0151] The stator of the second motor/generator 882 is secured to the transmission housing 860 . The rotor of the second motor/generator 882 is secured to the carrier member 826 .
[0152] The stator of the third motor/generator 884 is secured to the transmission housing 860 . The rotor of the third motor/generator 884 is secured to the carrier member 846 .
[0153] The hybrid transmission 814 receives power from the engine 12 , and also exchanges power with an electric power source 886 , which is operably connected to a controller 888 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Tenth Exemplary Embodiment
[0154] With reference to FIG. 10 , a powertrain 910 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 914 . Transmission 914 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 914 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0155] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0156] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 914 . An output member 19 of the transmission 914 is connected to a final drive 16 .
[0157] The transmission 914 utilizes three differential gear sets, preferably in the nature of planetary gear sets 920 , 930 and 940 . The planetary gear set 920 employs an outer gear member 924 , typically designated as the ring gear. The ring gear member 924 circumscribes an inner gear member 922 , typically designated as the sun gear. A carrier member 926 rotatably supports a plurality of planet gears 927 simultaneously, and meshingly engages both the outer, ring gear member 924 and the inner, sun gear member 922 of the planetary gear set 920 .
[0158] The planetary gear set 930 employs an outer gear member 934 , typically designated as the ring gear. The ring gear member 934 circumscribes an inner gear member 932 , typically designated as the sun gear. A carrier member 936 rotatably supports a plurality of planet gears 937 such that each planet gear 937 simultaneously, and meshingly engages both the outer, ring gear member 934 and the inner, sun gear member 932 of the planetary gear set 930 .
[0159] The planetary gear set 940 employs an outer gear member 944 , typically designated as the ring gear. The ring gear member 944 circumscribes an inner gear member 942 , typically designated as the sun gear. A carrier member 946 rotatably supports a plurality of planet gears 947 such that each planet gear 947 simultaneously, and meshingly engages both the outer, ring gear member 944 and the inner, sun gear member 942 of the planetary gear set 940 .
[0160] The input shaft 17 is continuously connected to the sun gear member 922 . The output shaft 19 is continuously connected to the ring gear member 944 .
[0161] A first interconnecting member 970 continuously connects the carrier member 926 with the carrier member 936 and with the sun gear member 942 . A second interconnecting member 972 continuously connects the ring gear member 924 with the sun gear member 932 .
[0162] A first brake 950 selectively connects the carrier member 926 , the carrier member 936 and the sun gear member 942 via interconnecting member 970 with the transmission housing 960 . This brake 950 enables series hybrid mode operation. A second brake 952 selectively connects the carrier member 946 with the transmission housing 960 . A third brake 954 selectively connects the ring gear member 924 with the transmission housing 960 . A fourth brake 956 selectively connects the ring gear member 934 with the transmission housing 934 . The brakes 954 and 956 may provide additional EVT ranges and/or fixed ratios.
[0163] The embodiment 910 also incorporates first, second and third motor/generators 980 , 982 and 984 , respectively. The stator of the first motor/generator 980 is secured to the transmission housing 960 . The rotor of the first motor/generator 980 is secured to the ring gear member 924 .
[0164] The stator of the second motor/generator 982 is secured to the transmission housing 960 . The rotor of the second motor/generator 982 is secured to the ring gear member 934 .
[0165] The stator of the third motor/generator 984 is secured to the transmission housing 960 . The rotor of the third motor/generator 984 is secured to the carrier member 946 .
[0166] The hybrid transmission 914 receives power from the engine 12 , and also exchanges power with an electric power source 986 , which is operably connected to a controller 988 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of an Eleventh Exemplary Embodiment
[0167] With reference to FIG. 11 , a powertrain 1010 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 1014 . Transmission 1014 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 1014 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0168] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0169] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 1014 . An output member 19 of the transmission 1014 is connected to a final drive 16 .
[0170] The transmission 1014 utilizes three differential gear sets, preferably in the nature of planetary gear sets 1020 , 1030 and 1040 . The planetary gear set 1020 employs an outer gear member 1024 , typically designated as the ring gear. The ring gear member 1024 circumscribes an inner gear member 1022 , typically designated as the sun gear. A carrier member 1026 rotatably supports a plurality of planet gears 1027 , 1028 such that each planet gear 1027 meshingly engages the inner, sun gear member 1022 and each planet gear 1028 simultaneously, and meshingly engages both the outer, ring gear member 1024 and the respective planet gear 1027 of the planetary gear set 1020 .
[0171] The planetary gear set 1030 also employs an outer gear member 1034 , typically designated as the ring gear. The ring gear member 1034 circumscribes an inner gear member 1032 , typically designated as the sun gear. A carrier member 1036 rotatably supports a plurality of planet gears 1037 such that each planet gear 1037 simultaneously, and meshingly engages both the outer, ring gear member 1034 and the inner, sun gear member 1032 of the planetary gear set 1030 .
[0172] The planetary gear set 1040 also employs an outer gear member 1044 , typically designated as the ring gear. The ring gear member 1044 circumscribes an inner gear member 1042 , typically designated as the sun gear. A carrier member 1046 rotatably supports a plurality of planet gears 1047 such that each planet gear 1047 simultaneously, and meshingly engages both the outer, ring gear member 1044 and the inner, sun gear member 1042 of the planetary gear set 1040 .
[0173] The input shaft 17 is continuously connected to the carrier member 1026 . The output shaft 19 is continuously connected to the carrier member 1046 .
[0174] A first interconnecting member 1070 continuously connects the sun gear member 1022 with the sun gear member 1032 and with the ring gear member 1044 . A second interconnecting member 1072 continuously connects the carrier member 1026 with the carrier member 1036 .
[0175] A first brake 1050 selectively connects the ring gear member 1034 with the transmission housing 1060 . A second brake 1052 selectively connects the ring gear member 1044 , the sun gear member 1032 and the sun gear member 1022 via interconnecting member 1070 with the transmission housing 1060 . This brake 1052 enables series hybrid mode operation. A third brake 1054 selectively connects the sun gear member 1042 with the transmission housing 1060 .
[0176] The embodiment 1010 also incorporates first, second and third motor/generators 1080 , 1082 and 1084 , respectively. The stator of the first motor/generator 1080 is secured to the transmission housing 1060 . The rotor of the first motor/generator 1080 is secured to the ring gear member 1024 .
[0177] The stator of the second motor/generator 1082 is secured to the transmission housing 1060 . The rotor of the second motor/generator 1082 is secured to the ring gear member 1034 .
[0178] The stator of the third motor/generator 1084 is secured to the transmission housing 1060 . The rotor of the third motor/generator 1084 is secured to the sun gear member 1042 .
[0179] The hybrid transmission 1014 receives power from the engine 12 , and also exchanges power with an electric power source 1086 , which is operably connected to a controller 1088 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
Description of a Twelefth Exemplary Embodiment
[0180] With reference to FIG. 12 , a powertrain 1110 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 1114 . Transmission 1114 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 1114 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0181] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a gasoline or diesel engine which is readily adapted to provide its available power output typically delivered at a selectable number of revolutions per minute (RPM).
[0182] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 1114 . An output member 19 of the transmission 1114 is connected to a final drive 16 .
[0183] The transmission 1114 utilizes three differential gear sets, preferably in the nature of planetary gear sets 1120 , 1130 and 1140 . The planetary gear set 1120 employs an outer gear member 1124 , typically designated as the ring gear. The ring gear member 1124 circumscribes an inner gear member 1122 , typically designated as the sun gear. A carrier member 1126 rotatably supports a plurality of planet gears 1127 such that each planet gear 1127 simultaneously, and meshingly engages both the outer, ring gear member 1124 and the inner, sun gear member 1122 of the planetary gear set 1120 .
[0184] The planetary gear set 1130 also employs an outer gear member 1134 , typically designated as the ring gear. The ring gear member 1134 circumscribes an inner gear member 1132 , typically designated as the sun gear. A carrier member 1136 rotatably supports a plurality of planet gears 1137 such that each planet gear 1137 simultaneously, and meshingly engages both the outer, ring gear member 1134 and the inner, sun gear member 1132 of the planetary gear set 1130 .
[0185] The planetary gear set 1140 also employs an outer gear member 1144 , typically designated as the ring gear. The ring gear member 1144 circumscribes an inner gear member 1142 , typically designated as the sun gear. A carrier member 1146 rotatably supports a plurality of planet gears 1147 such that each planet gear 1147 simultaneously, and meshingly engages both the outer, ring gear member 1144 and the inner, sun gear member 1142 of the planetary gear set 1140 .
[0186] The input shaft 17 is continuously connected to the sun gear member 1132 . The output shaft 19 is continuously connected to the carrier member 1126 .
[0187] A first interconnecting member 1170 continuously connects the ring gear member 1124 with the carrier member 1136 and with the carrier member 1146 . A second interconnecting member 1172 continuously connects the ring gear member 1134 with the ring gear member 1144 .
[0188] A first brake 1150 selectively connects the ring gear member 1134 , the carrier member 1136 and the carrier member 1146 via interconnecting member 1170 with the transmission housing 1160 . This brake 1150 enables series hybrid mode operation. A second brake 1152 selectively connects the ring gear member 1144 and the ring gear member 1134 via interconnecting member 1172 with the transmission housing 1160 .
[0189] The embodiment 1110 also incorporates first, second and third motor/generators 1180 , 1182 and 1184 , respectively. The stator of the first motor/generator 1180 is secured to the transmission housing 1160 . The rotor of the first motor/generator 1180 is secured to the sun gear member 1122 via an offset drive 1190 , such as a belt or chain, which may change the speed ratio.
[0190] The stator of the second motor/generator 1182 is secured to the transmission housing 11 60 . The rotor of the second motor/generator 1182 is secured to the ring gear member 1134 and the ring gear member 1144 via interconnecting member 1172 .
[0191] The stator of the third motor/generator 1184 is secured to the transmission housing 1160 . The rotor of the third motor/generator 1184 is secured to the sun gear member 1142 via offset gear 1192 , which may change the speed ratio.
[0192] The hybrid transmission 1114 receives power from the engine 12 , and also exchanges power with an electric power source 1186 , which is operably connected to a controller 1188 . Those with ordinary skill in transmission art will recognize that desired continuously variable input/output speed ratios can be realized by suitable selection of operating state of the brakes and speeds of the motor-generators.
[0193] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. | The electrically variable transmission (EVT) family of the present invention provides low-content, low-cost electrically variable transmission mechanisms including first, second and third differential gear sets, a battery, three electric machines serving interchangeably as motors or generators and at least one brake. The three motor/generators are operable in a coordinated fashion to yield an EVT with a continuously variable range of speeds (including reverse). One of the brakes enables series hybrid operation. | 5 |
[0001] The invention relates to the osteoinductive and/or osteogenic material useful in dental and maxillofacial surgery in case of bone surface deficiency for the induction of intraosseous dental implants.
STATE OF ART
[0002] Reconstruction of bone loss with an autogenic bone graft is nowadays considered as a golden mean among procedures for hard bones regeneration in maxillofacial and dental surgery.
[0000] Bone material is derived from the donor area in the form of bone chips obtained with bone scrapers most often from jaw nodule or retromolar gap or from larger bone fragments grinded in mills. Next, bone material is transferred and condensed in an acceptor area and fixed/immobilized with covering collagen film or polytetrafluoroethylene film (PTFE film) together with pins.
Autogenic bone engraft is also conducted in a form of bone blocks. Such blocks are fixed by bone loss impaction or are stabilized by pins and/or resorbable or non-resorbable screws. The latter ones require to be removed after graft engraftment period.
A method for simultaneous introduction of dental implants passing centrally through autogenic bone graft obtained from chin area and shaped in a form of ring is known. The method, due to limitations of the donor area, is limited to a maximum of four grafts. In case of a successful graft healing, the dental implant remains in the site of insertion and constitutes a foundation for prosthetic reconstruction.
Bone losses are also filled with allogenic, xenogenic or heterogenic material. An application of such methods of regeneration is analogous in its form to the methods of autogenic graft. Lack of available data regarding the method of simultaneous introduction of the dental graft together with bone replacing block in such a manner that the block is simultaneously a dental implant is an only exception. Materials for bone replacement and regeneration that are shaped such that they enable simultaneous introduction and fixation within an acceptor site by dental implant are not available on the market as well.
Specifically, blocks prepared from bone replacement material shaped in the form of a ring are not available. Furthermore, such formed three-dimensional scaffolds seeded with osteogenic cells have not been reported.
[0003] A golden mean in the field of regeneration of vertical and horizontal bone losses is a use of autogenic bone grafts. Such technique assumes deriving a bone from donor sites of the same patient whose bone surface is being reconstructed. A bone can be obtained from a donor site in a form of bone chips with scrapers. Such a form requires in an acceptor site a specific material shaping and its consolidation by means of resorbable and non-resorbable barrier films. Bone tissue can be derived also in the form of blocks excised with trepans, chisels, rotary drills and piezoelectric-type devices. Thus, obtained are shaped bone fragments that are then fixed to the bone loss with pins or screws. After successful reconstruction bone material is integrated with acceptor surface and elements fixing graft can be removed. In implantation a procedure for stabilizing elements removal is usually employed also to introduce dental grafts utilizing newly formed bone tissue for stabilization. After the period of implant healing they can be subjected to prosthetic reconstruction.
[0004] An essential modification of the described solution is to use grafts of bone tissue shaped at a donor site in the form of a ring. Such a ring is excised with two round trepans having various diameters, attached to a surgical drill. Both trepans are characterized in this procedure by the same central pivot point. The diameter of the smaller trepan is equal or a part of a millimeter smaller than the outer diameter of the dental implant that is supposed to be implanted in an acceptor site. The diameter of the larger trepan is about 2 millimeters larger than the outer diameter of the smaller trepan defining thereby the thickness of the bone ring. The height of the ring depends on the vertical size of the bone tissue defect being regenerated and it is supposed to be equal. Such an obtained ring is transferred into the acceptor site and fixed with a simultaneously installed dental implant. This implant is introduced through the middle part of the ring and its end is fixed in the previously prepared surface within the area of the acceptor site. Such a procedure ensures the primary stabilization of the implant as well as the fixation of the engrafted bone block that has been previously shaped in the form of a ring.
Technical Problem
[0005] An advantage of bone rings technique introduction is a reduction of a whole bone regeneration and dental implants transplantation procedure to one surgery. However, the use of bone rings did not eliminate basic problems regarding autogenic bones grafts comprising:
a) necessity to perform a traumatic surgery in a donor site (most often mandible, but other bones are also employed); b) limited amount of the material available for excision in a donor site—in some cases insufficient for a complete complement of the loss in an acceptor site (mandible bone usually ensures material for no more than 4 excisions of bone material for transplantation); c) significant amount of a cortical bone fraction which is depleted of cells and growth factors in respect to the poor content of cancellous bone in a transplanted material; d) non-standardized quality of the transplanted material depending on a donor body system as well as an anatomical site from which the material is derived; e) uncertain time of transplant resorption, usually too rapid in regard to clinical needs that results in rapid loss of a horizontal and vertical dimension of the bone surrounding transplanted implants, their exposure, infection and following premature loss.
One known attempt to resolve the aforementioned problems is to employ rings made of cancellous allogenic bone. However, it does not allow to overcome all of the aforementioned problems from c) to e). Despite cancellous structure, allogenic bone utilized to form rings is deprived of living cells and active growth factors. Additionally, performing a graft derived from a foreign donor involves additional problems, for example, may cause the risk of an infectious disease transmission.
Another technical problem requiring a solution is obtaining a better reconstruction of an acceptor bone, especially in the vertical dimension. Regeneration of polyhedral bone losses is a major problem in dental and maxillofacial surgery. In case of arrangements for a transplantation of dental implants, numerous surgical techniques are focused especially on the increase of the vertical bone dimension of an alveolar bone of mandible or alveolar process of maxilla. Autogenic bone transplantations or procedures for a controlled bone regeneration utilizing xenogenic bone do not ensure repetitive favorable results. Usually in the literature, the efficacy of those techniques during regeneration of 4 mm bone loss is estimated as below 50%. Such techniques disable a simultaneous introduction of dental implants, thereby, force a patient to be subjected to surgical procedures at least twice in order to restore toothing.
[0011] Another major problem with the controlled bone regeneration, particularly with the reconstruction of maxillary bone within the alveolus to enable dental implant transplantation, is soft tissues control. Soft tissues of the gum must cover newly formed bone volume, obtained as a result of regeneration procedure. The amount of soft tissue in the site of bone defect is insufficient and the full coverage of the reconstructed bone tissue is problematic. Formed and prepared lobes as well as grafts of soft tissues usually are insufficient to ensure a full coverage of the enlarged size of a bone surface. A necessity to sew tissues under tension often causes lack of tightness in the place of a stitch. The extension of utilized lobes and their distant displacement often result in significant hemodynamic disruptions within the lobe, decreasing its biological potential for healing. The aforementioned two factors often result in the dehiscence of wound edges and the exposure of the bone material. Such complication is the frequent cause of a failure of a dental implant engraftment procedure or the incidence of serious complications, such as mandible bone exposure after implant engraftment.
[0000] Another technical problem in a vertical bone loss augmentation with bone blocks, especially within an alveolus, is their premature resorption. The first clinical symptom of a transplanted bone tissue volume decrease is observed a few weeks after the procedure. Firstly, coving of the edge of engrafted bone block occurs and then its vertical and horizontal dimension is decreased. In extreme cases, it may even lead to almost full disappearance of an autograft. It leads to an exposure of titanium implants immersed in it, loss of aesthetics, function and even infection of the tissues and loss of the graft.
The solution for the aforementioned problems is provided by the present invention.
SUBJECT MATTER OF THE INVENTION
[0012] A subject matter of the invention is a ring and a kit comprising thereof as defined by the appended claims. As “cytocompatible material”, especially in regard to osteogenic cells, according to the present invention any material is meant that simultaneously meets the criteria as listed below:
a) viability of cells cultured directly on the surface of the material is at least 70% when compared to the result obtained in the same experimental conditions in a culture of identical cells grown on a surface of a control material; b) all cells that adhered to the surface, 24 h after seeding are flattened and fibrous in shape (i.e. their morphology is typical for osteogenic cells); c) cells adhesion to the material occurs within first 3 to 5 h after seeding; d) cells proliferation rate is 25 to 30 h in standard culture conditions.
Characteristics of a material being suitable for providing the ring according to the invention are determined in the introduction to example 6.
Unexpected Technical Effect
[0017] Surprisingly, the present invention provided a solution for the technical problems stated above.
[0018] The use of rings from the materials prepared by a human, seeded or non-seeded with recipients cells significantly decrease a trauma associated with an implantation procedure. In such cases, repetitive reconstruction up to 5 mm in vertical dimension of bone tissue is achieved.
[0019] In a particular embodiment concerning an application of the ring according to the invention seeded with viable osteogenic cells of the recipient, a significant improvement in soft tissues condition was achieved manifested, in particular, in accelerated healing and increased biological potential of the tissue lobes. Due to VEGF expression in the osteogenic cells within a ring according to the invention, a blood supply in an acceptor site i.e. in the site of implantation is stimulated due to the activity of transplanted cells. This, in return, will result in a better regeneration of soft tissues that was impossible to achieve with the present methods of medical treatment. Such an effect is presented in FIG. 1 and FIG. 2 .
[0020] A significant advantage provided by the employment of the present invention is the ability to influence the time of transplanted osteogenic material resorption, which in case of autogenic bone grafts is entirely out of control. The invention, when used, provides a solution to such a problem. The ring according to the invention is characterized by the prolonged time of the resorption. This effect is presented in FIG. 3 and FIG. 4 . Furthermore, in particular embodiments, the composition of the material that a carrier is formed from can be adjusted in such a way that the time of the resorption after engraftment into to the host body, depending on the biological needs of an acceptor site as well as expected clinical outcome can be intentionally controlled.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The subject matter of the invention is related to the application of a specifically shaped three-dimensional biomaterials produced by a human—synthetic or of natural origin, seeded or non-seeded with cells in the reconstruction of arising bone losses or in a production of a bone in the site of a deficiency of bone amount in the body system of a recipient.
[0022] Scaffolds, according to the invention, made therefrom are shaped in the form of a ring. It is acceptable to form a scaffold of any other geometrical shape depending on clinical needs according to principals described in the present invention hereinafter.
[0000] The height of the ring depends on the expected quantitative effect of the reconstructed or generated bone and remains in the range of 3 mm to 6 mm. In certain cases, it is acceptable to produce the ring of a different required height with respect to the biological potential of an acceptor site.
In the central part of a ring there is an aperture that enables the insertion of a dental implant through it. A non-centrally created aperture for the implant insertion is also acceptable. Therefore, the aperture diameter ranges depending on the diameter of the used dental implant, and is equal or slightly smaller to provide an adequate implant stabilization within a ring. The adjustment of the ratio of a diameter of aperture in a ring to implant diameter eventually depends on the flexibility of the material the ring is formed from, in order to prevent its cracking.
The thickness of the ring is the greater the more aggressive dental implant screw is used to fix a ring (it is acceptable to employ smooth implant without a thread) and the larger the extent of bone regeneration or forming is planned. A regenerative potential of the acceptor site as well as mimetic properties of a material used to produce a ring remain the limitation for ring thickness extension. Minimal possible thickness of a ring to apply finally depends on the biomechanical properties of the material used to produce a ring.
[0023] The ring according to the invention is stably fixed to atrophied bone surface with dental implants inserted through the developed aperture within a ring.
[0000] A methodology comprises a surgical access to the surface of a reconstructed or built up bone obtained in the manner typical for an anatomical site. After the periosteum detachment, bedding development for a planned dental transplantation is performed according to all principals mandatory for dental implantation with the exception for the depth of bedding development. Such depth should remain smaller than the length of the planned implant. Depth difference of the bedding developed for an implant and the length of an implant is even to the height of the ring utilized in the procedure. It is acceptable to use rings that are higher as well as lower than a difference between an implant length and a depth of a developed bone bedding retaining the stability of the whole system.
Bone bedding may comprise a compact bone as well as a cancellous bone or only one of those tissue forms.
After bedding development, the previously prepared ring is attached in such a way that the aperture prepared within it and the central part of the developed bedding overlap. Then, through the ring fixed by an operator the dental implant is introduced so as its lower part is placed in the prepared bone bedding of the acceptor site achieving desired depth and stability. It is acceptable to modify the sequence of the insertion of the system components.
After inserting, the dental implant should be blinded by a scarring ring, healing ring or other conventional element. Then, the wound is closed in layers, tightly, according to the principals mandatory in the art of the surgical field. Single layer sewing is acceptable.
[0024] The area treated in such a manner is allowed to heal. Healing time depends on the characteristics of the material the ring is made of and biological ability of the recipient body system. Usually, this time is between 6 to 9 months. It is acceptable to shorten or extend the time of healing in justified cases. After the time of healing, the dental implant can be exposed. Then, it can be utilized to form a prosthetic superstructure or as another retention element. In justified cases, an immediate loading of an implant inserted by the described method or its open healing are both acceptable.
[0025] The innovation of the described methodology provides simultaneous insertion of a dental implant together with the three-dimensional scaffold fixed by it, namely, a ring according to the invention. For the time being, the transplanted three-dimensional scaffolds have been fixed by means of impaction, by pins or fixing screws, sewed or immobilized by various types of tissue adhesives. However, dental grafts inserted through a developed compatible aperture within a scaffold have not been employed. The application of such a method in selected cases may spare a patient additional surgery planned to remove retention elements for previously applied scaffolds as well as to engraft dental implants after recipient's tissues overgrew scaffolds.
[0000] The similar solution of fixing transplantable dental material with implants was described only for engrafts of autogenic bone. In this method, rings of autogenic bone were obtained from genial fragment of the mandible. The proposed method, according to the invention, for a ring formation assumes applying other than autogenic transplantable materials. This significantly reduces the trauma of a patient, who avoids a surgery in a donor site. Furthermore, in the method described in the present application there are no quantitative limitations, except for biological potential of an acceptor site, which in case of techniques applying autogenic bone, remains of a significant difference due to limitations of a donor site.
[0026] For a better understanding of the subject matter the present invention is supplemented with a detailed description of the exemplary embodiments comprising also appended sequencing listing and figures in which:
[0027] FIG. 1 . VEGF release by human osteogenic cells in culture (O)—values evaluated by means of ELISA assay in days 1 and 4 of a cell culture. For a comparison, analogous values obtained in human endothelium cells culture (S) carried out in identical conditions are shown.
[0028] FIG. 2 . VEGF mRNA expression in human osteogenic cells (O) in days 1, 4, and 7 of a cell culture determined by means of a real time PCR technique. GAPDH was used as a reference gene; results were normalized to the value obtained for osteogenic cell culture in day 1. For a comparison, analogous values obtained in human endothelium cells culture (S) carried out in identical conditions are shown.
[0029] FIG. 3 . shows the results of a computed tomography performed for a control sample excised from an experimental animal. A sample is a ring prepared from an autogenic bone that was introduced into an acceptor site (in mandible) and stabilized by conical titanium implant. Observations were conducted for 6 weeks.
[0030] FIG. 4 . shows the results of a computed tomography performed for a ring prepared according to the invention and excised from an experimental animal after 6 weeks of implantation. A ring prepared according to the description in example 1 was introduced into an acceptor site (in mandible) and stabilized by a conical titanium implant.
[0031] FIG. 5 . shows an outline of a ring according to the invention where: x—internal diameter of a ring, y—outer diameter of a ring, z—ring wall thickness, h—height of a ring.
[0032] FIG. 6 . shows the result of a XTT test performed after 7 days of cells culture carried out on scaffolds prepared from Maxresorb® material. The results are expressed as a mean value for 6 measurements, as a percent of a control (value normalized to the result obtained in a control population i.e. cells cultured on a standard culture medium—expressed as %).
[0033] FIG. 7 . shows living cells (stained with green dye fluorescein) seeded and cultured for 7 days in in vitro conditions on a scaffold made of Maxresorb® material. Fluorescence corresponds to the presence of living cells on the material.
[0034] FIG. 8 . shows a picture of a histological slide taken after the decalcification of the sample and titanium implant removal. Paraffin embedded specimen was prepared by sectioning parallel to the long axis of titanium implant. Hematoxylin/eosin stained specimens depict a whole cross-section of a ceramic scaffold together with recipient's tissue surrounding the ring. The figure was prepared by an automatic assembling of the photographs taken with a 4× lens. It is shown in the picture that the shape of an engrafted scaffold was retained, no signs of resorption are apparent.
[0035] FIG. 9 . shows a picture of a histological slide taken after the decalcification of the sample and titanium implant removal. Paraffin embedded specimen was prepared by sectioning parallel to the long axis of titanium implant. Hematoxylin/eosin stained specimen depicts that all pores of the engrafted ring prepared according to the invention are filled with the connective tissue and bone tissue.
[0036] FIG. 10 . shows a picture of a histological slide taken after the decalcification of the sample and titanium implant removal. Paraffin embedded specimen was prepared by sectioning vertical to the long axis of titanium implant. Hematoxylin/eosin stained specimen depicts that all pores of the engrafted ring prepared according to the invention are filled with the connective tissue and bone tissue and a very good integration of this ring with the recipient's tissue.
[0037] FIG. 11 . shows a picture of a histological slide taken after the decalcification of the sample and titanium implant removal. The picture of a specimen stained with hematoxylin/eosin taken with a large magnification depicts even filling of scaffold pores with a new recipients tissue, penetration of a tissue through individual pores of a scaffold, which confirms the optimal size of the connections between pores.
[0038] FIG. 12 . shows a picture of a histological slide taken after the decalcification. A specimen stained with Goldner-Mason trichrome stain. In the picture, vascularization created between fragments of new bone tissue created inside the pores of the material a ring according to the invention is prepared from is shown (example 1).
[0039] FIG. 13 . shows results of the XTT test performed in the various time points of a cell culture carried out in calcite medium.
[0040] FIG. 14 . shows cellular nuclei stained with Hoechst stain. A picture confirms an even distribution of cells on a porous calcite base.
[0041] FIG. 15 . shows cells seeded on a calcite scaffold and cultured for 7 days. Living cells are stained in green (phalloidin staining), dead cells are stained in red (propidium iodide staining).
[0042] FIG. 16 . shows a ring formed from CaCO 3 twisted on a dental titanium implant.
[0043] FIG. 17 . shows rings made of chitosan (A) the lack of porosity is seen on the picture; (B) a titanium implant screwed into chitosan ring.
[0044] FIG. 18 . shows porosity of the rings made of chitosan and modified chitosan rings.
[0045] FIG. 19 . shows internal design of chitosan rings (A) and modified rings (B, C).
[0046] FIG. 20 . shows rings made of modified PLLA: a) initial sample, b) c) d)—rings after culturing in subsequent time points.
[0047] FIG. 21 . shows viability of osteogenic cells on the surface of ceramic materials with different phase composition in a culture on flat samples on the 3 rd day of the culture (a) and in three-dimensional porous samples (structure analogous to a ring) in the 3 rd week of the culture (b). The material symbols have the following meaning: K—control i.e. standard culture surface in a form of polystyrene culture plates, 1—two-phase ceramic material comprising 60% of hydroxyapatite (phase composition as in Maxresorb® material), 2—two-phase ceramic material comprising >99% of hydroxyapatite, 3—two-phase ceramic material comprising <18% of hydroxyapatite. When cells survival in a flat culture remains on the level that is not lower than in the control, a survival of cells cultured in a three-dimensional structure analogous to the ring is high—material “1”. When survival in a flat culture remains on the level that is statistically significantly lower than in the control (***-P<0.001), cells survive in a three-dimensional structure analogous to the ring to a very low extent. As an effect, materials “2” and “3” turned out to be a culture surface that was not suitable enough for a culture of osteogenic cells and did not provide suitable survival of those cells in a three-dimensional structure of a ring.
EXAMPLE 1. A RING PREPARED FROM 60% OF HYDROXYAPATITE (HA) AND 40% OF BETA TRICALCIUM PHOSPHATE (β-TCP) (DRY RING)
[0048] Commercially available synthetic ceramic material in a form of porous blocks is shaped to a form of a ring of a desired shape:
Sequence of the procedure steps:
1. from an available block with dimensions of 20×10×10 mm made of Maxresorb® material three blocks with dimensions of 10×10×5 mm are formed; from each of them cylinders with a height of 5 mm and diameter of 10 mm are developed using piezosurgery Surgysonic II manufactured by Esacromdevice and equipped with ES 002 diamond drill bit with a diameter of 150 microns and a power of 25 W and vibration amplitude of 160 microns; 2. in the prepared cylinder an internal aperture with the diameter of 3.2 mm is extracted using piezosurgery Surgysonic II manufactured by Esacromdevice equipped with ES 002 diamond drill bit with a diameter of 150 microns and a power of 20 W and vibration amplitude of 100 microns; 3. a shaped ring is packed and sterilized by means of radiation of 25 kGy. 4. a sterile ring is ready for an implantation into acceptor site and fixation with a dental implant.
In order to prepare rings commercial material available under the trademark of Maxresorb® was used. It is a synthetic material with a controlled resorption. Material consists of 60% of hydroxyapatite (HA) and 40% of beta tricalcium phosphate (β-TCP) (dry ring) It was prepared on the matrix of pores connected to each other that form material with a porosity of about 80% and pores with a size of from 200 to 800 μm.
EXAMPLE 2. A RING SATURATED WITH CELL CULTURE MEDIUM (WET RING)
[0053] Commercially available on the market synthetic ceramic material in a form of porous blocks is specifically shaped to the form of a ring with the desired dimensional shape (outer diameter—10 mm, internal diameter—3.2 mm, height—5 mm). The prepared ring is sterilized by means of radiation in a dose of 25 kGy—ring preparation according to the description in example 1.
The sterile ring is placed in a culture medium and using vacuum pump vented under vacuum. To vent a ring a pressure of about 0.5 to 0.6 Bar was applied.
While the ring is being vented, a standard medium for cell culture is transferred into its pores. Culture medium composition: DMEM medium (Life Technologies) enriched with an inactivated fetal bovine serum (FBS) in a concentration of 10%, supplemented with antibiotic in a form of an Antibiotic-Antimycotic preparation (product of Life Technologies, containing 10000 units of penicillin—in a form of sodium salt, i.e. penicillin G, 10,000 μg streptomycin—in a form of streptomycin sulphate), L-glutamine in a concentration of 2 mM (Life Technologies). After venting, rings are individually transferred into wells of 24-well plate (the diameter of a well is 15 mm) and from 1.5 ml to 2 ml of culture medium of a composition as described above is added. All the procedure steps are carried out in a laminar flow cabinet ensuring aseptic working conditions and samples remain in the culture medium for a period of time from 12 do 24 hours in order to wash out residual material created while material was developed technologically, if needed. After that time, the ring is being washed at least 3× for 5 min in a culture medium without FBS. Such prepared sterile ring is ready for an implantation into an acceptor site and fixation with a dental implant.
EXAMPLE 3. A RING SEEDED WITH CELLS
[0054] Cells are isolated from fragments of recipient's adipose tissue. For cells isolation a tissue fragment of a volume of min 20 ml to 40 ml is required. The tissue is mechanically purified to remove all kinds of tissues other than adipose and grinded to fragments of 2 mm. Tissue fragments are then washed at least 3× in PBS solution (product of Life Technologies) and then enzymatically digested in a collagenase solution (product of Life Technologies) in a concentration of 400 U/ml=0.15%. The volume ratio of the amount of adipose tissue to collagenase should remain 1:1. Such prepared solution should be incubated in 37° C. for 4 h with applied constant shaking of about 200 rpm. During this time adipose tissue is dissolved in collagenase. Having obtained possibly homogenous suspension, it is then centrifuged at 1500 rpm for 10 min then, the resultant supernatant is removed and remaining pellet is washed in a culture medium of a composition described in example II and centrifuged again at 1500 rpm for 5 min. Again, the resultant supernatant is removed and a pellet is suspended in a culture medium. Such an obtained mixture should be filtered through the nylon filter of a density of 100 μm. A filtrate comprising isolated cells is mixed with culture medium of the composition described in Example II and seeded into culture flasks (in the volume of about 15 ml) in the number of 1 million cells/1 flask. Sterile culture flasks manufactured by NUNC with the culture surface of 75 cm 2 are used. Cell culture is conducted in an incubator ensuring constant culture conditions, i.e., humidity of above 95%, temperature of 37° C. and presence of 5% carbon dioxide. The culture medium is replaced with a fresh one every 3-4 days. Cell culture is continued until confluence—preferably 70-80% confluence.
Then, cells are detached from the bottom of the flasks by means of trypsinization and subsequently are centrifuged at 1500 rpm for 10 min and counted in hemocytometer and resuspended in the adequate volume of a culture medium.
Ready to use, sterile (sterilized by means of radiation in the dose of 25 kGy) scaffold in the form of rings, prepared according to the description comprised in Example I and vented according to the procedure described in Example II, was seeded with cells isolated from adipose tissue and propagated during in vitro culture. The process of seeding scaffolds with cells is carried out in vacuum to ensure an even distribution of cells throughout the whole available surface of a ring.
Seeding method: vented scaffold in the form of a ceramic ring, prepared according to the procedures described in examples I and II, is transferred to a sterile 10 cm syringe. Cells detached from the culture surface are suspended in the culture medium—DMEM medium (Life Technologies) enriched with inactivated fetal bovine serum (FBS) in the concentration of 10%, supplemented with an antibiotic in the form of Antibiotic-Antimycotic preparation, L-glutamine in the concentration of 2 mM (Life Technologies) and vitamin C in the form of L-phospho-ascorbic acid in the concentration of 100 μM (SIGMA) in an amount of 700.000 cells/2 ml medium. Prepared cells solution is withdrawn with a syringe containing the ring inside. The air contained in a syringe is removed, then, after closing a syringe a vacuum is created inside by delicate dragging and loosing a piston. Such an activity is repeated 3 to 5 times. The scaffold seeded in such a manner is placed inside of a well of 24-well plate and covered with a volume of cells suspension that remained in the syringe. Such prepared scaffolds are transferred to an incubator ensuring constant culture conditions i.e. the humidity of above 95%, temperature of 37° C. and the presence of 5% carbon dioxide. After 24 hours, the culture medium is replaced with the fresh portion of a culture medium of the same composition in order to remove cells that do not adhere to scaffold and a scaffold itself is transferred into a new well within the culture plate. The cell culture on such a prepared scaffold is carried out for another 7 days in standard culture conditions, in an incubator with the constant humidity of above 95%, temperature of 37° C. and in the presence of 5% carbon dioxide. After that time, scaffold is washed at least 3× for 5 min in a culture medium without FBS. Such a prepared scaffold/ring is ready for an implantation into an acceptor site and fixation by a dental implant.
To ensure the quality control of the prepared graft, each time 2 additional scaffolds/rings seeded with cells are prepared. These scaffolds are used to assess viability of the cells cultured in applied conditions. Simultaneously, the cytocompatibility of the material used to prepare a ring is assessed. To evaluate cells viability, the XTT test (product of SIGMA)—measuring an activity of cellular mitochondrial dehydrogenase and live/dead type fluorescence staining—staining with fluorescein and propidium iodide reagents (products of Life Technologies) are performed enabling determination and comparison of the quantity of living and dead cells attached to the scaffold at the time of implantation. The biocompatibility of the material/ring was stated if the viability of cells cultured thereon quantified by XTT test was min. 70% when compared to the control cells. Controls are the cells cultured on the bottom of a culture plate in the same conditions as cells cultured on scaffolds.
EXAMPLE 4. PERFORMANCE VERIFICATION FOR THE PRODUCTS DESCRIBED IN EXAMPLES II AND ILL CARRIED OUT BY MEANS OF AN OBSERVATION AFTER IMPLANTATION INTO EXPERIMENTAL ANIMALS TISSUES
[0055] The rings seeded with cells and cultured in in vitro conditions were observed in the tissues of experimental animals (the description for the rings preparation method is comprised in example II and III). The rings were transplanted into the mandible of a small Göttingen minipig. Each implantation was carried out in an autogenic system. Two rings were transplanted into each animal: one seeded with cells according to the description comprised in example III and second non-seeded and prepared according to the description comprised in example II. Individual rings were implanted on the right and left side of a mandible in parallel. The observation in in vivo condition was carried out for 6 weeks. After that period of time, animals were euthanized and implanted rings together with a surrounding new tissue and a portion of mandible were excised.
[0056] Macroscopically no difference between seeded and non-seeded rings was noted. All rings were overgrown and grown through with tissue and stably embedded in a mandible bone (the mean implant stability was about 70 ISQ). After in vivo culture neither connective tissue capsule around rings nor macroscopic inflammation marks were observed. The excised rings were transferred into 10% buffered formalin solution (product of SIGMA). The prepared histological sections of the tested product after in vivo observation reveal the presence of well vasculated and organized connective and bone tissue (HE staining) that fill pores of both type materials ( FIGS. 8 to 12 ). The collagen fibers that are luminescent in a polarized light were visualized with Sirius red. The observations carried out by light microscopy confirm that the rings according to the invention serve their function and can be utilized to reconstruct vertical bone losses.
EXAMPLE 5. A RING PREPARED FROM CALCIUM CARBONATE
[0057] From a ceramic material made of calcium carbonate (CaCO 3 ) characterized with the calcite type crystal structure scaffolds in a shape of rings with the dimensions of: internal diameter 10 mm, outer diameter 3.2 mm, height 5 mm were prepared. The rings were characterized by the open porosity of 70-80% and the pores size of 200-500 μm; the compressive strength of the tested samples is about 0.7 MPa. The shape and technical parameters of the prepared samples suggested that the rings made of calcite might be utilized for prosthetic reconstruction. In further experiments rings were exposed to the culture medium of the following composition: DMEM medium (Life Technologies) enriched with an inactivated fetal bovine serum (FBS) in the concentration of 10%, supplemented with antibiotic in the form of an Antibiotic-Antimycotic preparation (product of Life Technologies, containing 10000 units of penicillin—in the form of sodium salt i.e. penicillin G, 10,000 ug streptomycin—in the form of streptomycin sulphate), L-glutamine in the concentration of 2 mM (Life Technologies). The rings were transferred into medium and incubated in the standard culture conditions i.e. the humidity of above 95%, temperature of 37° C. and in the presence of 5% carbon dioxide. After incubation lasting up to 35 days none changes in the structure of the material were observed—its integrity was sustained, the external and internal dimensions were not altered. In the further experiments human osteogenic cells were seeded on calcite rings (the response of the commercially available cell line—MG-63 (ATTC) was also studied in the separate experiments) to carry out a culture in a contact with ceramic rings. Cultures were maintained in dynamic conditions for the period of 7 to 35 days. After this time, a test evaluating cells viability—MTT test assessing the activity of cellular mitochondrial dehydrogenase was performed. Tests results indicate high tolerability of cells on the used biomaterial ( FIG. 13 ). Additionally, the possibility for an even distribution of living cells on the entire available culture surface of calcite biomaterial was confirmed ( FIGS. 14 and 15 ).
EXAMPLE 6 COMPARATIVE
[0058] Introduction. Selection of the Material Suitable for a Ring Preparation.
During the conducted research work a number of types of cytocompatible materials were tested against osteogenic cells, such materials potentially could be utilized to prepare a ring designated to regenerate losses within mandible or jaw.
As a result of the conducted in vitro and in vivo experiments, it has been recognized that in order to prepare rings according to the invention only cytocompatible material with the open porosity of 70 to 80%, pore size in the range from 200 μm to 800 μm, preferably from 200 μm to 500 μm and the size of junctions between pores not smaller than 100 μm can be used.
Also, preferably, its compressive strength is comparable to the compressive strength of a dried human cancellous bone, namely from 0.2 to 0.7 MPa, preferably, it should be about 0.7 MPa.
It is also desired that the material utilized to prepare the ring according to the invention is biodegradable, however, its degradation should not occur too rapidly and the aforementioned mechanical parameters should be sustained for at least the period of 30 days from the day of ring transplantation.
Additionally, it is desired that the material the ring is made of is hydrophilic. This feature ensures better absorption of the active substances from blood, which improves ring healing and bone tissue reconstruction as well as it facilitates cells seeding.
Moreover, it is desired that the ring is characterized by the microporosity and grittiness of a surface. The ring should be characterized by the ease of surgical convenience that should be understood such that despite its fragility typical for ceramic materials, it preserves its shape and does not crush while handling during the stage of the preparation for an implantation and the implantation itself.
In case of the ring designated to be seeded with osteogenic cells (as in Example 3) the material that the ring is made of should be a suitable culture surface for the osteogenic cells in culture. According to the invention, a material meets such criteria if cells survival on the surface made of a material identical in terms of chemical composition, in a form enabling to culture cells in the conditions comparable to a routine cell culture on the standard culture plates (polystyrene) is not statistically significantly lower than in such a routine culture. During work undertaken to obtain the invention, it was surprisingly founded that statistically significantly lower survival in the plate culture conditions is correlated with survival on the three-dimensional ring structure, and disadvantageous influence of a material that is observed in a plate culture is surprisingly potentiated in the three-dimensional structure. This effect is presented in FIG. 21 . Selected examples describing unsuccessful embodiments of a ring prepared from materials that did not meet the criteria of the invention are presented below.
Chitosan Rings
[0059] During the performed preliminary studies and an identification of the biomaterial suitable to reconstruct existing bone losses within a jaw or mandible rings made of chitosan were prepared. Chitosan is a polymer of natural origin. An elementary unit of a polymer chain is β (1-4) 2-amino-2-deoxy-D-glucose (or D-glucosamin). It is a material belonging to the resorbable polymers group that is being utilized in a production of various medical products. Accordingly, porous chitosan scaffolds of a ring shape and selected internal and external dimensions were prepared. Scaffolds were formed by the extrusion of the previously prepared chitosan granules carried out in an adequate form. The advantage of the obtained scaffolds is their high compressive strength and high biocompatibility. It was suspected that such properties of a material would ensure a suitable supporting construction for cells as well as future bone tissue reconstruction after sample implantation into an acceptor site. Cells were seeded on the prepared scaffolds and subjected to culture in standard experimental conditions. Additional studies on scaffold characteristics were performed in parallel. Based on the obtained results, it was stated that rings prepared by the described method were characterized by a low porosity and a small diameter of junctions between the pores ( FIGS. 17, 18 and 19 ). Results of the cells observations also confirmed that the architecture of the scaffold disables even cells distribution on the sample surface. Accordingly, such scaffold cannot be utilized in clinic because pores size disables blood vessels to invade the scaffold and therefore tissue nutrition.
Within additional experiments attempts for the modification of the chitosan rings preparation were undertaken, however, such attempts did not result in a significant improvement of the scaffolds architecture.
Porous Ring Prepared from Lactic and Glycolic Acid Copolymer
The rings were prepared in a following manner: the mixture of polymers PDLLA-PLGA and PLLA is dissolved in 1,4-dioxan and porogen (NaCl) with the granule size of 250-500 μm in the amount of 270 mg per sample is added. Then the mixture is frozen in the liquid nitrogen and freeze-dried for a minimum of 10 days. After freeze-drying, samples are pressed in forms under vacuum. Then NaCl is washed out from samples and the samples of scaffolds are dried in air for 24 hours following by vacuum drying. Due to such a procedure the material of a desired porosity and pore size was obtained.
Following seeding with cells rings are maintained in cell culture conditions i.e. in the culture medium analogous to the medium in an example presented in present application. Cells well tolerate the culture surface material and divide intensively in the culture, which proves the cytocompatibility of such a biomaterial.
In a continuous culture occurs macroscopically and microscopically visible material degradation such that eventually in in vitro condition (still outside the body system, before implantation to tissues) a product with complete scaffold disintegration is obtained. It is shown in FIG. 20 .
Such a disintegrated product does not meet the criteria that are stated for rings for augmentation despite the fact that the criteria regarding scaffold porosity and material cytocompatibility were met. Therefore, according to the invention it is required that the material a ring is made of was characterized by the stability in aqueous and biologically active environment lasting at least 30 days. | Disclosed herein is a ring prepared from osteoinductive and/or osteogenic material for a use in a dental and orthognathic surgery in case of bone surface deficiency for the introduction of intraosseous dental implants. | 0 |
PRIORITY CLAIM
[0001] This application is a continuation of co-pending International Application No. PCT/EP2014/056053 filed on Mar. 26, 2014, which designates the United States and claims priority from European Application No. 13161194.9 filed on Mar. 26, 2013 and European Application No. 13171754.8 filed on Jun. 12, 2013, each of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method and an apparatus for removing colorants from PET-flake which can be obtained by shredding commercially available used PET bottles.
[0004] 2. Description of Relevant Art
[0005] PET is the common abbreviation for “polyethylene terephthalate” or more precisely “poly(ethylene terephthalate)” (CAS: 25038-59-9). PET is a thermoplastic polyester and widely used for food containers and bottles, e.g. for water, carbonated soft drinks, beer or the like. Pure PET is transparent for visible light with wavelengths between 380 nm and 780 nm and thus colorless. For aesthetic reasons and as well as to protect the liquids to be handled by PET bottles from degrading when subjected to light, the bottles are often colored by organic colorants and/or pigments.
[0006] Large amounts of used bottles are to be recycled. Various chemical recycling techniques are known, in particular glycolysis, methanolysis, hydrolysis, and saponification. However, according to the Petcore PET knowledge centre these methods are unable to remove colors from the PET feedstreams (www.petcore.org/content/processing of 2 May 2013)
[0007] EP 1 153 070 B1 suggests to contact PET with a glycol, e.g. ethylene glycol (briefly “EG”) to thereby obtain oligomers and monomers of the PET, in particular bis-(2-hydroxyethyl) terephthalate (briefly “BHET”, CAS: 959-26-2) in an agitated reactor vessel at a temperature of about 150° C. to 300° C. and an absolute pressure of 0.5 to 3.0 bars. The ratio of EG to dicarboxylic acid is greater than 1 to 5 total glycol units to total dicarboxylic acid units. Lower density contaminants form a distinct top layer in the reactor vessel and are separated from a lower layer containing a remainder of a glycolysis reaction mixture. Remaining immiscible contaminants are removed by filtration or straining.
[0008] PET bottle recycling is addressed by the European Patent EP 1 437 377 B1. First PET bottles are unpacked, steel and aluminum residues are removed and the bottles are shredded. Subsequently, non-PET polymers are separated by winnowing and float-sink separation. The such obtained PET-flake are depolymerized by charging them into EG at 175-190° C. at 0.1-0.5 MPa to thereby obtain BHET which is later subjected to an ester interchange reaction for forming crude dimethyl terephthalate (briefly “DMT”, CAS: 120-61-6) and EG. DMT and EG can be separated, purified and again used as monomers in the polymer industry.
[0009] EP 1 914 270 suggest to recover colorants from dyed polyester fiber as used in PET-fabric by a dye extraction using ethylene glycol.
SUMMARY OF THE INVENTION
[0010] The invention is based on the observation, that the prior art methods for PET-recycling require transparent PET-flake or PET-flake of the same color i.e. include a color sorting step to obtain high quality recycling products.
[0011] The problem to be solved by the invention is to provide a method and apparatuses for the recycling of PET-flake without color sorting.
[0012] The method of the invention can be used for pre-processing PET-flake in particular prior to depolymerization. The PET-flake can be obtained for example by shredding PET bottles. PET-flake are preferably devoid of metal, paper and residues of beverages and other compounds previously stored in the bottles. This can be obtained by known prior art sorting and washing techniques, which are commercially available. The PET-flake may be of any color and may comprise a mixture of colors, e.g. brown PET-flake as well as blue, green, red, or black PET-flake.
[0013] The color removal process preferably comprises at least two process steps.
1) PET-flake are pre-treated in a hot organic liquid and (optional) and 2) Organic colorants are extracted from the PET-flake and the PET-flake are simultaneously embrittled using hot ethylene glycol (EG; IUPAC name: ethane-1,2-diol, CAS: 107-21-1).
[0016] Colorant extraction and simultaneous embrittlement of the PET-flake is obtained by contacting the PET-flake with preferably hot EG in a contacting vessel (step 2 ). Only for brevity this is subsequently summarized by referring only to “extraction”. Extraction (and thus simultaneous embrittlement) is performed preferably at or slightly below the boiling temperature of EG (satp) at about ambient pressure. The extraction temperature T ext is preferably about 197.5° C. (192° C.≦T ext ≦205° C., preferably 195° C.≦T ext ≦200° C., more preferably 196° C.≦Text≦199° C., particularly preferred 197.0°≦T ext ≦197.6° C.) at preferably ambient pressure p a (typically 850 hPa≦p a ≦1100 hPa). The EG extracts the organic colorants and embrittles the PET-flake, however without significant depolymerization. There is no need to add a catalyst to embrittle the PET, because in commercially produced PET, as used for the bottles from which the PET-flake preferably origin, catalysts used for poly-condensation of the PET are embedded in the polymer matrix.
[0017] Below the 194.5° C. (T ext <194.5° C.) the color removal slows down significantly. Above 200° C. (T ext >200° C.) the PET-flake lose their form, get sticky and tend to form a mush with the EG, being is difficult to handle.
[0018] Preferably, the extraction step and as well the optional pre-treatment step are performed at least approximately at ambient pressure (+−200 hPa).
[0019] Preferably, used EG, i.e. EG loaded with organic colorants is preferably continuously removed from the PET-flake and/or at least from the extraction vessel, i.e. the contacting vessel, containing the PET-flake. Fresh, i.e. colorless or at least less loaded EG is added to the PET-flake, preferably continuously.
[0020] Extraction of the PET-flake is preferably completed once the PET-flake are colorless. “Colorless” or the degree of decolorization can be defined using a color analysis in the CIE L*, a*, b* color space (1976) defining a CIE LAB color difference ΔE being the Euklidic Norm of a vector defined by the triple (L*, a*, b*), i.e. ΔE 2 =(L*) 2 +(a*) 2 +(b*) 2 . The mean color distance ΔE of the PET-flake when removing from the EG is preferably less or equal to 20, more preferably less or equal to 10.
[0021] Total depolymerization of the PET to BHET is avoided by the preferred temperature and pressure range and by limiting the contact time between PET and EG, respectively the residence time of PET under extraction conditions. The extraction process removes organic colorants from PET-flake. However, pigments like titanium dioxide (TiO 2 , CAS: 13463-67-7) remain in the solid PET. These pigments migrate very slowly in the amorphous phase of solid-state PET and can be removed by an optional downstream depolymerization process of PET to DMT or any other PET monomer. The mechanism of organic colorants removal is still not fully understood. The working hypothesis is that the organic colorants are extracted from a preferably pretreated amorphous polymer matrix by molecular diffusion and film diffusion.
[0022] PET-flake embrittle in the course of the extraction process. This could be explained by a reduction of the degree of polymerization of PET-flake. However, PET-flake are not fully depolymerized to PET monomers during the extraction step. The degree of polymerizations (Pn) is solely reduced from initially typically 134 to a Pn of about 50 to 25. For example, treatment of bottle grade PET-flake in an EG counter-current flow for about 30 min at about 196° C. yielded embrittled PET-flake with an intrinsic viscosity of IV=0.30 dL/g, a molar mass of Mn=7300 g/mol, and a degree of polymerization of Pn=38. Further extraction treatment for another 30 min yielded PET-flake with an intrinsic viscosity of IV=0.25 dL/g, a molar mass of Mn=5800 g/mol, and a degree of polymerization of Pn=30.
[0023] The extraction is preferably completed as soon as the PET-flake are sufficiently decolorized as explained above. The time to obtain sufficient colorant extraction depends on the residence time, i.e. the time the PET-flake are in contact with EG, the flow velocity of the liquid EG, the flake particle size, flake particle shape and the temperature. Apart from sufficient colorant extraction, the process should preferably be completed before the flake soften. Criteria for completing the extraction step can in addition or alternatively to the degree of decolorization as defined above be an intrinsic viscosity of IV≦0.20 dL/g and/or a molar mass Mn≦4000 g/mol and/or a degree of polymerization Pn≦20 (±5).
[0024] Extracting the organic colorants is preferably obtained by conveying the PET-flake in a conveying direction and simultaneously contacting the PET-flake with liquid EG. In a preferred embodiment extraction is obtained by establishing a counter-current flow of EG directed against the PET conveying direction.
[0025] Such counter-current flow can be realized by conveying the PET-flake in a conveyor, e.g. a screw-conveyor, in a PET conveying or flow direction. Extraction liquid, i.e. liquid EG can be fed to the screw conveyor via an EG inlet down-stream of the PET-flake inlet. The EG is removed from the screw conveyor upstream of the EG inlet. Thus, the EG flows in the opposite direction of the PET-flake flow, to which upstream and downstream refers. The EG flows through the voids of the PET-flake bulk. Such, the PET-flake and the EG are in close contact and the PET-flake are extracted by a counter-current flow of EG.
[0026] Preferably, the PET-flake are heated by heat transfer from condensing EG vapor while being extracted. In other words, at least a part of the EG being used for extraction of colorants from the PET-flake condenses from a gaseous phase into a liquid phase on the PET-flake and/or in already liquid EG. Such, the optimum temperature for colorant extraction can be obtained easily, which turned out to be only slightly below the boiling temperature of EG (197.3° C. at 1013 hPa). In other words, EG provided to the EG inlet or at least one of multiple EG inlets of the conveyor is at least partially in vapor phase and condenses in the conveyor. Additional heat can also be provided to the conveyor by heat transfer media at its shell or by electric heating devices via the shell or any other means.
[0027] Prior to extracting organic colorants from the PET-flake by contacting them with hot EG, the PET-flake are preferably pre-treated in a pre-treating liquid, referred to as pre-processing by pre-treatment. The pre-treatment liquid may at least comprise one of the following compounds: benzophenone (C 13 H 10 O, CAS: 119-61-9) and/or polyethylene glycol 600 (“PEG”, HO(C 2 H 4 O) n , CAS: 25322-68-3) and/or 1,2-dichlorobenzene (C 6 H 4 Cl 2 , CAS: 95-50-1) and/or limonene (C 10 H 16 , CAS: 5989-27-5) and/or 1,4-dioxane (C 4 H 8 O 2 , CAS: 123-91-1) and/or ethylene glycol (C 2 H 6 O 2 , CAS: 107-21-1) and/or triethylene glycol (“TEG”, C 6 H 14 O 4 , CAS: 112-27-6) and/or tetraethylene glycol (C 8 H 18 O 5 , CAS: 112-60-7) and/or methanol (CH 4 O, CAS: 67-56-1). In a particular preferred embodiment the pre-treatment liquid is ethylene glycol (“EG”).
[0028] During the pre-treatment step the PET-flake are brought in close contact with the pre-treatment liquid. For example, the PET-flake can be immersed in a pre-treatment vessel containing the pre-treatment liquid
[0029] The pre-treatment temperature T pre should be above the glass transition temperature (T gl ) of the PET-flake and below the melting temperature (T melt ) of the PET-flake. The glass transition temperature together with the melting point of the bottle grade PET-flake differs with the PET-flake and depends on the PET specification (i.e. the kind and amount of PET co-monomers). A typical glass transition temperature of “bottle grade PET” is about 80° C. (±5 K). The melting temperature of “bottle grade PET” is about 240° C. to 255° C. More preferably, the pre-treatment temperature T pre is below the temperature where significant softening of the PET-flake can be observed (T soft ), to thereby avoid that the PET-flake get “sticky” and agglomerate while pre-treated. This happens typically above 220° C. (±5 K). Briefly summarizing, the pre-treatment temperature interval can be chosen as T gl ≦T pre ≦T melt , more preferred T gl ≦T pre ≦T soft . Typical values for T pre are between 120° C. and 180° C. It has been observed that the PET-flake shrink and the wall thickness increases while pre-treated. It was shown experimentally that the PET relaxes above the glass transition temperature. However, almost no or at least no significant depolymerization has been observed while pre-treating the PET-flake. As well no or at least no significant color extraction and no measureable embrittlement can be observed during the pre-treatment step (step 1 ). However, surprisingly the pre-treatment step enhances subsequent color extraction in step 2 .
[0030] The mass ratio of PET-flake to liquid for pre-treating PET-flake in e.g. EG is preferably at least about 1:2 (possible 1:1 to 1:5). A pre-treatment vessel may be used to immerse the PET-flake in the pre-treatment liquid, e.g. EG. The pre-treatment vessel may be heated to T pre with T gl ≦T pre ≦T melt , and may preferably have a thermal insulation layer. A blanket of gaseous nitrogen (N 2 ) may be used on top of the pre-treatment liquid/PET-flake slurry to avoid contamination of the PET-flake with moisture and/or oxygen. Agitation, e.g. by stirring is preferred. A condenser e.g. on top of and/or above the pre-treatment vessel may be used to recover condensable components (e.g. EG and water from moist PET). Non-condensable components may be removed and e.g. burnt. The pre-treatment liquid can be provided, preferably continuously to the pre-treatment vessel, e.g. via a tube. The tube's outlet is preferably below the fluid level in the pre-treatment vessel. The pre-treatment liquid can be removed, preferably continuously from the pre-treatment vessel for example by an over-flow. A mesh may ensure that the PET-flake remain in the pre-treatment vessel. The PET-flake can be removed using a conveyor means, e.g. a screw conveyor with its lower end inside the pre-treatment vessel.
[0031] The pre-treatment has two advantages: firstly, the PET is dried. PET is hygroscopic and PET-flake being subjected to ambient air have typical moisture (water, H 2 O) content of up to 10,000 ppm by weight (typically 3000 ppm to 6000 ppm) and already small amounts of water may affect the boiling temperature of the extracting liquid and thus have an impact on extracting temperature Text. Secondly, the subsequent colorant extraction is enhanced. It is assumed that pre-treating the PET-flake somehow affects the amorphous part of the solid PET matrix by a kind of “swelling” effect. However, a profound microscopic understanding is still missing. During the pre-treatment step only minor color extraction is noticed.
[0032] The pre-treatment time t pre depends on the pre-treatment liquid and the pre-treatment temperature T pre . In case of pre-treatment in EG with, e.g. T pre =130° C., good results have been obtained with a residence time of t pre =60 min (±15 min). A higher pre-treatment temperature requires a lower residence time, but a non-linear relation between temperature and time is noticed.
[0033] An apparatus for extracting organic colorants from PET-flake preferably comprises a conveyor as extracting vessel for conveying a flow of PET-flake from a PET-flake inlet in a conveying direction to a PET-flake outlet. The conveyor can be for example a screw-conveyor with a screw housing and a conveyor screw for conveying PET-flake via the screw housing from at least one PET-flake inlet in a PET conveying direction to at least one PET-flake outlet. The conveyor has at least one EG inlet, i.e. an extraction liquid inlet in the screw housing. The EG inlet is downstream of said PET-flake inlet. At least one EG outlet, i.e. an extraction fluid outlet is upstream of the EG inlet for providing a counter-current flow. “Upstream” and “downstream” refer to the PET flow, i.e. the PET conveying direction. The apparatus may be used in particular for pre-processing PET-flake prior to depolymerization of PET-flake with an extraction fluid, in particular EG.
[0034] For example, the counter-current EG flow in opposite direction to the PET-flake flow can be obtained if the PET conveying direction is inclined against the horizontal or in other words sloped (including a vertical PET-flake conveying direction). In this case the extraction fluid pours or flows downwards in the conveyor through voids between the PET-flake, whereas the PET-flake are conveyed upwards. In the above example of the screw-conveyor, the screw axis may be sloped. However, the invention is not restricted to this possible arrangement. The EG can of course be provided to the extraction vessel at its lower end and removed at the top, while the PET-flake are conveyed in the opposite direction.
[0035] The apparatus may further comprise at least one EG vapor source being connected to the screw housing for providing gaseous EG, i.e. EG vapor, to the screw housing.
[0036] The conveyor housing may comprise at least one condenser, for example being attached to its screw housing. This arrangement ensures that vapor from the extraction apparatus (which consists at least mainly of EG) is condensed, thus ensuring ambient (or slightly above ambient) pressure in the extraction apparatus.
[0037] Preferably, the condensing chamber has at least one drain for removing condensed EG vapor, i.e. liquid EG. The drain may be connected to at least one extraction fluid-inlet of the screw housing and/or at least one vapor generator for providing a liquid to said at least one vapor generator.
[0038] Preferably, the apparatus further comprises at least a pre-treatment vessel for immersing PET-flake in one of the above specified a pre-treatment liquids at a temperature T pre of T gl ≦T pre ≦T soft . Such immersing is subsequently referred to as pre-treatment (optional step 1 ). Thus, the pre-treatment vessel and/or pre-treatment liquid (e.g. EG) is preferably heated. The pre-treatment vessel contains the pre-treatment liquid. By pre-treating the PET-flake e.g. in liquid EG, water can be removed from the PET. Further, pre-treatment enhances color extraction in the second step as explained above. In the pre-treatment step no significant color extraction or embrittlement is observed. The color of the pre-treatment liquid remains almost unchanged.
[0039] If the pre-treatment vessel comprises a PET strainer for removing PET from the pre-treatment vessel and feeding the PET-flake inlet of the screw conveyor, handling of large amounts of PET-flake is facilitated.
[0040] The pre-treatment vessel has been explained above with respect to EG as pre-treatment liquid. However, the other above cited pre-treatment liquids may as well be used for pre-treatment of PET-flake, e.g. in said pre-treatment vessel.
[0041] Preferably, the apparatus further comprises a rectification apparatus for rectifying liquid EG drained at the screw-conveyor's EG outlet to thereby obtain a colorless fraction and an a fraction comprising organic colorants and other high boiling residues. The colorless fraction may be reused for pre-treating and extracting PET-flake.
[0042] Only for clarity, the term “PET-flake” denotes the singular and the plural, i.e. a single PET-flake as well as a multitude of PET-flake. In an industrial scale process, only the plural is relevant. The terms extractions vessel and contacting vessel are used interchangeably throughout this application, as the color extraction and PET-flake embrittlement is obtained by contacting the PET-flake with hot EG. The pre-treatment vessel for immersing the PET-flake prior to the extraction step could thus as well be referred to as immersing vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] In the following, the invention will be described by way of example, without limitation of the general inventive concept, on examples of embodiment and with reference to the drawings.
[0044] FIG. 1 shows a process flow diagram of a method for extracting organic colorants from colored PET-flake.
[0045] FIG. 2 shows an apparatus for extracting PET-flake with hot EG.
[0046] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] According to the flow diagram shown as FIG. 1 , PET-flake are supplied by PET-flake supply 400 . The PET-flake are typically provided in so called bigbags and thus unpacked as indicated by reference numeral 405 . Subsequently, the PET-flake may pass an optional separator 460 for removing foreign material or PET-flake with a size out of a given specification and stored in a PET-flake reservoir 410 . The PET-flake reservoir 410 is a PET-flake source for the pre-processing PET-flake. Other bulk transport means can as well be used for providing the PET-flake. Required is only a preferable continuous PET-flake stream to the pre-treatment vessel 340 .
[0048] In this example, PET-flake from a PET-flake source, i.e. reservoir 410 , are supplied to a pre-treatment vessel 340 . In the pre-treatment vessel 340 the PET-flake are immersed in EG. EG is preferably continuously provided from an EG-source, in this case an EG-reservoir 110 . The EG is heated to a pre-treatment temperature T pre of typically 150° C. (preferred: T gl ≦T pre ≦T soft ). For heating the EG, EG is pumped from the pre-treatment vessel 340 by pump 124 , fed to a heater 134 and fed back to the pre-treatment vessel 340 . Other possibilities for obtaining the required temperature are as well suitable, for example an electrical pre-treatment vessel heating. EG is removed from the pre-treatment vessel, e.g. continuously via line 345 and may be provided to an EG treatment device, e.g. a filtration and/or rectification unit. Purified EG may be used again, e.g. by providing it to the EG reservoir 110 .
[0049] Pre-treated PET-flake are drained from the pre-treatment vessel and transported via a separator 360 to an extraction vessel 370 . Transporting may be obtained e.g. by use of a rotary feeder 350 . Most EG may be removed from the PET-flake flow using the separator 360 and then fed to a PET-flake inlet 374 of a conveyor 370 used as extraction vessel. For example, a screw-conveyer as shown in FIG. 2 may be used as extraction vessel 370 .
[0050] In the screw conveyor 370 , the PET-flake are conveyed by rotation of the screw from the PET-flake inlet 374 to a PET-flake outlet 375 . EG is provided in a counter-current flow (with respect to the PET-flake flow) to the conveyor. EG is provided from the reservoir 110 and may be split in two lines: In a first line 111 the EG is heated using a first heater 132 and fed as liquid EG to the downstream end of the conveyor. The temperature T l of the liquid EG provided to the extraction vessel should be adjusted to the extraction temperature T ext ,i.e. to: 195° C.≦T l =T ext ≦T boil preferably to T ext =196±1° C., where T boil stands for the boiling temperature of the EG. In the second line 112 , the EG is vaporized at least partially by an EG-vapor generator 130 , symbolized by two heaters 133 ; the number of heaters 133 is of course not essential, nor the energy source for heating the EG. The vaporized EG, i.e. gaseous EG is as well fed downstream of the PET-flake inlet to the conveyor. The gaseous EG thereby heats the PET-flake by condensation preferably to about 197° C., i.e. just below the boiling temperature of EG at ambient pressure. At the upstream end of the conveyor is an EG outlet from which EG is removed to thereby obtain a counter-current flow of EG and PET-flake. The removed EG can be provided to an EG treatment (indicated by arrow 361 ) for purification and reuse.
[0051] Organic colorants are extracted from the PET-flake in the conveyor 370 by contacting the PET-flake with a counter-current EG flow. The PET-flake are preferably at least almost colorless when leaving the conveyor 370 via the PET-flake outlet 375 . The PET-flake are not only at least almost colorless but as well brittle after passing the conveyor 370 . EG leaving the conveyor via the PET-flake outlet 375 can be separated using a strainer 380 . PET-flake from the outlet 375 can be further processed, e.g. by milling. The colorless brittle PET-flake (line 490 ) can be subjected to depolymerization, e.g. by methanolysis as indicated by arrow 499 .
[0052] FIG. 2 shows a simplified screw-conveyor 500 for pre-processing PET-flake, in particular for extracting organic colorants from PET-flake. In other words, the screw conveyor is a possible extraction vessel for extracting organic colorants from PET-flake while simultaneously obtaining an embrittlement of the PET-flake, as referred to as step 2 . In particular, the screw-conveyor as shown in FIG. 2 can be used as conveyor 370 in the scheme of FIG. 1 . The screw-conveyor 500 has a tubular screw housing 510 , the latter housing a conveyor screw 520 , briefly referred to as screw 520 . The screw 520 is preferably motor driven. The longitudinal axis 515 of the screw 520 and accordingly as well of the screw housing 510 is sloped. The screw housing 510 has a PET-flake inlet 374 , being connected to a down pipe 511 for feeding PET-flake to the PET-flake inlet 374 . The down pipe 511 is optional. The screw 520 conveys the PET-flake to a PET-flake outlet 375 at the upper end of the screw housing 510 . A further optional down pipe 519 is attached to PET-flake outlet. The screw housing 510 has nozzles 530 as EG inlets 372 for injecting vaporous EG into the screw housing and thereby heating the PET-flake to a temperature slightly below the boiling temperature of EG. The vaporous EG thus condenses inside the screw housing. The condensed, i.e. liquid, EG flows downwards through the voids in the PET-flake bulk to an EG outlet 373 . At the EG outlet 373 the EG is removed from the screw-conveyor. In addition to the vaporous/gaseous EG, liquid EG may as well be injected into the screw housing 510 for example via EG inlet 371 . The temperature in the conveyor can thus be adjusted by adjusting the amount of EG vapor provided to the extraction vessel. For better control of the temperature, the crew conveyor may have an additional shell for heat transfer by a heat transfer medium and/or other heating means like an electrical heater.
[0053] It will be appreciated to those skilled in the art having the benefit of this disclosure that this invention is believed to provide a method and an apparatus for decolorizing PET. Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
LIST OF REFERENCE NUMERALS
[0000]
100 EG supply
110 EG reservoir/EG source
121 pump
122 pump
123 pump
124 pump
125 pump
126 pump
130 steam generator
132 heater
133 heater
134 heater
340 pre-treatment vessel/immersing vessel
350 feeder (e.g. star feeder)
360 separator
361 to EG treatment (e.g. filtration and/or rectification)
370 conveyor (screw conveyor)/contacting vessel/extraction vessel
371 liquid extraction fluid inlet/EG inlet (fluid)
372 EG inlet (gaseous)
373 extraction fluid outlet/EG oulet (liquid)
374 PET-flake inlet
375 PET-flake outlet
400 PET-flake supply
405 unpacking station
410 PET-flake reservoir/PET-flake source
460 separator
470 transport means
490 decolorized brittle PET-flake line
499 to depolymerization facility
500 screw conveyor/contacting vessel/extraction vessel
510 screw housing
511 downpipe, PET-flake feed
519 downpipe, brittle PET-flake outlet
515 longitudinal axis of the screw 520 and the screw housing 510
520 conveyor screw
530 nozzle | Organic colorants incorporated in colored PET-flake, as being obtained by shredding PET bottles, can be extracted from the PET-flake by extracting the PET-flake with ethylene glycol (EG) at ambient pressure and at the boiling temperature of EG. Pre-treating of PET-flake in EG or other suitable organic compounds prior to extraction enhances the discoloration. | 2 |
TECHNICAL FIELD
The present invention relates to rolling bearing devices used in machine tools, industrial machinery, etc., and particularly to a rolling bearing device constituted as a combination of a rolling bearing and an oil supply unit.
BACKGROUND ART
A rolling bearing device which incorporates an oil supply unit therein is conventional (see Patent Literature 1). In this rolling bearing device, an oil supply unit is mounted on an inner diameter surface of one of two mutually opposed track rings of the rolling bearing, or a fixed-side track ring in this case. The oil supply unit includes a lubrication oil tank which stores lubrication oil; a pump which pumps out the lubrication oil stored in the lubrication oil tank into the bearing; and an electric power generator which drives the pump. The device also includes means which controls the pump in accordance with bearing conditions thereby controlling an amount of discharged oil.
Patent Literature 2 also discloses a rolling bearing device which includes a similar oil supply unit.
CITATION LIST
Patent Literature
Patent Literature 1: JP-A 2004-108388 Gazette
Patent Literature 2: JP-A 2004-316707 Gazette
SUMMARY OF INVENTION
Technical Problem
Often, the oil supply unit which is incorporated near the bearing is in an environment which is inaccessible from outside. In order to monitor, troubleshoot or otherwise service the oil supply unit, it is necessary to perform regular overhaul or provide communication lines, for example, extended to the outside. This poses limits on use and/or assemblability.
It is therefore an object of the present invention to provide a rolling bearing device which allows checking if its oil supply unit is functioning properly while the bearing device is under an assembled state, without any need for disassembly or communication lines, for example, extended to the outside.
Solution to Problem
As a solution to the above-described problems, the present invention provides a rolling bearing device comprising a combination of a rolling bearing and an oil supply unit which includes at least: a lubrication oil tank, a pump which sucks lubrication oil from the lubrication oil tank and discharges the lubrication oil from a discharge port; a driving section which drives the pump; and a generator section which supplies the driving section with electric energy. The oil supply unit is attached to a fixed-ring-side member of the rolling bearing or a spacer adjacent to the rolling bearing, and the oil supply unit further includes, within itself, a communication unit which transmits operation information of the oil supply unit to an outside.
The oil supply unit may have its constituent members incorporated inside a housing to form a unit for attaching to/detaching from the housing.
The communication unit may be provided by one which transmits the information by means of an oscillatory wave.
There may be a plurality of the oil supply units, each served by the communication unit so that these oil supply units are simultaneously usable.
The rolling bearing device according to the present invention can be usable in machine tools, wind turbines and railway systems.
Advantageous Effects of Invention
According to the present invention, a communication unit which transmits operation information of the oil supply unit to an outside is provided inside the oil supply unit. Therefore, it is possible to check the oil supply unit as assembled, that it is functioning properly. Further, detection by means of oscillatory waves provides such advantages as it enables wireless information communication possible, it makes it possible to improve assemblability, and it enables simultaneous use of a plurality of the oil supply units.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a sectional view taken in lines A-A in FIG. 3 .
FIG. 2 is a partial sectional view taken in lines B-B in FIG. 3 .
FIG. 3 is a sectional view of an oil supply unit taken in lines X 1 -X 1 in FIG. 1 .
FIG. 4 is an enlarged sectional view showing an example of an electric power source of an oil supply unit.
FIG. 5 is an enlarged sectional view showing an example of an electric power source of an oil supply unit.
FIG. 6 is an enlarged sectional view showing an example of an electric power source of an oil supply unit.
FIG. 7 is an enlarged sectional view showing an example of an electric power source of an oil supply unit.
FIG. 8 is a detailed block diagram of a controller.
FIGS. 9A and 9B are schematic illustrations which show an example of a communication device that utilizes oscillatory waves in information transmission. FIG. 9A shows a state before oscillation, whereas FIG. 9B shows a state after oscillation.
FIG. 10 is a schematic illustration which shows an example including a communication devices that utilize oscillatory waves in information transmission.
FIG. 11 is a schematic illustration which shows an example including a plurality of communication devices that utilize oscillatory waves in information transmission.
FIG. 12 is a schematic illustration which shows an example where an oil supply unit according to the present invention is mounted around a main shaft of a machine tool.
DESCRIPTION OF EMBODIMENTS
Hereinafter, embodiments of the present invention will be described based on the attached drawings.
The rolling bearing device 10 according to the embodiments shown in FIG. 1 through FIG. 3 includes a rolling bearing 11 ; a spacer 12 press-contacted onto an axial end of the rolling bearing; and an oil supply unit 13 incorporated in the spacer 12 ; and when used, is assembled into a space between a rotation shaft 14 and a housing 15 . The rolling bearing 11 has another end, on which another spacer 16 is press-contacted. These two spacers 12 , 16 provide axial positioning of the rolling bearing 11 . The rotation shaft 14 in this embodiment is horizontal.
The rolling bearing 11 may be provided by whichever of an angular contact ball bearing and a deep groove roller bearing, and includes a rotation-side track ring provided by an inner ring 17 ; an outer ring 18 on a fixed side; a predetermined number of rolling elements 19 placed between these track rings; and a retainer 21 which keeps a predetermined distance between the rolling elements 19 . The rolling bearing 11 is pre-packed with desirable grease, and a seal plate 22 is attached to an end on the spacer 16 side.
The spacer 12 includes an inner-ring-side spacer 12 a and an outer-ring-side spacer 12 b . The inner-ring-side spacer 12 a is fitted in and fixed to the rotation shaft 14 side and is press-contacted onto an end surface of the inner ring 17 . The outer-ring-side spacer 12 b is fitted in and fixed to an inner diameter surface of the housing 15 , and is press-contacted onto an end surface of the outer ring 18 . The other spacer 16 is also fitted in and fixed to the rotation shaft 14 side and the housing 15 side in the same fashion, and is press-contacted onto the other end surfaces of the inner ring 17 and of the outer ring 18 .
As shown in FIG. 3 , the oil supply unit 13 includes a generator section 41 , a charger section 42 , a controller 43 , a driving section 44 , a pump 45 , a lubrication oil tank 46 , a communication unit 49 which wirelessly transmits operating information of the oil supply unit 13 , and other components, which are arranged in an annular housing 24 in a circumferential direction thereof.
As shown in FIG. 2 , the annular housing 24 of the oil supply unit 13 is constituted by a housing main body 24 a which has a generally U-shaped section with an open end facing away from the rolling bearing 11 ; and a lid 24 b which closes the open end of the housing main body 24 a and is detachable from/attachable to the housing main body 24 a . The housing main body 24 a and the lid 24 b are made of the same thermally plastic resin material such as PPS.
The lid 24 b of the housing 24 is fixed to the housing main body 24 a with screws 24 c . By unscrewing the screws 24 c and removing the lid 24 b , it becomes possible to replenish the lubrication oil tank 46 inside the housing main body 24 a with lubrication oil without removing the entire oil supply unit 13 .
The housing main body 24 a has its outer circumferential surface adhesively fixed to an inner diameter surface of the outer-ring-side spacer 12 b . The adhesive for fixing the housing main body 24 a may be provided by epoxy resin for example.
Next, the lubrication oil tank 46 which is incorporated inside the housing main body 24 a is provided by a bag 46 a of an elastic resin, and is disposed in an arcuate form along the annular casing 24 .
The bag 46 a has a suction tube 45 a connected to the pump 45 . The suction tube 45 a may be integrated with the bag 46 a by sandwiching the tube between two films of resin which will be formed into the bag 46 a and then performing thermal welding to complete the bag 46 a.
When the bag 46 a is formed by blow molding, a suction tube 45 a may be blow-formed integrally with the bag 46 a.
The bag 46 a which constitutes the lubrication oil tank 46 can be formed of such a material as nylon, polyethylene, polyester and polypropylene; there is no specific limitation to the material as far as the material is not attacked by lubrication oil stored in the bag 46 a.
Lubrication oil which is loaded in the bag 46 a of the lubrication oil tank 46 desirably has a viscosity of VG22 for example, since an excessively high viscosity will cause too much burden on the pump and the power source.
The pump 45 has a suction tube 45 a which sucks lubrication oil from the lubrication oil tank 46 ; and a discharge tube 45 b from which the sucked lubrication oil is discharged. The discharge tube 45 b has a discharge nozzle 45 c at its tip, from which lubrication oil is supplied to between the fixed-side track ring and the rotation-side track ring of the rolling bearing 11 .
As the pump 45 is driven, lubrication oil in the lubrication oil tank 46 is sucked. The lubrication oil is supplied from the discharge nozzle 45 c at a tip of the discharge tube 45 b to between a fixed and a rotating track rings of the rolling bearing 11 . After a predetermined amount of the lubrication oil is supplied, the pump 45 is stopped.
Even if the pump 45 is stopped, interior of the pump 45 and interior of the tube are filled with lubrication oil, so there can be a case where lubrication oil inside the lubrication oil tank 46 is siphoned and leaked out of the discharge nozzle 45 c . In order to prevent this leakage, a leak prevention mechanism which prevents lubrication oil leakage is provided in discharge tubing of the pump 45 .
This leak prevention mechanism can be implemented as shown in FIG. 3 as an arrangement that the discharge tube 45 b is provided with an on-off valve 48 , and the on-off valve 48 opens only when the pump 45 is working whereas the on-off valve 48 is closed in all the other occasions. Another example is an arrangement that after the pump 45 is driven and the oil supply operation is finished, the pump 45 is driven in reverse direction to introduce air into the discharge tubing.
Timing of the supply of lubrication oil, i.e., timing to drive the pump 45 may be when electricity is charged in a condenser in the charger section 42 and a predetermined voltage is reached. If power generation efficiency is too good and the charging time is too short, the stored voltage may be discharged to a resister, for example, when a predetermined voltage value is reached, so that an interval may be made in operation timing of the pump 45 . In this case, there is a cycle(s) of charging and discharging before the pump 45 is operated. The number of this charge-discharge cycles can be used in controlling the operation interval of the pump 45 . As another example, a timer function may be used to trigger when the power storage voltage is reached a predetermined value, to provide an interval in the operation cycle of the pump 45 . In this case, the above-described charge-discharge cycle is not repeated.
The suction tube 45 a , which is connected to the suction side of the pump 45 , extends into the lubrication oil tank 46 to suck lubrication oil stored in the lubrication oil tank 46 .
On the other hand, the discharge tube 45 b which is connected to the discharge side has its tip connected to a discharge nozzle 45 c for discharging lubrication oil into the rolling bearing. It is desirable that the discharge nozzle 45 c has its tip disposed at a location between the inner and the outer rings of the bearing closely to the inner ring's outer circumferential surface. The discharge nozzle 45 c has a nozzle hole of an appropriate inner diameter based on a relationship between surface tension due to base oil viscosity and the amount of discharge.
The annular housing 24 incorporates, other than the lubrication oil tank 46 , the following and other components in its circumferential direction; the generator section 41 , the charger section 42 , the controller 43 , the driving section 44 , the pump 45 , and the communication unit 49 which wirelessly transmits operating information of the oil supply unit 13 .
As shown in FIG. 4 , the generator section 41 can be provided by one which generates electric power by way of Seebeck effect. When the rolling bearing device 10 is operating, temperature of the inner ring 17 and the outer ring 18 increases due to friction heat with the rolling elements 19 (see FIG. 1 ). In general configuration, the outer ring 18 is assembled into the housing 15 of the machine it serves, and therefore loses heat by thermal conduction, resulting in temperature difference between the inner ring 17 and the outer ring 18 . Different temperatures conducted to the respective heat conductors 52 , 53 causes the Seebeck element 54 to have temperature difference between its two end surfaces, causing the element to generate electric power according to Seebeck effect.
When using the above configuration where heat conductors 52 , 53 are provided to penetrate the inner circumferential surface and the outer circumferential surface of the housing main body 24 a respectively and a Seebeck element 54 is placed between these heat conductors 52 , 53 , an adhesive having good heat conductivity should desirably be used on a surface where the heat conductor 52 which penetrates the outer circumferential surface of the housing main body 24 a makes contact with the inner diameter surface of the outer ring-side spacer 12 b . It should be noted here that the heat conductor 52 which is on the outer ring-side has its outer diameter equal to an inner diameter of the outer ring spacer 12 b and is fitted thereto for improved heat release. On the other hand, the heat conductor 53 which is on the inner ring side has its inner diameter surface not in contact with the inner ring spacer 12 a . If possible, it is desirable that the outer ring-side and the inner ring-side heat conductors 52 , 53 have the same volume.
Preferably, thermal grease, for example, should be applied between the inner diameter surface of the outer-ring-side spacer 12 b and the heat conductor 52 ; between the heat conductor 52 and the Seebeck element 54 ; and between the Seebeck element 54 and the inner-ring-side heat conductor 53 , for improved contact and heat conductivity. Thermal grease generally contains silicone as a primary ingredient. The heat conductors 52 , 53 should be made of a metal which has a high heat conductivity rate. For example, silver, copper, gold, etc. are good candidates, among which copper is the most common due to cost reasons. In addition, copper alloys which contain copper as a primary ingredient can also be used. Further, sintered bodies containing copper as a primary ingredient are also usable.
Other than those which generate electric power by way of Seebeck effect, the generator section 41 may be provided by any of those shown in FIG. 5 , FIG. 6 and FIG. 7 .
The one shown in FIG. 5 is applicable when there is an alternating magnetic field inside the rolling bearing device 10 . Inside built-in spindles of machine tools, or near high-frequency apparatus which handle large amount of electric power, there is leakage magnetic flux or high-frequency radiation. The leakage flux is utilized to generate power by way of electromagnetic induction. More specifically, a combination of an iron core 55 which has an E-shaped profile with one of its sides open, and a coil 56 are combined to catch the alternating magnetic field efficiently to generate power by electromagnetic induction. The open end of the iron core 55 is provided with an insulating base 57 . If the frequency of the leak flux is known, the iron core 55 may be eliminated and the coil 56 which resonates with the frequency of the leak flux may be used.
The one shown in FIG. 6 is applied when there is vibration inside the rolling bearing device 10 . Specifically, a fixed-side insulation substrate 58 is opposed by a moving-side insulation substrate 59 , with each of the substrates being formed with a large number of electrodes 60 and only the electrodes 60 on the fixed-side insulation substrate 58 being laminated with electrets 61 to oppose to the electrodes 60 on the moving-side insulation substrate 59 , with a gap. The moving-side insulation substrate 59 is only movable in a direction indicated by Arrow a in the drawing by a mover 62 .
When there is vibration in the rolling bearing device 10 , the mover 62 causes the moving-side insulation substrate 59 to oscillate in the Arrow a direction. This generates electric charge between the electrodes 60 due to electrostatic induction caused by relative movement between the fixed-side insulation substrate 58 and the moving-side insulation substrate 59 , and by the electrets 61 thereon. The generated charge is tapped for use as electric power.
The one shown in FIG. 7 is also for application when there is vibration inside the rolling bearing device 10 . Specifically, an elastic sheet of piezoelectric body 64 is disposed between a fixed-side insulation substrate 58 and a weight 63 . Vibration generated in the rolling bearing device 10 causes the weight 63 to oscillate in the Arrow a direction due to the weight 63 and the piezoelectric body 64 . The process causes deflection in the piezoelectric body 64 , and an electromotive force by way of induced polarization. The generated electromotive force is tapped for use as electric power.
Electric charge generated by the generator section 41 is stored in the charging section 42 which is provided by a battery, condenser, etc. If a condenser is employed, an electric double layer condenser (capacitor) is desirably used.
As shown in FIG. 8 , the controller 43 has sensors such as a bearing temperature sensor 47 a , a bearing rotation sensor 47 b , a lubricant remaining quantity sensor 47 c , and a lubrication oil temperature sensor 47 d . Signals from these sensors are inputted to a CPU 51 , which then automatically controls the pump 45 in accordance with temperature and rotation status of the rolling bearing 11 , thereby controlling the amount of lubrication oil supply.
The communication unit 49 is attached to the outer-ring-side spacer 12 b as shown in FIG. 1 . The communication can be made by means of oscillatory waves. Use of oscillatory waves makes wireless communication possible and improves assemblability.
FIG. 9 shows an oscillatory wave generator 70 . Referring to FIGS. 9A and 9B , a piezoelectric body 71 b is pasted onto a metal plate 71 a . On a surface of the metal plate 71 a facing away from the piezoelectric body 71 b , a hammer 72 is provided. These are supported by a fixed case 73 , which is fixed to an oscillatory wave conduction medium 74 . The hammer 72 and the oscillatory wave conduction medium 74 are separated from each other by a small gap 75 . As a voltage is applied to the piezoelectric body 71 b in this component, a piezoelectric effect (inverse piezoelectric effect) causes the piezoelectric body 71 b to deform mechanically as shown in FIG. 9B . Accordingly, the metal plate 71 a is deformed, causing the hammer 72 to hit the oscillatory wave conduction medium 74 to become a source of oscillatory wave, to generate oscillatory waves inside the oscillatory wave conduction medium 74 . The oscillatory waves travel through the oscillatory wave conduction medium 74 . It should be noted here that in an actual application, the oscillatory wave conduction medium 74 is provided by the housing 24 or the like which houses the outer-ring-side spacer 12 b and the oil supply unit 13 in FIG. 1 .
By using the oscillatory waves obtained by the above-described methods, communication is performed as follows:
As shown in FIG. 10 , the oscillatory waves are detected by an oscillatory wave detector 77 which is disposed to oppose to the oscillatory wave generator 70 to sandwich the oscillatory wave conduction medium 74 .
In FIG. 10 , the oscillatory wave generator 70 is driven at a frequency generated by a wave-form generator 76 which generates an oscillatory wave A of a predetermined frequency. This oscillatory wave A travels through the oscillatory wave conduction medium 74 and reaches the oscillatory wave detector 77 . The oscillatory wave detector 77 converts the oscillatory wave A into an electrical signal. A reference symbol B indicates a detected wave form.
By utilizing the communication means described above, it is possible to wirelessly check a state of operation of the oil supply unit 13 which is assembled inside the relevant component. In FIG. 10 , a reference symbol 76 indicates the wave-form generator for generation of the oscillatory waves A, a reference symbol 78 indicates an amplifier, a reference symbol 74 indicates the oscillatory wave conduction medium, and a reference symbol 77 indicates the detector.
The state of operation of the oil supply unit 13 can be specifically identified by the following means: The oscillatory wave A is generated at each time of pump operation. Each time the oscillatory wave A is detected, it is counted in an accumulating fashion. This makes it possible to estimate how much lubricant remains. At the same time, it is also possible to confirm that the oil supply unit 13 is functioning properly.
A plurality of oil supply units 13 may be assembled to implement the communication means, as shown in FIG. 11 .
Basic constituent elements are identical with those shown in FIG. 10 ; however, each of the two components has one of two oscillators 76 a , 76 b which are different from each other in the frequencies they generate. Also, a filter 79 is provided on the detection side, to receive signals of specific frequencies. Utilizing this means makes it possible to check a state of operation of a specific oil supply unit.
FIG. 12 shows rolling bearing devices 10 each incorporating an oil supply unit 13 that has the functions described above. FIG. 12 shows part of a spindle (rotation shaft 14 ) around which the oil supply units 13 are mounted. The oscillatory wave A travels through the outer-ring-side spacer 12 b and the housing 15 . Then, the oscillatory wave A is detected by an oscillatory wave detector 77 which is attached to the housing 15 . The frequency of the oscillatory wave A is selected to be different from the vibration frequency generated by the rolling bearing 11 and from a natural frequency (resonant frequency) of the spindle 14 . By selecting such a frequency, it becomes easy to detect the oscillation generated by the oscillatory wave generator and to eliminate unnecessary resonance of the components.
As described above, by providing an oscillatory wave communication component inside the oil supply unit 13 , it becomes possible to check an electrical component as assembled, that the electrical component is functioning properly. Further, detection by means of oscillatory waves provides such advantages as it enables wireless information communication possible, it makes it possible to improve assemblability, and it enables simultaneous use of a plurality of the oil supply units 13 .
REFERENCE SIGNS LIST
10 Bearing Device
11 Rolling Bearing
12 Spacer
12 a Inner Ring Side Spacer
12 b Outer-Ring-Side Spacer
13 Oil Supply Unit
14 Rotation Shaft
15 Housing
16 Spacer
17 Inner Ring
18 Outer Ring
19 Rolling Element
21 Retainer
22 Seal Plate
24 Housing
24 a Housing Main Body
24 b Lid
24 c Screw
41 Generator Section
42 Charger Section
43 Controller
44 Driving Section
45 Pump
45 a Suction Tube
45 b Discharge Tube
45 c Discharge Nozzle
46 Lubrication Oil Tank
46 a Bag
46 b Thermally Welded Portion
47 a through 47 d Sensors
48 ON-OFF Valve
49 Communication Unit
51 CPU
52 , 53 Conductors
54 Seebeck element
55 Iron Core
56 Coil
57 Insulating Base
58 Fixed-Side Insulation Substrate
59 Moving-Side Insulation Substrate
60 Electrodes
61 Electrets
62 Mover
63 Weight
645 Piezoelectric Body
70 Oscillatory Wave Generator
71 a Metal Plate
71 b Piezoelectric Body
72 Hammer
73 Fixed Case
74 Oscillatory Wave Conduction Medium
75 Small Gap
76 a , 76 b Oscillators
77 Oscillatory Wave Detector
79 Filter | A rolling bearing device includes a rolling bearing and an oil supply unit. The oil supply unit includes a lubrication oil tank, a pump which sucks lubrication oil from the lubrication oil tank and discharges the lubrication oil from a discharge porta driving section which drives the pump and a generator section which supplies the driving section with electric energy. The oil supply unit is attached to a fixed-ring-side member of the rolling bearing or a spacer adjacent to the rolling bearing. The oil supply unit further includes a communication unit which transmits operation information of the oil supply unit to an outside. | 5 |
FIELD OF THE INVENTION
The invention concerns a current lead for superconducting rotary electrical machines. The function of such a device is to provide an electrical connection between a supply terminal at ambient temperature and one end of a superconductive conductor which requires as little cooling as possible to keep the end of the superconductor at a very low temperature, in spite of the heat input from the current lead.
BACKGROUND OF THE INVENTION
The cooling power required to do this is the mechanical or electrical power required by the cooling devices, such as helium liquifiers, for example, needed to keep the superconductors at their operating tempeatures. The invention is particularly suited to machines in which the superconductors are cooled to a temperature at which their superconductivity is maintained by means of a cryogenic fluid such as helium passed through cooling circuits. After passing through the machine, this fluid, or part of it, may be used for cooling the current leads. If all the cooling fluid is used, its flow rate depends on the requirements of the machine, and cannot be modified to take account of the specific requirements of the current leads.
SUMMARY OF THE INVENTION
The present invention provides, in one aspect, a current lead for superconducting rotary electrical machines comprising a mixed section including a superconductive conductor in thermal and electrical contact with a normal conductor.
A normal section includes a normal conductor continuous with the normal conductor of the mixed section.
A system is provided for circulating a cooling gas through said mixed section so as to cool it to a temperature compatible with superconductivity and then over said normal section to prevent excessive transfer of heat from the normal section to the mixed section.
Fins are provided for increasing the area of the lead in thermal contact with the cooling gas, and a tube of a material which is a good conductor of heat and electricity.
A superconductive conductor is fastened to the tube in good thermal and electrical contact with the tube and extends along it from a cold end of the tube to an intermediate point. This section of the tube constitutes said mixed section of the device and the remaining section of the tube constitutes said normal section of the device, which provides a zone of thermal transition between the intermediate point and a hot end of the tube.
A series of plates are contained within the tube and substantially perpendicular to the tube axis. The plates fill the tube so as to define a series of flat chambers between adjacent plates, each of which comprises a hole enabling the cooling gas to flow from the cold end of the tube to the hot end through the series of chambers, the gas passing from one chamber to the next via the hole in the plate separating the two chambers.
In another aspect, the present invention provides a rotor for a superconducting rotary machine comprising superconductive winding subject to high-intensity, variable magnetic fields.
Two normal conductors are provided for conveying current to said superconductive winding.
Two current leads are provided for effecting the transfer of current between the normal conductors and the superconductive winding, each of the leads having a cold end adjacent the superconductive winding and a hot end adjacent the normal conductor.
A system is provided for introducing a pressurised cooling fluid into the rotor and circulating it over the superconductive winding and the current leads with the fluid passing from the cold end of said leads to the hot end.
Each current lead is in the form of a tube of a material which is a good conductor of heat and electricity, a "mixed" section of the tube extends from the cold end to the hot end thereof and has fastened to it a superconductive conductor in good thermal and electrical contact with the tube, the remainder of which constitutes a "normal" section thereof.
A series of plates are contained within the tube and are substantially perpendicular to the tube axis, the plates filling the tube so as to define a series of flat chambers between adjacent plates, each of which comprises a hole enabling the cooling gas to flow from the cold end of the tube to the hot end through the series of chambers. The gas passes from one chamber to the next via the hole in the plate separating the two chambers and a pressure drop occurs as the fluid passes through said hole.
This is a different situation from that of conventional current leads used for the electrical supplies of superconducting devices bathed in liquid helium in a cryostat. These current leads, which dip into the cryostat, are cooled by the flow of gaseous helium resulting from the evaporation of the liquid helium. The cooling effect is sometimes improved by fitting transverse metal fins. As an increase in the electrical current results in increased l 2 R loses, the heat input to the cryostat from the current leads also increases, which increases the rate at which the liquid helium evaporates, which increases the cooling effect on the current leads. There is thus a self-compensating effect which tends to reduce fluctuations in the temperature of the current leads. There is no self-compensating effect with the current leads in accordance with the invention, which are cooled by a fluid in the vapour or hypercritical phase fed to the cold end at a rate imposed by the operating conditions of the machine.
In conventional current leads and in current leads in accordance with the invention it is possible to distinguish two successive zones with progressively increasing temperatures. These zones are:
(a) a cold zone, in which a superconductive conductor is in good thermal and electrical contact with a "normal" metal conductor, i.e., one without superconducting properties but with good thermal and electrical conductivity, such as copper or pure aluminium, and in which the temperature is always low enough to support superconductivity; and
(b) a transition zone, with only a normal conductor, and in which the temperature increases progressively from a low value adjacent the cold zone to ambient temperature, which will hereinafter be referred to as "hot".
A major problem in the design of a current lead is selecting the cross-section of the normal conductor in the transition zone. If the cross-section is too small there will be excessive I 2 R losses which will generate large amounts of heat to be removed by the cooling fluid. If the cross-section is too large, however, too much heat will be conducted along the normal electrical conductor, from the hot zone to the cold zone, and this too will have to be removed by the cooling fluid. A minimum value of the sum of these two quantities of heat, and thus a minimum value of the cooling power needed to remove it, corresponds to an optimum value of the cross-section, and is substantially proportional to the length of the transition zone. It is inadvisable to depart to too great an extent from the optimum value of the ratio of the cross-section of the normal conductor to the length of the transition zone. The length of the current lead cannot be reduced to any desired value, as it is within this length that the total quantity of heat mentioned above must be transferred to the cooling fluid. It is to limit this length that fins have been fitted to current leads dipping into cryostats. These fins increase the rate at which heat is transferred from the current lead to the cooling fluid. The transfer of heat is an even more critical problem in the case of current leads in accordance with the invention because, as there is no liquid bath at the lower end, the temperature of the fluid begins to rise as soon as it receives any heat, which reduces its capacity for removing heat from the current lead.
The current leads in accordance with the invention are fed at the cold end with gaseous or hypercritical helium drawn from the rotor cooling circuit. The flow rate is set by means of an expansion valve located downstream of the current lead and opening into the circuit for recovering the helium at ambient temperature. Unlike conventional current leads, the amount of heat conducted to the cold end along the current lead in accordance with the invention is practically zero.
For a given value of the current fed to a current lead in accordance with the invention, with a conductor of fixed cross-section, there is a threshold value for the helium flow rate below which part of the cold zone will fail to remain at a superconductive temperature. Thus it is possible to define a minimum flow rate for the maximum current such that the temperature of the mixed section will remain low enough for superconductivity to be obtained, the length of this mixed section being sufficient to permit transfer of current between the superconductor and the normal conductor to which it is welded.
Another serious problem occurs in the case of current leads for superconducting rotary machines. In the rotor of such a machine, centrifugal force causes variations in the pressure and temperature in the cooling fluid, depending on its distance from the rotor axis. The isotherms in the helium tend to stabilise as coaxial cylinders, the temperature and density increasing from the centre towards the outside. If the superconducting machine is stopped for a short period, the current leads must be effectively cooled to evacuate heat conducted from the hot end, whatever the angular position of the rotor. This means that free convection currents due to gravity must be eliminated. The differences may be considerable if the cooling fluid is a gas such as helium, and they favour the creation of convection currents which impede proper cooling of certain parts of the current leads. The cooling gas in some areas may flow at a much reduced velocity, or even in the opposite direction to the general flow of the gas. These factors indicate the use of radially arranged current leads, but this is not a practical solution in the case of rotary machines.
Preferred embodiments of the present invention provide a current lead for rotary electrical machines which is of simple design, compact, consistent with low levels of cooling power and capable of installation in any direction relative to the rotor axis, and especially parallel to that axis.
An embodiment of the invention will now be described, by way of non-limiting example only, and with reference to the accompanying diagrammatic drawings, in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an axial cross-section through a cryogenic alternator rotor comprising current leads for rotary electrical machines in accordance with the invention;
FIG. 2 is an axial cross-section through one of the current leads of the rotor shown in FIG. 1, the superconductive and normal conductors not being shown in this figure;
FIG. 3 is a cross-section through the current lead shown in FIG. 2, on the plane A--A which is perpendicular to the axis of the lead and passes through the "mixed" section thereof; and
FIG. 4 is a cross-section through the current lead shown in FIG. 2, on the plane B--B which is perpendicular to the axis of the lead and passes through the "normal" section thereof.
Parts common to more than one figure have the same reference numeral in all figures in which they appear.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the current lead to be described hereinafter may be used for supplying electrical power to the rotor 2 of a cryogenic alternator. The rotation axis of the alternator is indicated at 5. The rotor is supported by bearings 3, and the windings 4 consist of multifilament superconductors made of niobium-tin (Nb 3 Sn) or niobium-titanium (NbTi) filaments embedded in a copper matrix. The electrical current passed through the windings 4 is lead in through fixed conductors 9, brushes 10 and sliprings 12, and may have a value of several thousand amperes. The windings are cooled by a flow of helium introduced into the rotor through an axial conduit 6. The helium is at a temperature in the region of 4° K and at a pressure of 1 to 10 bars. A flow of approximately 1 g/s of helium is diverted from the helium for cooling the windings, and is used to cool the current leads 8 which connect the normal conductors 12 to the superconductors 14. The terms "upstream" and "downstream" used hereinafter refer to the direction of flow of the helium for cooling the current leads, the temperature of the helium increasing as it travels from the upstream to the downstream end of its path.
The helium leaving the current leads 8 is at a temperature close to ambient temperature, and is recovered in a separate chamber (not shown) which surrounds the rotor shaft and is isolated from the atmosphere by conventional rotary seals.
FIG. 2 shows one of the current leads 8 to a larger scale. It has a cold (upstream) end 20 which is connected to the superconductor 14 (FIG. 1), and incorporates a passage (not shown) through which is passed helium drawn from the windings 4 and already used to cool the superconductor 14. The current lead 8 has the general form of a cylindrical tube and is made of copper, which is a good conductor of heat and electricity. The helium enters the tube at the cold end and flows through to its hot end 22, which it leaves at a temperature close to ambient temperature.
The superconductor 14 is fastened in a groove 24 in the outer surface of the tube 8, but it could alternatively be welded in. The groove 24 extends parallel to the tube axis, over a portion of its length referred to in this specification as the "mixed" section, because in this section the electrical current is carried both by the tube 8 and by the superconductor 14 welded into the groove 24. In the mixed section, the wall 30 of the tube 8 is relatively thick, so that the longitudinal flow of electrical current generates only low I 2 R losses. This arrangement, in combination with the use of discs with the same configuration as those to be described below in relation to the "normal" section of the tube, provides a substantially uniform temperature throughout the mixed section which is low enough to maintain superconductivity in the superconductor 14 connected to it. The length of the mixed portion is sufficient to enable current to pass transversely through the wall of the tube 8 and the soldering into the superconducting filaments of the superconductor 14 without excessive heat generation and in spite of the resistive walls of the superconductor.
The remainder of the tube 8 constitutes the "normal" section of the current lead, extending to the "hot" end 22 to which the normal conductor 12 is connected.
The thickness of the wall 32 of the tube 8 in the normal section is such as to minimise the heat input at the intermediate point 26 which constitutes an interface between the mixed and normal sections of the current lead. This heat input results from two causes. One is thermal conduction from the hot end 22 to the intermediate point 26. The other is the generation of heat by the I 2 R losses due to the passage of the electrical current. If the wall is too thin, the heat generated by these I 2 R losses will be too great, but if the wall is too thick, the amount of heat input due to thermal conduction will be too great. For a given length of current lead, the optimum thickness depends on the effectiveness of the cooling system and on the value of the current. It is advantageous if the wall thickness in this normal section is less than that in the mixed section. From the point of view of reducing the cooling power requirements, it is advantageous to maximise the lengths of the mixed and normal sections, but these lengths are obviously limited by the space available in the machine.
The cooling of the normal section of the tube 8 is improved by filling it with discs 28 of the same material, these discs having the same area as the internal cross-section of the tube, but each being formed with a hole 38. There are similar discs 40 in the mixed section, but the discs 28 and 40 are not the same size. The discs are flat and perpendicular to the longitudinal axis of the tube. They form a series of chambers 34 and 36 separated from one another by one of the discs. The helium passes from the "upstream" chamber 34 to the "downstream" chamber 36 via the hole in the disc between the two chambers. Each of the chambers is defined by two of the discs and by the inside wall of the tube 8. The distance between adjacent discs is sufficiently large to produce a substantially uniform pressure in each chamber, the pressure dropping to a significant extent on each passage through a hole in one of the discs. This avoids the creation of unwanted gaseous convection currents. The diameter, number and separation of the discs are selected to ensure a large surface area in contact with the helium and a mean tangential helium flow rate resulting in a good heat transfer coefficient and a limited difference in temperature between the helium and the walls of the tube.
The holes in the discs are sufficiently small to prevent any alternating flow of helium due to free convection within the holes. As a result, the temperature of the helium in the chambers defined by the discs is staggered along the length of the tube.
The discs must not be too thick, as this would limit the surface area in contact with the helium by reducing the number of discs. They must not be too thin, however, as heat must be transferred from the tube walls to the central portion of each disc.
The following dimensions are in arbitrary units, to indicate the relative sizes of the various sections of the device. In a typical machine these dimensions might be expressed in millimeters:
______________________________________ Mixed section Normal section______________________________________Total length 200 - 500 500 - 1500Outside diameter of tube 8 50 - 100 50 - 100Wall thickness of tube 8 10 - 20 1 - 2______________________________________
Experience has shown that it is advantageous if the area of the holes is from 0.5 to 5.0% of the area of the disc in which they are formed, and if the axial length of the chambers 34 and 36 is between 1 and 10% of their diameter (or of the transverse dimension in the case of a non-cylindrical tube 8 with non-circular plates rather than discs as in this example).
FIG. 3 shows a disc 40 with its hole 42, as fitted to the mixed section of the current lead. FIG. 4 shows a disc 28 with its hole 38, as fitted to the normal section.
The holes 38 and 42 near the rims of the discs are preferably disposed on alternate sides of the rotor axis 5, so as to force the helium to flow across the chambers 34 and 36 in a direction perpendicular to that axis.
The current lead may be made by assembling the discs and spacing rings inside the tube and welding the whole together by electron bombardment from the outside of the tube, or by brazing.
The material used may be copper or a copper alloy.
As the device comprises a current lead for the input of current and another for the output of current, and helium inlet and outlet conduits, it is convenient to arrange the two current leads symmetrically, one on each side of the rotor axis.
The current leads in accordance with the invention are preferably located outside the zones subjected to high-intensity, variable magnetic fields, i.e., near or even outside the bearings 3. This avoids the generation of heat in the devices by eddy currents. | A current lead for a superconducting rotary machine is constituted by a copper tube having a superconducting conductor fastened (e.g. by soldering) to a portion of its length, the entire length of the tube having copper cooling plates each of which blocks the bore of the tube leaving only a small hole for the passage of gaseous or hypercritical helium. The current lead is particularly applicable to the generation of electric power using cryoalternators. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 61/135,309, filed Jul. 18, 2008, entitled “Aldehyde Reducing Coating.”
FIELD OF THE INVENTION
The present invention relates to materials for the interior building environment and specifically to building materials which have the capability to reduce the amount of volatile organic compounds (VOC's), such as aldehydes, in the interior building space. More specifically, compared to other known aldehyde reducers, the combination of amino silane (AS) and multivalent metal carbonate (MVMC) is unexpectedly superior in reducing formaldehyde with a longevity of reaction heretofore unachieved.
BACKGROUND OF THE INVENTION
A wide variety of building materials and finishing materials in static structures, such as homes, commercial buildings and schools are commonly coated and/or impregnated with compositions designed to impart the ability to reduce the concentration of VOC's. Porous building materials, such as ceiling tile substrates prepared from a slurry of fibers, fillers and binders, are exemplary of such materials.
In the following description, formaldehyde is used for illustrative purposes of a VOC which includes other aldehydes. The International Agency on Cancer Research has classified formaldehyde as a known carcinogen. Exposure to high concentrations of formaldehyde, as well as chronic exposure at lower concentrations, can cause watery eyes, burning sensations in the eyes and throat, difficulty in breathing and other symptoms. It is also common for people to develop sensitivity to formaldehyde, as well as other aldehydes, resulting in skin rashes, hives and the like. People are often exposed to formaldehyde in the interior building environment through its use in construction materials, wood products, textiles, home or office furnishings, paper, cosmetics, cigarette smoke, pharmaceuticals and indoor cleaning products. Formaldehyde levels are particularly high in new construction due to high emissions from new construction materials. Thus, there has been a long felt need to reduce or eliminate formaldehyde concentrations in the interior building environment.
Conventional attempts include but are not limited to reaction with amines and other formaldehyde reactive materials. Furthermore, there have been attempts, specifically in the art of ceiling tile and gypsum wallboard substrates, to include formaldehyde reducing additives in the overall formulation of the slurry from which the board is made as well as in the coatings applied thereto. Although some reduction of formaldehyde from the air has been achieved via these reactive systems, the formaldehyde reduction is short lived. As a result, a more effective formaldehyde reducer, and in particular, one having a long efficacy of substantial formaldehyde reduction is needed.
SUMMARY OF THE INVENTION
The present invention provides an aldehyde reducing composition for building materials, such as porous substrates and cellulose substrates; as well as other building materials such as metal and glass. The composition of the invention is especially suitable for adding to building product board substrates, such as acoustical ceiling panels and gypsum wallboards. The composition of the invention can be applied during manufacturing or can be post applied to already constructed room surfaces.
In one example embodiment, a composition formulation includes the dry product of water, amino silane (aminopropyl-triemethyoxy silane) and a multivalent metal carbonate. The multivalent metal carbonate is selected form the group consisting of calcium carbonate and magnesium carbonate. The composition may optionally include silica gel to achieve even greater aldehyde reduction. As will be evidenced by the following description, the combination of amino silane and a multivalent metal carbonate provides an unexpected superior spectrum of properties heretofore unachieved by known aldehyde reactive systems. The composition provides greater formaldehyde reduction over a long period of time heretofore unachieved. Also, the chemisorptions reaction results in aldehyde being permanently-bonded within the composition thereby preventing release of the aldehyde back into the air. Even more surprisingly, when silica gel is added to the amino silane and multivalent metal carbonate, even longer term efficacy is obtainable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic representation of Tables 5-8 showing data of percent of formaldehyde reduced (Y) vs. time (X).
FIG. 2 is a graphic representation of Table 10 showing data of percent of formaldehyde reduced (Y) vs. time (X).
DETAILED DESCRIPTION OF THE INVENTION
The primary ingredients of the composition of the invention are an AS and a MVMC. As set forth in more detail below, monoamino silane and diamino silane were each added to coating formulations which included a MVMC, and, specifically, calcium carbonate. The coating was applied via spraying, however, the coating can applied by any other method including roller, brush, roll coating, curtain coating, and knife coating. In the specific use of the system in a coating formulation, the solids content is in the range from about 1% to about 90% and is preferably around 50%. The composition of the invention is preferably waterborne, however, solvent mixtures can also be used as long as the solute can disperse the formaldehyde reacting additive.
Each example coating formulation set forth in Tables 1-4 was applied to glass microfiber filter paper to test its formaldehyde removal capability and efficacy. The formaldehyde reduction testing was conducted in a 65L stainless steel environmental testing chamber using the Environmental Chamber Test described in more detail below. Water, amino silane and optionally silica gel are first mixed together to form a wet mixture. Other additives, except for the binder, are then added to the wet mix. The binder is then mixed into the wet mixture now containing the other additives.
Table 1 below illustrates a first example coating formulation (formulation #1).
TABLE 1
Ingredient
Purpose
% of Wet Weight
% of Dry Weight
Water
Solute
30.00
0
Ethylene Vinyl
Binder
7.33
6.80
Chloride Latex
Diphenyl Amine
Antioxidant
1.00
0.92
Sodium Polyacrylate
Dispersant
0.08
0.15
Silicone Defoamer
Defoamer
0.06
0.12
Calcium Carbonate
Filler
46.53
64.34
Slurry
Diamino Silane
Aldehyde
5.00
9.27
(N-aminoethyl
Reactant
aminopropyl
trimethoxy silane)
Silica gel
10.00
18.4
Solids = 54%
Filler/Binder Ratio = 14.4
Wet Application = 20 g/ft2
Dry Application = 10.8 g/ft2
Calculated Amino Silane Application = 1.0 g/ft2
Calculated Silica Gel Application = 2.0 g/ft2
Table 2 below illustrates a second example coating formulation containing no silica gel (Formulation #2).
TABLE 2
% of Dry
Ingredient
Purpose
% of Wet Weight
Weight
Water
Solute
30.00
0
Ethylene Vinyl Chloride
Binder
7.33
6.80
Latex
Diphenyl Amine
Antioxidant
1.00
0.92
Sodium Polyacrylate
Dispersant
0.08
0.15
Silicone Defoamer
Defoamer
0.06
0.12
Calcium Carbonate
Filler
56.53
82.74
Slurry
Diamino Silane
Formaldehyde
5.00
9.27
(N-aminoethyl
Reactant
aminopropyl
trimethoxy silane)
% Solids = 54
Filler/Binder Ratio = 14.4
Wet Application = 20.0 g/ft2
Dry Application = 10.8 g/ft2
Calculated Amino silane Application = 1.0 g/ft2
Table 3 below illustrates a third example coating formulation containing no calcium carbonate (Formulation #3).
TABLE 3
Ingredient
Purpose
% of Wet Weight
% of Dry Weight
Water
Solute
83.94
0
Silicone
Defoamer
0.06
0.12
Defoamer
Diphenyl Amine
Antioxidant
1.00
0.92
Diamino Silane
Formaldehyde
5.00
9.27
(N-aminoethyl
Reactant
aminopropyl
trimethoxy silane)
Silica gel
10.00
18.4
% Solids = 16
Wet Application = 20.0 g/ft2
Dry Application = 3.2 g/ft2
Calculated Amino Silane Application = 1.0 g/ft2
Calculated Silica Gel Application = 2.0 g/ft2
Table 4 below illustrates a forth example coating formulation (Formulation #4) containing a monoamino silane.
TABLE 4
% of Wet
Ingredient
Purpose
Weight
% of Dry Weight
Water
Solute
30.00
0
Ethylene Vinyl Chloride
Binder
7.33
6.80
Latex
Diphenyl Amine
Antioxidant
1.00
0.92
Sodium Polyacrylate
Dispersant
0.08
0.15
Silicone Defoamer
Defoamer
0.06
0.12
Calcium Carbonate
Filler
46.53
64.34
Slurry
Monoamino Silane
Formaldehyde
5.00
9.27
(Aminopropyltriethoxy
Reactant
silane)
Silica gel
10.00
18.4
Solids = 54%
Filler/Binder Ratio = 14.4
Wet Application = 20 g/ft2
Dry Application = 10.8 g/ft2
Calculated Amino Silane Application = 1.0 g/ft2
Calculated Silica Gel Application = 2.0 g/ft2
The amino silane can be amino C 1-2 alkoxy silane selected from the group consisting of triethoxy silane, trimethoxy silane, methyldiethoxy silane and methyldimethoxy silane, or other silane materials that have amino functionality attached, which includes, but is not limited to, N-amino ethyl-aminopropyl-triemethoxy silane, N-amino ethyl-aminopropyl-triethoxy silane, N-amino ethyl-aminopropylmethyl-dimethoxy silane, N-amino ethyl-aminopropylmethyl-diethoxy silane, aminopropyl-triethoxy silane, aminopropyl-trimethoxy silane.
Although the preferred binder is ethylene vinyl chloride, any conventional binding agent can be used. For example, the binder can be any of the following: ethylene vinyl chloride, epoxies, urethanes, polyesters, natural and modified natural polymers (such as protein or starch), and polymers that contain any of the following monomers→vinyl acetate, vinyl propionate, vinyl butyrate, ethylene, vinyl chloride, vinylidine chloride, vinyl fluoride, vinylidene fluoride, ethyl acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl methacrylate, styrene, butadiene, urethane, epoxy, melamine, and any ester. The composition can optionally contain small amounts of processing additives including surfactants, defoamers, dispersing agents, thickeners, biocides and antioxidants. For example the antioxidant, diphenyl amine, though not required to achieve formaldehyde reduction, is included in the above formulations in order to prevent oxidation of the amine reactive groups when such amine groups are exposed to heat processes where the temperature exceeds 75 degrees Celsius. Thus, the antioxidant is unnecessary if no post drying process heating is required. Antioxidants can include, but are not limited to, diphenyl amines, tris(nonylphenyl) phosphite, benzophenone sulfonic acid, substituted benzophenone, di(tridecyl) thiodipropionate, and hindered phenols.
Method for Measuring Formaldehyde Reduction:
Purified air mixed with known amount of formaldehyde from a Permeation Oven is introduced continuously into an Environmental Test Chamber at a fixed flow rate. A sample with the test-coating is placed inside the chamber. The test chamber and the air are maintained at 73.5 F and the relative humidity of the air is 50%. The formaldehyde concentration in the output stream in measured in accordance with ASTM D-5197 Test Method at various time intervals. Based on the difference between the input and output formaldehyde concentrations, the percentage reduction in formaldehyde is estimated. In general, the overall methodology follows the guidelines provided in ASTM D-5116 and ISO 16000-23 (draft).
The extent of reduction in formaldehyde was determined at 2 levels of input concentration—1.6 ppm. and 0.1 ppm. The extent of reduction was found to be independent the input concentration for a given sample size. But the duration of reduction was inversely proportional to the input concentration and directly proportional to sample size. These results confirm that formaldehyde reacts with the test-coating following 1 st order reaction kinetics.
The longevity of formaldehyde reduction at typical room concentration of 0.013 ppm was estimated assuming 1 st order kinetics:
Conversion: 1.60 ppm/0.013 ppm/24 hrs/day/365 days/year=years
TABLE 5
Formulation #1 (Formaldehyde Input 1.60 ppm)
Formaldehyde
Time (hours)
Measured (ppm)
Reduced (%)
0
1.60
0
24
0.092
94.52
48
0.086
94.88
72
0.081
95.18
144
0.092
94.52
Sample size: 3 × 3 inches
Air Humidity 50% Rh.
Temperature 73.5 F.
Air flow rate - 1.3 Air Change per hour
TABLE 6
Formulation #2 (Formaldehyde Input 1.60 ppm)
Formaldehyde
Time (hours)
Measured (ppm)
Reduced (%)
0
1.60
0
24
0.14
91.3
72
1.47
8.70
168
1.60
0
Sample size: 3 × 3 inches
Air Humidity 50% Rh.
Temperature 73.5 F.
Air flow rate - 1.3 Air Change per hour
TABLE 7
Formulation #3 (Formaldehyde Input 1.60 ppm)
Formaldehyde
Time (hours)
Measured (ppm)
Reduced (%)
0
1.60
0
24
0.24
85.0
48
0.32
80.0
72
0.40
75.5
144
0.45
71.9
Sample size: 3 × 3 inches
Air Humidity 50% Rh.
Temperature 73.5 F.
Air Flow rate - 1.3 Air Change per hour
TABLE 8 Formulation #4 (Formaldehyde Input = 1.60 ppm) Time (hours) Measured (ppm) Formaldehyde Reduced (%) 0 1.60 0 24 0.12 92.50 48 0.16 90.00 72 0.20 87.50 144 0.21 86.87 Sample size: 3 × 3 inches Air Humidity 50% Rh. Temperature 73.5 F. Air flow rate - 1.3 Air Change per hour
Tables 5-8 are represented graphically in FIG. 1 .
The graph shown in FIG. 1 illustrates clearly that the system of the invention is highly effective in reducing formaldehyde. Surprisingly, the formulations #1, #2 and #4 having both an amino silane and calcium carbonate exhibit clearly the unexpected substantial improvement of high aldehyde reduction capability over a long period of time. FIG. 1 further illustrates that the amino silane and calcium carbonate combination without silica gel is clearly more effective for long term formaldehyde reduction than using an amino silane and silica gel alone, i.e. without the calcium carbonate. Further, diamino silane is clearly more effective than a monoamino silane. Moreover, the formulation of Tables 5 and 8 provided the best results, which, in turn, suggest that amino silane, silica gel and multivalent metal carbonate work synergistically to remove formaldehyde with superior and unexpected long term reactivity. It is believed that the amino silane spreads over the surface area of the silica gel forming a near monolayer of amino silane and that such monolayer is indeed formed without the need for chemical grafting which is conventionally required in the art to form such monolayers. Regardless of the actual mechanism, formulations which display this behavior are extremely useful in improving the air quality of the interior building environment.
The composition of the invention can be applied in the manufacturing of a building product board substrate or post applied to already constructed room surfaces. One anticipated application of the formaldehyde reducing coating of the invention is as the finish coating for mineral fiber acoustical ceiling tile such as CIRRUS ceiling tiles available from Armstrong World Industries, Inc. The following is to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. In the following example, all parts and percentages are by weight unless otherwise indicated.
Formulation #1 set forth above was applied to acoustical ceiling tiles, and particularly, to CIRRUS ceiling tiles and tested using the test method set forth above. The following conditions were used: Formaldehyde Input=1.60; Loading Factor=0.40/m; Relative Humidity=50%; Temperature=25 C.
Table 9 illustrates the longevity of formaldehyde reduction at typical room concentration of 0.013 ppm using the conversion set forth above.
TABLE 9 Time in Hours @ 1.60 ppm Measured (ppm) Time in Years @ .013 ppm** 0 1.600 0 24 0.121 0.34 72 0.119 1.01 144 0.130 2.02 216 0.150 3.03 312 0.240 4.38 384 0.450 5.40 480 0.900 6.74 552 1.110 7.76 650 1.350 9.13 720 1.416 10.12 816 1.450 11.46 888 1.490 12.48 984 1.500 13.83 **Conversion: 1.60 ppm/0.013 ppm/24 hrs/day/365 days/year = years
Table 10 illustrates Formaldehyde Reduction by Year @0.013 ppm.
TABLE 10
Formaldehyde
Time in Years *
Reduction (%)
1
92%
2
92%
3
91%
4
87%
5
78%
6
60%
7
40%
8
28%
9
19%
10
13%
11
10%
12
8%
13
6%
Table 10 is represented graphically in FIG. 2 . As can be seen from the above data in Table 9, surprisingly, the addition of an amino silane and silica gel to a MVMC based coating provided a dramatic increase in longevity up to about 12 years for interior spaces. More specifically, the average formaldehyde reduction for a system containing amino silane, MVMC and silica gel achieves an average formaldehyde reduction of: 94% for the first year; 88% over the first 5 years; 60% reduction over the first 10 years; and 55% reduction over the first 12 years. Although it is well known to use MVMC's, such as calcium carbonate and magnesium carbonate, in construction materials and finishes, there is no reason to expect that its use in combination with amino silane would provide enhanced formaldehyde reduction.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
For example, although the preceding description illustrates the use of the unexpected superior aldehyde reducing system of the invention in a coating to be applied to surfaces in the interior building environment, the aldehyde reducing system can be used in the core of a building material such as an acoustical mineral fiber panel or gypsum wallboard and is not intended to be limited to its use in a coating. In addition, although the discussion and examples refer to application of the aldehyde reactive substance as it is applied to ceiling panel substrates, it is not a requirement to achieve the aforementioned unexpected superior spectrum of properties. The aldehyde reactive system is useful in or on walls as well as other interior building materials, and, therefore, the system is not intended to be limited to its use in or on a ceiling panel substrate. Also, as stated above, other MVMC's, such as magnesium carbonate, could be substituted for calcium carbonate in the above examples. | A composition which provides enhanced removal of aldehydes from the air of the building interior. The composition includes an amino silane and a multivalent metal carbonate and is especially suitable for adding to building product board substrates, such as acoustical ceiling panels and gypsum wallboards. The composition of the invention can be applied during manufacturing or can be post applied to already constructed room surfaces. The composition provides longevity of aldehyde removal heretofore unachieved. | 1 |
BACKGROUND
[0001] Peer-to-peer scenarios may be exemplified by the absence of a “server” in a traditional client-server environment. Such a paradigm may be viewed as an instance of distributed computing, where a system of (often heterogeneous) nodes operate in a cooperative or confederated fashion to complete a given task. A number of examples have been recently reported, including hybrid approaches such as that of Napster, which uses a centralized client-server model for lookups and direct peer-to-peer communication for file transfers, as well as completely distributed file sharing architectures such as Gnutella.
[0002] In general, peer-to-peer applications thus contrast to a traditional client's dependence on a server. In reality, however, the distinction between peer-to-peer and client-server is often blurred, and peer nodes can be viewed as taking on the roles of both a client and a server.
[0003] Current peer-to-peer infrastructures, however, typically do not provide flexible/dynamic support for operations such as multimedia services. For example, typical peer-to-peer infrastructures implement “download”-style data transfers via Transmission Control Protocol (TCP) only, despite the fact that multimedia can be streamed and viewed in real time using an unreliable protocol such as User Datagram Protocol (UDP). Compounding this problem, some peer-to-peer infrastructures do not even support direct source-to-destination transfers, instead propagating data node-by-node through the network.
[0004] Moreover, many current systems limit the scope of user queries to queries by filename, making it difficult for users to devise innovative new query mechanisms that can take advantage of the richer semantics of media content. Finally, multimedia files exhibit different characteristics than other files. Multimedia files can exist in a variety of different formats, resolutions, and qualities. Hence, depending on the end user's requirements, a multimedia-aware delivery system should be able to send the same in different format to different users.
[0005] As such, there is a need to support a more dynamic peer-to-peer platform for exchanging diverse data such as multi-media data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a block diagram of the interoperation of peers within a Global Network Universe according to one embodiment.
[0007] [0007]FIG. 2 is a block diagram illustrating the support module according to one embodiment.
[0008] [0008]FIG. 3 is a block diagram of the interoperation of peers within a Global network Universe according to one embodiment.
[0009] [0009]FIG. 4 is a flow diagram describing the operations according to one embodiment.
DETAILED DESCRIPTION
[0010] The present application describes a peer-to-peer (P 2 P) support module to improve sharing of data/resources in a peer-to-peer environment. Illustrated in FIG. 1 is a P 2 P network configuration of peers (e.g., nodes, computers, set-top boxes, ect.) One or more of the nodes within the network configuration may include a P 2 P support module of the present invention to improve the sharing of data/resources. As further illustrated in FIG. 1, node 120 includes a P 2 P support module, according to one embodiment, in the memory of the node.
[0011] One characteristic of a Peer-to-peer environment is transparency of the physical location of a resource. That is, the location of data and other resources need not be determined by the applications using the peer-to-peer network. The data or resources (e.g., computation/Central Processing Unit (CPU) bandwidth, storage, etc.) can exist anywhere in the peer-to-peer global network universe, and the system handles the discovery and the delivery/utilization of the data/resource to the requesting application of a peer node. To support the transparency, in one embodiment, the P 2 P support module is separated from the traditional Operating System, as illustrated in more detail in FIG. 2. The P 2 P support module interfaces with the network transport services 104 of the operating system 102 , according to one embodiment.
[0012] The P 2 P support module, in one embodiment as illustrated in node 120 , includes P 2 P service layer 106 (described in greater detail below). In addition, the P 2 P support module includes support handlers 108 , which provide transformation and computation services on the data/resources obtained via the peer-to-peer service layer 106 . The handlers assist in making the system modular, flexible and extensible. For example, in one embodiment, the support modules may provide transcoding (format conversion) support (e.g., MPEG 2 to MPEG 4 ). In addition, the support modules may also provide multimedia watermarking, and other security features.
[0013] In addition, a scripting language interpreter 110 , may also be provided to support applications 112 with programmatic access to the services provided by the P 2 P support module below.
[0014] In alternative embodiment, additional components/services may be provided and/or some of the components/services discussed above may not be included, without departing from the present invention.
[0015] A subset of the P 2 P support module, Tthe peer-to-peer service layer 106 , supports providing the illusion of data location transparency throughout a network of nodes via the following features discussed in detail.
Transport Mechanisms
[0016] In a peer-to-peer environment, data is likely to be transmitted over a variety of heterogeneous communication medium including telephone lines, high-speed wired networks, wireless local area networks, Bluetooth networks, and mobile cellular networks etc. Typically, in existing peer-to-peer networks, the transport protocols used are typically reliable in nature. While this approach masks the specifics of the underlying channel and is amenable to rapid prototyping and implementation, it may not be well suited for real-time delivery of multimedia data. Further, even in the case of delay-insensitive media data, wireless peers are likely to have limited storage resources and the concurrent playback and streaming of the data may thus be limited.
[0017] As such, considering the variety of different network conditions and setups on the Internet, a flexible peer-to-peer framework should support different transport mechanisms. In one embodiment, the network transport interface 104 between the peer-to-peer Service Layer 106 and the OS 102 , is hot-pluggable. In particular, the network transport interface supports the incorporation of different transport handlers (e.g., TCP, RTP/UDP, etc.). As a result, in one embodiment, the peer support module allows the transport mechanism to be specified by the application, chosen from the set of available protocols supported by the network transport services.
[0018] For example, a video player application on a wireless handheld device might request to the peer services layer 106 that it only receive a video via RTP/UDP in combination with Forward Error Correction (FEC) and Automatic Repeat Request methods, in order to support real-time viewing of the stream. In contrast, a delay-insensitive application that prefetches and downloads videos on to a home server might specify the use of a simpler default protocol such as TCP as its transport protocol. The peer services layer 106 of the peer support module obtains the requested data at the source host(s) via the necessary protocol(s), pursuant to the request of the application.
[0019] Furthermore, in an alternative embodiment, the peer services layer provides support for wireless devices. In particular, the peer services layer is aware of the status of the wireless peer, such as battery state, location, mobility, etc., in addition to parameters common to the other peers (e.g. available bandwidth, screen resolution, available media players, etc). In one embodiment, wireless peers can announce their capabilities and status, for other peers to better accommodate media delivery to them. For example, if a wireless peer signals a low battery state, the other peers react by changing the media transport protocol for this wireless peer to be more power efficient (usually at the expense of reducing, e.g., media quality).
[0020] Furthermore, in an alternative embodiment, the application support module may adjust the personalization of content delivered to the device depending on its (device) location. For example, in a museum/exhibition a wireless peer device may receive access to the media content, which is linked to a particular item located in the vicinity on the peer device. Another example is having media data delivered to both the mobile device and another device (e.g., speakers, standalone monitor, display wall) that is located in the vicinity of a mobile device for synchronized delivery of multimedia data.
Data Naming
[0021] In one embodiment, the peer-to-peer service layer 106 of the P 2 P support module supports user-defined representations of data. In one embodiment, the P 2 P service layer 106 may map user-defined names or metadata to a fixed Globally Unique Identifier (GUID), which may then be used by all peers to identify a piece of data and optionally track different copies of the data around the network.
[0022] In one embodiment, peer nodes throughout the network include directory services, which provide a view of where data is stored in the network. In one embodiment, the directory is a hash table mapping user-assigned names to the GUIDs, although in alternative embodiments, the directory may also support a tree structure or other organization structures. The directory services of different peer nodes may work in a cooperative fashion to help establish a view of the global network universe for each peer node. In another embodiment, which may be appropriate for relatively smaller systems requiring fast directory service lookups, global directory information may be duplicated across nodes.
[0023] In one embodiment of the P 2 P support module, user-specified query/resource handlers are provided in the peer nodes, to support customized queries better suited to individual content types. In this approach, in one embodiment, a user-specified query/resource handler in a peer node is used to locate a resource matching a given query. For example, a query for “video stream with mountains in the background” may be routed to a user-specified query/resource handler, which can use peer daemon Application Program Interfaces (APIs) to locate the requested resources.
[0024] In the case of directory service lookups, in one embodiment a peer daemon invokes the same query on other peers that support the same query mechanism. In an alternative embodiment, in addition to supporting user-defined queries, the system may provide a number of pre-defined query types that are available on all peers, e.g. to locate resources by filename, by file type, etc. Furthermore, in one embodiment of the system, peers on the network may cache the results to previous queries.
Dynamic resource retrieval (transcoding)
[0025] In one embodiment, locating a version of a resource on the network is determined by a computation of a user-defined cost function (i.e., a metric that attempts to rank and prioritize available paths to the resource). In this context, a path consists of both a conventional network route and/or sequence of transformations throughout the network that are necessary to deliver the requested resource to the requesting node.
[0026] In order to deliver the requested version of a resource, existing copies of the requested resource may need to be transformed by the support modules 108 to satisfy constraints of the application/peer node requesting the resource. For example, in the case of requested video, existing content in MPEG- 2 format may need to be downscaled spatially and temporally, quantized, and converted to a low bitrate MPEG- 4 stream for viewing on a wireless device.
[0027] In another example, a user without access to Microsoft® PowerPoint® may request a version of a presentation as a GIF file only, which could result in dynamic transformation of the content to the necessary format. Such transcoding may be accomplished on demand on sufficiently powerful machines, or in another embodiment as the result of background processes operating on host nodes, which may perform speculative content adaptation, e.g. based on previous requests.
[0028] In one embodiment, the cost function and constraints imposed by the user would determine whether a new copy of the content would be generated, targeted specifically for the specific requirements, or whether an existing copy would suffice. By minimizing the computed cost function, the peer service layer determines the most appropriate technique for computing and obtaining the transformed resource or accessing a pre-stored version.
[0029] In addition, in one embodiment, the data to be transmitted could be transcoded based on the network bandwidth/error rate between peer nodes. In one embodiment, the data could be transcode into a low-bitrate content when network is congested and cannot handle a higher-bitrate streaming in real-time. In another embodiment, the data could be transcoded into a more error-resilient format when the communication link is wireless and the channel coding quality is low.
System Implementation
[0030] In one embodiment, as illustrated in FIG. 3, the peer-to-peer nodes each include a peer-to-peer daemon 220 and a client API 222 to be linked into applications using the peer-to-peer service. The peer-to-peer daemon is responsible for connecting with the peer-to-peer daemons at other peer-to-peer nodes to form neighboring relationships and to transmit queries/data/resources.
[0031] In one embodiment, the peer-to-peer daemon provides support for peer-to-peer operations. The daemon handles the transport of metadata, actual data, and query requests.
[0032] In one embodiment, the basic unit of traffic on the peer-to-peer network is a packet. One embodiment of a packet contains the following fields:
[0033] 1. Command: the type or the purpose of the request contained in the packet.
[0034] 2. Arguments: the list of arguments specific to the command.
[0035] 3. Auxiliary information for the packet (e.g., GUID, made time, expiration time, sequence number, time to live value, a cost value, and ID of the node that send this request).
[0036] In one embodiment, the following example commands are used as described in the method described in the flow diagram of FIG. 4. In step 402 NAME GUID is announced. The NAME is a user-provided meta-description of a resource, and the GUID is the system-assigned id for the resource. This command informs neighboring peer nodes of the presence of a new resource.
[0037] In step 404 , a query SEARCH-STRING is issued by a node searching for data/resource. The SEARCH-STRING is a user-specified query searching for data/resources. In one embodiment, each node interprets the query as it sees fit; and the requesting node does not specify a standard query language or query semantics.
[0038] For example, in one embodiment, a request for media data consist of two parts: a description of the media data requested as well as, a description of the format in which the media data should be delivered. An example of a video delivery format description is: width=320; height=240; bit rate=512kbits/s; type=mpeg 4 .
[0039] For retrieval purpose, media data is described by metadata such as the time of creation, place of creation, content of the data, etc. In one embodiment, each media data has one special metadata field called GUID. The GUID assumes that each media data is unique at its insertion time into the peer-to-peer network, and therefore a globally unique ID should be assigned to it. Replicas (with the same binary representation or in a transcoded representation) will have the same GUID in order to show that they all represent the same ‘unique’ media data.
[0040] An example of a metadata description for videos is: title=“The Matrix”; Content=“Meeting Morphius”; or GUID=87245792438952394-SDGK-3453 [MH1][ik2]
[0041] In step 406 , an answer SEARCH-STRING GUID is sent as a reply in response to the query requests. The resource that satisfies the query SEARCH-STRING is identified by GUID. In one embodiment, the command only answers queries and informs of the existence of resources but does not provide the actual data. In one embodiment, the GUID of the resource may change as the ANSWER packet passes through a separate peer node. More specifically, when the data is actually forwarded from the separate subsequent node, the data with an old GUID will be converted to a new copy with a different GUID representing the separate subsequent node.
[0042] In step 408 , a Get GUID requesting a resource identified by GUID is sent by the node requesting the resource/data. In step 410 , a Put GUID DATA [expiration-time] command is sent actually carrying the DATA or the content resource identified by GUID. For a PUT packet, the GUID may change and the data may get transformed to a new format at a separate subsequent node as the packet is transmitted throughout the peer network.
[0043] In one embodiment, a cost value inside each packet is used when passing an ANSWER packet. In particular, each node has a cost function that adds a cost value to the cost of the request. The cost function contains the cost function computation handler, which can be installed dynamically by the user and takes two arguments: the request data specification and the real data specification. Given the specifications, the handler computes the actual cost of doing data conversion from the real data specification to the request data specification at this node, if the response node has the capability to do the conversion. The cost value is then added to the Answer packet. The answers are presented to the original querying client who can then choose one data resource/GUID.
[0044] In one embodiment, if a local node cannot provide the desired information, it forwards the requests to all its neighbors, minus the node where the request originally comes from. Moreover, in one embodiment, the answer command leaves a record in the nodes along the path of its return to the original querying node. As a result, in one embodiment, each node may keep a record of the GUID of the Answer, the GUID of the answered resource, its metadata, and the GUID of a new copy of the resource if the node supports data conversion and has trancoded/converted the resource.
[0045] Thus when a Get command arrives at a node the node may proceed to check its records of past Answers and may change the GUID argument of the Get packet to the incoming GUID of the past Answer packet. Similarly, when the requested resource identified by the incoming GUID actually arrives, the peer node may invoke an external data conversion program to create the resource identified by the outgoing GUID and then put the new resource in the Put packet before forwarding it.
[0046] The architecture and methods described above can be stored in the memory of a computer system (e.g., set top box, video recorders, etc.) as a set of instructions to be executed. In addition, the instructions to perform the operations described above could alternatively be stored on other forms of machine-readable media, including magnetic and optical disks. For example, the operations of the present invention could be stored on machine-readable media, such as magnetic disks or optical disks, which are accessible via a disk drive (or computer-readable medium drive). Further, the instructions can be downloaded into a computing device over a data network in a form of compiled and linked version.
[0047] Alternatively, the logic to perform the operations as discussed above, could be implemented in additional computer and/or machine readable media, such as discrete hardware components as large-scale integrated circuits (LSI's), application-specific integrated circuits (ASIC's), firmware such as electrically erasable programmable read-only only memory (EEPROM's); and electrical, optical, acoustical and other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.); etc.
[0048] Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A method and apparatus to support a first peer node receiving an inquiry for data from a second peer node. In one embodiment, the first peer node transcodes the data before transmitting the data to the second peer node, wherein the transcoding includes converting the data into a format that can be processed by the second peer node, and transmitting the data to the second peer node in a transport specification as requested by the second peer node. | 6 |
This application is a continuation of application Ser. No. 09/789,100 filed Feb. 20, 2001, now abandoned, which in turn is a divisional of application of Ser. No. 09/076,192 filed May 12, 1998, which issued Mar. 27, 2001 as U.S. Pat. No. 6,207,020.
FIELD OF THE INVENTION
The invention relates to the art of papermaking, and particularly to a method for conditioning fibrous webs such as paper and paperboard webs on a papermaking machine after the web is dried to improve the properties of the web.
BACKGROUND
The conventional process of papermaking involves formation of a web of fibers on a papermaking machine using a moving porous foraminous support wherein water is drained from a dilute slurry of fibers deposited on the support with further water removal from the web in a press roll section and final removal of water in a dryer section of the machine. In a typical papermaking process, the fibrous web from the press roll section contains about 32 to 45 wt. % solids. The solids may include wood pulp and/or synthetic fibers along with various additives such as sizing agents, binders, fillers, pigments and the like. The wet web is then passed through a series of internally heated rolls or steam-filled cylinders in the dryer section where the web is dried to about 94% to about 99% solids content by weight. The number of drying cylinders in the dryer section is determined by the amount of water to be evaporated based on a typical evaporation rate of about 3 to about 5 pounds per hour per square foot of total dryer surface.
In the dryer section of the paper machine, water is removed from the web mainly by evaporation. Typically, the wet web is alternately contacted on its opposite sides in serpentine fashion with a series of heated co-rotating cylinders to heat the web to a temperature sufficient to evaporate water from the web to the desired dryness.
Once dried, the paper or paperboard is often further treated to improve various properties such as smoothness, gloss, wet strength and folding endurance. This further treatment may include adjusting the moisture content of the dried-web, densification on high pressure rolls, calendering and/or heat-treating the product.
Various problems have persisted in the drying and calendering of paper webs on large, high-capacity paper machines. For example, drying and calendering of the products remains a high energy, capital intensive operation. Hence, the industry is challenged to develop newer and more energy efficient drying and calendering techniques. Such techniques include high-intensity drying methods where high temperatures and mechanical pressure is applied to the web during drying. Examples of currently used high-intensity drying techniques include press drying, impulse drying, and thermal/vacuum drying. However, the use of high temperature dryers and/or impulse dryers has led to additional problems such as delamination of multiply board products.
Furthermore, in the presently used drying and calendering processes, the paper may shrink in width by as much as 5 to 6% which can lead to a significant reduction in the overall production rate, and adversely affect product quality.
Accordingly, even with modern, state-of-the-art drying and calendering techniques, there remains a need to further improve the drying and calendering of paper and paperboard products to reduce energy costs and limit paper shrinkage without adversely affecting the physical properties of the finished product.
Uneven drying and streaking are other problems which have persisted in production of paper and paperboard webs. The weight and moisture irregularity of the fiber web before drying and calendering, irregularities in the heat transfer from the cylinders, edge effects and variations in the ventilation of the papermaking machine all tend to cause nonuniform drying in the cross-machine direction of the product. Such nonuniformity of drying can lead to further adverse effects on paper quality and increased waste.
U.S. Pat. No. 4,378,639 to Walker and U.S. Pat. No. 4,474,643 to Lindblad propose a solution to the problem of uneven drying across the width of the web by periodically spraying water on the web in selected areas across width of the web where low moisture or dry streaks have been detected. Because the water sprays are intermittent and used only when necessary to prevent streaks, such techniques do not effectively increase the drying rate of the web and can introduce nonuniformity in the web surface properties. These and other such approaches also present problems in that the spray nozzles can drip onto the web or otherwise tend to wet the paper in spots or unevenly, resulting in poor efficiency and surface discontinuities in the rewetting, drying and calendering steps, as well as other operational problems.
It is therefore an object of the invention is to improve the efficiency, uniformity and product quality of drying and/or calendering steps in a papermaking process.
A further object of the invention is to provide a more effective method for conditioning paper and paperboard products prior to rewetting the products.
Yet another object of the invention is to increase the drying efficiency of a papermaking process.
Another object of the invention is to provide a method for conditioning a paper or paperboard product for calendering which reduces operational problems associated with prior methods, and improves surface finishing.
Another object of the invention is to provide an efficient means of cross-directional moisture profiling of a paper or paperboard product on a papermaking machine.
SUMMARY OF THE INVENTION
With regard to the foregoing and other objects, the present invention provides, in accordance with its more general aspects, a method for treating an elongate moving web which comprises conditioning the web by applying a flow of moistened gas to a surface of the moving web across its width and along at least a portion of its length from a plurality of substantially overlapping flow zones wherein the flow in each zone is sufficient to create a combination of suction and pressure forces on the surface of the web to promote convective heat transfer and thereby decrease its surface temperature.
As used herein, “moistened gas” means a carrier or motive gas, such as air, which has an absolute humidity of 0.01 or higher. The state of the water in the moistened gas may be vapor, or more preferably primarily liquid in the form of a relatively fine dispersion of small droplets such as a mist combined with evaporated water in the form of gas. As will be described in greater detail hereinafter, it is a feature of the invention that the water droplets are, by virtue of the flow regime used to deliver the moistened gas, propelled against the surface of the web so as to make contact therewith in a relatively even and highly dispersed manner to thereby achieve uniform and rapid cooling and moisturizing of the web.
In one embodiment, the method comprises treating a fibrous web proceeding from a dryer unit of a papermaking machine, the web having a moisture content below about 8 wt. % and a temperature of at least about 80° C., which comprises conditioning the web by applying a flow of moistened gas having a temperature in the range of from about 10° to about 65° C. to a surface of the moving web across its width and along at least a portion of its length from a plurality of substantially overlapping flow zones wherein the flow is sufficient to create a combination of suction and pressure forces on the surface of the web to enhance convective heat transfer and thereby decrease its temperature. Depending on the amount of water applied to the web via the moistened gas, the conditioning may, in addition to decreasing the temperature of the web, increase the moisture content of the web. After the conditioning treatment, the web may be further treated in a process such as calendering, coating and the like. If desired, the web surface, after conditioning may be further moistened using a steaming device.
In a preferred embodiment, moistened gas is applied to the web in the aforementioned manner of overlapping flow zones using one or more arrays of radial jet reattachment nozzles. The nozzles are configured and spaced relative to each other and to the surface of the web to cause the moistened gas to be delivered relatively evenly across the web surface in flow patterns which create a combination of suction and pressure forces on the web. This enables the desired rapid surface cooling and moisturizing effect on the web as it proceeds from the dryer unit to any subsequent steaming and/or calendering steps.
In another aspect, the invention provides a papermaking process which comprises depositing an aqueous slurry of cellulosic and/or synthetic fibers at a consistency of from about 0.2 to about 1.5% by weight on a moving web former screen thereby forming a layer of slurry on the screen. The slurry is dewatered on the moving screen to form a fibrous web which is passed from the screen and then pressed with one or more wet press nips to provide a pressed web having a solids content in the range of from about 32 to about 45% by weight. The pressed web is then dried such as on a series of drying cylinders or other suitable drying equipment to provide a dried web having a moisture content of from about 0.2 to about 6% by weight. Thereafter, the dried web is conditioned by applying a flow of moistened gas to the web surface using a plurality of radial jet reattachment nozzles placed in close proximity to the web on one or both sides of the web to provide a conditioned web having a moisture content which is substantially uniformly increased across its width by at least about 0.2% relative to the moisture content prior to conditioning. The conditioned web may then be further rewet, if desired, by steaming or other means, and subsequently smoothed in a calendering unit or such operation. Alternatively, the conditioned web may be coated, which conditioning provides improved coating holdout.
One advantage of treating a web on a papermaking machine according to the invention is that the web may be uniformly and efficiently moisturized and cooled substantially below the temperature of the dried web proceeding from the dryer unit, preferably reducing the surface temperature to less than about 80° C. using an even application of moistened gas so that any subsequent rewetting of the web occurs in the absence of deleterious effects associated with rewetting higher temperature product before calendering. For example, adverse effects on the cross directional shrinkage of the paper or paperboard product may be limited and desired density, tensile strength compression and caliper in the cross machine direction of the finished product may be achieved more readily and consistently with improved control over these and other properties of the finished product.
Another advantage of conditioning a web according to the invention in the papermaking context is that the resulting web thickness and stiffness after calendering to a desired smoothness may be improved as compared to webs conditioned using conventional techniques. Accordingly, the paperboard product can be made with increased bulk for a given basis weight and a product having a reduced basis weight will still meet caliper specifications. The more efficient surface cooling and moisturizing of the web obtained by use of the invention also enables increased spring back properties during calendering since the moisture is retained by the surface fibers of the web more efficiently than with other moisturizing techniques.
In some applications, it may be desirable to cool the web surface without significantly increasing the moisture content of the web. To this end, it will be appreciated that the invention may be practiced to cause emanation of a mist of minute water droplets from an array of radial jet reattachment nozzles wherein the water droplets have sufficient momentum to penetrate the boundary layer of hot, dry air attached to the moving web so that they impact the web surface. The moisture impacting the web surface rapidly cools the surface by acting as both a latent and a sensible heat sink. The applied surface moisture flashes to vapor upon contact with the hot web, thereby cooling the web. By use of an appropriate amount of moisture in the gas, the web surface is cooled without significantly increasing the moisture content of the web. Very high shear rates are attainable using the reattachment nozzles in a reattachment zone of the nozzle flow pattern which provides high convective heat transfer and high mass transfer coefficients to effectively “scrub” the web surface resulting in more efficient heat transfer from the web surface.
In applications requiring both cooling and moisturizing, higher mist loadings may be applied to the web surface with the reattachment nozzles resulting in substantial retention of moisture on the web surface. Hence, the web is both cooled and moisturized. This limits or avoids entirely the need to apply moisture to the web using conventional water spray nozzles or other means. If additional surface moisture application is desired, existing methods of applying surface moisture become more effective because of the cooling effects provided by this invention. Furthermore, the reattachment nozzles have fewer moving parts than water spray nozzles thereby reducing the maintenance costs associated with cooling and/or moisturizing a web.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the invention will now be further described in the following detailed description of preferred embodiments of the invention considered in conjunction with the drawings in which:
FIG. 1 is an elevational view of a radial jet reattachment nozzle for use in conditioning a paper or paperboard web according to one embodiment the invention;
FIG. 2 is an elevational view of an alternative design of a radial jet reattachment nozzle for use in conditioning a paper or paperboard web according to another aspect of the invention;
FIG. 3 is yet another elevational view of an alternative design of a radial jet reattachment nozzle for use in conditioning a paper or paperboard web according to still another aspect of the invention;
FIG. 4 is another elevational view of an alternative design of a radial jet reattachment nozzle for use in conditioning a paper or paperboard web according to yet another aspect of the invention;
FIG. 5 is a cross-sectional view of a portion of the radial jet reattachment nozzle of FIG. 4;
FIG. 6 is a plan view diagrammatically illustrating the use of an array of radial jet reattachment nozzles adjacent the surface of a moving web of paper;
FIG. 7 is a diagrammatic view illustrating steps in a web conditioning process using radial jet reattachment nozzles for conditioning a moving web of paper according to one embodiment of the invention; and
FIG. 8 is a diagrammatic end view of a plenum arrangement useful for providing pressurized gas to a plurality of radial jet reattachment nozzles.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference characters designate like or similar parts throughout the several views, features of various radial jet reattachment nozzles 10 for use in practicing the invention will now be described. With initial reference to FIG. 1, a preferred nozzle 10 comprises an elongate cylindrical sleeve 12 and flow director 14 which includes an outwardly flared, trumpet-shaped head 16 supported on an elongate cylindrical rod 18 . The rod 18 is coaxially centered in sleeve 12 to provide an annular flow space 20 between sleeve 12 and rod 18 . The head 16 extends out of circular open end 22 of sleeve 12 and, at its widest point or base, has a slightly greater diameter than that of sleeve 12 .
As will be hereinafter described in greater detail, sleeve 12 and flow director 14 of nozzle 10 may be supported on a plenum or manifold (see FIG. 7) along with a plurality of other like nozzles to provide an array of nozzles for conditioning web 28 across its width as the web moves past the array of nozzles.
Moistened gas 24 , preferably air containing a fine water mist, is directed along annular space 20 between sleeve 12 and rod 18 so that it exits the nozzle 10 through sleeve open end 22 . Moisture may be added to the gas by a variety of atomization techniques well known to those of ordinary skill.
At the prevailing gas velocities in the annular space 20 , the shear rate provided by the flowing gas stream will be sufficient to break liquid contained in the air stream into fine droplets, resulting in a turbulent mist emanating radially outwardly from the nozzle 10 as indicated by arrows 26 . The shape of head 16 in conjunction with its spacing, dimension and arrangement relative to open end 22 of sleeve 12 creates a turbulent flow regime which has the effect of causing flows of gas both toward the web surface 28 as indicated by flow arrows 31 and away from the surface of the adjacent web 28 as indicated by flow arrows 30 near the center of the nozzle 10 , while providing a cushion of gas which limits contact between the web 28 and the head 16 with a minimum of fluttering or other undesired movement of the web 28 in a direction normal to its surface.
The relative positions of flow director 14 and sleeve 12 may be fixed, or they may be adjustable relative to one another. It is preferred that the position of flow director 14 be adjustable relative to the sleeve 12 by axial movement of rod 18 within sleeve 12 so that the distance between the head 16 and open end 22 of sleeve 12 may be increased or decreased. By adjustment of the position of the flow director 14 in this fashion, the velocity and/or flow rate of moistened gas impinging on web 28 can be varied as well as the flow pattern. In an alternative design, flow director 14 may be fixed and sleeve 12 may be supported for axial movement relative to head 16 so that the distance between the head 16 and open end 22 may be increased or decreased.
It will be appreciated that both sleeve 12 and flow director 14 may be also supported for movement as a unit in a direction normal to the surface of web 28 , whereby the spacing between head 16 and open end 22 of sleeve 12 may be adjusted as well as the spacing of head 16 from the surface of web 28 . Combinations of adjustments in the positions of sleeve 12 and flow director 14 therefore may be employed to adjust the mass flow rate and/or velocity of moistened gas impinging on the web 28 , the pattern of flow onto and across the web and the spacing between head 16 and the surface of the web.
A combination of appropriate nozzle design and adjustment of the distance between the head 16 and sleeve opening 22 will provide a nozzle 10 having a wide range of operating conditions. By way of example, and not for purposes of limitation, sleeve 12 may have an inside diameter of from about 25 to about 75 millimeters and an outside diameter of from about 26 to about 80 millimeters, and rod 18 may have a diameter of about 4 to about 5 millimeters so that annular space 20 has a radial dimension of about 10 to about 35 millimeters. Head 16 may have a diameter at its widest point within ±10 percent of the outside diameter of sleeve 12 . In this example, the separation space between head 16 and sleeve opening 22 may be varied between operation limits of from about 2 to about 7 millimeters.
Suitable radial jet reattachment nozzles 10 and associated structure for use in practicing the invention are described in U.S. Pat. No. 4,274,210 to Stengard and U.S. Pat. No. 5,331,749 to Thiele, the disclosures of which are incorporated herein by reference as if fully set forth.
An alternative nozzle design is illustrated in FIG. 2 wherein the nozzle 10 ′ comprises an elongate cylindrical sleeve 12 ′ and a flow director 14 ′, the latter of which includes an elongate cylindrical tube 32 coaxially centered in sleeve 12 ′ to provide an annular flow space 20 ′ between sleeve 12 ′ and tube 32 . As with rod 18 shown in FIG. 1, tube 32 may have an outside diameter ranging from about 4 to about 5 millimeters.
A liquid inlet ejector 34 having an orifice 36 is provided for introducing a liquid 38 such as water in the form of a spray into the interior 40 of the tube 32 . A gas 42 such as air introduced into the interior 40 of the tube 32 entrains the spray so that moistened gas 44 containing a fine mist of liquid entrained droplets is produced.
A high velocity flow of gas 24 ′, which may also be moistened, is directed along the annular space 20 ′ between sleeve 12 ′ and the outside surface of tube 32 so that it exits the nozzle 10 ′ through sleeve open end 22 ′. The resulting flow of gas as indicated by arrows 26 ′ exiting the nozzle 10 ′ is induced by the shape of head 16 ′ in conjunction with its spacing, dimension and arrangement relative to open end 22 ′ of sleeve 12 ′ to a turbulent flow regime which has the effect of causing flows of gas both toward the web surface 28 ′ as indicated by flow arrows 31 ′ and away from the surface of a web 28 ′ as indicated by flow arrows 30 ′ adjacent the center of the nozzle 10 ′, while providing a cushion of gas which limits contact between the web 28 and the head 16 ′ with a minimum of fluttering or other undesired movement of the web 28 ′ in a direction normal to its surface. In this embodiment, head 16 ′ is circular and has a dome shape on its upper surface as shown.
A circular deflector plate 46 is attached by means of a plurality of circumferentially spaced-apart rods 47 , preferably at least three, in depending relation to the head 16 ′ spaced from the open end 48 of tube 32 to provide a gap 50 between the open end 48 and the plate 46 . The gap preferably ranges from about 4 to about 12 millimeters and provides a means for inducing entrainment of the moistened gas 44 from the tube 32 into the turbulent gas flow 26 ′ exiting the nozzle 10 ′. It is preferred that the diameter of plate 46 be somewhat less than that of head 16 ′ and be centered in relation thereto. A preferred diameter of plate 46 is about equal to that of the inner diameter of the tube 12 .
FIG. 3 illustrates a further alternative embodiment wherein nozzle 10 ″ comprises an elongate cylindrical sleeve 12 ″ and a flow director 14 ″ which includes an elongate cylindrical rod 52 having a distal solid or otherwise flow-blocked section 54 , a proximal solid-walled tubular section 56 and a porous section 58 disposed between tubular section 56 and solid section 54 . The porous section 58 may be provided by sintered metal or by a perforated, or slotted tube filled with a granular material such as sand, gravel or other inert particulate material. Porous section 58 is preferably at least about 25 millimeters long.
A flow of liquid 38 ′ such as water is directed into the tubular section 56 of the elongate rod 52 . The liquid weeps or otherwise passes out of section 58 in a manner sufficient to form small droplets 59 which are entrained in a flow of gas 24 ″ directed along the annular space 20 ″ between the sleeve 12 ″ and the elongate rod 52 .
As with the previously described embodiments, gas 24 ″ flowing into space 20 ″ may be dry gas or may be moistened gas which is additionally moistened and entrains a fine mist of liquid droplets as it flows along the annular space 20 ″ between the inner surface of sleeve 12 ″ and the outside surface of the rod 52 . The moistened gas exits the nozzle 10 ″ through sleeve open end 22 ″. Head 16 ″ in this embodiment preferably has a shape, dimension and spacing relative to sleeve 12 ″ and its open end 22 ″ corresponding substantially to that of head 16 of FIG. 1 .
The resulting flow of moistened gas exiting the nozzle 10 ″ is induced by the shape of head 16 ″ in conjunction with its spacing, dimension and arrangement relative to open end 22 ″ of sleeve 12 ″ to a turbulent flow regime as indicated by arrows 26 ″ which has the effect of causing flows of gas both toward the web surface 28 ″ as indicated by flow arrows 31 ″ and away from the surface of a web 28 ″ as indicated by flow arrows 30 ″ adjacent the center of the nozzle 10 ″, while providing a cushion of gas which limits contact between the web 28 ″ and the head 16 ″ with a minimum of fluttering or other undesired movement of the web 28 ″ in a direction normal to its surface.
FIGS. 4 and 5 illustrate features of a further alternative design of a nozzle 10 ′″ for use in practicing the invention wherein liquid 42 ′ such as water is directed through elongate tube 43 of flow director 14 ′″ which supports head 16 ′″ at the distal end 60 thereof. The terminal end 60 of the tube 43 contains an orifice 62 in the form of a circular opening which may range from about 0.006 to about 0.018 inches in diameter. Orifice 62 is configured to produce a fine stream or spray of high pressure liquid 64 which is directed against deflector plate 46 ′ attached to head 16 ′″ by means of a plurality of circumferentially spaced apart rods 47 ′, preferably at least three, thereby producing a fine mist of liquid droplets 66 which is entrained in the moistened gas exiting the nozzle 10 ′″ between the head 16 ′″ and plate 46 ′ as shown by arrows 26 ′″.
Deflector plate 46 ′ is preferably a circular disc as shown in FIG. 2 and preferably contains a circular, cone-shaped upwardly projecting portion 68 for improved formation of fine liquid droplets resulting from the impact of the liquid on deflector plate 46 ′ and to promote radially outward flow into a turbulent flow regime and the inwardly swirling flow pattern as shown by arrows 30 ′″. The sloped side walls of portion 68 form included angles with respect to the planar surface of plate 46 ′ of about 45°. The apex of portion 68 is preferably axially aligned with orifice 62 and spaced therefrom a distance of from about 4 to about 12 millimeters. Head 16 ′″ preferably has a configuration and is dimensioned corresponding substantially to that of heads 16 ′ and 16 ″ of FIGS. 2 and 3, respectively, as well as a corresponding adjustable separation distance from sleeve opening 22 ′″. Plate 46 ′ is also preferably dimensioned and spaced from head 16 ′″ in substantially the same manner as plate 46 of FIG. 2 . In an alternative embodiment, portion 68 is dome shaped rather than conical to aid in droplet generation and distribution.
As with the embodiments of FIGS. 1-3, the flow of moistened gas as indicated by arrows 26 ′″ and 30 ′″ provided by nozzle 10 ′″ of FIGS. 4-5 causes flows of moistened gas both toward and away from the adjacent surface of moving web 28 ′″, while providing a cushion effect which limits contact between web 28 ′″ and head 16 ′″ with a minimizing of fluttering or other undesired movement of web 28 ′″ in a direction normal to its surface facing head 16 ′″. All the while, by virtue of the relatively high velocity flow produced by the various nozzle designs described herein and the swirling turbulent flow regime, the moistened gas effectively “scrubs” away the flow boundary of relatively high temperature air adjacent the surface of the web enabling water droplets in the moistened gas to be carried into contact with the web surface, whereby rapid evaporative cooling and moisturizing of the web may be achieved.
As long as sufficient turbulent air flow is maintained for the moistened gas exiting the nozzles, they do not need to be heated to avoid condensation of the mist on the nozzle surfaces. However, if desired, a heating system may be used to maintain the nozzle temperature above the dew point of the moisturized gas.
The nozzles described herein may be made from a variety of materials appropriate for use in the environment of a papermaking machine. Suitable materials include non-oxidizing or corrosion resistant metals such as stainless steel, nickel, titanium, alloys of iron and nickel, alloys of titanium and aluminum and the like. Other materials may be used provided they are resistant to moisture, stable under high temperature conditions and resilient enough to withstand thermal and mechanical shock such as may occur as a result of a paper web break during production as well as periodic adjustment or maintenance.
In contrast to conventional air nozzles, the nozzles used in practicing the present invention provide a highly effective turbulent gas flow adjacent the surface of the web which creates a negative force on the web urging the web toward the nozzle rather than away from the nozzle which is determined to be particularly effective in application of moistened gas to the web. In particular, the gas flow rate and ejection angle of the moistened gas exiting the nozzle induces unusual eddy currents creating areas of reduced pressure between the nozzle and the surface of web urging the web toward the nozzle. However, the flow of moistened gas between the nozzle and the web effectively prevents contact between the web and the nozzle.
As the web is urged toward the nozzle, moist gas flowing from the nozzle contacts the web radially in substantially all directions. Such gas flow rapidly lowers the surface temperature of the web and, in certain embodiments, increases the moisture content of the web. Some or all of the added surface moisture may flash from the web surface, depending on the web temperature, the weight of the web and the moisture loading of the gas, thereby cooling the web and in some cases increasing its moisture content to within a desired range.
In the practice of the invention, a plurality of nozzles are used and are arranged in spaced apart fashion in an array spread across the width and along a portion of the length of the web supported in close proximity to the surface of the web, preferably on both sides of the web. The actual number and arrangement of nozzles across the width of the web will be determined on a case-by-case basis depending on factors such as the paper basis weight and width, machine speed and the like. In order to achieve optimum web conditioning with the fewest nozzles, the nozzles are preferably arranged in a staggered pattern as illustrated in FIG. 6 so that adjacent rows of nozzles are offset from each other both in the cross machine direction and in the direction of web movement as shown by arrow 70 . Many other nozzle arrangements may be used provided the number and arrangement of nozzles is sufficient to effectively condition the web across its width 72 . The inlet end of each nozzle is preferably connected to an inlet gas plenum for providing a high velocity gas stream to the nozzles.
By reason of the arrangement shown in FIG. 6 employing one or more arrays of nozzles according to the various embodiments thereof (FIGS. 1 - 5 ), moistened cooling gas is caused to flow against the web 74 simultaneously from a plurality of spaced-apart locations across the width 72 and along a portion of the length of the web as it moves past the nozzle arrays. The gas flow creates a plurality of overlapping zones of influence on the web 74 characterized by a combination of vacuum or suction forces as well as pressure forces on the web surface which, along with the turbulence and eddy currents created thereby, penetrates, strips away or significantly disturbs the boundary layer adjacent the web surface for enhanced heat and mass transfer. Furthermore, small water droplets in a fine water mist delivered through nozzles have sufficient momentum to penetrate the boundary layer of hot dry air carried along the web surface from a dryer unit so that a significant portion thereof can readily reach and be absorbed by the web surface. The result is a highly efficient, uniform and rapid moisturizing and cooling effect on the web across its width even at relatively high machine speeds in the order of about 1200 to about 1500 meters per minute.
Referring now to FIG. 7 in conjunction with FIG. 6, a preferred sequence of steps according to the invention for conditioning a paper web 74 on a papermaking machine is illustrated. In this embodiment, nozzles according to the nozzle design 10 of FIG. 1 are illustrated in use, but it is understood that the nozzle designs of FIGS. 2-5 as well as other functionally equivalent designs may be used.
As shown in FIG. 7, web 74 proceeding from the wet press section (not shown) is conducted in a conventional fashion through any of several papermaking unit processes and ultimately through a dryer unit 76 comprising a plurality of internally heated dryer cylinders (illustrated diagrammatically as two cylinders, for sake of simplicity) where its moisture content is decreased to about 0.2 to about 6% by weight. Web 74 proceeds from dryer unit 76 at a temperature which may range from about 80° to about 170° C. past one or more arrays 78 of nozzles 10 arranged as shown in FIG. 6 above and below the web 74 to condition the web in the aforedescribed manner, lowering its surface temperature in this embodiment by at least about 20° C. and increasing the web moisture content to at least from about 0.2 to about 1.0 percent over the moisture content of the web emerging from dryer unit 76 . However, it will be appreciated that by adjustment of the nozzle configuration and their spacing relative to the surface of the web, as well as the water loading of the moisturized gas, the invention may be practiced so that there is essentially little or no increase in the moisture content of the web while its temperature is nevertheless decreased substantially in a relatively short length of time. It will also be appreciated that the invention may be practiced by treating only one surface of the web, depending on manufacturing and product requirements.
It is preferred to place the nozzle arrays 78 in the production line outside of the dryer unit 76 , which is typically an enclosed or hooded structure containing a series of stacks of rotating cylinders. Because the nozzles 10 are not located in the dryer unit 76 , fewer operational problems are likely to occur due to, web 74 hanging up on the nozzles 10 when a break in the web 74 occurs in the dryer unit. Furthermore, replacement, maintenance or adjustment of the nozzles 10 can be accomplished without having to enter the dryer unit 76 .
The nozzle arrays 78 are preferably mounted on retractable/adjustable support units illustrated diagrammatically at 80 so that the nozzles can be retracted away from the web 74 automatically when a web break occurs. The retractable nozzle arrays 78 also provide for easier maintenance and movement of the nozzles toward and away from web 74 as indicated by arrows 82 . Units 80 preferably also provide a plenum or manifold function for directing gas and liquid delivered into units 80 as by conduits 84 and conduits 86 , respectively, wherein individual flows of gas and liquid may be directed to the separate nozzles 10 , or the gas and liquid pre-mixed in units 80 or even prior to delivery to units for being directed onto the web 74 as moistened gas in the aforedescribed manner. Suitable fans or pumps are employed as necessary to develop the pressure required for the desired flow velocities and flow patterns of moisturized gas from nozzles 10 onto web 74 .
From nozzle arrays 78 , the web 74 may be further treated in a steaming unit 88 containing a plurality of steam nozzles 90 wherein steam is applied to the web to increase its moisture content to desired degree which may be an increase of from about 0.3 to at least about 2% by weight over and above that of web proceeding from nozzle arrays 78 to a final moisture content of from about 1.5 to about 8% by weight. It will be understood that multiple steam nozzles 90 in multiple rows along the machine direction may be used to effectively rewet the web 74 , however, for simplicity, only a single steam nozzle 90 is shown.
After the steaming unit 88 , web 74 is preferably then processed through one or more calender units 92 for enhancement of the web surface smoothness and caliper uniformity and other purposes. Typically, one or more rolls in the calendering unit 92 are heated and are arranged relative to one another to nip the product proceeding therethrough at pressures ranging from about 100 to about 1500 pli, although the pressure can vary outside these limits depending on the product being processed and the effect to be produced on the web. The web 74 emerging from calendering unit 92 typically has a moisture content below about 7 wt. % and a substantially uniform thickness and smoothness across its width.
It will be appreciated that in contrast with conventional practice, use of arrays 78 of radial jet reattachment nozzles 10 according to the invention effectively conditions the web 74 by cooling the web with moist gas resulting in more effective rewetting of the web with steam in the steaming unit 88 . Because the nozzles 10 provide relatively uniform conditioning of the web prior to rewetting the web with steam, the efficiency of web calendering is also improved without adversely affecting other properties of the web such as strength, dimensional stability, streaking, shrinkage in the cross machine direction and the like.
As an exemplary embodiment involving the production of 180 lb/3000 ft 2 basis weight paper having a width 72 of 100 inches at a machine speed of about 800 ft/min., a nozzle array believed to be effective for conditioning the web prior to calendering includes 100 nozzles arranged in four staggered rows (see FIG. 6) with 25 nozzles per row across the width of the web. Adjacent nozzles are preferably uniformly spaced a distance of 4 inches measured from the centers of the adjacent nozzles. The ends of the nozzles are preferably spaced from about 0.5 to about 2 inches away from the surface of the web, which spacing is adjustable to achieve optimum effect.
Gas delivered to the nozzles is air and liquid delivered to nozzles is water and the gas is moistened by atomized water droplets to an absolute humidity of at least about 0.01 at a temperature of about 32° C. In this exemplary arrangement, moistened gas is emitted from the nozzles at flow velocities in the range of from about 100 to about 300 feet per second. The amount of moisture contained in the moistened gas is dependent on the particular cooling and moisturizing requirements of the web. A typical amount of water applied to a moving web ranges from about 0.05 to about 1.0 pounds per minute per foot width of the web.
In one of many variations in the operational sequence illustrated in FIG. 7, there may be employed a step of rewetting the web in the dryer unit 76 as described in U.S. Pat. No. 5,470,436 to Wagle et al. incorporated herein by reference as if fully set forth, which enables increased heat transfer to the interior of the web. Combined with web conditioning according to the invention, significantly improved drying rates may be achieved by employing the rewetting concept of the '436 patent with improved calendering performance and improved web properties and uniformity. The moisture profile of a web may also be improved by selectively applying moisture to dry areas of the web.
FIG. 8 illustrates an end view of one embodiment of a plenum 100 for providing a pressurized gas to an array of radial jet reattachment nozzles 110 . Plenum walls 112 , as seen from the end view of the plenum, define a substantially sealed plenum chamber 114 . Pressurized gas from a gas source is caused to flow into the plenum chamber 114 from an end thereof (the gas inlet connection and gas source not being shown), which chamber 114 is in flow communication with annular flow space 116 of nozzles 110 . The upper ends 118 of sleeves 120 of nozzles 110 may be straight or may be flared for greater air flow and/or less pressure drop adjacent the entrance thereof. In the embodiment of FIG. 8, reattachment nozzles 110 correspond substantially to nozzle 10 ′ described with reference to FIG. 2 in configuration and operation. Accordingly, additional pressurized gas is introduced by means of inlet 122 (as seen from an end view of an inlet conduit, not shown) and distributor 124 into conduits or tubes 126 of nozzles 110 .
Pressurized liquid is delivered from inlet 128 (as seen from an end view of an inlet conduit, not shown) and distributor 130 to liquid ejectors 132 for introducing a spray or mist of liquid into the interior of tubes 126 in order to provide a moisturized gas 134 for impact on a moving web 136 as described with reference to FIG. 2 .
The pressurized gas inlet 122 and pressurized liquid inlet 128 and associated conduits (not shown) are preferably independently supported for movement of either the tubes 126 or entire plenum 100 toward or away from the web. Accordingly, sleeves 120 may be slotted for movement thereof relative to the liquid ejectors 132 without the need for elaborate sealing methods because the interior of sleeves 120 and the exterior of sleeves 120 adjacent the liquid ejectors 132 are wholly within the plenum chamber 114 .
It will be understood that plenum 100 is merely one preferred structural arrangement for use in delivering gas and liquid to nozzles 110 , and that other suitable structural plenum arrangements may be devised to suit particular circumstances. Also, other nozzle designs such as those of FIG. 1, FIG. 3 and FIGS. 4-5 as well as variations and modifications of any of the foregoing within the scope of the invention as claimed may be used with any plenum configuration such as the plenum 100 by suitable adaptations devisable by those of ordinary skill.
Furthermore, while the foregoing apparatus and process has been described with reference to a papermaking process, it will be recognized that the apparatus and method may be applied to any continuous web handling equipment such as converting equipment where there is a need to moisturize and/or cool a moving web. Furthermore, the invention is not limited to cellulosic webs and may be applied to other continuous moving webs made of natural and synthetic materials amenable to treatment for the effect enabled by the present invention.
Having now fully described the invention and various known embodiments thereof, it will be recognized by those of ordinary skill that the invention is capable of numerous modifications, rearrangements and substitutions without departing from the spirit and scope of the invention as defined by the appended claims. | The specification discloses embodiments of a process and related apparatus for conditioning a fibrous web in order to improve the efficiency of drying and calendering thereof. In the process, a moving fibrous web is conditioned after the drier unit of a papermaking machine by applying a flow of moistened gas through one or more arrays of radial jet reattachment nozzles placed in close proximity to the web surface prior to a calendering unit or prior to a steaming unit placed between the nozzles and the calender unit to cool the web and/or increase its moisture content. Webs treated according to the invention exhibit improved properties including less moisture streaking, enhanced smoothness and avoidance of optical property loss. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a non-provisional patent application claiming priority to U.S. Provisional Application No. 61/648,917 filed on May 18, 2012. The applications name the same inventors.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the fields of architecture and building construction. More specifically, the invention is comprised of a bracket system which is mounted against extruded columns.
2. Description of the Related Art
Large glass windows, walls and doors are common in both industrial and residential buildings. Open concept floor plans and advances in glass safety, efficiency and overall manufacturing technology have led to an increase in the installation of glass walls and windows by residential homeowners and commercial business alike.
Although glass walls and windows are desirable, one problem they present is of lack of shelving, storage space and structures for load support. It is simple and straightforward to build a temporary or permanent shelf or structural element attached to a wall consisting of primarily drywall with wooden studs. However, it is difficult to install a sturdy shelving unit or other structural element affixed to glass or similar material. As illustrated in FIG. 1 , glass wall construction 10 typically consist of extruded columns 12 (preferably aluminum) connected together by an inner wall 18 , a structural medium 14 (preferably glass) and a series of gaskets 16 . The structural medium 14 sits between extruded columns 12 and is held tightly in place by gaskets 16 on either side. The design and construction of the wall may vary. For example, structural medium 14 may be double paned and include a spacer 20 as illustrated.
Prior art shelving units or anchoring systems for glass wall construction 10 were primarily designed to drill directly into the extruded columns 12 . One such prior art unit is illustrated in FIG. 2 . As shown, extruded columns 12 extend toward the interior of the building include drilled holes 22 which accept shelving unit 24 . The holes 22 in the extruded columns 12 are often difficult to drill and are more permanent than a hole drilled into drywall. Thus, in the event that the shelf is no longer desired, the holes in the extruded columns 12 (typically metal) are permanently visible. Further, commercial businesses may desire temporary shelving which does not compromise the integrity of the extruded columns 12 and are easy to install. There is not presently an anchor system which achieves these objectives.
Therefore what is needed is an anchor system which allows a bracket to be easily and non-permanently installed on the constructed wall as described. Additionally, the brackets should be sturdy and strong to support a shelving unit or other structural element. The present invention achieves these objectives and more as described herein.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises an anchoring system of brackets which utilize thin blades, preferably made from metal but potentially made from a plurality of materials, which are locked into place between a gasket attached to an extruded column and a structural medium, such as a plate glass window. The anchoring system preferably allows for some an additional plurality of structures to be attached, connected, or alternatively placed on top of or below said system. In a preferred embodiment, the anchoring brackets are composed of two pieces which can be linked together after the blade of each side is inserted between the gasket and the structural medium. The anchoring system is preferably split into two sections which can then be linked together. The linking connection can be achieved through a plurality of mechanisms, preferably a male female type overlapping connection between the two sections. This allows for a more secure fit and for the anchoring system to hold more weight.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view, showing the components of a prior art construction of a glass wall.
FIG. 2 is a perspective view, showing the installation of a prior art structural element on a prior art glass wall.
FIG. 3 is a perspective view, showing the present bracket system installed on a wall construction.
FIG. 4 is a perspective view, showing the present bracket system inverted and installed on a wall construction.
FIG. 5 is a perspective view, showing the brackets of the present bracket system installed on an extruded column.
FIG. 6 is a perspective view, showing the brackets of the present bracket system.
FIG. 7 is a perspective view, showing the brackets of the present bracket system fitting together.
FIG. 8 is a perspective view, showing the brackets coupled together to form anchoring bracket.
FIG. 9 is a perspective view, showing the brackets installation in a preferred embodiment of the invention.
FIG. 10 is a top plan section view, showing brackets placement around extruded column.
FIG. 11 is a top plan section view, showing brackets coupled together and installed on extruded column.
FIG. 12 is an exploded view, showing the bracket blade between gasket and structural medium.
REFERENCE NUMERALS IN THE DRAWINGS
10
wall construction
12
extruded column
14
structural medium
16
gaskets
18
inner wall
20
spacer
22
holes
24
shelving unit
26
bracket blade
27
bracket blade
28
bracket side flap
29
bracket side flap
30
anchoring bracket
32
first bracket
34
second bracket
36
bracket top flange
37
bracket top flange
38
bracket side flange
39
bracket side flange
40
bracket back flange
41
bracket back flange
42
linking mechanism
44
bracket section
45
bracket section
46
bracket blade bend
48
external structure
50
bracket system
52
void
54
void
DETAILED DESCRIPTION OF THE INVENTION
As described above, FIG. 1 illustrates a prior art wall construction 10 . Wall construction 10 is constructed in order to provide support for large glass or similar material structural mediums 14 . Extruded columns 12 are connected by an inner wall 18 which support structural medium 14 between extruded columns 12 and gaskets 16 . Glass or structural medium 14 can be double paned with a spacer 20 between the panes for or single paned. The assembly of wall construction 10 is important to the functioning of the present bracket system 50 .
FIG. 3 provides a perspective view of bracket system 50 attached to a glass wall construction 10 . At least two anchoring brackets 30 are illustrated which attach around extruded columns 12 . Anchoring brackets 30 are formed by first and second bracket 32 , 34 described and illustrated herein. External structure 48 such as a shelf sits on top of and can optionally connect to anchoring brackets 30 . Anchoring system 50 provides considerable support and does not require drilling or screwing into the extruded columns 12 .
Bracket system 50 can also support an external structure 48 attached to at least two anchoring brackets 30 , as shown in FIG. 4 . Anchoring brackets 30 are inverted but installed in the same manner. An external structure 48 can be affixed by any means to the anchoring brackets 30 to support a load. As an example, a window treatment, such as blinds, can be affixed to anchoring brackets 30 and hung from the window. Thus, the blinds are not drilled into the existing window structure and are easier to install.
A view of anchoring bracket 30 , composed of first bracket 32 and second bracket 34 (not visible in FIG. 5 ) assembled together attached around extruded column 12 is illustrated in FIG. 5 . First bracket blade 26 (and second bracket blade 40 , not visible) slide behind extruded column 12 and are frictionally engaged between structural medium 14 and gaskets 16 . The pressure of gasket 16 against bracket blade 26 , 40 holds the anchoring bracket 30 in place against the force of gravity. While anchoring bracket 30 is shown in a configuration in which top flange 37 (or 36 ) is providing an upward facing support, anchoring bracket 30 can also be configured such that top flange 37 (or 36 ) provides a downward facing support. In such a configuration, anchoring bracket 30 can support a hanging load.
FIG. 6 provides a perspective view of first bracket 32 and second bracket 34 which make up anchoring bracket 30 . As illustrated, first bracket 32 and second bracket 34 are made up of a bracket blade 26 , 27 , bracket side flap 28 , 29 , bracket top flange 36 , 37 , bracket side flange 38 , 39 and bracket back flange 40 , 41 . A central void 52 , 54 is formed by the structural elements of first and second bracket 32 , 34 . When installed, illustrated in FIG. 5 , extruded column 12 fills void 52 .
FIG. 7 shows the manner in which first and second brackets 32 , 34 interlock by sliding one bracket on top of the other. While second bracket 34 is illustrated sliding on top of first bracket 32 , the alternative could be true. When brackets 32 , 34 are in place, as shown in FIG. 8 , anchoring bracket 30 has the following configuration: bracket top flange 37 fits on top of bracket top flange 36 ; bracket side flange 39 rests on top of bracket side flap 28 ; bracket back flange 41 (not shown) rests on top of bracket back flange 40 ; bracket side flap 29 rests on top of bracket side flange 38 ; and bracket blade 26 lies on the same plane as bracket blade 27 . In a preferred embodiment first bracket 32 and second bracket 34 of the anchoring bracket 30 are held in place by gravity. In an alternative embodiment first bracket 32 and second bracket 34 could be held together by an adhesive or putty.
A perspective view of the placement of first bracket blade 26 on first bracket 32 and second bracket blade 27 on second bracket 34 around extruded column 12 on wall construction 10 is shown in FIG. 9 . Structural medium 14 is separated from extruded column 12 and gaskets 16 for clarity, to show the position of bracket blades 26 , 27 between gaskets 16 and structural medium 14 . The first bracket 32 is attached to extruded column 12 by sliding first bracket blade 26 between gasket 16 and structural medium 14 . The second bracket 34 fits around extruded column 12 and second bracket blade 27 is inserted between gasket 16 and structural medium 14 on the opposing side of extruded column 12 . Second bracket 34 is inserted either above or below first bracket 32 . The reader will appreciate that when first and second brackets 32 , 34 are mated together to form anchoring bracket 30 (as illustrated in FIG. 5 ) the pressure applied by gasket 16 which holds anchoring bracket 30 in place relative to the ground, received additional structural support from the back flange 40 , 41 which is proximate to extruded column 12 . When pressure is placed on top of anchoring bracket 30 , the back flange will press against extruded column 12 opposing the downward pull. Anchoring bracket 30 is sized in such a way that the space defined by the intersection of bracket blade 26 , bracket side flap 28 , and the inner side of anchoring bracket 30 proximate to extruded column 12 snugly fits extruded column 12 . Bracket blade 26 should be sized to tightly fit gasket 16 , not being so large that it does not fit behind extruded column 12 but not so small that bracket blade 26 will not slide behind gasket 16 .
FIG. 10 shows a top sectional plan view of anchoring bracket 30 as it fits against structural medium 14 , which in a preferred embodiment is glass, and gasket 16 . Extruded column 12 is shown proximate to gasket 16 . Bracket blade bend 46 in a preferred embodiment is shaped in such a way that gasket 16 fits inside anchoring bracket 30 . Bracket side flange 38 , 39 is shown proximate to extruded column 12 . As stated before, bracket blades 26 , 27 are held in place by the pressure from gasket 16 . Bracket blades 26 , 27 are also held in place against gravity by frictional forces between bracket blades 26 , 27 , gasket 16 , and structural medium 14 , said forces may be increased based off the material chosen for bracket blades 26 , 27 . The preferred linking mechanism is the first and second brackets 32 , 34 simply locking together. The linking together is seamless as illustrated in FIG. 9 .
FIG. 11 displays a plan view showing an alternative linking mechanism 42 between the two pieces of the anchoring bracket. Anchoring bracket 30 is broken into two sections, bracket section 44 and bracket section 45 . Bracket section 44 and bracket section 45 are held in place by linking mechanism 42 . A variety of mechanically simple linking mechanisms are viable for linking mechanism 42 , however linking mechanism 42 depicts an interlocking style. As in FIG. 9 , bracket back flange 40 is shown proximate to extruded column 12 . Bracket back flange 40 provides additional structural support for the anchoring bracket 30 by pressing against extruded column 12 when downward pressure is applied to the anchoring bracket 30 . Gasket 16 is shown proximate to extruded column 12 . Gasket 16 holds bracket blade 26 , 27 in place against structural medium 14 , which in a preferred embodiment is glass.
FIG. 12 provides an exploded section view showing bracket blade 26 as it fits against structural medium 14 and gasket 16 . FIG. 9 also displays bracket blade bend 46 which in a preferred embodiment is shaped in such a way that gasket 16 fits inside. Bracket side flap 28 is shown proximate to extruded column 12 . As stated before, bracket blade 26 is held in place by the pressure from gasket 16 . Bracket blade 26 is also held in place against gravity by frictional forces between bracket blade 26 , gasket 16 , and structural medium 14 , said forces may be increased based off the material chosen for bracket blade 26 . | An anchoring system for extruded columns which is useful in supporting structures in a way that does not require drilling or screwing into the column structure. The anchoring system is comprised of brackets which are mounted against extruded columns by inserting a bracket blade into place between a gasket and a structural medium. The anchoring brackets are preferably composed of two pieces which link together for increased support. The anchoring system can support a variety of mountings which can be either physically attached to the anchoring brackets or rest atop the anchoring brackets. | 4 |
CLAIM OF PRIORITY
[0001] None.
FIELD OF INVENTION
[0002] This invention relates, generally, to the class of apparatus for the application of heat. Specifically apparatus having means to direct solar radiation and support means for an article to be heated by the directed.
BACKGROUND OF INVENTION
[0003] Currently, most of the world's economies are reliant heavily on fossil fuels. Fossil fuels have many drawbacks. Fossil fuels pollute and are largely responsible for deleterious Global Warming, commonly referred to as the greenhouse effect. Additionally, pollution from fossil fuels makes air in many major cities, such as Mexico City, Beijing, and Los Angeles, unhealthy to breathe for many people. Power-lines, refineries, and pipelines are also ugly ubiquitous installations. The procurement of fossil fuels, whether in mining coal or drilling for petroleum, is inherently polluting. Mountaintop removal for coal and hydraulic fracturing (“fracking”) for natural gas both contaminate ground water, endangering the life and health of those nearby. Drilling for and transportation of petroleum, coal and gas are also fraught with hazard witness the BP drilling catastrophe in the Gulf of Mexico in 2010, the grounding of the Exxon Valdez in 1989, or the pipeline rupture in Arkansas in 2013.
[0004] Fossil fuels give undue influence to governments who control large exportable quantities. The majority of exported crude comes from areas of the world with known unstable, unpopular governments, and/or those in tension with the West. For instance, much of the imported oil America receives comes from the Middle East, Venezuela, Angola and Nigeria—all meeting the above description. Many oil-exporting Middle East regimes are openly hostile to and contemptuous of the United States, notably Iran. Many other autocratic “friendly” regimes such as Saudi Arabia and Kuwait are clearly unstable and vulnerable, in light of the Arab Spring. The U.S. secures additional petroleum from Venezuela, which in recent history has badly strained relations with the U.S. Western Europe procures much of its fossil fuels (natural gas) from Russia, an historic competitor with the West. Even without these serious national security issues, to the extent that fossil fuels are imported needlessly, a nation exports its wealth, needlessly.
[0005] Fossil fuels are also becoming increasingly scarce, meaning that their price is rising. The United States International Energy Agency estimates that 2006 was the peak year of petroleum production. The global output of petroleum will now slowly decline. Meanwhile, the BRIC countries (Brazil, Russia, India, and China) are rapidly growing, driving demand for petroleum upward. This has led to volatility in the oil markets, with the cost of a barrel of oil peaking at $140 in 2008. Since then, the price for crude oil has varied from a low of $70 per barrel to a high of $110 per barrel; such swings of 50% in a basic commodity are painful all by themselves. All indicators are that the price of a wide variety of fossil fuels will steadily increase, faster than other goods, until they are exhausted.
[0006] In response to these drawbacks of fossil fuels, industry, governments, and academic institutions have been pouring resources into finding renewable energy sources for years. To date, the results are mixed. Current renewable resources all have three drawbacks: cost, environmental impact, and consistency of availability. The cost of a renewable energy source is measured by various metrics: Return on Investment (“ROI”), cost per kilowatt hour (“CPkWH”), levelized cost of energy (“LCE”), etc. In order to be competitive, the CPkWH must be comparable to that of fossil fuel. Alternately, the ROI (reciprocal of payback period) must be realistic with a short number of payback years. Currently, no renewable sources are cheaper than fossil fuels over the short-run (3 years or less).
[0007] Specifically, photovoltaic panels are far from optimized, in that they have significant environmental impact, limited hours of operation, and suppressed operating efficiencies. Photovoltaic (“PV”) panels, like many renewable energy sources, have a significant environmental impact. Environmental impact means not only pollution, but also a visible, intrusive installation foot-print. For example, in order to generate usable quantities of solar energy using PV panels, one needs a sunny location and a very large surface area due to their characteristic conversion efficiencies of 20% or less.
[0008] Other operational limitations exist for PV panels. Most types of PV only provide significant power with direct beam sunlight. Yet peak electricity demand is typically in hours around and after dusk, just when PV loses its generating capacity. In areas in which snow fall is common, PV panels stop operating after a snow fall, until such time as the snow pack is removed from the surface of the PV panel. When PV arrays have a cloud pass overhead, the electrical grid, suddenly, must be able to provide power using other, more reliable means. Furthermore, those types of PV and thermal panels which can collect the diffuse radiation under a cloud deck are unable to rapidly change tilt angle toward horizontal to maximize the 180° of incoming diffuse radiation. Those arrays which are fixed or otherwise unable to adjust tilt in this way suffer significant losses of potential performance during each period of cloud cover. In worst case scenarios, this performance variability can lead to grid destabilization, threatening regional blackouts. Moreover, the grid requires 100% of its former fossil capacity as backup, since PV panels have zero baseline stability. The inconsistency of power generation greatly reduces the appeal of these renewable energy resources.
[0009] Perhaps most important, the actual efficiency achieved using PV panels is much lower than the rated efficiency. The output power efficiency of PV panels is normally measured, for rating purposes, at an idealized 25° C. This is a self-serving measurement, in that the selected temperature for the rating measurement also corresponds with the peak output of the panel. In reality, PV panels are exposed to ambient environments between −40° F. and 140° F., resulting in non-ideal performance. PV panels become less efficient as they are heated. In a sunny, warm location, in which a PV panel operates at or near 60° C. (140° F.), its output will be suppressed by as much as 40% when compared to its rated efficiency. This means that an installed system with a rated output of 10 kW would, in actuality, operate, during the early and mid-afternoon period of peak potential, at between 6 kW and 8 kW, depending on ambient conditions. Rarely, then, will ambient thermal conditions permit PV panels from operating at rated output.
[0010] Additionally, the peak output of PV panels is only briefly available, while the rays of sunshine are orthogonal to the face of the PV panel. For the remainder of the day, the PV panel will produce less than its rated amount of power. How much less depends on a number of factors: the cleanliness of the PV panel surface; whether the PV panel surface has any scratches; the reflectivity, refraction index and transmissivity of the PV panel's surface material; the latitude of the installation; the season; and the ambient weather conditions, inter alia. These factors of efficiency degradation also affect thermal solar panels, albeit to a lesser extent. Typically, solar thermal panel installations are focused on collecting warm heat energy only, limiting their functionality to approximately one-half of the day.
[0011] All types of panels, whether PV, thermal or other, suffer losses of efficiency from pollution, dust, leaves, and even bird droppings. All these contribute to prevent sunlight from reaching the working surfaces of the panel. The more dirt, the lower the amount of energy a panel gathers. According to the National Renewable Energy laboratory, losses due to surface contamination may range as high as 25% in some areas. Individual dealers have reported losses that exceed even this number, due to customers failing to clean their panels. Improper cleaning can also impair performance, resulting, in extreme cases, in a polarity inversion. When contamination build-up causes a polarity inversion, the performance of an entire array can be affected.
[0012] Clearly, then, the art is searching, still, for an optimized renewable energy resource. By merely allowing new and existing PV, thermal and other renewable energy panels to achieve their rated efficiency for more hours of the day, the generating capacity of renewable energy panels would increase significantly. Additionally, helping PV panels to generate electricity, and thermal panels to generate heat immediately after snow storms would further increase the generating capacity of installed panels. This necessitates a system that lowers the operating temperature of panels on hot days, melts snow immediately after a snow-fall, and removes grime and other surface contaminates.
[0013] Lastly, if the renewable energy panels could track the sun, the amount of radiant energy absorbed in a given day would increase significantly. Tracking could either be simple, such as a single-axis horizontal tracking mechanism, taking advantage of the diurnal cycle; or it could be more complex, such as a two-axis tracking mechanism that adjusts for both season and time-of-day. The improvement in total energy generation depends on the tracking system deployed, the accuracy of the tracking mechanism, the energy required to run the tracking system, and the latitude of the installation.
[0014] The human body cools itself in warm climates through perspiration. Dogs achieve evaporative cooling via exhaling/inhaling across the moisture brought to their tongues and mouths. Likewise, evaporative cooling is a well-known alternative method for cooling air in patio settings, used in many warm locations. In the US Southwest, “swamp coolers” using this principle were long used to cool indoor air, since the resultant relative humidity gain was acceptable in such dry climates. Evaporative cooling can be extended from making cool air to cooling the surface of a hot object. For example, by misting the surface of a PV panel on a warm, sunny day, its output at peak times (10 a.m. until 2 p.m.) improves by 16%-25%. This improvement in output is the direct result of a lower operating temperature caused by evaporative cooling of the PV panel's upper surface.
[0015] Mists, sprays and trickles can also be used to reduce or eliminate snow packs, due to melt-off and the change in surface tension between the panel and the snow-pack. A fine mist of water immediately reduces a snow pack by melting the surface snow. A relatively small amount of water can be made to melt a large amount of snow, depending on the ambient temperature of the water, air, and snow. The trickle of water changes the surface tension between the snow and the panel, creating a slippery slope underneath the snow. With the proper panel tilt and surface tension, the snow will slide off in a mass.
[0016] Fine sprays or mists can also be used to wash or clean surfaces without contact. Car washes are an extreme example of this concept. A fine spray of water, repeated, can clean a grimy surface without any contact, as occurs with rainfall. Since rainfall is an intermittent and unreliable dust-remover, programmatic approaches are considerably more effective. Adding surfactants or detergents to the spray improves the results.
[0017] A tracking mechanism for renewable energy panels requires mounts that can, on a single axis, rotate slowly parallel with the horizon; and mounts that can rotate about the mounting system's center of gravity. Rotating about a single axis, parallel to the horizon, allows the panel to track the sun during the course of the day. Rotating about the center of gravity allows the panel to make both gross and fine adjustments: gross adjustments can be made to compensate for the time of the year, aiming the panel directly at the sun; fine adjustments can be made on a minute-by-minute basis in response to cloud cover and other emergent conditions. Such a tracking system is compatible with new technologies, such as thermal panels that collect cold thermal energy, available in the winter and at night. The tracking system can aim such panels to optimize for cold thermal energy collection, while simultaneously protecting the panel from wind damage. In order to be useful, the system would have to be weather-proof, low-energy, accurate, and quiet, so as not to disturb owners and neighbors.
SUMMARY OF THE INVENTION
[0018] The present invention is a simple system, intended for use with new or existing PV, thermal or other renewable energy panel installations. The system can mist the panels and allow the panels to track, in accordance with a variety of environmental inputs. The misting and tracking can be used, either individually or together, in order to improve the efficiency of the panel. The misting system is easily integrated into new panel installations and retro-fitted into existing panel installations. It has a plurality of small nozzles, which are mountable to the top of the panels. The nozzles are fed by a piping system, which can be fabricated from PVC, PEX, ABS, copper, or other suitable plumbing material. The nozzles are controlled by a controller, which determines the appropriate amount of misting.
[0019] The misting system can have accessories to improve performance, depending on the environment. In climates with frequent winter snow, a warming reservoir and trickling nozzles can be added to the system, to warm the mist and create slippery slope, respectively. The warming reservoir would be incorporated into the system between the piping and the nozzles. The warmed mist can then be used to melt snow on the panel from the upper layer on down. The trickling option additionally encourages the entire snow mass to slide, due to gravity, all at once. This accessory would come with an additional controller, to control, amongst other things, the heating of the water, and to sense whether or not snow is on the panel.
[0020] In dusty, dry climates, a reservoir for surfactant or detergent can be added to the system, to allow the mist to remove dust and grime. This accessory would come with an additional controller, to control, amongst other things, the level of surfactant or detergent, to sense the cleanliness of the panels, and to establish when the panels are clean enough.
[0021] The system would also come with an optional mounting system that allows the panels to track the sun. The tracking system would have two methods by which to improve panel efficiency: first, the system would improve direct radiant energy capture by allowing the panel to remain orthogonal to the sun's rays; and second, the system would quickly adjust tilt to the horizontal during periods of diffuse radiance (cloud cover).
[0022] The mounting system that enables tracking would have two embodiments: a pole-type mount and floating-type mount With a pole-type mount, the panels would be fastened to a cross-member. The cross-member would fasten to a pole at a rotational coupling. The rotational coupling would be motor-driven or cable-driven, allowing the panels to be rotated about the coupling. The coupling could be oriented in multiple ways, to allow for optimizing the rotational aspects of the tracking system. The pole would be on a rotational mount, also. The combined movement of the coupling and the pole's rotational mount would allow the tracking system to optimize the position of panels in order to maximize energy absorption. Among the factors that the tracking system would account for are time of day, time of year, cloud-cover, wind, and radiant temperature.
[0023] With a floating-type mount, the panels would be mounted to a plane member. In one embodiment, the plane member would be positioned over a water tank. In another embodiment, the plane member would be positioned over a shallow pool, pond, or other suitable body of water. The underside of the plane member would be constructed so as to make the plane member, mounts and panels float on top of the water. The panels could be positioned with pumps actuated by controllers. The controllers would use an algorithm to optimize the position of the panels, taking inputs, that include, but are not limited to, time of day, date, cloud cover, temperature, and latitude.
[0024] Another embodiment of this type of mount, called the turntable type, would be having the plane member attached to a turntable. The turntable would ride on bearings and would be driven by an electric motor. The controllers would use largely the same algorithm inputs, as mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] There are nine (9) figures used to illustrate the invention.
[0026] FIG. 1 shows a prospective view of the combined misting and tracking systems.
[0027] FIG. 2 shows a top view of the combined misting and tracking system.
[0028] FIG. 3 shows a front view of the combined misting and tracking system.
[0029] FIG. 4 shows a side view of the combined misting and tracking system, highlighting another of the potential motions of the rotational coupling.
[0030] FIG. 5 shows a prospective view of the misting system being retrofitted to an existing panel installation on a residential or other sloping rooftop.
[0031] FIG. 6 shows an isolated prospective view of the misting system on a panel installation.
[0032] FIG. 7 shows an isolated prospective view of an alternative embodiment of the misting system.
[0033] FIG. 8 shows a perspective view of a turntable-type tracking system, with a turntable member supporting the renewable energy panels.
[0034] FIG. 9 shows a perspective view of a floating-type tracking system with the plane member positioned over a water storage tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The detailed description is intended to illustrate the present invention, without, in any way, limiting its scope.
[0036] The invention is a system for a PV, thermal or other panel implementation of a renewable energy system for use in residential, commercial, and industrial buildings. The system is a misting and tracking system, for use in conjunction with renewable energy panels, and intended to improve the efficiency of said panels. The system is tailorable and scalable. The system can be implemented as just an evaporative misting system, just a solar tracking system, or both. The system has embodiments which will work for new installations and embodiments which will work for existing PV panel installations.
[0037] FIG. 1 shows a perspective view of the system mounted with solar panels 105 . The panels 105 can be PV, solar thermal, or other type of solar panels. The panels 105 can be constructed flat, parabolic, 3-D/cubic, or other types of mountable constructions. The system allows for panels 105 to track the sun. Various types of panels 105 can be mounted on a pole 101 . The pole 101 can be fabricated from any suitable construction material: steel, aluminum, PVC, etc. The mounting pole 101 can be specifically installed for the mounting of panels, or already existing. The cross-member 102 , also, can be fabricated from any suitable construction material. The cross-member 102 is designed to handle the load imposed by the panels 105 , allowing for rotation about an axis, in order to facilitate tracking the sun. The cross-member 102 is connected to the mounting pole 101 at a housed coupling 103 . The housed coupling 103 allows the cross-member 102 and panel 105 to pivot about the axis of the cross-member 102 . The tracking system is controlled by a controller, which will adjust the housed coupling 103 , to optimize output for a number of input variables, including, but not limited to, time of day, shading by nearby object, wind losses, and wind shear.
[0038] Continuing with FIG. 1 , the system also includes a method and apparatus to provide the panels 105 with an evaporative mist 107 . The evaporative mist 107 is supplied by a nozzle 106 . The nozzle 106 is supplied water by a system of piping 114 , which is connected to a reservoir or barrel 113 . Alternately, the piping 114 can be connected directly to a municipal water source (not shown). When using a reservoir or barrel 113 , the system relies on a pump to create pressure in the piping 114 to get the mist 107 to the nozzle 106 . The system has a rain gutter 111 , that funnels run-off into a series of tubes 112 , which feeds the reservoir or barrel 113 .
[0039] FIG. 2 shows a top view of the system, highlighting the tracking capabilities. The mounting pole 101 can rotate about its axis, allowing the panel array 105 to pivot. The cross-member 102 and nozzles 106 are constructed so that they pivot with the system. This allows the system to track the sun and be evaporatively misted 107 , simultaneously.
[0040] FIG. 3 is a front view of the system. In this view, the drive and control mechanism 108 , 110 is shown. The drive and control mechanism 108 can be mounted to the ground, roof, or other appropriate place. As an alternative embodiment, the drive and control mechanism 110 can be pole mounted. The drive and control mechanism 108 , 110 controls a cable-pulley system 109 , which is capable of adjusting both degrees of freedom. The cable-pulley system 109 can be housed inside of a hollow mounting pole 101 , or can be externally mounted in a weather-secured fashion.
[0041] FIG. 4 is a side view of the tracking and misting system. This view shows all of the elements described: mounting pole 101 ; cross-member 102 ; housed coupling 103 ; piping 104 , 114 ; panel 105 ; nozzle 106 ; evaporative misting 107 ; drive and control mechanism 108 , 110 ; cable-pulley system 109 ; a rain gutter 111 ; and tubing 112 to funnel run-off into a reservoir or barrel 113 .
[0042] FIG. 5 shows a perspective view of a new or existing panel 201 installation with a misting system. The misting system can be easily retro-fitted to an existing PV or thermal solar panel installation. The system has a plurality of nozzles 202 , which are fed by piping 206 . The system contains a plurality of sensors 205 . The run-off, either from rain or misting, is captured in a gutter 203 and fed to a piping system 207 . The system has a control and pump mechanism 204 , which allows either automatic control or manual control in order to regulate the flow of water out of or into the reservoir or barrel 208 .
[0043] FIG. 6 shows an alternative embodiment of the misting system, in which the reservoir or barrel 208 , is mounted under the panel installation. FIG. 7 shows another alternative embodiment of the misting system, in which the panels are mounted on wedges 208 . The wedge is integral 208 , containing in its bulk a reservoir or barrel 208 , which allows the system to have a nearby water supply. The gutter system 203 in both of these embodiments feeds the run-off back to the reservoir or barrel 208 . Both of these systems are controlled, in part, by a plurality of sensors 205 mounted to the panels.
[0044] FIG. 8 shows a turntable-type tracking system. A plurality of renewable energy panels 301 are secured to a turntable member 302 . The turntable member 302 is positioned over an upper surface 303 . The housing 304 of the overall system supports the upper surface 303 , and contains the support, bearings, drive system, and controller needed to move the turntable 302 so that the renewable energy panels 301 track the sun.
[0045] FIG. 9 shows a float-type tracking system. A plurality of renewable energy panels 301 are secured to a turntable member 302 . The turntable member 302 is positioned over a water storage tank 305 . The water storage tank 305 is filled such that the turntable member 302 floats on the water in the water storage tank 305 . The system includes pumps and controllers (not shown) needed to move the turntable 302 so that the renewable energy panels 301 track the sun. | A method and system for improving the efficiency of renewable energy panels. The invention is comprised of a means for evaporatively misting renewable energy panels and for allowing the renewable energy panels to track the sun. Depending on the environment and installation, the systems can be used individually or together. The invention improves the efficiency of the renewable energy panels by lowering their operating temperature and allowing the panels to optimize energy collection. | 7 |
TECHNICAL FIELD
[0001] The invention disclosed herein is directed to wipes, preferably wipes for use in graphic arts or lithography, made from a hydroentangled nonwoven fabric, whereby the outer surface fibers of a single fibrous batt are highly hydroentangled and the inner fibers of the single fibrous batt are lightly entangled, the resulting fabric thus exhibits a low linting, lofty structure, and favorable tactile and ductile softness while obtaining sufficient physical strength.
BACKGROUND OF THE INVENTION
[0002] The use of natural fiber materials in industrial applications has been found to be highly advantageous in situations where a non-linting, absorbent pad or wiper is required. A material that has been employed in such applications is found in the Webril material from the Kendall Company of Massachusetts. The Webril material is a compressed, mercerized cotton fibrous batt. The mercerization process involves the swelling of the natural cotton's ribbon like profile into an approximately round profile of larger diameter. Typically, caustic washes are utilized while the cotton batt is under tension to induce the swelling of the cotton fiber. Because of the use of a caustic solution, it is necessary to subsequently treat the cotton material with an acidic solution so as to neutralize the material and render it useable. A number of complicated steps are required to successfully perform the process, with a significant amount of environmentally harmful effluent being produced.
[0003] In the interest of forming natural fiber nonwoven pads or wipers without the by-products of mercerization, the application of a resin binder in conjunction with hydroentanglement was explored as evidenced by U.S. Pat. Nos. 2,862,251, 3,033,721, 3,769,659, and 3,931,436 to Kalwaites et al., and U.S. Pat. Nos. 3,081,515 and 3,025,585 to Griswold et al, the disclosures of which are herein incorporated by reference. The application of resin binder was found to have a deleterious effect on the softness of the corresponding nonwoven fabric.
[0004] The findings by Evans, U.S. Pat. No. 3,485,706, the disclosure of which is herein incorporated by reference, suggested that the impedance of energetic water streams on a fibrous batt could produce a nonwoven fabric by the entanglement of those fibers with one another through the depth of the fibrous batt, thus obviating the need for a resin binder. However, the action of the water streams upon the fibrous batt and the action of entangling the fibers result in a fabric having significantly decreased bulk, and correspondingly decreased tactile and ductile softness.
[0005] Various attempts have been made in order to obtain a durable natural fiber nonwoven fabric while maintaining sufficient strength and softness. In U.S. Pat. No. 5,849,647 to Neveu, the disclosure of which is herein incorporated by reference, a hydrophilic cotton stratified structure is formed by interceding an air-randomized core in between two previously formed, highly fiber oriented carded layers. The stratified layers are subsequently treated with a soda liquor which is then boiled off to render an integrated structure. While a cotton structure performed by the manner described can render an ultimate material that is low linting, the material must undergo substantial processing in the forming of separate and distinct layers and the juxtaposition of those layers during the caustic integration step. U.S. Pat. No. 4,647,490 to Bailey et al., the disclosure of which is herein incorporated by reference, formed an apertured, cotton fiber nonwoven material by hydroentanglement induced by oscillating water streams. In the Bailey process, the fibers of the fibrous batt are washed down and through the fibrous batt in order to entangle the fibers and form apertures in the fabric. U.S. Pat. No. 4,426,417 to Meitner et al., the disclosure of which is herein incorporated by reference, incorporated the use of thermoplastic meltblown during the formation of a fibrous batt as a means for attaining the loft for absorbency and maintain sufficient physical strength by bonding the fibers together. As the nature of the Meitner process is based upon the total and effective binding of the fibers to the thermoplastic meltblown there are potential issues with unbound or loosely bound fibers being disengaged from the meltblown.
[0006] Given the prior art attempt to form a nonlinting, soft and yet strong absorbent materials, there remains a need for a nonwoven fabric exhibiting these characteristics and yet is formed in an expeditious and uncomplicated manner.
[0007] A method for forming a suitable nonwoven fabric meeting the aforementioned requirements has been identified in the application of fluidic energy such that a single fibrous batt is imparted with a highly entangled surface of outer fibers while retaining the loft and absorbency of a lightly entangled central layer of core fibers.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a method of forming a nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired.
[0009] In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a fibrous batt comprising a fibrous matrix. While use of natural fibers is common, the fibrous matrix may comprise synthetic fibers or blends of natural and synthetic fibers. The synthetic fibers are chosen from the group consisting of viscose cellulose, polyacrylates, polyolefins, polyamides, polyesters and combinations thereof. Further, the synthetic fibers may comprise homogeneous, bicomponent and/or multi-component profiles, and the blends thereof.
[0010] In a particularly preferred form, the fibrous batt is carded and cross-lapped to form a fibrous batt. The fibrous batt is then continuously indexed through a station composed of a rotary foraminous surface and a fluidic manifold. Fluid streams from the fluidic manifold impinge upon the fibrous batt at a controlled energy level so as to integrate a portion of the overall fibrous content. The energy level is controlled such that the energy is sufficient to induce high levels of entanglement in the surface fibers, but has insufficient transmitted energy to induce high levels of entanglement of the inner fibers. A plurality of such stations can be employed whereby fluid streams are at the same or differing energy levels, impinging one or alternately both surfaces of the fibrous batt. The resulting differentially entangled nonwoven web exhibits a highly entangled fibrous outer surface and a lightly entangled fibrous core.
[0011] Subsequent to hydroentanglement, the present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, the disclosure of which is herein incorporated by reference. In a typical configuration, the image transfer device may comprise a drum-like apparatus that is rotatable with respect to one or more hydroentangling manifolds.
[0012] It is within the purview of this invention that tension control means can be employed to further enhance the physical performance of the resulting lofty material.
[0013] A further aspect of the present invention is directed to a method of forming a nonwoven fabric which exhibits a sufficient degree of softness and nonlinting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications. The fabric exhibits a high degree of loft and absorbency, thus permitting its use in those applications in which the fabric is applied as a cleaning wipe. Further, the material exhibits pleasant aesthetics, thus lending itself to application in medical applications.
[0014] A method of making the present durable nonwoven fabric comprises the steps of providing a fibrous matrix or batt, which is subjected to controlled levels of hydraulic energy. A homogeneous cotton fibrous batt has been found to desirably yield a fabric with soft hand and good absorbency. The fibrous batt is formed into a differentially entangled nonwoven fabric by the application of sufficient energy to entangle only the outer layers of the fibrous batt. Subsequently, the fabric can be passed over an image transfer device defined by three-dimensional elements against which the differentially entangled nonwoven fabric is forced during further application of further energy, whereby the fibrous constituents of the web are imaged and patterned by movement into regions between the three-dimensional elements of the transfer device.
[0015] It is within the purview of the present invention that physical property altering chemistries can be incorporated into the resulting differentially entangled fabric. Such chemistries include for example antimicrobial and antistatic agents that can be durably applied to the constituent fibers of the fibrous batt, to the fibrous batt during manufacture, and/or to the resulting fabric.
[0016] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a diagrammatic view of an apparatus for manufacturing a differentially entangled nonwoven fabric, embodying the principles of the present invention; and
[0018] [0018]FIG. 2 is a diagrammatic view of five consecutive entangling sections and an image transfer station.
DETAILED DESCRIPTION
[0019] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0020] The present invention is directed to a method of forming nonwoven fabrics by hydroentanglement, wherein the outer surface of the fabric is substantially more entangled than the core layer. Hydroentanglement by this method is controlled by the application of fluidic energy such that the energy imparted into fibers of the fabric is sufficient to highly entangle only the outer fibers. The inner fibers are lightly entangled such that the overall structure is resistant to separation of the layers, yet retain much of the loftiness or bulk of the fibrous core layer that is responsible for tactile and ductile softness as well as absorbency. By advancing the fibrous batt with a relatively low tension through one or more entanglement stations, differential fiber entanglement is achieved, with the physical properties, both aesthetic and mechanical, of the resultant fabric being desirably achieved.
[0021] In accordance with a further aspect of the present invention, a nonwoven fabric for application as a wipe can be produced such that the level of surface entanglement can be controlled resulting in surface layers that are extremely resistant to Tinting while the fabric retains some loft of the fibrous inner layer. A material of this nature is found to have use in the graphic arts and lithography as it can be employed as a non-abrasive, drapeable, absorbent wiper. Excessive linting from the wipe would be detrimental to the application, so increasing the level of entanglement of the surface fibers should act to decrease Tinting from the highly entangled surface layer, which should act as a barrier to loss of fibers or particulates form the lightly entangled core. The level of entanglement energy can be continuously varied to modify the physical properties of the wipe material to meet the required performance. It is within the scope of the present invention to control the level of entanglement in the resulting fabric to obtain materials with varying degrees of loft, absorbency, strength, and linting performance.
[0022] Nonwoven fabrics are frequently produced using staple length fibers, the fabric typically has a degree of exposed surface fibers that will lint if not sufficiently retained into the structure of the fabric. The present invention provides a finished fabric that can be cut, processed or treated, and packaged for retail sale. The cost associated with forming and finishing steps can be desirably reduced.
[0023] With reference to FIG. 2, therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous batt that typically comprises natural fibers, but may comprise synthetic staple fibers and natural/synthetic fiber blends. The fibrous batt is preferably carded and cross-lapped to form a fibrous batt, designated P. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. In this current embodiment, the fibrous batt has a draft ratio of approximately 2.8 to 1. U.S. Pat. No. 5,475,903, the disclosure of which is herein incorporated by reference, illustrates a web drafting apparatus.
[0024] [0024]FIG. 2 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 02 upon which the fibrous batt P is positioned for pre-entangling by entangling manifold 01 into a wetted, lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′ sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 effecting entanglement of the web. Further entanglement of the web may be effected on the foraminous forming surface of a drum 20 by entanglement manifold 22 , with the web subsequently passed over successive foraminous drums 30 , 40 and 50 , for successive entangling treatment by entangling manifolds 32 , 42 and 51 . The total, optimal energy input to the fibrous batt to give the desired level of surface entanglement is in the range of about 0.040 to 0.060 hp-hr/lb.
[0025] The entangling apparatus of FIG. 2 may further include an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 61 , 62 , 63 and 64 , which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed. The total energy applied to the fibrous batt of the imaging manifolds is adjusted to maintain the energy input in the range of about 0.040 to 0.060 hp-hr/lb.
[0026] The present invention contemplates that the fibrous web P′ be advanced onto the moveable imaging surface of the image transfer device at a rate which is substantially equal to the rate of movement of the imaging surface. A J-box or scray can be employed for supporting the precursor web P′ as it is advanced onto the image transfer device to thereby minimize tension within the fibrous web. By controlling the rate of advancement of the fibrous batt P and the web P′ through the process so as to minimize, or substantially eliminate, tension within the web, differential hydroentanglement of the fibrous web is desirably effected.
[0027] Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web preferably in the form of a natural and/or synthetic fibers, most preferably a cotton or cotton blend, which desirably provides good tactile and ductile softness and absorbency. During development, it was ascertained that fabric weights on the order of about 1 to 8 ounces per square yard, with the range of 2 to 5 ounces per square yard being most preferred, provided the best combination of loft, softness, drapeability, absorbency, and durability.
EXAMPLES
Example 1
[0028] Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made in accordance with the present invention by providing a fibrous batt comprising 100 weight percent cotton fiber. The fibrous batt had a basis weight of 3.4 ounces per square yard (plus or minus 7%). The fibrous web was 100% carded and cross-lapped, with a draft ratio of 2.8 to 1.
[0029] The fabric comprised 100 weight percent cotton as available from Barnhardt Manufacturing Company under code number RMC#2811. The fibrous batt was entangled by a series of entangling manifold stations such as diagrammatically illustrated in FIG. 1 and in greater detail in FIG. 2. FIG. 2 illustrates disposition of fibrous batt P on a foraminous forming surface in the form of belt 02 , with the batt acted upon by a pre-entangling manifold 01 operating at 55 bar to form a wetted and lightly entangled fibrous web. The web then passes through a series of entangling stations comprising drums having foraminous forming surfaces, for entangling by entangling manifolds, with the web thereafter directed about the foraminous forming surface of a drum 10 for entangling by entanglement manifold 12 operating at 40 bar. The web is thereafter passed over successive foraminous drums 20 , 30 , 40 and 50 , with successive entangling treatment by entangling manifolds 22 , 32 , 42 and 51 . In the present examples, each of the entangling manifolds included 120 micron orifices spaced at 42.3 per inch, with manifolds 22 , 32 , 42 and 51 successively operated at 55, 40, 55, and 0 bar, with a line speed of 45 meters per minute. The total energy input into the fibrous batt is calculated to be 0.052 hp-hr/lb. A web having a trimmed width of 127 inches was employed.
Comparative Example
[0030] The comparative example is selected from a commercially available product in the form of Webril 100% Cotton Handi-Pad as available from the Kendall Company. This product is formed by compression forming cotton fiber during a mercerization process.
[0031] The accompanying Table 1 sets forth comparative test data for a fabric made by the present invention compared against a commercially available mercerized cotton fabric. Testing was done in accordance with the following test methods.
Test Method Basis weight (ounces/yd 2 ASTM D3776 Bulk (inches) ASTM D5729 Tensiles MD and CD Grabs (lb/in) ASTM D5034 Elongation MD and CD Grabs (%) ASTM D5034
[0032] The physical test data for Example 1 and the Comparative Example are given in Table 1. The data in Table 1 show that the two materials have similar basis weights, but the nonwoven fabric manufactured by the present invention has much greater tensile strength in both the machine and cross direction, 20 and 40 times greater, respectively, than that of the Comparative material. In addition, the tensile properties of Example 1 are more uniform when comparing the machine direction to the cross direction tensile and elongation properties.
[0033] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
TABLE 1 Comparative Physical Property Units Example 1 Example Basis Weight osy 3.4 3.2 Bulk inches 0.033 0.061 Grab Tensile - MD lb./in. 23.3 1.3 Grab Tensile - CD lb./in. 23.3 0.5 Combined Grab Tensile/Basis Weight 13.7 0.6 Grab Elongation - MD % 32.9 35.4 Grab Elongation - CD % 76.1 118.7 Combined Grab Elongation/Basis 32.1 48.2 Weight | The invention is directed to a hydroentangled nonwoven wipe, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Wipes formed in accordance with the present invention exhibit a sufficient degree of strength, softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications utilizing wipes, such as graphic arts and lithography. | 3 |
FIELD OF THE INVENTION
The present invention relates to panel systems, for example, but not exclusively, ceiling panel systems for false ceilings, panelling members to be made up into such panel. systems and methods of manufacturing and installing the panel and panelling members.
BACKGROUND OF THE INVENTION
Prefabricated panels are commonly used to form ceilings or walls and in many other places. Such panels are commonly made of sheets of material, for example aluminum alloy, and it is generally desirable to reduce the thickness of the panelling material so as to reduce its cost and weight. Reduction of thickness is however restricted by the necessity to retain sufficient strength and rigidity. It is also desirable that the panel is cheap to manufacture and easy to assemble in numerous different applications.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a panelling member comprising at least two elongate sheet members hingedly joined along adjacent edges.
The sheet members are hingedly joined so that the panelling member can be folded or laid flat. When folded it will be rigid but when flat may be coiled. The present invention thus provides a panelling member which is easy to manufacture and may be readily stored and transported whilst rolled. The panelling member of the invention may be easily installed by unrolling it and hanging it on an appropriate carrier. If provided in long lengths it can be cut to fit on site so that there is no waste scrap.
The sheet members may be joined by strips of suitable flexible material such as plastic or fabric adhered or welded to the sheet members. They may also have a curved lateral cross section side by side.
The widths of the different elongate sheet members may be different, with central ones preferably wider. Decoration or perforation may be applied as desired for the particular application. The sheet members are preferably relatively rigid and may be made of, for example, aluminum alloy, other metals or rigid plastics type materials. The invention also provides a panel system comprising at least one panelling member mounted on a carrier.
When mounted on the carrier the or each central sheet member of the or each panelling member forms the outer surface of the panel while side sheet members are turned inwards for connection to the carrier and to provide rigidity.
The panelling member may be easily made in long lengths by drawing strips of the sheet material off rolls, bringing them side by side and applying a flexible connecting strip, such as an adhesive tape, along the join to form the hinge. With the multiple sheet members still retained generally coplanar, the panelling member may be easily coiled for ease of storage or transportation, but on installation, when the free edges are moved towards one another by folding the joint, sufficient rigidity is imparted to retain an elongate straight structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further described hereinafter with reference to the following description of exemplary embodiments and the accompanying drawings, in which:
FIG. 1 is a cross-sectional view of an embodiment of a panelling member according to the invention in a flat state;
FIG. 2 is a cross-section of the panelling member of FIG. 1 in a folded state;
FIG. 3 is a schematic diagram of an assembly line for manufacturing panelling members according to the invention;
FIG. 4 is a sectional view of a false ceiling constructed from panelling members according to the invention;
FIG. 5 is a close-up view of part of FIG. 4 showing how the panelling members are attached to carriers;
FIG. 6 is a view of an alternative method of fixing panelling members to the carrier;
FIGS. 7 a) to f) are sectional views of how panels may be constructed from a plurality of panelling members;
FIGS. 7 g) to l) are perspective views of example ceilings formed from panelling members according to embodiments of the invention;
FIG. 8 is a schematic view of how the false ceiling may be constructed using panelling members according to the invention;
FIGS. 9, 10 and 11 are cross-sectional views of false ceilings according to an embodiment of the invention;
FIG. 12a) shows a blank to be formed into a carrier for use in the invention;
FIG. 12b) shows that carrier when folded;
FIG. 12c) is an enlarged view of a part of that carrier;
FIG. 13a) shows a blank to be formed into another carrier for use in the invention;
FIG. 13b) is an enlarged view of a part of that carrier;
FIGS. 14a) and b) are side views of a further carrier for use in the invention and FIG. 14c is a side view of that carrier; and
FIGS. 15a) and b) show the two components of a still further carrier according to the invention and that carrier as assembled.
DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-section of an embodiment of a panelling member or panel embodying the present invention with the panel shown in a flat state. The panel comprises three curved metal sheets or slats, 1, 2 and 3, joined together by a flexible tape 4. The panelling member according to the invention may also comprise only two slats. The slats are preferably made from a metal such as an aluminum alloy, and the adhesive tape from a plastics material. The middle slat 1 is considerably wider than the outer slats 2 and 3. FIG. 2 shows the same slat in cross-section when the side slats 2, 3 are folded upwards so as to form a channel. While in the FIG. 1 configuration the panelling member is quite flexible and may be coiled for ease of storage, in the FIG. 2 configuration it is much more rigid, sufficiently so to form a panel or part of a false ceiling.
FIG. 3 illustrates a mechanism by which the panelling member can be constructed. The center slat 1 is unrolled from a supply roll 5 and the side slats 2, 3 are unrolled from supply rolls 6 and brought alongside the center slat at pinch rollers 8. If the slats are already crowned then rollers 8 may simply guide them together; however, if they are supplied flat rollers 8 may cold roll them into the desired cross-section. The adhesive tape 4 is supplied from a roll 7 and pressed onto the joint at rollers 9. The complete panel may then pass through a perforating station 11 which punches any holes desired for mounting or ventilation purposes, and a decorating station 12 which may apply any necessary surface finish or coating. The finished product is then rolled onto roll 10 or alternatively cut into lengths.
FIG. 4 shows a false ceiling constructed using panelling members according to the invention. A carrier 13 is suspended from the true ceiling 14 at the desired height and perpendicular to the direction the elongate panelling members are to be arrayed. The carrier 13 has regularly spaced mounting points along its length onto which the lengths 16 of panelling are hung. FIG. 5 shows a carrier 13 and mounting points 15 in greater detail. The carrier 13 comprises an elongate inverted channel and the mounting points comprise notches 16 cut up into the side walls with a barbed projection 17 pointing downwards. During mounting of the panelling member, the free edges of the side slats are introduced into the notches 16 and slots 21 therein hook onto the barbs of the projection 17. The shape and width of the notches 15 relative to the side slats is chosen such that the side walls engage the opposite sides of the notches from the barbs to retain the slots 21 on the projection 17 and prevent movement of the side slats relative to the carrier
FIG. 6 shows an alternative construction of the mounting point in which a single barb 19 is provided on one side of the notch 18 onto which are hung the side slats of two adjacent panelling members. As with the arrangement of figure 5, the notch is shaped to receive and retain the side slats. Alternatively a barb might be provided on each side of the notch. Many alternative constructions of the carrier are possible, for example it might comprise a long bar with appropriately spaced barbed projections depending therefrom.
FIGS. 7 a) to f) illustrate potential variations in form of ceilings that can be provided with different panelling members. In FIG. 7a) the center slat of each panelling member is concave downwards while the side slats are convex facing one another. In FIG. 7b) the center slats are convex downwards while the side slats alternate concave convex so as to nestle together more closely. FIG. 7c) is similar but the center slats are concave downwards. In FIG. 7d) the center and side slats all have the same curvature but the side slats are overlapped and joined together rather than being hinged upwards.
FIG. 7 e) illustrates possible effects which may be achieved with panelling members alternately having convex and concave center slats. FIG. 7f) illustrates effects that may be achieved or with panelling members having center slats of different widths.
FIGS. 7g) to l) are perspective views of ceilings constructed from arrangements of panelling members similar to the panels of FIGS. 7a) to f). FIG. 7g) is a perspective view showing "open" joints between panelling members with three convex slabs. The arrangement in FIG. 7h) is similar but in this case the middle slat of each parallel member is concave. The side slats are still convex to produce "open" joints.
FIG. 7i) illustrates the "wave" effect achievable with alternate panel members having convex and concave central slats, in this case all of the side slats are concave to produce "open" joints.
FIGS. 7j) to 7l) show arrangements similar to FIGS. 7f) to 7i) but with "closed" joints formed by using panel members with side slats curved in opposite senses of curvature. The concave side slat of one panel member nests in the convex side slat of the adjacent panel member so as to provide a continuous outer surface.
FIG. 8 shows how a false ceiling using panelling members according to the invention may be put up. First the carriers 13 are hung from the ceiling and then panelling member is unrolled from a roll 10, the sides hinged up and hung on the carriers. The roll 10 is provided on a trolley 20 which is then wheeled along as the panelling member is paid out and hooked onto the carriers.
The invention may also provide stiffening members with three or more similarly sized slats which can be folded to have a closed cross-section (not shown), in which form it is very rigid, yet when unfolded can be laid out flat for rolling or storage.
A length of panelling member may be formed of several simple three part members joined side by side in any of the arrangements shown above.
FIG. 9 shows in cross-section a false ceiling according to the invention similar to that shown in FIG. 5. In this embodiment the panel member 16 is constructed from a convex central slat and two side slats 2 and 3 one of which is convex and the other concave. Adjacent panelling members nest to provide a closed joint and the two side slats engage the barred projection 17. An additional detent projection 23 is provided on the side of notch 15 to engage the side slats of the panel members and hold them onto the barbed projection. Two adjacent side slats are engaged to one of slots formed on one side of the barbed projection.
FIG. 10 shows a similar arrangement using the same carrier but in which all slats of the panel member are convex so as to provide "open" joints, and one side slat is engaged in each of the two slots formed beside the barbed projection.
FIG. 11 is a still further similar embodiment in which different panelling members are combined on the same carrier as in FIGS. 9 and 10 so as to produce a desired arrangement of open and closed joints.
FIGS. 12a) to c) show a carrier which may be used with panelling members described above to form a false ceiling. FIG. 12a shows how notches are cut into the flat blank whilst FIG. 12b illustrates how that blank is folded by roll forming to form the channel shaped carrier. The notches cut on alternate sides of the blank are asymmetrical so that when folded a side slat hanging on barb 24 is held in place by detent 25 provided on the opposite side of the carrier. FIG. 12c is an enlarged side view of the folded carrier showing how the two notches cooperate to form two barb and detent pairs for holding side slats. This form of notch is advantageous in that it may be cut with a more sturdy punching tool.
FIG. 13a shows the blank of a further form of carrier according to the invention, again with asymmetric notches. In this instance two barbs 24 are provided on one side and two detent members on the other. As will be seen in FIG. 13b, which is an enlarged view showing how the notches will overlap once the blank is folded into a channel section, these will cooperate to retain a side slat. The two forms of notch shown in this figure may be alternated on each side so as to eliminate any tendency of the long carrier to tilt.
A still further form of carrier is shown in FIGS. 14a) to c). As will be seen the notch 15 in the carrier is very deep and has gently sloping sides. A relatively short barbed projection 19 is provided at the base apex, or deepest part of each notch 15. The curved relatively gently sloped sides of the notch 15 serve to guide the side slats 2 and 3 on to the projections during assembly. As shown in FIG. 14a) members having alternate convex and concave central slats are provided so as to form a wavy appearance. All of the side slats 2 and 3 are concave and engage opposite sides of the barbed projection so as to provide "open" joints. In FIG. 14b all of the central slats are convex but the side slats alternate concave and convex and engage the same side of the barbed projection so as to form "closed" joints.
As shown in FIG. 14c the carrier itself is asymmetric. Only one of the depending flanges bears notches and the other is cut off short so as not to project below the top of the notches in the other flange.
A still further example of a carrier according to the invention is shown in FIGS. 15a) and b). This carrier comprises two separate components both formed from a flat strip of metal or plastic. The first component or flexible, elongate web 26 has notches 15 and 19 cut at regular intervals into its lower edge and from its upper edge has upwardly directed projections 27 having holes 28 therein. The notches and barbed projections are preferably the same shape as in the embodiment of FIGS. 14a) and b). The upper projections 27 are also provided at regular intervals, but not necessarily the same as the lower notches. The second component or stiffening means 29 comprises a flat strip having apertures 30 at regular intervals matching those of the projections 27 on the first component 26. Both the first and second components 26, 29 may be coiled for easy storage and unrolled for assembly. The projections 27 are passed through the apertures 30 to form a composite body having sufficient rigidity. Some of the projections 27 are used to hang the carrier, while the remainder may be bent or twisted sideways to hold the two components together.
Because the two parts of this form of carrier may be rolled when separate they share the same advantages as the panelling member of the invention. For example, they are easy to manufacture, easy to transport and store when rolled and may be quickly and conveniently assembled without generating scrap. | A panel system, particularly a false ceiling is constructed from a plurality of elongate panelling members arranged side by side. Each panelling member comprises three elongate slats arranged side by side and joined by flexible tape along adjacent edges. When laid out flat the panelling member may be coiled or easily stored but for installation in a ceiling the outside slats are folded perpendicular to the cental slat so as to provide the necessary rigidity. | 4 |
FIELD OF THE INVENTION
The present invention is directed to a post print finishing device in which imaging material is used to bind a printed documented.
BACKGROUND OF THE INVENTION
Current devices and methods for printing and binding media sheets involve printing the desired document on a plurality of media sheets, assembling the media sheets into a stack, and separately stapling, clamping, gluing and/or sewing the stack. In addition to imaging material used to print the document, each of these binding methods require separate binding materials, increasing the cost and complexity of binding. Techniques for binding media sheets using imaging material are known in the art. These techniques generally involve applying imaging material such as toner to defined binding regions on multiple sheets, assembling the media sheets into a stack, and reactivating the imaging material, causing the media sheets to adhere to one another.
The present invention was developed to integrate an imaging material binder into a post print finishing device such as the stapler/stacker devices commonly used with middle to high end printers and copiers. The modular implementation shown in the drawings and detailed below was developed for use in the Hewlett-Packard Company model C8085A stapler/stacker with the imaging material binder module replacing the stapler module. Various techniques and structural configurations for binding documents using imaging material are described in U.S. patent application Ser. No. 09/320,060, filed May 26, 1999 titled Binding Sheet Media Using Imaging Material, Ser. No. 09/482,124, filed Jan. 11, 2000 titled Apparatus and Method For Binding Sheet Media, and Ser. No. 09/866,017, filed May 24, 2001 titled Apparatus and Method for Binding Sheet Media, all of which are incorporated herein by reference in their entirety.
When imaging material binding is used, each sheet of paper or other print media includes imaging material, such as toner, applied to one or more selected binding regions in addition to the print image applied to each sheet. The binding regions are usually located along one edge of the media sheet on one or both sides. All of the imaging material applied to the sheet is activated as part of the print process. The imaging material applied to the binding region(s) is reactivated in the binder to bind the multiple sheets of a document together. The bound document may be formed by reactivating the imaging material in a stack of sheets in the document at the same time or by individually binding each sheet one after another to the stack. The strength of the inter-sheet bond is a function of the type, area, density, and degree of reactivation of the imaging material applied to the binding region of each sheet. By varying these parameters the inter-sheet bond can be made very strong to firmly bind the document or less strong to allow easy separation. When the imaging material is toner, such as that used in laser printers, the imaging material will usually be reactivated by applying heat and pressure as in the exemplary embodiment of the invention detailed below. Other imaging materials and reactivation techniques may also be used, such as those described in the '060 application.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a post print finishing device that incorporates an imaging material binder into the post print handling and finishing functions. In one exemplary embodiment of the invention, the finishing device includes a flipper module, an accumulator module and a binder module. The binder module binds sheets together by reactivating imaging material applied to binding regions on the sheets by a printing device. The flipper module receives a sheet leading edge first and discharges the sheet trailing edge first. That is to say, the flipper module flips the sheet before discharging the sheet for further processing. The accumulator module stacks the sheets, presents the sheets to the binder for binding and then discharges the bound stack to the output bin.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a printer and attached stacker illustrating one type of document printing and finishing system in which the invention may be implemented.
FIG. 2 is a side elevation view of a modular stacker constructed according to one embodiment of the invention showing the flipper, paper path, accumulator and binder modules.
FIGS. 3-10 are side elevation views showing the routing of media sheets through the stacker of FIG. 2 . FIG. 3 shows a sheet routed to the upper/single sheet output bin. FIGS. 4-7 show a sheet routed to the stack of sheets in the accumulator in preparation for binding. FIGS. 8-10 show the stack routed to the binder, bound and then discharged to the lower/stacker output bin.
FIG. 11 is a detailed perspective view of the binder module of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The invention will be described with reference to the printer 10 and attached stacker 12 shown in FIG. 1 . The invention may be implemented in any document production system in which it is necessary or desirable to use an imaging material binder. Printer 10 and stacker 12 , therefore, represent generally any suitable printing device (e.g., printers, copiers, and multi-function peripherals) and associated post print finishing device in which imaging material is used to bind a printed documented.
Referring to FIG. 1, printer 10 and stacker 12 together make up a document production system designated generally by reference number 14 . Printed sheets are output by printer 10 to stacker 12 where they are routed to an upper/loose sheet output bin 16 or to a lower/stacker output bin 18 . Unbound sheets are collected face up in loose sheet bin 16 . Bound documents are collected face down in stacker bin 18 .
A stacker 12 constructed according to one embodiment of the invention will now be described with reference to FIG. 2 . FIG. 2 is a side elevation view looking into stacker 12 showing the flipper module 20 , paper path module 22 , accumulator module 24 and binder module 26 . Each module is mounted to a frame 28 . Frame 28 , which forms the main body or “skeleton” of stacker 12 , is made from sheet metal or other suitable structurally stable materials. A power supply 30 and controller 32 are mounted to the lower portion of frame 28 . Power supply 30 and controller 32 are electrically connected to the operative components of modules 20 , 22 , 24 and 26 . Controller 32 contains the electronic circuitry and programming necessary to control and coordinate various functions of the components in stacker 12 . The details of the circuitry and programming of controller 32 are not particularly important to the invention as long as the controller design is sufficient to direct the desired functions as described below.
The modular design of stacker 12 shown in FIG. 2 is adapted from the Hewlett-Packard Company model C8085A stapler/stacker. Each module 20 , 22 , 24 and 26 is operatively coupled to but otherwise independent of the adjacent module. In the stacker of the present invention, the stapler module used in the C8085A stapler/stacker is replaced with binder module 26 and controller 32 is modified accordingly to control the operation of an imaging material binder rather than a stapler.
For sheets that will be stacked, bound and output to bin 18 , flipper 20 makes the leading edge of each sheet output by printer 10 the trailing edge for routing to paper path 22 and accumulator 24 . Flipping the sheets in this manner from face up to face down is necessary to properly stack the sheets in accumulator 24 prior to binding. Paper path 22 moves each sheet face down to accumulator 24 where the sheets are collected, registered, moved to binder 26 (when binding is desired) and then output to bin 18 (bound or unbound). Binder 26 reactivates the imaging material applied to select binding regions on sheets collected in accumulator 24 to bind the sheets together.
The operation of flipper 20 , paper path 22 , accumulator 24 and binder 26 will now be described in more detail with reference to FIGS. 3-10. FIG. 3 shows a sheet routed to loose sheet bin 16 . FIGS. 4-7 show a sheet routed to accumulator 24 in preparation for binding. FIGS. 8-10 show the stack routed to binder 26 , bound and then ejected to stacker bin 18 .
Referring to FIG. 3, a sheet of paper or other print media 34 is output by printer 10 to stacker 12 through printer output rollers 35 and received into flipper 20 through flipper receiving port 37 . As flipper entry sensor 36 detects sheet 34 entering flipper 20 , flipper entry rollers 38 and flipper tray rollers 40 are driven forward as indicated by arrows 42 to move sheet 34 toward bin 16 . For sheets routed to loose sheet bin 16 through flipper discharge port 39 , rollers 38 and 40 are continually driven forward until sheet 34 reaches bin 16 . In the embodiment shown in the Figures, flipper entry rollers 38 and flipper out rollers 44 share the same drive roller 46 . Drive roller 46 is movable up or down to engage an opposing idler roller as necessary to move sheet 34 along one of two desired paper paths, as best seen by comparing FIGS. 3 and 4.
Referring now to FIG. 4, for sheets routed to accumulator 24 , flipper entry and tray rollers 38 and 40 are driven forward until just after the trailing edge of sheet 34 clears flipper entry rollers 38 , as detected by flipper middle sensor 48 , such that the trailing edge of sheet 34 clears directional guide 50 . Then, drive roller 46 is moved down to flipper out roller 44 and reversed along with flipper tray rollers 40 to route sheet 34 toward paper path 22 through flipper routing port 41 and paper path receiving port 53 . Paper path rollers 52 move sheet 34 through paper path 22 down to accumulator 24 . Flipper exit sensor 54 detects when sheet 34 has cleared the flipper module 20 . Paper path exit sensor 56 detects when sheet 34 has cleared the paper path module 24 through paper path discharge port 55 . Exit sensors 54 and 56 are used to control paper path rollers 52 . When paper path exit sensor 56 detects that sheet 34 is leaving the paper path module 24 , then paper path rollers 52 are stopped unless another sheet has cleared the flipper module 20 as detected by flipper exit sensor 54 .
Referring to FIGS. 5-7, sheet 34 is guided down from accumulator receiving port 59 through accumulator 24 to accumulator entry rollers 58 and on to accumulator eject rollers 60 . An accumulator entry sensor 62 is positioned immediately upstream from entry rollers 58 . As the trailing edge of sheet 34 passes through entry rollers 58 , as detected by entry sensor 62 , eject rollers 60 move the top sheet 34 back on to stack 64 in accumulator holding tray 66 , as best seen by comparing FIGS. 5, 6 and 7 . In the embodiment shown in the Figures, eject rollers 60 are configured as a pair of variably spaced rollers that are selectively driven as necessary to move top sheet 34 or stack 64 . As shown in FIGS. 5 and 6, eject rollers 60 are spaced apart or “open” to receive top sheet 34 . Then, the rollers come together and the top roller is driven counter-clockwise to move top sheet 34 on to stack 64 , as shown in FIG. 7 . Eject rollers 60 are driven together, as shown in FIGS. 8 and 10, counter-clockwise to move stack 64 into binder 76 (FIG. 8) or clockwise to move stack 64 into lower output bin 18 (FIG. 10 ). Although not shown, at the same time each sheet 34 is routed to holding tray 64 , sheet 34 is aligned with the other sheets in stack 66 .
A binding operation will now be described with reference to FIGS. 8-11. Referring to FIG. 8, once all the sheets in the document are accumulated in stack 64 , eject rollers 60 draw stack 64 back slightly from registration wall 68 , registration wall 68 is dropped and eject rollers 60 are reversed to move the edge of stack 64 forward into binder 26 through accumulator binding port 63 . Retainer 70 is then lowered against stack 64 to hold stack 64 in position during binding.
Referring now also to FIG. 11, binder 26 includes mounting brackets 72 , reversible motor 74 (not shown in FIG. 11) and press 76 . Press 76 includes base 78 , carriage 80 , top support plate 82 , lead screw 84 and gear 86 . Motor 74 is operatively connected to carriage 80 through gear 86 and lead screw 84 . Carriage 80 moves alternately toward and away from base 78 along guide posts 90 at the urging of motor 74 . Base 78 and carriage 80 are constructed as heated platens by, for example, applying resistive heating strips 88 along opposing surfaces of base 78 and carriage 80 . Preferably, both platens (base 78 and carriage 80 ) are heated when all sheets in the stack are bound at the same time. Only the top platen (carriage 80 ) needs to be heated when each page or small numbers of pages are bound to the stack using page by page binding techniques such as those described in the '124 application referenced in the Background.
Base 78 and carriage 80 , the binder platens, form an opening immediately adjacent to accumulator holding tray 66 . Preferably, holding tray 66 and platens 78 and 80 are aligned at substantially the same angle to allow stack 64 to move easily into the opening between platens 78 and 80 . Once the edge of stack 64 is positioned in binder 26 , heating strips 88 are activated and motor 74 is energized to close press 76 by driving carriage 80 against stack 64 and base 78 , as shown in FIG. 9 . Heat and pressure are thereby applied to the imaging material applied by printer 10 to the binding region along the edge of the sheets in stack 64 . Motor 74 is then reversed to open press 76 by driving carriage 80 away from stack 64 and base 78 . Retainer 70 is raised off the now bound stack 64 , ejector rollers 60 are reversed again to route the bound stack 64 through accumulator discharge port 61 to stacker bin 18 , and registration wall 68 is raised in preparation for stacking the next print job, as shown in FIG. 10 .
While the present invention has been shown and described with reference to the foregoing exemplary embodiment, it is to be understood that other forms, details, and embodiments may be made without departing from the spirit and scope of the invention which is defined in the following claims. | A post print finishing device that incorporates an imaging material binder into the post print handling and finishing functions. In one exemplary embodiment, the finishing device includes a flipper module, an accumulator module and a binder module. The binder module binds sheets together by reactivating imaging material applied to binding regions on the sheets by a printing device. The flipper module receives a sheet leading edge first and discharges the sheet trailing edge first. That is to say, the flipper module flips the sheet before discharging the sheet for further processing. The accumulator module stacks the sheets, presents the sheets to the binder for binding and then discharges the bound stack to the output bin. | 8 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present apparatus relates to the field of hair styling instruments, and more particularly to holders therefor.
2. Brief Description of the Prior Art
Many instruments are widely used throughout the hair cutting and styling trade. Aside from combs and brushes, many styling instruments include electrically powered devices. Among such devices are blowdryers, and other heating and styling means such as curling irons, hot combs, and the like. In many instances these devices generate a substantial amount of heat during their use and even for a prolonged period of time after use, even when the device is turned off. These devices must therefore be set aside after use when they are hot, thereby posing a potential danger to anyone who would accidentally come into contact with the hot styling instrument.
While barbers, hairstylists and beauticians are careful to maintain these instruments away from themselves and their customers, and others who may walk by the area in which these devices are used, the exposed electrically heated device, such as, for example, a curling iron, still poses a danger in the work area. In some instances, these devices come with collapsible support means to permit the device to rest slightly away from a countertop or other surface. However, although the device may then not be hazardous to a countertop or other items, it is still hot for some time after it is used and remains a potential hazard for those who would accidently come into contact with its hot surfaces. Further adding to the danger is that many of these electrically powered appliances have cords which may also get tangled or disrupted by those passing by or in close proximity to the device. For example, when a curling iron has just been used, the general practice is to set it on a counter with the hot part raised slightly off of the counter surface. Since the device remains hot for sometime after use, it cannot be simply put away in a drawer or cabinet space. In addition, the device, such as for example, a curling iron, may not be readily transportable immediately after use because of the heat of its surfaces.
While the stands provided for electrically powered heated appliances used in the beauty and styling trades may have means to prevent a countertop from burning, such as the curling iron stand mentioned above, there exists a need for a device which would prevent injuries, namely burns, caused from accidently knocking or bumping into the curling iron or cord thereof, and enabling such a heated styling instrument to be immediately portable after use.
SUMMARY OF THE INVENTION
The present invention provides a removable heat insulating/absorbing protective holder to safely store an electrically powered heated styling device, such as, for example, a curling iron, after the device has been used and while the device is still hot. With the holder of the present invention, injuries which might otherwise occur due to coming in contact with the hot surface of the curling iron are prevented when the holder is placed on the curling iron or other heated device. The protective holder also provides cord containing and coiling means which permit total storage of the device by allowing the cord to be coiled around a pair of hooks.
It is an object of the present invention to provide a novel holder which insulates the heat from an electrically powered heated styling instrument after use of the instrument to permit safe storage of the device by preventing contact with the hot surface of the device after it has just been used.
It is another object of the present invention to provide a holder which permits a curling iron or other electrically powered heated styling instruments while still hot, to be readily transportable immediately after use.
It is another object of the present invention to provide a holder which is comprised of a heat resistant or material which can absorb or insulate the heat from the curling iron and be cool enough to handled.
It is a further object of the present invention to provide a holder having means for taking up and holding the cord of the electrically powered device.
Another object of the present invention is to provide means for holding the cord of the electrically powered device wherein the holding means comprises a pair of hooks about which the cord may be coiled.
Additional objects and advantages of the present invention will be recognizable to one of ordinary skill in the art by reading the detailed description of the drawings and the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a side perspective view of a curling iron and the holder of the present invention shown in position to receive the curling iron within its pocket.
FIG. 2 is a rear elevation view of the holder of the present invention with the curling iron enclosed therein showing the cord holding means retaining the cord in position.
FIG. 3 is a right sectional view of the curling iron holder shown with a curling iron contained within the pocket of the holder, and the cord being secured with the cord holding means.
FIG. 4 is a partial right perspective view of the upper portion of the curling iron holder showing the securing means which retain the curling iron within the holder pocket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, the holder 10 for an electrically powered heated styling instrument is shown comprising a body portion 12 which encloses a hollow space or pocket 13 (FIG. 3) within which the electrically powered heated styling device, such as the curling iron 11, can be stored after use. The holder 10 is also provided with a closure member 14 at one end of the body portion 12 having a pair of flaps 15 and 16 which are separated by a groove or notch 17 disposed therebetween. The flaps 15 and 16 also comprise a meeting portion 18 which is located below the groove 17.
Suitable securing means are provided for securing the closure member 14 onto the body portion 12. These securing means may comprise any such suitable means which allow attachment and detachment of the closure flaps 15 and 16 to and from the body portion 12. Preferably, as shown in FIGS. 1 and 4, a surface of hooks and matingly associated attaching pile surface, such as, for example, velcro® material, may be used such that the closure flaps contain one portion of the velcro® connector 20 and 21 and the body portion contains the other of a portion of mating velcro® surfaces, respectively 22 and 23. This permits easy closing and opening of the closure member 14 in relation with the body portion 12. The securing means, while shown as velcro® components 20, 21, 22 and 23, may also comprise snaps, magnetic means, or any other like suitable fastening members. The curling iron 11 is shown as an example of the type of electrically powered heated styling devices which may be safely stored with the holder of the present invention. The curling iron 11 is shown having a tubular end portion 25, a handle 26, an operating lever 27, and a power cord 28. The tubular end portion 25 contains a heating element (not shown) which remains hot during and for a period of time after use. If left exposed, the end portion 25, wherein hot, presents a potential hazard for anyone encountering the device 11.
The holder 10 is shown in FIG. 4 with the curling iron 11 contained therein within the pocket 13 formed by the body portion 12. The cord 28 of the curling iron 11 is shown extending through the groove 17 adjacent the closure flaps 15. The cord 28 extends over the closure member 14 and is held in place with securing means provided on the back of the body portion 12 of the holder 10. The securing means are shown comprising a pair of hooks 31 and 32 which are secured to the body portion 12 at one end thereof and extend outwardly therefrom. The hooks 31 and 32 are preferably L-shaped members which extend in opposite outwardly directions from one another to facilitate the securing of the cord thereabout. The outwardly extending portions 33 and 34 of the respective hooks 31 and 32 provide a ledge to maintain the cord against slippage or unraveling.
The body portion 12 may comprise a single layer, or preferably as shown, may comprise an outer cover portion 35 and an inner cover portion 36. The inner cover portion 36 preferably comprises a material which will insulate heat from passing through its outermost edge and thereby permit the cover to be picked up and handled when there is a curling iron 11 inside which is still hot from having been used. The outer cover portion 35 may comprise any suitable material for adding support to the heat resistant inner cover portion 36, or may comprise additional heat resistant heat insulating material. The outer cover portion 35 preferably may comprise nylon or leather or any other suitable material which can be flexible to conform to the shape of the appliance, such as the curling iron 11, or a variation of that or another appliance, which may be a different model requiring different holder dimensions. Therefore, the inner and outer cover portions 35 and 36, respectively, are flexibly provided in order to accommodate the curling iron 11. In addition, the closure member 14 can comprise the material of the outer cover portion 35 and furthermore may be reinforced at the back of the holder 10 as shown in FIG. 2 with any suitable reinforcement means, such as the enhanced stitching 37 shown in FIG. 2.
Referring to FIG. 4, a perspective view of the closure member 14 with the closure flaps 15 and 16 shown coming into position over the top of the curling iron 11 to secure the closure member 14 to the front of the body portion 12 of the holder 10. Also, in FIG. 2, the securing means, preferably shown comprising velcro components 20, 21, 22, 23, is shown as a means to attach and detach the closure member 14 to permit insertion and removal of the curling iron 11 or other electrically powered heated styling instrument which is to be contained within the holder 10. The cord 28 of the curling iron 11 is shown extending through the groove 17 defined between the closure flaps 15 and 16. This permits the cord 28 to be safely and securely coiled for storage about the hooks 31 and 32, as shown in FIGS. 2 and 3.
While not shown, the body portion 12 of the holder 10 may comprise a single material or multi-layered material that is suitable for withstanding the heat of a recently used electrically powered heated styling instrument, such as a curling iron 11, blowdryer, hot comb, or the like (not shown), and preventing the heat, whether by insulation or dissipation or absorption, from being transmitted to the exterior surface of the body portion 12, so that a user may handle, transport or otherwise move or store the device, such as the curling iron 11, within the holder 10 by touching the holder 10.
The curling iron, while described as an electrically powered device may be powered by an alternate source such as battery power or solar power, or other suitable powering means, consistent with the scope of the invention described herein. Also while not shown, a suitable handle for carrying the holder 10 may be provided for facilitating transport and storage of said holder 10 and the styling instrument.
Other modifications consistent with the scope of the invention discussed above and as recited in the appended claims attached hereto may be made, as one of ordinary skill in the art will realize. | A transportable holder for an electrically powered heated styling instrument including an insulated body portion for containing a recently used styling instrument that is still hot, with the walled body portion having insulating properties to prevent heat transmission from the instrument to the exterior of the body portion which may be contacted for handling by an individual. A closure member is also provided to secure the instrument within the holder and cord holding hooks are provided to retain the cord on the holder. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wheeled carriers such as surgical tables, and, in particular, to an apparatus for supporting a wheeled carrier in a fixed location.
1. Description of the Invention Background
In various environments, it has proven necessary to support a wheeled carrier in a fixed location. For example, in connection with surgical tables it is necessary to allow a surgical table to be wheeled from a surgical patient preparation station to a surgical suite while supporting a surgical patient. However, while in the surgical suite, the surgical table must be maintained in a fixed location to allow the necessary surgery to be performed. Alternatively, if a wheeled surgical table is intended for use while supporting a patient within an image amplification apparatus, the table must be capable of being wheeled into position and locked in a fixed location relative to the image amplification apparatus.
Previously, wheeled tables were provided with a mechanical floor locking system. In such tables, casters were provided on the base of a surgical table. In order to fix such a table in a specific location, legs provided adjacent to each caster were lowered from the table base to support the table on the legs rather than on the casters. In order to deploy the supporting legs, a manually operated foot pedal was provided on the table base. The foot pedal was connected by an extended link to a cam member. The cam member was operatively connected to extended pivoted levers. In addition, the remote ends of the lever were pivotally connected to the supporting legs.
In the operation of such an apparatus, the activation of the foot pedal caused the cam member to be rotated. Such rotation caused the cam member to displace the inboard ends of the levers upwardly. The movement of the inboard ends of the levers caused the outboard ends of the levers to be lowered. This action caused the respective supporting legs to be lowered. The lowering of the legs allowed the table to be supported thereon in a fixed location rather than on the casters.
Applicants have discovered various problems with the prior mechanical cam/lever arrangement. First, it will be appreciated that the table weight to be lifted by the legs was significant; many such tables may weigh in excess of 800 pounds in addition to the weight of the patient. As such, the force required to lift the table by means of the legs in a single movement has proven excessive for hospital personnel. Further, the force required to raise the table yet further preliminary to the lowering of the table may also be unreasonably high. As such, means for raising a surgical table onto supporting legs which requires, at most, only a reasonable manual force is needed by the industry.
The functional requirements of such tables pose serious design problems which must be overcome in designing an alternative floor lock system. For example, the frequent use of such tables in connection with image amplification equipment requires that the means for deploying the supporting legs be compact in configuration. Meanwhile, as the tables must be completely portable, such as being capable of crossing elevator thresholds, the floor lock system must be retractable to a considerable degree. Accordingly, significant design constraints are imposed on surgical table floor lock systems.
The subject invention is directed toward an improved surgical table floor lock apparatus which overcomes, among others, the above-discussed problems and provides a table support system which is effective to support the table in a fixed location while requiring, at most, a minimum amount of manual exertion.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided apparatus for supporting a wheeled table on deployable legs. The base member of the table is provided with a plurality of wheeled casters. Disposed adjacent to each of the wheeled casters is a supporting leg which may be lowered into ground engagement.
The means for lowering the respective legs is hydraulically powered. Such hydraulic power may be provided by means of an electric motor which drives a hydraulic pump. Alternatively, hydraulic pressure may be provided by a foot pedal which may be manually actuated. The actuation of the foot pedal causes a manual hydraulic pump cylinder to be displaced thereby creating hydraulic pressure. In either event, the hydraulic pressure is provided to hydraulic cylinders disposed adjacent to the floor lock legs. In particular, a central unlock control valve is connected to the rod ends of each hydraulic cylinder while a central control valve is in communication with the barrel ends of the hydraulic cylinders.
The rods of the hydraulic cylinders are each connected to corresponding link assemblies. The link assemblies each comprise an upper link which is also pivotally attached to the table base and a lower link which is also pivotally attached to the upper portion of each supporting leg. As such, when the rods of the hydraulic cylinders are extended by the application of hydraulic pressure to the barrel ends of the hydraulic cylinders, the central pivot of each of the linkage assemblies is caused to pass over its center. This action causes the respective supporting legs to be lowered which causes the entire surgical table to be raised off the casters and thereby fixed in a specified location. Because the links are passed over center, no hydraulic pressure is required to maintain the legs in a locked condition. In order to raise the legs, the rods of the hydraulic cylinders are retracted, the links are pivoted and the legs are raised.
Accordingly, the present invention provides solutions to the aforementioned problems present in connection with wheeled tables. As this invention provides an effective means of deploying supporting legs, which means may be manually actuated and yet does not require hydraulic pressure to maintain the table in a locked condition, the problems caused by prior art floor lock systems are alleviated. In addition, as the present invention provides a compact hydraulic/mechanical system, the design requirements relating to the available space and the minimization of manual effort are solved.
These and other details, objects and advantages of the present invention will become apparent as the following description of the present preferred embodiment thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, I have shown a present preferred embodiment of the invention wherein:
FIG. 1 is a side elevation view of a surgical table provided with the floor lock system according to the present invention;
FIG. 2 is a plan view of the base portion of the table;
FIG. 3 is an end elevation sectional view taken along lines III--III in FIG. 2;
FIG. 4 is an end elevation sectional view taken along lines IV--IV in FIG. 2; and
FIG. 5 is a schematic representation of the hydraulic components of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for purposes of illustrating the present preferred embodiment of the invention only and not for purposes of limiting same, the Figures show a surgical table 10 which is provided with wheeled casters, generally shown as 12, and deployable supporting legs, generally shown as 14.
More particularly, and with reference to FIG. 1, the surgical table 10 includes a base portion 16 from which the casters 12 and the supporting legs 14 depend. Surgical table 10 includes a column portion, generally designated as 18, which, in turn, supports the patient supporting assembly, generally 20. FIG. 1 also shows a foot pedal 22 which is connected to base assembly 16 and which may be folded into the retracted position shown therein.
The base member of the surgical table 10 includes a base frame member 24. Frame member 24 supports the casters 12, supporting legs 14 and all other components of the surgical table 10. Pivotally attached to frame member 24 are the casters 12 which each include a bracket member 26 and rotatable wheels 28.
As noted above, supporting legs 14 may be lowered from frame member 24 in order to support surgical table 10 thereon. In accordance with the present invention, two rear supporting leg mechanisms 30 are attached to frame member 24 adjacent the casters 12 disposed on the widened foot end of surgical table 10. In order to support the head end of surgical table 10, a single supporting leg mechanism 52 is employed.
The foot end of table 10 may be supported by rear supporting leg mechanisms 30. The rear supporting leg mechanisms 30 disposed at the foot end of surgical table 10 are identical and reference will now be made to FIG. 3 which illustrates their structure. The rear supporting leg mechanisms 30 are each provided with a longitudinal leg member 34 which includes a widened base portion 36. Rear leg members 34 are each supported by frame member 24 for vertical movement within a corresponding surrounding bushing 38 which is retained by a corresponding collar 40 attached to frame member 24. In order that rear leg members 34 may be raised and lowered, a corresponding pair of rear hydraulic cylinders 42 is provided. Each rear hydraulic cylinder 42 includes a barrel portion 44 which is pivotally attached to frame member 24. A rod member 46 extends from each of the rear hydraulic cylinders 42. The outboard ends of rod members 46 are each pivotally connected to a corresponding first upper link 48 which is, in turn, pivotally attached to the corresponding collar 40. The outboard ends of rod members 46 are each also pivotally attached to a corresponding lower link 50. The lower ends of lower links 50 are pivotally attached to the upper ends of the corresponding rear leg members 34. As such, when a rear rod member 46 is extended by the application of hydraulic fluid under pressure to the barrel 44 of its rear hydraulic cylinder 42, the horizontal movement thereof is translated into a vertical movement which is applied by upper link 48 and lower link 50 to its leg member 34. Therefore, rear leg members 34 are lowered relative to frame member 24 in order to lift surgical table 10 from the wheels 28 of rear casters 12 in order to support surgical table 10 on the bases 36 of the rear supporting legs 30. It will be appreciated that, by virtue of the present system, the hydraulic pressure is translated by means of rear hydraulic cylinders 42 to a horizontal linear movement which is, in turn, translated by means of upper links 48 and lower links 50 to a vertical motion to deploy the rear supporting leg members 34. In addition, when the upper links 48 and lower links 50 are moved beyond their vertical positions over center, the rear supporting legs 34 are mechanically locked into their lowered positions. However, when hydraulic pressure is applied to the rod ends of each rear hydraulic cylinder 42, the rod members 46 pivot upper links 50 and lower links 48 thereby causing the retraction of rear leg members 34.
The structure of the front floor lock mechanism 52 is shown in FIG. 4. In particular, front floor lock mechanism 52 includes a front leg member 58 which is provided with a front base portion 60. Front leg member 58 is surrounded by a front bushing 62 which is retained within a front supporting collar 64 which, in turn, is secured to base frame member 24. A front hydraulic cylinder 66 includes a barrel portion 68 which is pivotally attached to frame member 24 and an extended rod portion 70. The end of rod 70 is pivotally attached to dual front upper links 72 which are also pivotally attached to a pin 74 which is attached to front collar 64. In addition, the end of rod 70 is pivotally attached to a front lower link 76. The other end of front lower link 76 is pivotally attached to front leg member 58. As such, when the rod 70 of front hydraulic cylinder 76 is extended, its horizontal movement is translated by front upper link 72 and front lower link 76 into a vertical movement to thereby lower front leg member 58 in order that its base portion 60 may engage the floor surface. Such action causes the front of surgical table 10 to be lifted from the front casters 12.
Frame member 24 also supports an electrically powered hydraulic motor 78 which drives a hydraulic pump 80. Hydraulic pump 80 provides hydraulic fluid under pressure for use in actuating rear floor lock mechanisms 30 and front floor lock mechanism 52. For use in lieu of electric motor 78 and pump 80 in lowering legs 14, a manually actuated hydraulic pump 82 is supported on frame member 24 and includes a spring-biased rod 84. Manual pump 82 also supports the foot pedal 22 by means of bracket 85 having a supporting pin 86. Foot pedal 22 is pivotally attached by means of pin 86 to manual pump 82 such that foot pedal 22 may be moved between the retracted position shown in FIG. 1 and the lowered position shown in FIG. 2. The actuation of rod 84 by the manual pivoting of foot pedal 22 about pin 86 by the foot of an operator provides the pumping action for manual pump 82 in order that an output of pressurized hydraulic fluid is provided thereby. In particular, manual hydraulic pump 82 is actuated by the engagement of an activating member 88 on foot pedal 22 with the end of rod 84. In operation, the engagement of activating member 88 with the end of rod 84 causes manual pump 82 to pressurize the fluid therein; the rod 84 is spring returned fon continued operation.
The hydraulic circuitry employed to accomplish the functions described herein is depicted in FIG. 5. The input to powered hydraulic pump 80 and manual hydraulic pump 82 is provided through a common strainer 90 from a reservoir 92. The output of motor driven hydraulic pump 80 passes through a first check valve 94 and is joined with the output of the manual hydraulic pump 82 which passes through a second check valve 96. The pressurized hydraulic fluid may then be passed through a pressure relief valve 98 to the reservoir 92 if excessive hydraulic pressure is developed. Preferably, the hydraulic fluid passes through a filter 100 to the controlling mechanism for each of the rear floor lock cylinders 42 and the front hydraulic cylinder 66. The pressurized hydraulic fluid from pump 80 or from manual pump 82 is provided to each of the rear and front hydraulic cylinders 42 and 66, respectively, under the control of either a central electric solenoid actuated lock control valve 102 or an electric solenoid actuated unlock control valve 104; however, for purposes of clarity, only the front hydraulic cylinder 66 is shown in FIG. 5. When pressurized hydraulic fluid is provided to the unlock control valve 104 or the lock control valve 102, the actuation thereof will cause the retraction of deployment, respectively, of the supporting legs 14. In particular, when the lock control valve 102 is actuated, hydraulic fluid is provided from hydraulic pump 80 or manual pump 82 to the barrel ends of rear hydraulic cylinders 42 and front hydraulic cylinder 66 in order to cause their respective legs, 34 and 58, to be deployed. Similarly, when pressurized hydraulic fluid is provided to the unlock control valve 104, the hydraulic cylinders 42 and 66 are retracted thereby causing the retraction of their respective supporting legs 34 and 58.
The actuation of the solenoids of lock and unlock control valves 102 and 104, respectively, is electrically controlled. Lock control valve 102 is connected to a source of electric potential 106 through a switch 108 while unlock control valve 104 is connected to the source 106 through a switch 110. Electric potential source 106 preferably comprises house electrical power. However, in the event such is unavailable, electrical power may be provided to switches 108 and 110 by means of batteries 112 mounted on frame member 24.
In the operation of the present invention in the event house electrical power is available, the lock and unlock control valves 102 and 104, respectively, and the electric motor 78 are powered thereby. In such event, motor 78 causes the rotation of powered pump 80 to create pressurized hydraulic fluid. In the event house electrical power is unavailable, the batteries 112 provide the required electrical power to control lock and unlock control valves 102 and 104, respectively. In either event, the actuation of lock switch 108 causes the electric solenoid coupled to lock control valve 102 to provide pressurized hydraulic fluid to the barrel ends of rear hydraulic cylinders 42 and front hydraulic cylinder 66 to cause the rear and front leg members, 34 and 58, respectively, to be extended. Further, the actuation of unlock switch 110 causes pressurized hydraulic fluid to be supplied to the rod ends of rear hydraulic cylinders 42 and front hydraulic cylinder 66 to cause the rear and front leg members, 34 and 58, respectively, to be retracted.
In accordance with the present invention, therefore, in the event that the hydraulic motor 78 is disabled, hydraulic pressure for the application or release of the supporting legs 14 is provided by the manual pump 82. In the normal operation of the present invention, the hydraulic pressure is provided by means of hydraulic pump 80 which is driven by electric motor 78. However, in the event that electrical power is unavailable, manual pump 82 may be employed to raise or lower the supporting legs 14. Due to the mechanical configuration of the rear and front floor locking assemblies 30 and 52, respectively, the manual effort required is minimized to a completely acceptable level.
It will be appreciated that various changes in the details, materials and arrangements of parts which have been herein described and illustrated to explain the nature of invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | An apparatus for locking an wheeled table into a fixed location is disclosed. The base of the table is provided with both an electric motor coupled to a hydraulic pump and a manually operated hydraulic pump either of which may provide a source of pressurized hydraulic fluid. Extendable and retractable legs are provided on the base of the surgical table. Hydraulic cylinders disposed adjacent to each of the legs are provided with upper link members pivotally attached to the table's base and lower link members which are pivotally attached to the deployable legs. When pressurized hydraulic fluid is provided by the electrically driven or manually powered hydraulic pumps, the hydraulic cylinders disposed adjacent to the deployable legs are extended. Such extension is translated by means of the respective upper and lower link members into a vertical movement which lowers the supporting legs to fix the table in a specified location. | 0 |
BACKGROUND OF THE INVENTION
It is well known that hardness and suspended solids in water sources vary widely in composition depending on the source and will result in scale deposition and sedimentation on surfaces wherever water is used. Scale deposition and sedimentation is particularly troublesome in water distribution pipe systems which service the residential and commercial customers of municipalities, private water companies and the like along with industrial process water distribution pipe systems as found in the mining, petroleum, agriculture and the like industries. In these systems, the formation of scale and sediment can reduce the water flow through the pipe system which will limit the capacity of the pipe to service the requirements of the customers or to provide the required water necessary for an industrial process, irrigation, etc. For instance, in municipal systems an increase in the fire risk would be obvious if the fire hydrant did not supply sufficient water to extinguish the fire due to scale and sediment deposits in the feed pipe line. At some point, the water distribution pipe would have to be replaced due to these restrictions at a high cost and with prolonged interruption of service.
Additionally, scale and sedimentation will increase the possibility of corrosion in the water distribution pipe along with promoting the growth of organisms. The organisms also can be a health hazard, promoting corrosion and biomass which binds scale and sediment together and to the surfaces of the system. Corrosion will eventually lead to the leakage of the system and the necessity to replace the leaking section.
Strong acids have been used to clean water wells, however, submersible pumps are removed prior to treatment to prevent corrosion by the acids employed. Also, organic acids, mixtures of mineral acids and organic acids or inhibited acid compositions have been found to clean water wells without the necessity of removing the pumps or other equipment. These methods for cleaning water wells have involved static and surging treatment.
A proper cleaning and maintenance program for water distribution systems will prevent decreased water flow capacity, corrosion and the necessity to replace the system or portions thereof. A simple and effective method for cleaning and maintaining these systems is needed.
SUMMARY OF THE INVENTION
This invention is directed to a method of cleaning and maintaining water distribution systems. Water systems having interior scale and sediment deposits are cleaned by introducing and circulating an effective amount of an aqueous treatment solution for a sufficient period of time which results in the solution, loosening and suspension of the undesired scale and sediment. Thereafter, the spent treating solution containing the dissolved or suspended scale and sediment is flushed from the water distribution system to provide a clean system with improved water flow and operation. Additionally, further flushing with high pressure water will also remove additional scale that had been loosened by the treating solution.
The cleaning solution may be acidic, neutral or basic. In the most preferred form, in potable water pipe systems, mineral acids or organic acids, and mixtures thereof, are employed as acidic treatment solutions. The acidic treatment solution may contain further additives such as inhibitors, chelating agents, penetrating and/or dispersing agents to assist in the removal of scale and sediment and to minimize any adverse effects on the pipes, valves, or other system surfaces due to the acids employed.
This invention provides a simple, low cost and effective method of removing water scale and sediment from water distribution systems in order to maintain proper water flow, operation and to prevent corrosion of the system which would require the high cost and inconvenience of replacement.
Other advantages and objectives of this invention will be further understood with reference to the following detailed description and drawings.
DETAILED DESCRIPTION OF THE INVENTION
Among the acidic treatment solutions found to be useful in practicing the method of this invention are aqueous solutions of mineral acids such as hydrochloric, nitric, phosphoric, polyphosphoric, hydrofluoric, boric, sulfuric, sulfurous, and the like. Aqueous solutions of mono-, di- and polybasic organic acids have also been found to be useful and include formic, acetic, propionic, citric, glycolic, lactic, tartaric, polyacrylic, succinic, p-toluenesulfonic, and the like. The useful treatment solutions may also be aqueous mixtures of the above mineral and organic acids.
Alkaline, acid, or neutral cleaning solutions may also be employed, as indicated above, depending upon the type of scale that needs to be removed. Sequestering or chelating agents such as EDTA (ethylenediamine tetraacetic acid), NTA (nitrilotriacetic acid), and derivatives, i.e., basic alkali salts, and the like have also been found to be useful in the treatment solution in certain cases.
The acidic treatment solution may also contain acid inhibitors which substantially reduce the acidic action on metal surfaces of the water distribution system, particularly valves, fire hydrants, etc., and these various inhibitors for acids have been well documented in the patent art. Typical, but not necessarily all inclusive, examples of acid inhibitors are disclosed in the following U.S. Pat. Nos. 2,758,970; 2,807,585; 2,941,949; 3,077,454; 3,607,781; 3,668,137; 3,885,913; 4,089,795; 4,199,469; 4,310,435; 4,541,945; 4,554,090; 4,587,030; 4,614,600; 4,637,899; 4,670,186; 4,780,150 and 4,851,149 which are incorporated herein by reference.
The treatment solution may also contain dispersing, penetrating or emulsifying agents to assist in the removal of the scale and sediment. These surface active agents may be anionic, cationic, nonionic or amphoteric as defined in the art. Compounds such as alkyl ether sulfates, alkyl or aryl sulfates, alkanolamines, ethoxylated alkanolamides, amine oxides, ammonium and alkali soaps, betaines, hydrotropes such as sodium aryl sulfonates; ethoxylated and propoxylated fatty alcohols and sugars, ethoxylated and propoxylated alkylphenols, sulfonates, phosphate esters, quarternaries, sulfosuccinates, and mixtures thereof, have been found to be useful in admixture with the acid treating solution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a laboratory test system illustrating the method of this invention.
FIG. 2 is a diagram of a field system for cleaning a potable water distribution system.
DETAIL DESCRIPTION OF PREFERRED EMBODIMENT OF THE PRESENT INVENTION
With reference to FIG. 1, a laboratory test system is shown to evaluate the removal of scale and sediment by acidic treating solutions from a test pipe sample taken from a water distribution system. This system includes a 15 gallon acidic treating solution reservoir 5, submersible acidic treating solution circulation pump 6 rated at 1200 gallons per hour, 1" inlet transfer line 7, drain valve 8, heavy rubber diaphragm seals 9 for the ends of the test pipe specimen 10, 1" outlet transfer line 11 and the treating solution 12. The test pipe specimen 10 is mounted at about a 30 degree angle so that the test solution will contact essentially the entire inner pipe surface to be treated.
A laboratory test, for example, was run on a four foot section of 6" diameter pipe which had been removed from a potable water distribution system that had been used for over 40 years. The scale on the inside of the pipe consisted of nodules of up to 1 to 11/2 inches in height covering 100% of the inside pipe surface which had substantially reduced the opening inside the pipe for water to flow. Analysis of the scale indicated it consisted of primarily iron with some calcium, magnesium and manganese in the form oxides, hydroxides and carbonates along with fine mineral acid insoluble solids and some "biomass". This is typical scale associated with sulfate-reducing and iron bacteria along with the associated corrosion.
About 10 gallons of a 12.5% aqueous inhibited hydrochloric/glycolic acid solution containing a penetrating agent was placed in the reservoir 5 and circulated through the test pipe 10 for a period of 24 hours. After 2 hours of circulation, particles of the scale were breaking loose and could be heard in the outlet transfer line 11 and observed entering the reservoir 5. The color of the treating solution also became increasingly darker with circulation time. After 24 hours the circulation was stopped and the system was drained of the treating solution. The diaphragms 9 were removed and the inside of the test pipe was observed to be about 80% cleaned of scale and sediment solids.
On treating the test pipe with a second identical treating solution for a period of 21.5 hours, about 80% of the interior surface of the test pipe was observed to still be covered over with a scale and/or sediment that was a soft and paste-like semi-solid which contained some grit and could be easily removed with a probe. The remaining scale nodules had been substantially reduced in size since the end of the first treatment. It was concluded that the second treatment would probably not be necessary if a high pressure water flush was employed to remove the insoluble soft sediment which had coated the remaining scale nodules after the first treatment.
With reference to FIG. 2, a field equipment and system diagram is shown which may be employed in the cleaning of a potable water pipe distribution system. Two 500 gallon treating solution reservoir tanks 20 and 21 along with a 100 gallon per minute circulation pump 22 and sight glass 23 are mounted on a flat bed truck (not shown). In this example, a 21/2 inlet pipe 24 is secured to a 650 foot section of 6" water distribution pipe 25 after the main shut off valve 26. The fire hydrant 27 and fire hose 28 were employed for the acidic treating solution return to tanks 20 and 21.
The section of pipe 25 to be treated was isolated by closing off the two water main shut-off valves 26 and 29 along with all service line valves, typically 30 and 31. With valves 32 and 33 closed, 1000 gallons of acidic treating solution was prepared in tanks 20 and 21- With the coupling 34 open, the treating solution was allowed to enter the system by opening valves 33 and 35 and turning on the circulation pump 22. The pH of the water coming from the open coupling was then monitored until a decrease was noted which indicated the acid treating solution had displaced the water in the section to be treated. The circulation pump 22 was turned off and the coupling 34 connected. Valves 36 and 37 were then closed and valve 32 opened for circulation. The circulation pump 22 was then started again for the treatment period. Valve 37 was closed to allow for scale solids to accumulate in tank 20 while the treating solution could overflow at 38 to tank 21 which reduces the chances of plugging during treatment.
The treating solution was then circulated in the system of FIG. 2 for a period of 5 hours. Observation of the treating solution through the sight glass 23 showed an increasingly darker discoloration with time. At the end of the treatment period, the circulation pump 22 was turned off, and valves 33 and 35 were closed. The main shut-off valve 26 was slowly opened and fresh water allowed to enter the system until the treating solution was displaced as noted when the tanks 20 and 21 were full. Valve 32 was then closed. The fire hose 28 was then disconnected from the fire hydrant 27 and the main shut-off valve 26 opened full to allow high pressure flushing of the treated water main 25. As the flush water emerged from the fire hydrant 27 it was dark in color with considerable scale and sediment solids. Flushing continued until the flush water was clean of solids for a period of time prior to putting the treated section of the water distribution system back into service.
The flow rate through the fire hydrant 27 prior to treatment had been determined by a Pitot Gauge to be 588 gallons per minute. After treatment, the flow rate was determined to be 790 gallons per minute. This was an increase of 34.5%.
Also, improved mechanical operations of the hydrants and valves of the system were achieved. The flow of cleaning solution may also be reversed in the system to further improve cleaning efficiency. The above cleaning solutions met the requirements of the National Sanitation Foundation (NSF International, Ann Arbor, Mich.), Standard 60 for potable water distribution systems.
In view of the above detailed description, other method variations to clean domestic and industrial water distribution systems, like houses, hotels, plants, offices, etc., will be apparent to a person of ordinary skill in the art without departing from the scope of this invention. | A method of cleaning and maintaining water distribution systems which have reduced flow due to an increase of water scale deposits, sediment, and the like on the inside surface of the pipe is disclosed. An aqueous acidic cleaning solution is introduced and circulated through the pipe to be treated for a sufficient time to dissolve and loosen the scale and sediment, and the spent solution containing dissolved or suspended scale and sediment is flushed from the pipe to provide a cleaned pipe with improved water flow. It is also desirable to flush the water distribution pipe system with high pressure water after the treatment to remove loosened scale and sediment that was not removed during the circulation and flushing of the treating solution. | 1 |
BACKGROUND OF THE INVENTION
This invention concerns stable aqueous dispersions of polyurethane-urea modified polyacrylics. Polyether or polyester urethane-urea emulsions are high Mw, thermoplastic type polymer dispersions which give outstanding mechanical properties in various applications. The balance of properties is believed to come from the block structure with rigid urea-urethane semi-crystalline phase in a flexible polyether or polyester matrix. Problems with these disperisons are poor rheology and thermoplastic behavior.
Polyether urethane polymers have less than optimum durability, especially in outdoor exposure, and polyester urethanes lack good hydrolysis resistance.
Polyurethanes based on aliphatic or cycloaliphatic di- or polyisocyanates are also high priced while those based on aromatic diisocyanates completely lack good outdoor durability due to yellowing on exposure. The typical thermoplastic behavior and poorer rheology is inherent to the technology of making high Mw polyurethane-urea dispersions since the many techniques (see a review article by Dieterich in Progress in Organic Coatings 9(1981 281-340) available for making such aqueous dispersions do not permit easy handling and control of functionality (acid, hydroxyl, amide, etc.) within the polymer architecture needed to give it thermoset behavior and built-in rheology. Acrylic dispersions or emulsions on the other hand prepared via free radical initiated reactions do easily allow the formulator to build in reactive groups to give the polymer the necessary rheological and thermoset behavior. It would therefore be preferable to combine the good rheological and thermoset properties of reactive acrylics with the outstanding mechanical properties of polyurethanes.
Both types of polymers, however, are in many cases incompatible due to large solubility parameter differences. Incompatibility does show up in many examples as a phase separation or complete kick-out of the mixed blend polyurethane-urea with acrylic or as a loss in film integrity and physical properties, when applied afterwards. The present invention provides for a method of making a polyurethane-urea modified polyacrylics in which the acrylic has functional groups such as hydroxyl, acid, amine and amide by chain extension of an acrylic dispersion or emulsion having primary or secondary amine groups to form a polyurethane-urea polyacrylic dispersion.
DESCRIPTION OF THE PRIOR ART
The production of linear or cross-linked aqueous polyurethane-urea dispersions is known as shown in several patents including U.S. Pat. Nos. 3,479,310; 3,870,684; 4,066,591; 4,092,286; 4,203,883; 4,237,264; 4,238,378; 4,408,008, and 4,701,480. The aqueous polyurethane-urea dispersions may be used in a wide range of commercial applications such as adhesives and coatings.
The production of functional acrylic dispersions or emulsions has been described in many patent applications as U.S. Pat. Nos. 4,558,092; 4,403,003; 4,322,328; 4,609,690; 4,522,973; 4,733,786; 4,442,257; 4,525,510, and European patent EP 007107.
Acrylic emulsions or dispersions are also used in many commercial applications as adhesives and coatings. Polyurethane-urea modified acrylics are described in some patent applications, however, prior art does not allow to produce the dispersions as actually claimed in our invention.
U.S. Pat. No. 4,318,833 to M. Guagliarde and EP No. 189,945 to Witco, do not permit having acid, amine or hydroxyl functional monomers in the acrylic since this would react with or terminate the NCO prepolymer. Witco describes formation of the polyurethane isocyanate terminated prepolymer in a monomer blend which obviously should be unreactive versus isocyanate dispersing into water, chain extending and polymerizing the monomer blend.
U.S. Pat. No. 4,153,778, Union Carbide, does not mention polyacrylics. They cap isocyanate terminated prepolymer with hydroxyl functional monomer before dispersing in water. Canadian Pat. No. 1,201,244 describes polymer polyurethane acrylate polymer dispersions however different from the present invention, since the acrylic capped polyurethane-urea is dispersed in an inert polymerizable monomer. The end use is in molded articles. Japan Kokai 79/77,795 to Dainippon teaches polymerizing a blend of acrylic monomers in water in the presence of an aqueous urethane dispersion. Japan Kokai 59/157,101-3, Toho, concerns modifications of the above using GMA and HEMA.
Ashland Oil U.S. Pat. No. 4,609,690 describes a blend of an hydroxyl functional latex with a dispersible multifunctional isocyanate based crosslinker for structural adhesives in laminates.
"Aqueous Dispersions of Crosslinked Polyurethanes" by Terpak and Markusch in Journal of Water Borne Coatings -- Nov. 1, 1986, pages 13-21, teaches the use of polyfunctional amine for crosslinking with dispersed isocyanate prepolymer modified with ethylene oxide and ionic hydrophilic groups.
SUMMARY OF THE INVENTION
The invention provides a method of preparing a stable aqueous dispersion of polyurethane modified polyacrylic comprising
preparing a reaction mixture in the form of an aqueous dispersion or emulsion of amine-functional or amine- and hydroxyl-functional polyacrylic,
adding to the reaction mixture prepolymer chain of polyisocyanate or isocyanate-terminated polyurethane, and
reacting the resultant mixture to cause chain extension of the ingredients.
DETAILED DESCRIPTION OF THE INVENTION
A. Acrylic Dispersions
Typical acrylic dispersions can be produced in water dilutable solvents or other solvents which are not water soluble. In the latter case, the solvents can be stripped-off after inverting into water. The following exemplary lists are not limiting.
Examples of water dilutable solvents:
alcohols such as methanol, ethanol, isopropanol, ethylene glycol, butanol and 2-ethylhexanol,
glycolethers such as ethylene glycolmonoethylether, diethyleneglycol monobutylether and propylene glycol methyether,
ketones such as acetone and methylethylketone,
solvents such as N-methylpyrolidone, dimethylformamide and tetrahydrofuran. Examples of solvents partially or non-miscible with water:
aromatic such as toluene, xylene, Solvesso 100 from Esso;
aliphatics such as heptane and mineral spirits,
glycolether acetates such as methylether of propylene glycolacetate.
The composition of the acrylic is based on typical unsaturated compounds, and in order to be anionically dispersible the acid value should be at least 25. Preferred is an acid value between 30 and 150 and more preferred between 40 and 100. Typical acid functional monomers are
organic types--acrylic acid, methacrylic acid, maleic acid, fumaric acid and itaconic acid,
inorganic types--2 acrylamido-2-methylpropanesulfonic acid (AMPS), 2-methacryloxyethyl phosphate (MOP), described in PCT patent publications W088/02381, Apr. 7, 1988 and W088/02382 of the same date, and 2-sulfoethyl methacrylate.
Other functional or non-functional monomers can be copolymerized as:
______________________________________esters methyl-, ethyl-, butyl-, isobutyl-, lauryl-, 2-ethylhexylacrylate and/or methacrylatehydroxy hydroxyethyl acrylate and/or methacrylate, hydroxypropyl acrylate and/or methacrylatearomatic styrene, vinyltolueneamide acrylamide, methacrylamide, N--methylolacrylamide, butoxy methylacrylamide or methacrylamide, methoxy methylacrylamide and/or methacrylamidesilane methacryloxyethyltriethoxysilanenitrile acrylonitrile, methacrylonitrilechloride, acetate vinylacetate, vinylchloride, reaction product of monofunctional epoxies such as, Shell's Cardura E, phenylglycidyl ether with acrylic acid, methacrylic acid.______________________________________
The acrylic copolymer can also be acid functionalized via anhydride capping of hydroxy groups or via anhydride copolymerization, e.g., maleic anhydride, itaconic anhydride, capping of hydroxy functional copolymer with succinic anhydride, phthalic anhydride, trimellitic anhydride.
The polymer is formed via radical initiated copolymerization using eventually chain transfer agents.
Initiators
Azo: AIBN azobisisobutylronitrile and the like
peroxide: t-butylperoxide, t-butylperacetate, etc.
Chain Transfer Agents
2-mercaptoethanol, t-dodecylmercaptan, laurylmercaptan, or
chlorinated solvents.
The acid functional prepolymer can be amine converted by reaction with an imine such as propylene imine, ethyleneimine or hydroxyethylethyleneimine.
A certain part of the acid groups are neutralized with tertiary amine so as to make the polymer water dispersible: triethylamine, dimethylethanolamine, etc.
The amount of neutralization can be between 20-200% of the free acid groups left after imination reaction, preferably between 70 and 130%.
The molecular weight can be between 1500 and 50,000 number average molecular weight, preferably between 3000 and 20,000. The glass transition temperature can be between -80° C. and +130° C.
The total composition of the copolymer can vary, preferably it is based on 3-30% of an acid functional monomer, 0.2-15% of amine functional monomer obtained through imination of part of the acid groups after the polymer is formed, 0-40% of hydroxy, silane, alkoxymethylamide, nitrile, amide or other functional monomers. Balance: aromatic, acrylic or methacrylic, vinyl non-functional monomers.
The acrylic copolymers can be produced by thermally initiated radical polymerization in the temperature range between 40° and 200° C., preferably between 60° and 180° C., specifically between 60° and 120° C. in case there are more than one different functional groups present that can react with each other that might gel the polymer. When this is not the case, polymerization temperatures can be up to 180° C. The amounts of initiators and chain transfer agents present can be between 0.05 and 10% on monomer weight, preferably between 0.2 and 4%.
B. Acrylic Emulsions
Typical acrylic emulsions can be produced in water which contains a surfactant and optionally some solvent present. Examples of surfactants can be anionic, nonionic or cationic or blends.
Typical examples of nonionics are alkyl phenolethoxylates and alkyl ethoxylates represented by the following chemical structures: ##STR1## with R for instance octyl, isononyl or nonyl.
Typical examples of anionic surfactants are salts of alkylsulfates, alkylsulfonates, alkyl phosphates, and sulfated alkylphenolethoxylates.
Typical examples of cationic surfactants are alkyltrimethylammonium chloride, and laurylpyridinium chloride.
The amount of surfactant used can vary between 0.01 and 20% calculated on monomer but is preferably between 0.2 and 5%. Emulsion polymerization typically uses water soluble initiators such as persulfates but it is not limited to them. One could also use partial soluble or water insoluble initiators as the one mentioned under dispersion polymers.
The composition of the copolymer can vary as mentioned under dispersion polymers.
Acid functional monomers need not be present, but they can be present. The presence of acid groups in an emulsion polymer can also vary and can have various purposes such as to provide a reaction site for an imine to make the amine group on the polymer, additionally stabilizing the latex, building in rheology or pigment wetting.
The amine group however can also be formed through reaction of an epoxy functional unsaturated monomer with ammonia, mono, di, or polyamines which are primary, secondary and/or blends.
Examples of an epoxy functional unsaturated monomers are: glycidylacrylate, glycidylmethacrylate.
Examples of mono amines are aliphatic, cycloaliphatic, aromatic such as ethanol amine, alkylamines (methyl, ethyl, propyl, butyl or lauryl), cyclohexylamine, benzylamine and aromatic amines such as aminobenzene.
Examples of diamines are aliphatic, cycloaliphatic, aromatic such as ethylenediamine, hexamethylenediamine, isophoronediamine, xylylenediamine or diaminobenzene.
Examples of polyether amines are polyethyleneoxidediamines or polypropyleneoxide diamines as known under the tradename Jeffamine from Texaco.
Examples of polyamines can be aliphatic, cycloaliphatic or aromatic, diethylene triamine or triethylenetetramine.
The amount of ammonia, mono-, di- or polyamines is calculated based on the amount of glycidyl group but can vary and is only limited to the final stability of the amine functional emulsion.
If one uses di- or polyamines the emulsion formed can be microgelled.
Other bi- or polyfunctional monomers can be used in the emulsion prepolymers to form microgels, e.g., allylmethacrylate, diethyleneglycol dimethacrylate, butanedioldiacrylate, trimethylolpropanetriacrylate, etc.
The amounts used of such bi- or polyfunctional monomers can vary and the only limiting factor is the final stability of the emulsion.
A typical composition of an emulsion would be
0.2-10% of a primary or secondary amine functional monomers that can be obtained (1) through reaction of an acid functional group with an imine and (2) through reaction of ammonia, a mono-, di- or polyamine with an epoxy functional group, in both cases after polymer has been formed;
0.30% Of an acid functional unsaturated monomer.
0-40% Of a hydroxy, alkoxymethylamide, nitrile, amide, silane or other functional monomers. 0-10% Of poly-unsaturated monomers. Balance aromatic, acrylic or methacrylic vinyl or other non-functional monomers.
The emulsion polymer is typically produced between room temperature and 100° C. In case of lower temperature (20°-60° C.) reducing agents as sodium bisulfite can be used to accelerate decomposition of the initiator. The pH of the final emulsion can be adjusted accordingly using amines for anionic emulsions or acids for cationic emulsions. Another way of crosslinking or "chain extending" the emulsion is the use of hydrazides which are known to react with ketones or aldehydes. Examples of such functional unsaturated monomers are acrylein, diacetone acrylamide. The "hydrazide" funtional emulsion can be further reacted with aldehydes as, e.g., formaldehyde. To further modify the emulsion other additives can be added as fungicides, preservative, external crosslinkers, etc.
C. Polyurethane Dispersions and Emulsions
Isocyanate terminated prepolymers to modify the amine functional dispersions or emulsion.
Many patents describe methods of making chain extended polyurethane dispersions using built-in ionic salt groups to stabilize the dispersion or external surfactants. An article by Dieterich in Progress in Organic Coatings 9(1981) 281-340 reviews the various technologies that can be used to make the polyurethane prepolymer before dispersing and chain extending in water. Numerous patents exist in this field.
Chain extending the amine or hydrazide functional acrylic dispersion or emulsion can be done by using aliphatic, cycloaliphatic or aromatic polyfunctional isocyanates, preferably bifunctional aliphatic or cycloaliphatic diisocyanates.
Examples of such diisocyanates are hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, bis (4-isocyanatocyclohexyl)-methane such as Desmodur W from Bayer, xylylene diisocyanate, tetramethyl xylene diisocyanate.
Examples of aromatic and polyfunctional isocyanates are: toluene diisocyanate, diphenylmethane diisocyanate, Bayer's Desmodur N (trifunctional biuret of hexamethylene diisocyanate), or Desmodur N3390 (cyclotrimer of hexamethylene diisocyanate).
Chain extension can also be done by a polyester, polyether-urethane which has an isocyanate as terminal groups.
The polyester can be linear or branched and is typically based on aliphatic, aromatic, mono-, di- or polyacids and mono-, di- or polyfunctional alcohols.
Preferably the isocyanate terminated prepolymer is linear and based on difunctional reactants with the diisocyanate in excess. Bifunctional polyesters which are hydroxy terminated are made by reacting dialcohols with diacids, stripping off water in the temperature range of 150°-250° C., then using esterification catalysts such as tin salts or strong acids, e.g., dibutyltindioxide or p-toluene-sulfonic acid can be used. Polyesters are characterized by the OH value and/or the number average molecular weight which can vary between OH value 10-300 with MW of 150-11000. Typical examples of diacids or anhydrides are phthalic anhydride, isophthalic acid, terephthalic acid, adipic acid, succinic acid, maleic anhydride fand fumaric acid. Typical examples of dialcohols are propane diol -1,2 or -1,3 ethylene glycol, dimethyl 2,2-propanediol, butanediol (1,2 or 1,3 or 1,4), hexanediol (1,2 or 1,6), dimethylol 1,4 cyclohexane, etc. The polyurethane prepolymer can contain water soluble or ionic groups which will after dispersion in water additionally stabilize the polyolefin polyurethane dispersions.
An example of a cationic group is diethanolmonomethylamine in its amine salt. An example of an anionic group is dimethylol-propionic acid in its salt form. An example of non-ionic stabilizing group is a hydroxyl functional polyethyleneoxide chain. In the case of anionically stabilizing groups the acid function can be neutralized with a base which can be metal (such as potassium) or a tertiary amine. In case of cationically stabilized disperisons, the amine group can be stabilized with a mono acid (e.g., acetic acid). The polyester prepolymer can also be formed using chain extension of a lactone on a diol (e.g., capa linear polycaprolactones available from Interox). Linear polyethers are available from many companies and are based on, e.g., ethylene-, propylene- and or butyleneoxide. The prepolymer might also contain ether difunctional polymers such as hydroxy fifunctional acrylics, polycarbonates or polyubtadienes.
The urethane prepolymer is formed at 100% active ingredients or in an inert solvent. An inert solvent means a chemical compound which does not have an active hydrogen atom according to the Zerewitinoff test, J. Amer. Chem. Soc. 49, 3181 (1927).
The molecular weight of the various difunctional reaction partners can vary between 200 and 6000. The temperature of forming the prepolymer can vary up to 160° C. but typically is run to avoid side reactions of the diisocyanate at 60°-100° C. Suitable catalysts such as amines or metal salts can be used to accelerate the reaction. The end point is typically determined by running the NCO content.
Chain extending the amine functional dispersion or emulsion with the isocyanate or polyurethane prepolymer can be done at any temperatures below reflux of the water/solvent blend. The ratio of equivalent isocyanate in the prepolymer to equivalent amine in the dispersion/emulsion can also vary between 1/5 and 5/1 and is mainly determined by getting sufficient cross reaction to make both polymers fully compatible. Additional additives can be used in the chain extension step. Part or a whole of the isocyanate groups might also be blocked with labile blocking agents such as methylethyl ketoxime or caprolactam.
The polymers are typically used for further crosslinking in case they still have functional groups. Crosslinkers can be water soluble or dispersible melamine, urea or benzoguanamine resins.
EXAMPLES
In the following examples, parts, proportions and percentages are by weight (such as in grams) except where indicated otherwise. Instead of butanol, other solvents such as xylene can be used and later stripped off after dispersing into water.
EXAMPLE 1
Polyacrylic-amine Functional Dispersion
The following ingredients were fed from feed tanks into a reactor equipped with a stirrer and a condenser and temperature control unit.
______________________________________n-Butanol (B) 600Heat at reflux - 120° C. in reactorStyrene (S) 600Methylmethacrylate (MMA) 600Butylacrylate (BA) 1200Hydroxyethylacrylate (HEA) 360Acrylic acid (AA) 240Tert-butylperoxy-2-ethylhexanoate 60 (Trigonox21S from Akzo) (tBPEH)B 60Feed over 3 hours at refluxB 40Rinsing step for feed tank - Add to reactor -Hold 15 minutestBPEH 4add to reactor from feed tankB 16Rinsing - Hold 30 minutes at 120° C. refluxRepeat 4 times - additional 4 parts tBPEH forrinsingCool to 70° C. - Test prepolymer______________________________________
Test results on prepolymer diluted to 60% theoretical solids with B
______________________________________Solids 60.4%Visc. Gardner Holtz Z4AN (Acid Number) 58.7Continue the reaction by iminating the acidfunctional prepolymer to form an aminefunctional dispersionPropylene imine (PI) 96Add to reactorB 64Rinsing - Hold till AN = 30 by reaction at 70° C.Triethylamine (TEA) 125.6Add neutralizerDeionized water (DW) 6194.4DisperseTest results:Solids 30%pH 9.5MN 8800MW 95,200AN after imination 30.9Amine value 27.8______________________________________
EXAMPLE 2
Polyurethane Prepolymer
This example describes the formation of an isocyanate terminated polyester-urethane prepolymer.
______________________________________(based on neopentylglycol (NPG), hexanediol (HD), 606.9adipic acid (ADA) - MN = 546, OH ≠ 205)Dibutyltindilaurate catalyst 0.1(DBTDL)Heat 70-75° C. under nitrogen purge in a reactorequipped with condensor, addition funnel andtemperature control unit.Isophoronediisocyanate (IPDI) 444Add slowly over 45 minutesNMP 49Rinsing - Hold 3 hours at 95° C.______________________________________
EXAMPLE 3
Polyurethane Modified Acrylic Dispersion
This example describes chain extension of the isocyanate terminated prepolymer of Example 2 with the amine functional acrylic dispersion of Example 1.
______________________________________Example 1 1580DW 516Mix with high shear mixerExample 2 212.1Add over 30 minutes and stir till NCO in IR hasdisappearedTest results:solids 29.3pH 8.4MN 5,500MW 362,500______________________________________ (Biomodal MW distribution showing chain extension).
EXAMPLE 4
Polyacrylic-amine Functional Dispersion
Formula see Example 1 but instead of 96, PI, 64 PI was used
______________________________________ Test results______________________________________ solids 29.2 pH 8.2______________________________________
EXAMPLE 5
A, B, D Urea Modified Acrylics
These examples describe chain extension of an amine functional acrylic dispersion with diisocyanate.
______________________________________ C A B (control) D______________________________________Example 4 255.3 255.3 255.3 255.3DW 77.6 77.6 51.06 77.6Mix until homogeneousunder high shearIPDI 3.12 6.24m-xylylenediisocyanate 3.55solids 24.7 24.4 24.2 26.9pH 8.6 8.4 8.6 8.4______________________________________ Control had MN = 10,100 MW = 125,700
All other samples were insoluble (microgelled) in THF for GPC run, showing chain extension.
EXAMPLE 6
Polyacrylic-amine Functional Emulsion
This example describes formation of an amine functional acrylic emulsion.
______________________________________DW 504Fenopon CO436 (F) from GAF 29(ammonium salt of sulfated alkylphenolethoxylate)Heat at 60° C. under N.sub.2 purge in a reactor equippedwith condensor, addition funnel and temperaturecontrol.Ammoniumpersulfate (AP) 0.8DW 19.2Add to reactor. Start next feedMMA 160BA 160Hydroxypropylmethacrylate (HPMA) 60Clycidylmethacrylate (GMA) 20Add 10%. Hold 20 minutes. Feed rest over 3 hours at60° C.DW 10Rinsing - Heat 90° C.Ammonia solution (25% in DW) 9.5DWAdd to reactor. Hold 45 minutes at 90° C.DW 22Thin downSolids 41.3%pH 10Total ammonia 0.48%Total ammonia bound to polymer 0.15%______________________________________
Equipment and processes equal to previous examples was used to prepare examples 7-18.
EXAMPLE 7
Polyurethane Prepolymer
______________________________________Polyester based on butanediol-adipic acid 400.02000 MN and OH = 56Dimethylolpropionic acid (DMPA) 53.6NMP 156TEA 38.4Heat till 80-85° C. till dissolved. Cool 55° C. undernitrogen purge.IPDI 199.8Add over 20 minutes at 65° C. max reactor temperatureNMP 85.6Rinsing - hold for NCO % = 1.8%.______________________________________
EXAMPLE 8
A, B, Polyurethane Modified Acrylic Emulsion
______________________________________ A B______________________________________Example 6 1000 1000DW 334.1 334.1Dimethylethanolamine 5 5Antorox CO730 from GAF 25(Nonylphenolpolyethyleneoxide)Heat to 50° C. while stirringExample 7 334.1 334.1Add over 20-30 minutes while stirringSolids 43.7 43.5pH 6.5 6.6Control Test 1 - Polyurethane-urea DispersionDW 933.4High shear mixingExample 7 933.4Add slowly while dispersingEthylenediamine 9.6DW 100Add over 20'DW 68.4Rinsing - Hold 1 hourSolids 33.2%pH 6.8______________________________________
To prove the advantages of chain extending the polyurethane in presence of the amine functional acrylic emulsion following test was run:
______________________________________Control A: Blend of acrylic (amine functional) andpolyurethane-urea.Example 6 100Example 9 77Control B: Chain extended acrylic (amine functional)with polyurethane.Example 8A 100DW 40______________________________________
Both control A and B contain the same solids and ratio of acrylic/urethane. Control A resulted in a strong viscosity increase on blending while Control B was fluid and low in viscosity. A draw-down on glass was made of both A and B and baked 20 minutes at 120° C. Control A gave a slightly cloudy structured film with low hardness (80" Persoz) while B resulted in a smooth transparent hard film (209" Persoz). This show incompatability in Control A compared to Control B which represents the invention.
EXAMPLE 9
Polyacrylic-amine Functional Dispersion
This dispersion contains no cosolvent.
______________________________________Cardura E (Shell) 294Dimethylmaleate 147Heat at 170° C.Butylmethacrylate (BMA) l96S 147AA 196Ditertiarybutylperoxide 20Feed over 6 hours at 165-170° C. Hold 30 minutes.Cool to 120° C.Dimethylethanolamine (DMEA) 119.4Add and cool to 105° C.DW 2505.6Add over 30' and disperse. Heat 65-70° C.Propyleneimine 13Add to reactorDW 414Rinsing - add to reactor and hold 90' at 70-75° C.Solids 24.7%pH 8MN 3000MW 13,400______________________________________
EXAMPLE 10
Polyurethane-urea Modified Acrylic Dispersion
______________________________________Example 9 1200Mix under high shearExample 7 160.2Add slowly while dispersing. Mix 1 hour.Solids 30.4pH 7.6______________________________________
EXAMPLE 11
Polyacrylic-amine Functional and Crosslinked (Microgel)
______________________________________DW 504Disponil SUS87 from GAF (Sulfo 29succinic acid semi ester-disodium salt)Heat to 60° C. under nitrogen purge.AP 0.8DW 19.2Add to reactor. Start next feed.MMA 156BA 120Polypropylene glycol monomethacrylate 60(Bisomer PPM5) from BPGMA 48Methacrylic acid MAA 16Add 10%. Hold 20 minutes. Feed rest over 3 hours.DW 10Rinsing - Heat 90° C.Ammonia solution (25% in DW) 35Add to reactorDW 2Rinsing - Hold 45 minutes at 90° C.Solids 40.6%pH 10.2______________________________________
EXAMPLE 12
Polyurethane Prepolymer
______________________________________Polyester based on neopentylglycol and 1028adipic acid MN = 1028 OH = 110DMPA 93.8TEA 35.35NMP 130.60Heat at 100° C. till dissolved. Cool 80° C. undernitrogen purgeIPDI 599.4NMP 15Add over 20 minutes - Temperature maximum 95° C.NMP 16.5Rinsing - hold for NCO = 3.2NMP 106.3Thin down.______________________________________
EXAMPLE 13
Polyurethane-urea Modified Acrylic Emulsion
______________________________________Example 11 1000DW 29.7DMEA 9Heat at 70° C.Example 13 497Add slowly while dispersing. Hold 90'Solids 47%pH 7.1______________________________________
EXAMPLE 14
Polyacrylic-hydrazide Functional Emulsion
______________________________________DW 351.9Fenopon CO436 from GAF 2.6Heat 81° C. under N.sub.2Fenopon CO436 3.7MMA 136.9BA 152.1Diacetoneacrylamide 10DW 258Preemulsifying monomer blend. Add 5% to reactor.AP 1DW 25.4Add to reactor. Hold 20 minutes. Feed rest of freeemulsion over 60 minute at 85-86° C.DW 13.8RinsingAdipic dihydrazide 5.2DW 19.4Add - hold 60 minutes at 86-88° C.DW 20Rinsing______________________________________
EXAMPLE 15
Polyurethane Prepolymer
______________________________________Polyester based on butanediol and adipicacid MN2000 OH = 56 400 gmDMPA 53.6NMP 156Heat 70° C. till dissolved under nitrogen purgeIPDI 199.8Add over 20-25 minutesNMP 65.6Rinsing - hold till NCO = 1.1%TEA 38.4Add - neutralizeNMP 20Rinsing______________________________________
EXAMPLE 16
Polyurethane-urea Modified Acrylic Emulsion
______________________________________Example 14 1000DMEA 5DW 120Heat 50° C.Prepolymer Example 16 94Add slowly while dispersing. Hold 60 minutes.______________________________________
EXAMPLE 17
Polyacrylic-amine Functional Emulsion
______________________________________DW 504Fenopon CO436 2.4Heat 60° C. under N.sub.2AP 0.8H508 19.2Add to reactorMMA 176BA 176HPMA 40GMA 8Feed 10% - hold 20 minutes - feed rest over 3 hours.DW 10Rinsing - heat 90° C.Ethylenediamine 2DW 13Add to reactor - hold 60 minutes at 90° C.DW 27Rinsing 1000Test results:Solids 40.9%pH 9.8______________________________________
EXAMPLE 18
Polyurethane-urea Modified Acrylic Emulsion
______________________________________Example 17 1000DW 140High shear mixingExample 7 140Add - stir for 1 hourDMEA 6.3AddTest results:Solids 39.6%pH 7.8.______________________________________
All polyurethane-urea modified acrylic emulsions or dispersions were stable. | A method for preparing a stable aqueous dispersion of polyurethane modified polyacrylic involving chain extension of polyacrylic with isocyanate and hydroxyl- or amino-functional groups. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] None
FIELD OF THE INVENTION
[0002] The field of this invention is image processing. More precisely, the invention relates to the processing of images produced from 3D image obtained from a device such as CT and MRI scans. More precisely again, the invention relates to the 3D image structure to find out how many tunnels (wholes) in the image.
[0003] The invention can be used to recognize wholes and cracks in a 3D object, If genus is zero that simply indicates there is no wholes. Its applications include medical images and CT applications.
[0004] Industrial automation and inspection in many industries (e.g., automotive manufacture, electronics manufacture, food and agriculture production, printing and textiles, just to name a few)
medical applications (including artificial vision for the blind) automobile driver assistance digital photography film and video analysis (e.g., sports analysis) computer games image searching people tracking safety monitoring security and biometrics 3D modeling traffic and road management
[0016] Application can also include cultural applications, games and/or cooperative work.
REFERENCES
[0000]
[1] L. Chen, Y. Rong, Linear time recognition algorithms for topological invariants in 3D, Proceedings of International Conference on Pattern Recognition (ICPR), 2008. pp 1-4.
[2] L. Chen, Discrete Surfaces and Manifolds , SP Computing, Rockville, 2004.
[3] C. J. A. Delfinado, H. Edelsbrunner, An Incremental Algorithm For Betti Numbers Of Simplicial Complexes On The 3-Sphere, Computer Aided Geometric Design 12 (1995), 771-784.
[4] T. K. Dey, S. Guha, Computing Homology Groups Of Simplicial Complexes In R3. Journal Of The ACM 45 (1998) 266-287.
[5] A. Hatcher, Algebraic Topology , Cambridge University Press, 2002.
[6] T. Kaczynski, K. Mischaikow And M. Mrozek, Computing Homology, Homology, Homotopy And Applications, Vol. 5(2), 2003, Pp. 233-256
[7] T. Kaczynski, K. Mischaikow, M. Mrozek, Computational Homology Springer Series: Applied Mathematical Sciences, Vol. 157, 2004,
[8] W. D. Kalies, K. Mischaikow And G. Watson, Cubical Approximation And Computation Of Homology, Banach Center Publ. 47, 115-131 (1999).
BACKGROUND OF THE INVENTION
[0025] Computing topological properties for a 3D object in 3D space is an important task in image processing [1][2]. The recent developments in medical imaging and 3D digital camera systems raise the problem of the direct treatment of digital 3D objects. In the past, 3D computer graphics and computational geometry have usually used triangulation to represent a 3D object [3][4][6][7].
[0026] Basically, the topological properties of an object in 3D contain connected components, genus of its boundary surfaces, and other homologic and homotopic properties [5]. In 3D, this problem of obtaining fundamental groups is decidable but no practical algorithm has yet been found. Therefore, homology groups have played the most significant role. Research shows that a key factor of computing homology groups of 3D objects is the genus of the boundary surface of the 3D object [3].
[0027] Theoretical results show that there exist linear time algorithms for calculating genus and homology groups for 3D Objects in 3D space [3]. However, the implementation of these algorithms is not simple due to the complexity of real data samplings. Most of the algorithms require the triangulation of the input data since it is collected discretely [3-7]. However, for most medical images, the data was sampled consecutively, meaning that every voxel in 3D space will contain data. In such cases, researchers use the marching-cubes algorithm to obtain the triangulation since it is a linear time algorithm. However the spatial requirements for such a treatment will be at least doubled by adding the surface-elements (sometimes called faces).
[0028] In this invention, we look at a set of points in 3D digital space, and our purpose is to find homology groups of the data set. The direct algorithm without utilizing triangulation was proposed by Chen and Rong in 2008 [1].
[0029] In [1], we discuss the geometric and algebraic properties of manifolds in 3D digital spaces and the optimal algorithms for calculating these properties. We consider digital surfaces as defined in [2].
[0030] We presented a theoretical optimal algorithm with time complexity O(n) to compute the genus and homology groups in 3D digital space, where n is the size of the input data [1].
[0031] The key in the algorithm in [1] is to find the genus of the closed digital surfaces that is the boundary of the 3D object. This INVENTION will provide a process that deals with simulated and real data in order to obtain the topological invariants such as connected components, boundary surface genus, and homology groups (not generators as described in [4]).
BRIEF SUMMARY OF THE INVENTION
[0032] These objectives, and others that will become clear later, are achieved a process for directly calculating the genus without a triangular mesh. The said mesh is defined as an arrangement of vertices and triangular faces, each being defined by three references to the vertices that it connects, and with three edges connecting each of the said vertices.
[0033] In this invention, the representation of data sets is only based on the natural cubic three-dimensional (3D) object. The said cubic is eight-integer points (or vertices) at the corners of a cube in 3D.
[0034] According to the invention, this process comprises several steps for final genus result. In the past, people only do this based on local search and merge of 2D faces. Thus, the invention is based on a total innovative and inventive approach to an object in three dimensions. Also the representation of an object only uses natural cubic not simplical complexes (triangulations). The speed will be much improved.
[0035] The invention is based particularly on the application of the Gauss-Bonnet theorem in digital space. That Gauss-Bonnet theorem says, in general, the genus is based on total curvature of the boundary surface of a 3D object. Such Gauss-Bonnet method is said to be a global method since it does not working on each individual path through the point as the existing method does.
[0036] Advantageously, this type of process according to the invention also comprises a fast process to find all boundary points.
[0037] Gauss-Bonnet Theorem and Closed Digital Surfaces: The Gauss-Bonnet theorem states that if M is a closed manifold, then
[0000] ∫ M K G dA= 2πχ( M )
[0000] E {p is a point in M} K ( p )=2π·(2−2 g )
[0038] Applying this theorem to digital space, we obtain in [1] that g=1+(M5+2M6−M3)/8.
[0039] We now describe a procedure for computing the homology group of 3D objects in 3D digital space. The theoretical foundation that verifies this procedure can be found in [1].
[0040] Assuming we only have a set of points in 3D. We can digitize this set into 3D digital spaces.
[0041] There are two ways of doing so: (1) by treating each point as a cube-unit that is called the raster space, (2) by treating each point as a grid point, which is also called the point space. These two are dual spaces. Using the algorithm described in [2], we can determine whether the digitized set forms a 3D manifold in 3D space in direct adjacency for connectivity.
[0042] Let us assume that we have a connected 3D object M. If it is not, use a labeling or search method, a computer machine can separate M to be several 3D objects.
The Main Procedure:
[0043] Step 1. Track the boundary M, said B, which is a union of several closed surfaces. This algorithm only needs to scan though all the points in M to see if the point is linked to a point outside of M. That point will be on boundary.
Step 2. Calculate the genus of each closed surface (e.g. B(1) . . . , B(k)) in the boundary B. The method is the following: since there are six different types of boundary points (on the boundary surface), two of them has 4 neighbors, and two of them has 6 neighbors in the surface ( FIG. 1 ). We can use M3, M4, M5, M6 to denote the numbers of different types. Mi represents the number of points each of which has i-neighbors. The genus g=1+(M5+2M6−M3)/8 [1].
Step 3. Using the Theorem 2.2, we can get homology groups H0, H1, H2, and H3. H0 is Z. For H1, we need to get b1(B) that is just the summation of the genus in all connected components in B. H2 is the number of components in B. H3 is trivial.
[0044] Therefore, we can use linear time algorithms to calculate g and all homology groups for digital manifolds in 3D [1, 2].
[0045] Theorem There is a linear time algorithm to calculate all homology groups for each type of manifold in 3D.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Other characteristics and advantages of the invention will be understood more clearly upon reading the following description of a preferred embodiment, given solely for illustrative purposes and that is in no way limitative, accompanied by the appended figures wherein:
[0047] FIG. 1 shows a block diagram of the different steps applied during the process for genus calculation according to the invention;
[0048] FIG. 2 The six types of boundary configuration of the local points according to the process in FIG. 1 ;
[0049] FIGS. 3 a , 3 b and 3 c 3 a A 3D cube according to the process in FIG. 1 ;
[0050] FIGS. 4 a , and 4 b Examples of Real 3D Objects.
[0051] FIG. 5 . Machines that obtain the data presented in FIG. 4 ;
[0052] FIG. 6 Result displayed illustrated in FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0053] The following detailed description of the preferred embodiments 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. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
GLOSSARY
[0054] The following definitions are used throughout this specification to describe the preferred embodiment:
3D Digital Image
[0055] A 3D array stored in computer memory in which each element is numerical value usually an integer.
3D Object
[0056] A part of the 3D image usually form a thing that is not separated. In other words, it is connected.
Foreground and Background in the 3D Image.
[0057] In a 3D image, the foreground is the all elements that are above value 0. the Background are all elements that are 0.
Boundary of a 3D Object
[0058] The collection of those elements in the object each of which has a neighbor in background.
Digital Surface Point in 3D
[0059] One of the six configurations is called a digital surface point in 3D. The six configurations are shown in FIG. 2 .
(Closed) Digital Surface
[0060] A set of elements in a 3D image (their values are above zero), each element is digital surface point.
A Connected Component
[0061] Some foreground elements (points) are linked together. Meaning that there is path to link them.
Pathological Configuration
[0062] Some boundary points might not be categorized into the six types as in FIG. 2 . Those are some noises or some none surface factor. We need to display the local configuration, and modify it using human interaction to fix it. Will be only a few of them.
[0063] In this patent, we are not dealing with an automated procedure for deleting the Pathological configuration.
EMBODIMENTS
[0064] Get data from the device shown in FIG. 5 . Store the data in memory as M. Set up a clip level (for instance 10). Every element whose value is below 10 means the background pixels. All other pixels are also called M.
[0065] Get all connected components of M. Each of the component will still called M. So M is a single 3D object. For instance, M can be the image shown in FIG. 4 a or 4 b.
[0066] Find the boundary of M, called B. B may contain several closed surfaces B(1), . . . , B(k) as shown in FIG. 3 b or 3 c . Each the digital point on the surface is one of the six configurations shown in FIG. 2 .
[0067] Use the formula g=1+(M5+2M6−M3)/8 to find genus of B(i). Such as the genus for FIG. 3 c is 2.
[0068] Calculate homology group H0 is Z, the integer; homology group H1, is equivalent to b1 of boundary that is just the summation of the genus in all connected components in boundary; homology group H2 is the number of components in the boundary; homology group H3 is equivalent to 0.
CONCLUSION AND FAQ
[0069] 1. What are the objectives of the invention?
A fast method to get structural information for complex 3D images
2. What problem or problems does the invention solve
The Practical and fast method for 3D image classification.
3. How does the invention solve the problem or problems
Write software based on the method and associated algorithms. Use computers or embedded chip processors to process a 3D image that can be captured by 3D camera or medical instruments such as CT or MR, and other methods.
4. How does the invention differ from already patented or made inventions
Before the invention of this method, the only method that calculate genus for 3D objects is using triangulation method. That transfers the 3D digital image into 3D geometric object described by tetrahedral (3D polyhedrons). Our method directly use the image collected. The algorithm based on the new digital method and a new formula.
5. What improvements or new features are part of the invention
The method uses the raw image directly and the algorithm reaches the minimum in terms of time and space costs in computers. The speed is at least 10 time fast than existing methods.
6. How does the invention work or what process steps are involved
Input a 3D image into a computer or directly save 3D images into computer memory, our method will calculate the invariants of the image and to make classification. | The invention concerns the calculation of genus of digital or cubic three-dimensional object (3D), said genus is the number of tunnels indicating holes such as in donates. The invention is characterized in that said method comprises a step in selecting (counting) numbers of different types of points on the boundary of the object then obtaining genus. | 6 |
BACKGROUND
Radio frequency identification (RFID) tags are known for there usefulness in identifying items. RFID tag readers may be used in various venues, such as point-of-sale checkout, where RFID tag readers read RFID tags on merchandise items.
The compact disc (CD) and digital video disc (DVD) are leading portable digital media storage devices. Hundreds of millions of discs are produced each year. These discs are used to store digital media files including, but not limited to movies, television shows, music, music videos, video game software, productivity software and a wide array of additional file types and file formats. These discs are available in pre-recorded, recordable and rewritable formats.
Entertainment kiosks may store, dispense, and capture CD and DVD discs. Some kiosks may be equipped with radio frequency identification (RFID) tag readers for reading RFID tags on CD and DVD discs.
RFID tags uniquely identify a disc as originating from or belonging to the kiosk or kiosk provider. Thus, for example, the kiosk may determine whether a disc placed in a return slot by a customer includes an RFID tag and whether the RFID tag is associated with the kiosk or kiosk provider.
RFID readers may have limited output power (250 mW). Also, a conventional RFID antenna mounted in front of a return slot may produce a field which is covers more than the return slot, squandering what limited power is available. The RFID reader may not be able to read an RFID tag anywhere it may be located within the return slot. An RFID tag mounted on a CD/DVD or similar media may have reduced sensitivity as the RFID read field is attenuated by conductive material in the recording surface of the media.
It would be desirable to further provide an RFID tag reading antenna for a media transaction kiosk which would facilitate reading of an RFID tag anywhere it may be located within the return slot.
SUMMARY
A media transaction kiosk and method are provided.
A media transaction kiosk with an antenna which provides better field coverage around a return slot. The media transaction kiosk includes a return portion including a wall containing an aperture for receiving a storage device containing media, and an antenna. The antenna includes a first antenna portion in a first position relative to the aperture, wherein the first antenna portion is coupled to a tag reader, wherein the first antenna portion is for radiating an electromagnetic field at a tag reading frequency for reading a tag on the storage device. The antenna further includes a second antenna portion in a second position relative to the aperture, wherein the second antenna portion is located within the electromagnetic field from the first antenna portion, and wherein the second antenna portion is for resonating at the tag reading frequency and for radiating another electromagnetic field for reading the tag.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an example media transaction kiosk.
FIG. 2 is a front view of a user interface with an example return slot.
FIG. 3 is a rear view of the user interface.
FIG. 4 is a cross-sectional view of the use interface at a dispense and return portion.
FIG. 5 is a view illustrating an example first antenna portion.
FIG. 6 is a view illustrating an example second antenna portion.
DETAILED DESCRIPTION
Referring now to FIG. 1 , example media transaction system 10 primarily includes kiosk 12 .
Kiosk 12 dispenses digital media in storage devices 40 , which may include compact discs (CDs) and digital video discs (DVDs). Kiosk 12 may also dispense digital media in other storage devices 40 , such as Secure Digital (SD) cards, or may also electronically download digital media to customer provided storage devices.
Storage devices 40 may store media of various types, including, but not limited to movies, television shows, music, music videos, video game software, productivity software and a wide array of additional file types and file formats.
Kiosk 12 may include computer 20 , display 22 , input device 24 , payment peripheral 26 , printer 28 , radio frequency identification (RFID) tag reader 30 , transport system 34 , and inventor data store 36 .
Computer 20 includes a processor, memory, program and data storage. Computer 20 may execute an operating system such as a Microsoft operating system, and a web browser for viewing web pages.
Computer 20 controls operation of kiosk 12 . Computer 20 executes transaction software 38 , which displays images of screens and records operator selections from those screens during a digital media transaction.
A digital media transaction may include a sale of digital media or licenses to digital media. Digital media may include, but not be limited to, movies, television shows, music, music videos, video game software, productivity software and a wide array of additional file types and file formats.
Display 22 displays the images of the transaction screens.
Input device 24 records operator selections during a digital media transaction. Input device 24 may include a touch sensitive device or a keyboard. Input device 24 and display 22 may be combined as a touch screen.
Payment peripheral 26 may include one or more of a card reader for reading credit, debit, and/or loyalty cards; a currency acceptor; a currency dispenser; a coin acceptor; and a coin dispenser.
Printer 28 includes a receipt printer, but may print additional information, such as coupons or other offers or promotions.
RFID tag reader 30 couples to antenna 32 , which in this example, is located in the vicinity of a digital media dispense/return slot of kiosk 12 . RFID tag reader 30 identifies dispensed or returned digital media or both.
Dispensed or returned storage devices 40 , such as CDs and DVDs, are equipped with RFID tags 42 . Alternatively, or in addition, containers of storage devices 40 , such as sleeves, jewel cases, or other types of cases may include RFID tags 42 .
Delivery system 34 delivers digital media to customers following selection and payment. For example, delivery system 34 may deliver digital media discs from storage locations within kiosk 12 or may burn digital media onto blank discs and deliver a newly burned disc. As another example, delivery system 34 may electronically download digital media to suitable electronic storage devices, such as customer provided mobile devices. Delivery system 34 also captures and stores returned digital media to the storage locations within kiosk 12 .
Inventory data store 36 contains an inventory of digital media within kiosk 12 , either physical discs or digital media files or both. Transaction software 38 updates the inventory of digital media each time a digital media item is dispensed or received. Transaction software 38 may also send updated inventory information to host server 16 via network 14 . Host server 16 may manage inventory in a plurality of kiosks 12 .
Network 14 may include a cellular communication network, a global communications network also known as the Internet, a wired or wireless network, or any combination of such networks.
Referring to FIG. 2 , an example kiosk 12 is illustrated. Example kiosk 12 may be based upon the entertainment kiosk disclosed in commonly-assigned published U.S. application Ser. No. 10/866,387, publication number 2004/0254676, entitled “AUTOMATED BUSINESS SYSTEM AND METHOD OF VENDING AND RETURNING A CONSUMER PRODUCT”. This published application is hereby incorporated by reference.
Example kiosk 12 includes housing 50 for storing digital media. Kiosk 12 further includes user interface 52 , which includes touch screen 54 , card reader 56 , printer 58 , and dispense and retrieve slot 60 .
Example kiosk 12 may further include auxiliary display 62 for displaying movie trailers, promotions, and other information under the control of transaction software 38 .
Dispense and retrieve slot 60 includes a slot from which digital media items in cases are dispensed and into which empty cases may be inserted. RFID tag reader 30 may be located in dispense and retrieve slot 60 or on delivery system 34 .
With reference to FIG. 3 , the rear side of user interface 52 illustrates the location of dispense and retrieve portion 70 , including antenna portions 72 and 74 . Antenna portion 72 is mounted or located below dispense and retrieve portion 70 , while antenna portion 74 is mounted or located above dispense and retrieve portion 70 .
During a return procedure at kiosk 12 , a customer inserts protective storage case 80 into dispense and retrieve portion 70 and into slot 60 . RFID tag reader 30 senses and reads RFID tag 42 on digital media storage device 40 . Transaction software 38 looks up the digital media item associated with RFID tag 42 and verifies that digital media storage device 40 belongs in kiosk 12 . Delivery system 34 transports digital media storage device 40 to a storage location with kiosk 12 . Transaction software 38 updates inventory data 36 to reflect storage of digital media storage device 40 within kiosk 12 .
With reference to FIG. 4 , a storage device 40 having RFID tag 42 is located between antenna portions 72 and 74 and within dispense and retrieve portion 70 . Storage device 40 may be located within a protective storage case 80 .
The walls of dispense and retrieve portion 70 should be constructed of a non-conductive, RF transparent material. The walls form a recess defining a position for a customer to insert a returned storage device 40 or retrieve a dispensed storage device 40 . Antenna portion 72 is located below bottom wall 76 , and antenna portion 74 is located above upper wall 78 . Antenna portion 74 is inclined at an angle relative to antenna portion 72 , but other configurations are envisioned as user interface requirements change.
Antenna portion 72 is driven by RFID tag reader 30 to produce an electromagnetic field at an RFID frequency, such as 13.56 MHz. Antenna portion 74 is tuned to the same frequency and passively resonates to produce another electromagnetic field, thereby supplementing the electromagnetic field produced by antenna portion 72 to cover most of the volume in front of slot 60 where RFID tag 42 is located. Coverage is provided both below and above storage device 40 and is concentrated between antenna portions 72 and 74 .
In an alternative embodiment, antenna portion 74 may be driven and antenna portion 72 may be passive.
RFID tag 42 receives the energy from the electromagnetic field and responds with a signal containing information identifying digital media storage device 40 . Transaction software 38 uses the information to determine whether to accept digital media storage device 40 . Transaction software 38 may deny acceptance if no RFID tag 42 is present or if the identification information in RFID tag 42 is not included in inventory records within inventory data store 36 .
For example, transaction software 38 may cause delivery system 34 to either prevent insertion of digital media storage device through aperture 60 , for example, by closing or failing to open a gate, or to allow insertion by opening the gate and to transport digital media storage device 40 to an internal storage location.
With reference to FIG. 5 , example antenna portion 72 includes active loop antenna 80 , which includes two conductive loops 82 and 84 . Other configurations are also envisioned in which active loop antenna 80 includes one or more loops.
Antenna portion 72 further includes active loop tuning components 86 and coaxial connector 90 . Connector 90 may include any suitable coaxial connector, such as a standard reverse polarity subminiature version A (RP-SMA) connector. The coaxial cable may include a fifty-ohm coaxial cable between connector 90 and RFID tag reader 30 . Any transmission line suitable for 13.56 MHz RF can be used, for instance twisted pair cable and connectors.
Example antenna portion 72 may be constructed as a printed circuit board with loops 82 and 84 , active loop tuning components 86 on one side and connector 90 on an opposite side. Antenna portion 72 may be fastened with loops 82 and 84 facing bottom wall 76 of dispense and retrieve portion 70 using screws or other suitable fasteners applied through apertures 92 .
With reference to FIG. 6 , example antenna portion 74 includes passive reflective loop antenna 100 , which includes two conductive loops 102 and 104 . Other configurations are also envisioned in which active loop antenna 80 includes one or more loops.
Antenna portion 74 further includes reflective loop tuning components 106 , which may include capacitors. Reflective loop tuning components 106 may be selected or adjusted to produce resonance with active loop antenna 80 at the desired frequency of 13.56 MHz.
Example antenna portion 74 may be constructed as a printed circuit board with loops 102 and 104 and reflective loop tuning components 106 on one side. Antenna portion 74 may be fastened with loops 102 and 104 facing upper wall 78 of dispense and retrieve portion 70 using screws or other suitable fasteners applied through apertures 108 .
Although particular reference has been made to certain embodiments, variations and modifications are also envisioned within the spirit and scope of the following claims. | A media transaction kiosk with an antenna which provides better field coverage around a return slot. The media transaction kiosk includes a return portion including a wall containing an aperture for receiving a storage device containing media, and an antenna. The antenna includes a first antenna portion in a first position relative to the aperture, wherein the first antenna portion is coupled to a tag reader, wherein the first antenna portion is for radiating an electromagnetic field at a tag reading frequency for reading a tag on the storage device. The antenna further includes a second antenna portion in a second position relative to the aperture, wherein the second antenna portion is located within the electromagnetic field from the first antenna portion, and wherein the second antenna portion is for resonating at the tag reading frequency and for radiating another electromagnetic field for reading the tag. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention is directed to a connector assembly (or "sub") for use with various downhole tools and apparatuses. It is particularly useful with milling tools, taper taps, jars, die collars, overshots, spears, washpipe, fishing apparatuses, and junk baskets. This invention is also directed to the various combination tools and apparatuses which include the connector assembly.
2. Description of the prior art
Prior art connection assemblies are complex and often require a trip out of a wellbore for various phases of operation. Prior art tools and apparatuses, e.g. milling tools are complicated and also offer require multiple trips into and out of the hole to achieve their desired functions.
The prior art Baker Model C-1 milling tool has a connector assembly with a milling shoe or "burning shoe" and a stinger with an expandable grapple and a milling end. This miling tool is used, e.g., to remove a packer from a wellbore. In order to remove a packer using the Baker Model C-1 milling tool, the stinger with its grapple must be inserted through ("sting through") and beyond the packer. This usually requires some milling of the exterior of the packer by the burning shoe and of the interior of the packer by the milling end of the stinger, particularly if there is any obstruction inside the packer. After stinging through the packer, the grapple is expanded to hold the packer so that the milling tool and packer can be pulled out of the wellbore.
Many packers have extendable slips which extend from the packer to secure it in the wellbore. These slips must either retract back into the packer before its removal or they must be milled off prior to pulling the packer out of the hole.
Various problems are encountered when using the Baker Model C-1 milling tool. In various situations it is necessary to remove the tool from a packer, for example: When a stinger is accidentally stung into a packer (as when the depth of the packer has been misjudged); when an attempt is made to pull the packer and it hangs up in the wellbore; when the packer has not been properly milled; or when the slips either fail to retract or have not been properly milled). The grapple has to be contracted or unseated to relinquish its hold on the packer so that the tool can be removed from the packer. In order to re-set the grapple, the entire tool must then be removed from the wellbore, the packer must be re-set, and then be run back into the well-bore to the packer. This in an expensive procedure in an environment in which rig time can cost over $100,000 per day. A trip out and into a wellbore of 10,000 feet can take eight hours.
With prior art devices, the use of an overshot for removing pipe or other items from a hole can require multiple trips into and out of the hole. For example, a string with an overshot may be lowered into a hole to retrieve a piece of pipe. In pulling out of the hole once the pipe has been grappled by the overshot, the pipe may hang up or catch on some element in the wellbore. The overshot would have to be released and a milling tool inserted to mill away the obstruction. The milling tool would then have to be removed from the hole and the overshot would be re-inserted and another attempt made to grapple the pipe and pull it out.
There has been a long-felt need for a connection assembly which is simple, efficient, and easily repairable; and for a connection assembly for use with tools and apparatuses, e.g. a milling tool, which does not require multiple trips into and out of a wellbore to achieve its purposes.
SUMMARY OF THE PRESENT INVENTION
The present invention is directed to a connector assembly useful with various down hole tools and mechanisms and particularly useful with and as a milling apparatus. The connector assembly has a T-shaft and a slot cylinder for receiving and holding the T-shaft. The T-shaft is rotatable within the slot cylinder or it can be held against rotation. The T-shaft is an elongated cylindrical member having two opposed radially extending shoulders. For convenience the ends of the T-shaft may be threaded or otherwise fashioned for connection to other tools or mechanisms. There may be a channel throughout the length of the T-shaft from one end to the other. This channel may be used for running other tools or lines through the shaft, e.g. for wireline work required within pipe or casing. The T-shaft may be solid or it may have partial recesses at one or both ends, depending on the tools, mechanisms, or subs to be connected to the T-shaft. As required, T-shaft extensions may be connected to the T-shaft.
The slot cylinder is a generally hollow cylinder with an inner intermediate holding ring for receiving and holding the T-shaft. The ring has a slot into which the T-shaft's shoulders can fit and pass through. The slot communicates with a recess in the ring into which the T-shaft's shoulders can be moved once they have passed through the ring slot. When the shoulders have been received in the ring recess, turning the T-shaft slightly secures the shoulders within the ring recess so that they are prevented from moving back out of the slot cylinder until the T-shaft is again turned in the opposite direction. The recess also supports the T-shaft and whatever is connected to the T-shaft. The surface of the ring which first comes in contact with the T-shaft's shoulders can be bevelled so that the shoulders move easily into the ring recess. Such bevelling will also make it unnecessary to have the shoulders aligned precisely with the ring slot in order to insert the shoulders through the slot and into the recess.
The slot cylinder may be threaded or otherwise fashioned at one or both ends for facilitating its connection to other tools, mechanisms or subs. For example, one end of the slot cylinder can be threaded for connection to a milling shoe so that the combination of the connector assembly and milling shoe can be used effectively as a milling tool. Such a combination can also be used with a conventional fishing spear connected to the T-shaft. Hollow cylindrical extensions may be added to the slot cylinder. For example, if a relatively long packer is to be removed a corresponding cylinder extension can be used between the slot cylinder and a burning shoe.
The connector assembly according to the present invention can also be used effectively with an overshot to pull a retrievable packer. An overshot is a tool which grips (or "grapples") the outside of a member such as a piece of pipe or packer in a wellbore. Such an overshot cannot be used with the Baker Milling Tool, because an overshot is positioned at the bottom of a tool and such positioning at the bottom of Baker's Milling Tool would prevent the Baker Tool stinger from functioning. A connector assembly according to the present invention can be used with an extension on the T-shaft which has connected to it an overshot. If the overshot grapples a packer or a piece of pipe to be retrieved and then gets hung up, the overshot is released and pulled back up into the extention of the slot cylinder. Without removing the tool from the hole, the burning shoe can mill the obstructing element. Then when milling is completed, the overshot can again be lowered to grapple the packer or pipe and another attempt can be made to remove it.
The positive holding or stopping of the T-shaft shoulders within the ring recess insures that the T-shaft will not be disengaged from the ring recess unless the T-shaft is turned. If a spear is used at the end of the T-shaft it may have a grapple, but such a grapple need not ever be re-set above the hole, since it can be maintained in position within, but not beyond, (i.e. below) the packer. The spear grapple could be released within the packer simply by taking tension off of the string to which the tool is connected, and turning the T-shaft thereby causing the spear grapple to move into a release position disengaging from the packer's interior walls.
Use of the connector assembly with a milling shoe connected to the slot cylinder and a spear/grapple connected to the T-shaft, permits milling and then stinging with the spear and, if necessary, re-setting of the spear grapple within the hole without having to completely pull the tool to the surface.
In operations to retrieve an element ("fish") from a wellbore which require some milling, an apparatus according to the present invention is very useful. Initially the element to be fished out may need milling to free it from its position in the wellbore. An apparatus according to the present invention is lowered to the location of the fish and milling is commenced. By slightly turning the T-shaft, it is disengaged from the slot cylinder and the T-shaft with a spear connected to it can then be lowered to engage, to jar, or to pull on the fish. If the fish is not loosened, the T-shaft with its spear are pulled back into the slot cylinder (or into a cylinder extension), engaged in the ring recess, and the milling shoe is again lowered to further mill the fish. This procedure may be repeated until the fish is free and can be removed from the hole.
It is therefore an object of the present invention to provide a novel and efficient connector assembly for a variety of downhole tools and apparatuses.
It is also an object of the present invention to provide a variety of combination tools which include such a connector assembly.
Another object of the present invention is the provision of a connector assembly having an outer member and an inner shaft; the shaft being selectively movable from a disengaged position to an engaged position within the outer member; and the shaft being held within a recess in the outer member in the engaged position.
Yet another object of the present invention is the provision of such a connector assembly in which when the shaft is held in the outer member's recess so that it cannot rotate, the recess also serves to support the shaft and whatever is connected to it.
A further object of the present invention is the provision of a combination tool which includes such a connector assembly and one of a variety of other tools, subs, or mechanisms, including but no limited to: milling tools, milling shoes, back off safety subs, taper taps, jars, die collars, overshots, spears, washpipes, fishing apparatuses and junk baskets.
An additional object of the present invention is the provision of a milling tool having grapple means which can be re-set without removing the tool from a wellbore in which it is being used.
A particular object of the present invention is the provision of a connector assembly or a combination using a connector assembly which eliminates the need for multiple trips into and out of a wellbore to effectively perform the operation.
Another particular object of the present invention is the provision of a tool which can effectively utilize an overshot apparatus in fishing operations and in retrieving retrievable packers without the necessity of multiple trips into and out of the wellbore.
An additional object of the present invention is the provision of processes and methods for using the items mentioned in the foregoing objects.
To one of skill in this art who has the benefit of this invention's teachings other and further objects and advantages will be clear from the following description of presently-preferred embodiments of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a connector assembly and of a milling tool with the connector assembly according to the present invention.
FIG. 2 is a partial cutaway view of the assembly and of the tool of FIG. 1.
FIG. 3 is a cross-sectional view of a T-shaft useful in an assembly or tool according to the present invention.
FIG. 4 is a cross-sectional view of a T-shaft and slot cylinder of the assembly of FIG. 1.
FIG. 5 is a cross-sectional view of the slot cylinder of the assembly and of the tool of FIG. 1.
FIG. 6 is an end view of the assembly of FIG. 1 showing the T-shaft in the slot of the slot cylinder.
FIG. 7 is an end view of the assembly as in FIG. 6 in which the T-shaft has been slightly rotated to move the T-shaft shoulders into a recess beyond the slot of the slot cylinder.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 a connector assembly 10 has a T-shaft 20 and an outerslot cylinder 40. In the embodiment shown in FIG. 1 a milling shoe or burning shoe 12 is threadedly connected to a "down" end 42 of the slot cylinder 40 so that the combination of the connector assembly 40 and the burning shoe 12 may be used as a milling tool. (FIG. 1 does not depict the means within the connector assembly for receiving and holding the internal shaft).
The T-shaft 20 is shown in detail in FIG. 4. It has a central shaft body 21, "down" end 22, and an "up" end 23. As shown in FIG. 3 the ends 22 and 23 are threaded for mating connection with other elements; but these ends need not be threaded for mating connection with other elements. They can be fashioned with some other means or structure for connection to other elements. Also, in the embodiment of FIG. 3, there is shown a channel 24 extending through the length of the T-shaft 20a and a channel 26 extending through the threaded portion of the end 22, the two channels communicating with each other. This channel 24 is useful for permitting the passage of other apparatuses through the T-shaft, such as a wireline and its associated tools and apparatuses.
The T-shaft 20 has dual opposed radially extending shoulders 25 which may be positioned somewhere between the ends 22 and 23, and are shown in FIG. 3 as being closer to end 22 than to end 23. Of course two or more shoulders may be employed as desired, but the use, e.g. of three shoulders will require a corresponding member of slots in the slot cylinder for receiving the shoulders.
The slot cylinder 40 is shown in detail in FIGS. 2 and, 5 and 6. It has a generally cylindrical body member 41 having a "down" end 42 and an "up" end 43. A ring member 44 is connected to or formed integrally of the up end 43 of the slot cylinder 40's body member 41. A slot 45 is provided in the ring member 44 for receiving the shoulders 25 of the T-shaft 20. The disposition of the ring member 44, slot 45, and recess 46 are shown in FIG. 2. The edges of the slot 45 can be bevelled (as at 49 in FIGS. 5, 6, 7) to facilitate the reception in and transmission through the slot 45 of the shoulders 25. Also, the bevelled edges 49 make it unnecessary for the shoulder 25 to be precisely aligned with the slot's opening so that a turning of the T-shaft 20 eases the shoulders 25 into the slot 45.
Once the shoulders 25 have passed through the slot 45 they are received in a ring recess 46 in the ring member 44. This ring recess 46 is configured so that upon turning of the T-shaft 20, the shoulders 25 move into and are held within the ring recess 46. As shown in FIG. 6, the T-shaft 20 is thereby prevented from falling out of or moving out of the ring member 44, unless and until the T-shaft 20 is again rotated in the opposite direction permitting the shoulders 25 to move out through the slot 45. The ends 47 prevent the T-shaft 20 from moving out of the ring recess 46. The ends 48 stop the motion of the T-shaft toward the up end 43 of the slot cylinder 40.
The down end 42 of the slot cylinder 40 is threaded for mating with elements such as burning shoe 12 as shown in FIG. 5. As required, the slot cylinder or shaft may be extended in length or extensions may be added to the slot cylinder or to the T-shaft. For example, when a spear or overshot is connected to the T-shaft, an extension can be used between the slot cylinder and a milling shoe to prevent the spear or overshot from engaging an item downhold (e.g. packer or stuck pipe) during milling. For example, if a packer six feet in length is to be milled, speared, and retrieved, it is preferred to use an extension of about twenty feet in length between the slot cylinder and the milling shoe (or multiple connected extensions with an overall length of about twenty feet), so that milling can be completed without the spear contacting the packer until the T-shaft is rotated releasing the T-shaft from the ring recess and freeing it for lowering to and into the packer. As shown in FIG. 2 the slot cylinder 40 may have 0-rings disposed in the end 43 for sealing against the T-shaft 20. (Alternatively, 0-rings may be emplaced on the T-shaft itself.)
In a typical packer or fish removal operation employing a tool according to the present invention, a milling shoe (such as shoe 12) is connected to an extension (not shown) which is connected to the cylinder 40. A spear (not shown) is connected to the T-shaft 20 and the T-shaft 20 and spear are raised into the extension and cylinder 40. This combination is run into the wellbore to the location of the packer or fish. With the spear in the raised position (not in contact with the packer or fish), milling on the packer or fish is commenced and accomplished as required. Then, the string to which the tool is connected may be raised slightly to take weight off the milling shoe. The tool is then rotated about a half-turn to permit the T-shaft to disengage from the recess 46 and its shoulders to pass through the slot 45. The T-shaft with its connected spear is then lowered to and into the packer or fish (or if an overshot instead of a spear is being used, the overshot is lowered to and then around the fish). The spear then grips the packer or fish and the tool with the packer or fish is removed from the wellbore. If the packer or fish does not come loose, the T-shaft can be retracted to permit further milling before removal.
To one of skill in this art who has the benefit of this invention's teachings, it will be clear that certain changes can be made in the methods and apparatuses according to this invention without departing from the spirit and scope of the invention as set forth above and in the claims which follow. | For use in a wellbore, a connector assembly for connection to and use with a variety of downhole tools and apparatuses and methods for effecting such use; and tools including such a connector assembly in combination and methods for the use of such tools. The connector assembly has a T-shaft with shoulders extending therefrom and a slot cylinder for receiving, holding, and supporting the T-shaft. Slots and recesses are provided in the slot cylinder for receiving, transmitting and encompassing the T-shaft's shoulders. | 4 |
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to electronic communications. Specifically, the present invention relates to methods, computer program products and systems for breadth-first, asynchronous expansion of distribution lists with throttling control.
2. The Prior State of the Art
E-mail systems typically use a directory service (sometimes hereinafter referred to as the “DS”) or database to look up the locations of mailboxes of intended recipients specified in an e-mail message. Typically, two types of records are recognized—mailboxes and distribution lists. A mailbox record directly specifies the location, in terms of an exact storage location on a specified server, of the mailbox itself. Sending e-mail to a mailbox recipient has the effect of delivering the mail to the specified storage location.
On the other hand, a distribution list (sometimes referred to hereinafter as a “DL”) is an e-mail recipient that is actually a list of mailbox recipients and/or other distribution lists. A distribution list is a data record kept in a directory service or a database, wherein the data record has an attribute that represents the members of the distribution list. The members are represented as pointers to other records in the directory service or database. The pointers can be to mailbox records or other distribution lists. Sending e-mail to a distribution list has the effect of sending e-mail to all members of that list.
To identify all of the mailbox recipients contained in a particular distribution list, requires expansion of the distribution list. And since distribution lists can also contain other distribution lists as members, any method used to expand a distribution list must also be capable of handling the situation of a circular reference. As shown in FIG. 1, distribution lists can be graphically represented as a tree, wherein the individual members of the distribution list are related to one another in a hierarchical fashion.
Most e-mail systems found in the prior art use a “depth-first” method of expanding distribution lists. In simple terms, this means the system resolves each branch of a distribution list tree until it reaches a leaf node before proceeding on to a different branch of the distribution list tree. The current algorithm for expanding DLs in a depth-first manner is:
Procedure Expand(Record record, Stack parents)
Begin
DirectoryService.Lookup (record);
If (record.type==mailbox)
Save(record.storage Location);
return;
End If
parents.push(record);
For each records.member
If (not parents.find(record.member[I]))
Expand(record.member, parents)
Else
//circular loop—do nothing
return;
End For
End Procedure
The foregoing algorithm has the characteristic that the directory service lookup operation (“DirectoryService.Lookup”) happens once for each member of a distribution list, and the next lookup operation will not occur until the current lookup operation has finished and returned the data record. In the event that the directory service is located on a different server than the server of the e-mail system, the lookup operation may have a high latency. If this latency were x seconds per lookup, the algorithm set forth above would require n*x seconds to complete the expansion of the entire distribution List, where n is the number of members. However, depth-first has the advantage of being relatively efficient in terms of the amount of system resources necessary to complete an expansion process. As a general rule, the amount of system resources needed to complete a depth-first expansion is proportional to log n , where n is the number of members in the distribution list.
Another possible method of expanding a distribution list is “breadth-first” expansion. In simple terms, breadth-first expansion means that each level of a distribution list tree is completely resolved before proceeding to the next level of the distribution list tree. This method has some advantages over depth-first expansion in that it allows multiple records to be batched together and sent as a single lookup operation, thereby reducing the number of separate lookup operations and, therefore, reducing the total time required to complete the expansion operation. Unfortunately, doing this in a simplistic fashion will cause a large amount of resources (in terms of the stack objects required to keep track of parents for each DL that is being expanded) to be allocated. As a general rule, the system resources needed to complete a breadth-first expansion can be as great as n 2 , the square of the number of members in the distribution list.
Therefore, what is needed is an efficient method of expanding distribution lists that can be optimized in terms of speed and the amount of resources needed to complete the operation.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention is a technique for doing an asynchronous, breadth-first expansion of e-mail distribution lists, while being able to control the amount of resources needed to complete the expansion operation. The breadth first DL expansion technique described here correctly handles circular references while expanding Distribution Lists asynchronously, in a breadth-first fashion, and without requiring large amount of resources.
The method for breadth first expansion of a DL consists mainly of a priority queue. The method begins by examining a piece of e-mail for all intended recipients. A lookup request is inserted into the priority queue for each recipient specified in the e-mail message. The priority of these requests is set to the lowest priority (i.e., lowest numerical value) possible for the queue. None, some, or all of these recipients can be DLs.
A connection manager module manages connections to a directory service and is responsible for sending lookup requests and processing the responses. The connection manager pulls requests from the priority queue in priority order (i.e., requests with the largest numerical value are pulled first). It then combines a predetermined number of individual requests into one large request and sends it off to the directory service. It continues to pull requests from the priority queue until the maximum number of pending requests is hit, at which point it stops. This provides a throttling control on the process.
When the DS returns the results of the search request, the combined response is split apart by the connection manager. If the result indicates that a lookup request resulted in finding a final recipient (i.e., a mailbox recipient), then information about that recipient is recorded in the e-mail message itself. If the result indicates that the request was for a distribution list or a user with a forwarding address, then a new lookup for each of the members of the distribution list or the forwarding address is inserted into the priority queue. The priority of this subsequent request is incremented to be higher than its previous priority. Also, a stack is allocated, and the original request is inserted as a parent, and is associated with the new lookup request.
When a result is returned by the DS and a stack is associated with its request, the stack is checked to see if the result is already present in the stack. If so, then this indicates a circular DL or forwarding address loop, and this loop detection is recorded in the e-mail recipient.
The combination of throttling mechanism and priority queue provides the mechanism to control how many lookup requests are performed in parallel and the maximum amount of memory resources required to complete the DL expansion.
It is, therefore, a primary object of the invention to provide improved methods, computer program products and systems for expanding distribution lists. Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other objects and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a simple distribution list represented in the form of a tree diagram;
FIG. 2 illustrates an exemplary system that provides a suitable operating environment for the present invention;
FIG. 3 is a functional block diagram of the present invention;
FIG. 4 is another distribution list represented in the form of a tree diagram; and
FIGS. 5A-5F are block diagrams used to graphically illustrate the method steps of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to systems and methods for breadth-first, asynchronous expansion of distribution lists with throttling control. The embodiments of the present invention may comprise a special purpose or general-purpose computer including various computer hardware, as discussed in greater detail below.
Embodiments within the scope of the present invention also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store the desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computer, the computer properly views the connection as a computer-readable medium. Thus, any such a connection is also properly termed a computer-readable medium. Combinations of the above should also be included within the scope of computer-readable media. Computer-executable instructions comprise, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions.
FIG. 2 and the following discussion are intended to provide a brief, general description of a suitable computing environment in which the invention may be implemented. Although not required, the invention will be described in the general context of computer-executable instructions, such as program modules, being executed by computers in network environments. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represent examples of corresponding acts for implementing the functions described in such steps.
Those skilled in the art will appreciate that the invention may be practiced in network computing environments with many types of computer system configurations, including personal computers, hand-held devices, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like. The invention may also be practiced in distributed computing environments where tasks are performed by local and remote processing devices that are linked (either by hardwired links, wireless links, or by a combination of hardwired or wireless links) through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
With reference to FIG. 2, an exemplary system for implementing the invention includes a general purpose computing device in the form of a computer 20 , including a processing unit 21 , a system memory 22 , and a system bus 23 that couples various system components including the system memory 22 to the processing unit 21 . The system bus 23 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The system memory includes read only memory (ROM) 24 and random access memory (RAM) 25 . A basic input/output system (BIOS) 26 , containing the basic routines that help transfer information between elements within the computer 20 , such as during start-up, may be stored in ROM 24 .
The computer 20 may also include a magnetic hard disk drive 27 for reading from and writing to a magnetic hard disk 39 , a magnetic disk drive 28 for reading from or writing to a removable magnetic disk 29 , and an optical disk drive 30 for reading from or writing to removable optical disk 31 such as a CD-ROM or other optical media. The magnetic hard disk drive 27 , magnetic disk drive 28 , and optical disk drive 30 are connected to the system bus 23 by a hard disk drive interface 32 , a magnetic disk drive-interface 33 , and an optical drive interface 34 , respectively. The drives and their associated computer-readable media provide nonvolatile storage of computer-executable instructions, data structures, program modules and other data for the computer 20 . Although the exemplary environment described herein employs a magnetic hard disk 39 , a removable magnetic disk 29 and a removable optical disk 31 , other types of computer readable media for storing data can be used, including magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, RAMs, ROMs, and the like.
Program code means comprising one or more program modules may be stored on the hard disk 39 , magnetic disk 29 , optical disk 31 , ROM 24 or RAM 25 , including an operating system 35 , one or more application programs 36 , other program modules 37 , and program data 38 . A user may enter commands and information into the computer 20 through keyboard 40 , pointing device 42 , or other input devices (not shown), such as a microphone, joy stick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 21 through a serial port interface 46 coupled to system bus 23 . Alternatively, the input devices may be connected by other interfaces, such as a parallel port, a game port or a universal serial bus (USB). A monitor 47 or another display device is also connected to system bus 23 via an interface, such as video adapter 48 . In addition to the monitor, personal computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 20 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computers 49 a and 49 b. Remote computers 49 a and 49 b may each be another personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 20 , although only memory storage devices 50 a and 50 b and their associated application programs 36 a and 36 b have been illustrated in FIG. 2 . The logical connections depicted in FIG. 2 include a local area network (LAN) 51 and a wide area network (WAN) 52 that are presented here by way of example and not limitation. Such networking environments are commonplace in office-wide or enterprise-wide computer networks, intranets and the Internet.
When used in a LAN networking environment, the computer 20 is connected to the local network 51 through a network interface or adapter 53 . When used in a WAN networking environment, the computer 20 typically includes a modem 54 , a wireless link or other means for establishing communications over the wide area network 52 , such as the Internet. The modem 54 , which may be internal or external, is connected to the system bus 23 via the serial port interface 46 . In a networked environment, program modules depicted relative to the computer 20 , or portions thereof, may be stored in the remote memory storage device. It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
Within the context of the system described above, the present invention provides improved methods, computer program products and systems for expanding email distribution lists. As discussed and illustrated in more detail below, the methods of the present invention generally comprise the following steps: (a) generating a directory service lookup request for the root of the distribution list, wherein the lookup request is assigned a lowest priority, and placing the directory service lookup request in the directory service request queue; (b) pulling up to a predefined number of directory service lookup requests from the directory service request queue and transmitting them to the directory service for processing, wherein the predefined number of directory service lookup requests are pulled from the directory service request queue in the order of their assigned priorities; (c) analyzing the results returned by the directory service in response to the predefined number of directory service lookup requests and, for each mailbox recipient returned by the directory service in response to the previous predefined number of directory service lookup requests, saving each such mailbox recipient and, for each other distribution list returned by the directory service in response to the previous predefined number of directory service lookup requests, performing circular reference detection and discarding the other distribution list if a circular reference is detected; (d) generating, for each other distribution list returned by the directory service in response to the predefined number of directory service lookup requests, a new directory service lookup request, wherein the new directory service lookup request is assigned a priority equal to one level higher than the priority associated with the previous lookup request in response to which the other distribution list was returned; and repeating steps (b) through (e) until all mailbox recipients included in the root distribution list have been determined and saved.
Referring now to FIG. 3, the present invention includes an e-mail server 100 , which includes a connection manager 102 . Connection manager 102 manages communications between the e-mail server 100 and the directory service 104 . The directory service 104 may be physically located within the same computer as the e-mail server 100 or, as illustrated in FIG. 3, the directory service 104 may be physically located on a separate server 106 and may be logically connected to e-mail server 100 via a network 108 . The particular physical arrangement and connection of these components, as well as the particular type of network (i.e., local area network, wide area network, internet, etc.) are not critical to the present invention, but are discussed simply for purposes of illustration.
As will be explained in more detail below, connection manager 102 includes a DS request queue, in which pending directory service lookup requests are queued up for transmission to directory service 104 . In accordance with one presently preferred embodiment, connection manager 102 will combine one or more directory service lookup requests and to transmit the multiple requests in a single batch for processing by directory service 104 . The methods of the present invention allow a system administrator to designate and modify the maximum number of directory service lookup requests that connection manager 102 is allowed to combine into a single batch. Setting this predefined limit to a relatively high number will reduce the number of separate, sequential calls that may need to be made to directory service, which potentially speeds up the expansion process, but will also potentially require more resources. On the other hand, setting this predefined limit to a relatively low number will help conserve system resources, but may also potentially slow down the expansion process.
The method of the present invention begins with e-mail server 100 examining a particular piece of e-mail, which includes a list of intended recipients. As discussed above, most e-mail systems support the creation and use of distribution lists, which comprise a list intended recipients and which may include one or more specific mailbox recipients and/or one or more other distribution lists. Before e-mail server 100 can transmit the e-mail message to all intended recipients, the identity and addresses of all intended recipients must first be determined. To do so, the e-mail server sends a directory service lookup request to the directory service to request the address of each intended recipient specified in the e-mail message. If a particular e-mail message specifies only mailbox recipients, then the directory service returns to the e-mail server the specific address for each mailbox recipient, and the email server then saves the specific mailbox addresses as part of the e-mail message and then transmits the e-mail message. However, if the e-mail message specifies a distribution list as an intended recipient, the distribution list must first be expanded to determine all of the mailbox recipients that are included in the distribution list.
Reference is now made to FIG. 4, which illustrates a distribution list DL 1 , represented in the form of a tree diagram. It should be understood that DL 1 is simply one representative example of a distribution list, which has been arbitrarily selected to illustrate the principles and features of the present invention. As shown in FIG. 4, DL 1 specifies four members DL 2 1 , DL 2 2 , MB 1 and DL 2 3 . For purposes of this discussion, members labeled as “DL” are intended to represent a distribution list, and members labeled as “MB” are intended to represent a mailbox recipient. Therefore, DL 1 includes as its members three other distribution lists, DL 2 1 , DL 2 2 and DL 2 3 , and one mailbox recipient MB 1 . DL 2 2 , in turn includes members DL 3 1 , MB 2 and DL 3 2 , and so on and so forth. The individual members of distribution list DL 1 are hierarchically related in a parent-child relationship. As will be demonstrated in detail below, the single reference to DL 1 , once fully expanded, ranslates into reference to 17 separate and distinct mailbox recipients.
Assume, for the sake of discussion, that e-mail server 100 receives a piece of e-mail that specifies distribution list DL 1 as an intended recipient. E-mail server 100 , via connection manager 102 , sends a directory service lookup request to directory service 104 , requesting the identity of the members that make up distribution list DL 1 . In accordance with the present invention, the connection manager 102 prioritizes each directory service lookup request and sends the requests in order of priority. For purposes of this discussion, the higher the priority number assigned to a particular request, the higher the priority. Because DL 1 happens to be the root of the tree, the connection manager 102 will assign a priority of 1 to the initial request.
As graphically illustrated in FIG. 5A, the connection manager 102 sends the directory service lookup request to directory service 104 , which determines the identity of the members of distribution list DL 1 and returns the results. In this example, the results indicate that distribution list DL 1 refers to DL 2 1 , DL 2 2 , MB 1 and DL 2 3 . The connection manager then examines each of the returned items. If the returned item is a mailbox recipient, as in the case of MB 1 , then the connection manager saves the address of MB 1 as part of the e-mail message. On the other hand, if a returned item is another distribution list, as in the cases of DL 2 1 , DL 2 2 and DL 2 3 , then the connection manager creates another directory service lookup request for each of the returned distribution lists DL 2 1 , DL 2 2 and DL 2 3 and, as illustrated in FIG. 5B, places the new lookup requests in the DS request queue. As further illustrated in FIG. 5B, the connection manager also creates a stack for each of these requests, in which DL 1 is associated with each such request, indicating that DL 1 is the parent of each of distribution lists DL 2 1 , DL 2 2 and DL 2 3 .
As discussed above, a feature of the present invention is that it allows the administrator to control the amount of system resources used to expand a distribution list by limiting the number of directory service lookup requests that are batched together by connection manager 102 and, therefore, processed together by directory service 104 . The present invention permits a system administrator to vary this number so as to achieve, for a particular system, an optimal balance between the speed of the expansion process versus the amount of system resources needed to complete the expansion process. The higher the number of individual directory service lookup requests that are allowed to be batched together, the faster the expansion process works and the greater the amount of system resources required. Conversely, the lower the number of individual directory service lookup requests that are allowed to be batched together, the slower the expansion process works and the smaller the amount of system resources required. For purposes of this discussion, this predefined limit for the number of requests to be batched together by connection manager 102 was arbitrarily selected to be set at two.
Referring again to FIG. 5B, following the processing by connection manager 102 of the results returned by directory service 104 in the previous step, the DS request queue will contain three new directory service lookup requests, one for each of DL 2 1 , DL 2 2 and DL 2 3 . Because these requests relate to the second level, as indicated by the presence of DL 1 in the stack associated with each such request, the priority of these requests will be incremented, resulting in a priority equal to two (P=2) for each such request. Connection manager 102 then pulls out the first two of the highest priority requests currently in the queue (i.e., DL 2 1 and DL 2 2 ) and transmits a directory service lookup request for DL 2 1 and DL 2 2 . After performing the lookup operation, directory service 104 returns the results to connection manager 102 , indicating that the members of DL 2 1 are DL 3 1 , MB 2 and DL 3 2 and that the members of DL 2 2 are DL 3 3 , MB 3 and DL 3 4 . Again, connection manager 102 scans the results returned by directory service 104 and saves the addresses of any mailbox recipients (i.e., MB 2 and MB 3 ) returned by directory service 104 in response the previous requests. In addition, connection manager 102 generates new directory service lookup requests for each new distribution list (i.e., DL 3 1 , DL 3 2 , DL 3 3 and DL 3 4 ) returned by directory service 104 in response the previous requests and, as illustrated in FIG. 5C, places these new requests in the DS request queue. Here, again, connection manager 102 adds DL 2 1 the stack of the new requests for DL 3 1 and DL 3 2 and adds DL 2 2 to the stack of the new requests for DL 3 3 and DL 3 4 , and increments the priority (P=3) associated with each of these new requests.
Referring again to FIG. 5C, it will be seen that the request for DL 2 3 appears at the end of the DS request queue. This is due to the fact that the priority of the request for DL 2 3 (P=2) is lower than the priority of the requests for DL 3 1 , DL 3 2 , DL 3 3 and DL 3 4 (P=3). The process continues with connection manager 102 pulling from the DS request queue the next two requests having the highest priority (i.e., the requests for DL 3 1 and DL 3 2 ) and transmitting directory service lookup requests for those two distribution lists. As illustrated in FIG. 5C, directory service 104 returns the results of the lookup operation to connection manager 102 , indicating that DL 3 1 consists of members MB 4 , MB 5 and DL 4 1 and that DL 3 2 consists of members MB 6 , MB 7 and DL 1 . Connection manager 102 again examines the returned results, and saves any mailbox recipients as part of the e-mail. Following this operation, as further shown in FIG. 5C, the partially expanded distribution list will comprise mailbox recipients MB 1 through MB 7 . Connection manager 102 then examines any new distribution lists returned by directory service 104 and compares them to the stacks associated with their corresponding requests for loop detection. In this case, the lookup request for DL 3 2 reveals that one of the members of DL 3 2 is DL 1 , which also appears in the stack associated with the lookup request for DL 3 2 . This indicates a distribution list loop and, therefore, connection manager 102 simply discards or ignores this recurrence of DL 1 . Connection manager 102 then creates another directory service lookup request for DL 4 1 , inserting DL 3 1 in the stack and incrementing the priority (P=4) associated with the DL 4 1 request, and places the new request in the DS request queue. Because the priority of the DL 4 1 request has the highest priority of any of the requests currently in the queue, the DL 4 1 request immediately moves the front of the queue, as illustrated in FIG. 5 D.
Connection manager 102 again pulls from the DS request queue the next two requests having the highest priority (i.e., DL 4 1 and DL 3 3 ) and transmits directory service lookup requests to directory service 104 , which performs the lookup operation and returns the results. In this case, the lookup operation reveals that DL 4 1 consists of members MB 8 and MB 9 , and that DL 3 2 consists of members DL 4 2 and MB 10 . Connection manager 102 processes the returned results and saves the addresses for MB 8 , MB 9 and MB 10 as part of the e-mail message. At this point, the partially expanded distribution list DL 1 comprises mailbox recipients MB 1 through MB 10 . Connection manager 102 also compares DL 4 2 with the stack associated with the DL 3 2 request for loop detection. Connection manager 102 then creates a new directory service lookup request for DL 4 2 , adding DL 3 2 to the stack and incrementing the priority (P=4) and placing the new request in the DS request queue, as illustrated in FIG. 5 E. Again, since DL 4 2 request has a priority (P=4) that is higher than any of the other requests already in the queue, the DL 4 2 request immediately moves to the front of the queue.
Connection manager 102 again pulls from the DS request queue the next two requests having the highest priority (i.e., DL 4 2 and DL 3 4 ) and transmits directory service lookup requests to directory service 104 , which performs the lookup operation and returns the results. In this case, the lookup operation reveals that DL 4 2 consists of members MB 11 and MB 12 , and that DL 3 4 consists of members MB 13 , MB 14 and MB 15 . Connection manager 102 processes the returned results and saves the addresses for MB 11 through MB 15 as part of the e-mail message. At this point, the partially expanded distribution list DL 1 comprises mailbox recipients MB 1 through MB 15 .
Finally, connection manager 102 pulls the last request remaining in the DS request queue (i.e., DL 2 3 ) and transmits a directory service lookup request to directory service 104 , which performs the lookup operation and returns the results. In this case, the lookup operation reveals that DL 2 3 consists of members MB 16 and MB 17 . Connection manager 102 processes the returned results and saves the addresses for MB 16 and MB 17 as part of the e-mail message. This completes the expansion process and the fully expanded distribution list for DL 1 consists of mailbox recipients MB 1 through MB 17 .
If the predefined limit for the number of directory service lookup requests that are to be batched together were set at one, the methods of the present invention described above would result in a purely depth-first expansion operation commonly found in the prior art. At the other extreme, if the predefined limit of directory service lookup requests that are to be batched together were set at infinity, the methods of the present invention would result in a purely breadth-first expansion of the distribution list. Setting the predefined limit somewhere between one and infinity results in a hybrid operation that is part breadth-first and part depth-first.
Permitting this predefined limit to be specified and varied allows system administrators to fine tune the expansion operation based on the particular system, its configuration and available resources. For example, if a particular system has a relatively low latency associated with directory service lookup operations, then multiple, successive directory service lookup operations may not pose a serious performance issue. If that same system also has limited system resources, then the need to conserve system resources also probably outweighs the need to batch multiple directory service lookup requests together. Therefore, the predefined limit may be set relatively low.
The other end of the spectrum is an extremely robust system with vast system resources, but a high latency associated with directory service lookup operations. In that situation, the predefined limit should be set relatively high to reduce to maximize the number of individual directory service lookup operations that can be batched together, thereby minimizing the number of successive calls that must be made to the directory service.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | The present invention is a technique for doing an asynchronous, breadth-first expansion of e-mail distribution lists, while being able to control the amount of resources needed to complete the expansion operation. The breadth first DL expansion technique described here correctly handles circular references while expanding distribution lists asynchronously, in a breadth-first fashion, and without requiring large amount of resources. The present invention provides a mechanism to control how many lookup requests are performed in parallel and the maximum amount of memory resources required to complete the DL expansion. | 7 |
FIELD OF THE INVENTION
The present invention is related to image compression/decompression systems, and more particularly to a compression/decompression system for improving the perceived image quality of a video signal and the like, being transmitted from a wide bandwidth system to a narrow bandwidth that is, lower bit rate, system.
BACKGROUND OF THE INVENTION
Video compression methods used on the Internet today use block transform coding similar to the coding scheme set by the Motion Picture Experts Group (MPEG). To this end, blocks of pixels from the representing image, or the difference from a previous image, are transformed. The transformed components are then rounded so as to require fewer bits to encode them. In the process of decoding, the blocks of rounded components are back transformed and used to reconstruct an approximation of the original image. To achieve the very high rates of compression required for the broadcast of video over the Internet, most of the transform components must be rounded to zero. The highest frequency components are zeroed out first. However, the result of setting non-zero transform components to zero does more than just reduce the image resolution, it also causes transition at the block edges in the decoded image. This blockiness becomes disturbing in Internet video.
The use of non-blocked encoding schemes such as sub-band coding avoid the blockiness but require more computer power to encode and decode the signals, precluding their use on the Internet. Another approach used on the Internet to reduce blockiness is to send frame updates less often. This results in ajerky video signal which also is objectionable.
Pre encoding filtering is provided to remove visually unimportant frequencies and particularly those frequencies that generate alias frequencies at the reduced size image that will be viewed on, for example, the Internet. Traditionally video filtering has been done with sharp cutoff filters that separate the pass band from the stop band. Such filters are used in digital television to remove components above half the sample frequency which cause unwanted alias frequencies in the video band. Flat pass bands are desired so that multiple passes of the video signal through equipment using such filters does not degrade the signal. However, sharp cutoff filters have a ringing impulse response. The resulting filter rings are detrimental to the encoding process since the encoder must encode both the feature and the ring associated with the feature, since the ring may not be in the same block as the feature. A ring associated with a feature is an artifact of filtering and reduces the perceived image quality.
Accordingly, it would be highly desirable to provide a video compression technique for use on the Internet, and other comparable transmission mediums, which minimizes the visual artifacts which presently are generated when video images are compressed for transmission through very narrow band channels, such as used on the Internet.
SUMMARY OF THE INVENTION
The present invention provides a method and associated apparatus for overcoming the shortcomings of the prior art compression schemes of previous mention presently in use for example on the Internet.
To this end, it is an object and associated advantage of the present invention to pre-filter the video image so as to improve the perceived image quality of, for example, Internet video signals when using typical Internet video coding/decoding (codec) systems.
It is another object and associated advantage of the present invention to provide the pre-filtering process prior to the processes of sizing and encoding the video signal, using a gaussian-like filter.
Another object and associated advantage of the invention is to provide the pre-encoding filtering with a two dimensional spatial impulse filter which has good pulse fidelity, rapid cutoff at high frequency and minimal impulse response width.
A still further object and associated advantage of the present invention is to provide a gaussian type pre-filter which removes alias frequencies in the video band without producing ringing.
A further object and associated advantage of the invention comprises removing spatial frequencies corresponding to the higher order discrete cosine transform components prior to the compression process to prevent the occurrence of blocky artifacts and loss of resolution which inherently are caused by setting the components to zero.
Accordingly, the present invention comprises a two dimensional spatial impulse filter with good pulse fidelity, rapid cutoff at high frequency and minimal impulse response width, which is inserted in the compression/transmission/decompression path of the video signal prior to the compression stage. Because the video only passes through the encoder once in, for example, an Internet transmission channel, filters with good pulse fidelity are used in the present invention. Such filters are similar to gaussian impulse response filters or raised cosine amplitude response filters. One dimensional spatial filters of this kind applied in both vertical and horizontal directions combine to make a two dimensional spatial impulse filter with circularly symmetric impulse response and frequency response. Thus the diagonal response is the same as the vertical and horizontal responses, which results in the best visual use of bandwidth.
By way of illustration of the invention, a raised cosine filter which is 6 db down at the cutoff frequency of a sharp cutoff filter actually has a narrower impulse response and almost no ringing. However, 6 db down at the spatial band edge (half the pixel frequency of the video to be coded) is not enough to remove all alias frequencies. It has been found that moving the 6 db point of a pulse filter to about 0.7 (0.6 to 0.9) of the spatial band edge removes visible aliases in the image while being a good compromise between subjective image sharpness and total picture entropy, that is, the amount of information in the picture.
The two dimensional spatial bandwidth resulting from applying sharp cutoff filters with spatial bandwidth k both horizontally and vertically is k{circumflex over ( )}2. The two dimensional spatial bandwidth resulting from applying an impulse filter with 0.7k bandwidth both horizontally and vertically is approximately (Pi/8) * k{circumflex over ( )}2. Thus for images with uniform spectral content the pre-filtering of the present invention reduces the amount of information to be encoded by about 60%. This allows video to be transmitted down narrow band, that is low bit rate, digital channels with visually improved results.
The reason for visual improvement is that for typical image sequences sent on very narrow band data channels, at least this much information will be removed by the encoder anyhow. When the encoder removes a large amount of information it introduces blockiness and loss of resolution which is more objectionable than the resolution loss introduced by the pre-filter. It follows therefore that the invention provides the visually improved results by preventing blockiness while removing the large amount of high frequency information to enhance the compression process.
Further objects and advantages of the invention will be more fully understood and appreciated by reference to the drawings and the following description of the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a block diagram illustrating the application of the present invention to a narrow band channel, that is, a lower bit rate digital channel.
FIG. 2 is a block diagram illustrating an embodiment of the present invention.
FIGS. 2A and 2B are block diagrams illustrating alternative embodiments of the invention of FIG. 2 .
FIG. 3 is a diagram of a 4×4 pixel block illustrating the filter cutoff relative to discrete cosine transform (DCT) components in accordance with the invention.
FIG. 4 is a graph illustrating the impulse response of a sharp cutoff filter in comparison with that of a gaussian-type filter of the invention with the same 6 db bandwidth.
FIG. 5 is a graph comparing the frequency response of a gaussian filter to a raised cosine filter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram illustrating a compressed video system with spatial impulse filtering in accordance with the present invention. The environment of the compressed video system may comprise, for example, the Internet, a high definition television (HDTV) system, a digital video disc (DVD) processing system, etc. Therefore, although the invention is described herein with respect to primarily the Internet environment, it is readily adaptable for use in other applications. Likewise, although the invention is described in terms of video images, other forms of images such as computer data images, etc., can be processed using the invention techniques.
In FIG. 1, a suitable video source 12 , such as a video camera, a scanning device, a prerecorded tape or memory device, etc., supplies video images herein termed, “input images,” to a pre-compression spatial impulse filter means 14 of the present invention. The spatial impulse filter means 14 is a gaussian type filter such as a gaussian impulse response or raised cosine amplitude response filter, which has good pulse fidelity, rapid cutoff at high frequencies and minimal impulse response width. The filter means are applied in both the vertical and horizontal directions to provide the present invention as a two dimensional spatial impulse filter (depicted in FIG. 2 ), with circularly symmetric impulse response and frequency response. Therefore, in accordance with the invention, the diagonal impulse and frequency response is the same as the vertical and horizontal responses which results in the best visual use of bandwidth. The filtered images are then scaled to a smaller size in pixels compatible with the channel bandwidth, that is, the lower bit rate, with which they will be sent. The scaled down images are herein termed “output images.”
It is to be understood that the invention operates in the digital domain, whereby the video images, etc., are digital signals. Likewise, since the pre-filtering and compression/decompression system preferably is a digital system, the narrow bandwidth system corresponding to the actual transmission channel is herein termed a lower bit rate channel or system.
The impulse spatial filter means 14 supplies the video output images, pre-filtered and scaled down to smaller size in accordance with the invention, to a generally conventional digital compression means 16 , such as employed for example for streaming video over the Internet. The pre-filtered digitally compressed video images are transmitted, or otherwise transferred, to a use apparatus via a narrow bandwidth, that is, a lower bit rate digital channel 18 , wherein the digital images are decompressed via decompression means 20 . The decompressed digital video images of lower bit rate are supplied to suitable display means 22 such as a video monitor of a computer, video game device, etc.
However, in accordance with the invention, the pre-filtering, that is, the pre-compression filtering, with the subsequent scaling down, prior to the compression process, reduces the artifacts of compression introduced by the video compression and decompression processes, thus improving the apparent image quality.
FIG. 2 is a block diagram further illustrating the pre-compression spatial impulse filter means 14 of the present invention. The video images from the source 12 , hereinafter termed “input images,” are supplied to a two dimensional spatial impulse filter 15 with circularly symmetric gaussian impulse response. The two dimensional filter 15 preferably is realized using a combination of separate horizontal and vertical filters such as depicted in FIGS. 2A, 2 B. However, the two dimensional filter 15 also may be realized without separate filters by implementing it as a two dimensional kernel, which is a more complicated and thus less practical implementation. The pre-filtered video images are supplied to a scaling means 28 comprising for example a poly-phase filter, which does the interpolation function required in scaling down to the smaller images, that is, the “output images,” which are then compressed to the data rate suitable for a lower bit rate system
FIG. 2A illustrates further details of the two dimensional filter 14 of FIG. 2 . The input images from the source 12 are supplied to a horizontal impulse filter 24 which pre-filters in the horizontal direction, and thence to a vertical impulse filter 26 which pre-filters in the vertical direction. The filters 24 , 26 have gaussian like response whereby their combination provides the basically circularly symmetric impulse and frequency response of previous mention, and thus the same response in the diagonal direction. As depicted in FIG. 2B, vertical filtering can be done before the horizontal filtering with the same effect. The pre-filtered output images provided via the separate filters 24 , 26 in FIGS. 2A, 2 B then are supplied to the scaling means 28 as depicted in FIG. 2 .
FIG. 3 is a diagram depicting a filter 6 db point of the present invention relative to the DCT components for, for example, a 4 by 4 pixel block. The black dots represent the DCT component spatial frequencies, while the letter d is the pixel separation distance. As depicted, a 4 by 4 pixel block of the video image is transformed into its DCT components, resulting in a DC component at black dot (0,0) and then first, second, third, etc., order vertical and horizontal components.
In accordance with the invention, the two-dimensional impulse filter means is 6 db down at 0.7 of the Nyquist frequency, that is, ½d, where d is the pixel separation in the output image, as shown by the cutoff line 30 in FIG. 3 . Although the value 0.7 is used in this example, the value can range, for example, from about 0.6 to 0.9. The diagram thus portrays the relative positions of the DCT components with respect to the 6 db point. As shown, most of the DCT components fall outside of the 6 db point, which illustrates in turn the fact that the present filter gets rid of a large amount of image entropy.
Table I below is a matrix illustrating the magnitude of a two dimensional spatial filter with a 6 db point at ½d for equally spaced spatial frequencies between 0 and ½d in both the vertical and horizontal directions. If a spatial frequency exists in the image block, its magnitude will be multiplied by the magnitude of the filter. High magnitude spatial frequency components cause high order DCT components. The compression algorithm in the video codec will set many of the high order DCT components to zero. It is the setting of large DCT components to zero that causes the blocky artifacts in compression. Since the high order components are likely to be set to zero and these same components are greatly reduced by the pre-filter, blockiness in the picture is greatly reduced.
TABLE I
1.0
0.854553
0.533282
0.243026
0.854553
0.730262
0.455718
0.207679
0.533282
0.455718
0.28439
0.129601
0.243026
0.207679
0.129601
0.0590617
FIG. 4 is a graph showing a comparison of the impulse response 36 of, for example, a sharp cutoff filter whose passband is normalized to 1 Hz, versus the impulse response 34 of an impulse filter means of the invention that is 6 db down at 1.0 Hz. Thus, the filters have the same 6 db bandwidth. As may be seen, even though the two filters have the same nominal bandwidth, the sharp cutoff filter has a wider impulse response 36 , so has a wider blur function. More importantly, the sharp cutoff filter generates ringing, as shown by the oscillating curve portions 38 in FIG. 4 . When using a sharp cutoff, a feature in one image block may cause a high frequency ring which extends into an adjacent image block.
On the other hand, the impulse filter means of the invention fails to generate ringing because it is a non-ringing filter as shown in FIG. 4, and thus for a given pulse width has less bandwidth. A non-ringing response is highly advantageous since ringing, which is high frequency, can extend from one block into an adjacent block as previously mentioned, and will be truncated in the adjacent block, resulting in the generation of a noisy block. It follows that the present impulse filter means does not generate DCT components which have to be dealt with across block boundaries.
FIG. 5 is a graph showing a comparison of the amplitude response vs. frequency normalized to 0.5 (6 db down) at one hertz, of two different impulse filter means of the invention. A curve 40 depicts the frequency response of a gaussian filter and a curve 42 depicts the frequency response of a raised cosine filter. As may be seen, the respective responses are quite similar and either filter, or any linear phase filter with similar frequency response, can be employed to provide the pre-compression filtering of the present invention.
As may be seen from the above description, the impulse filter with the 6 db point moved to about 0.6 to 0.9 of the spatial band edge of the output image, is well suited in the transmission of compressed video images where the output image being sent is smaller than the input image captured by the image capture device, i.e., the image source. As previously discussed, the Internet is one such system, where the number of pixels in the transmitted output images is less than the pixels in the original input images.
By way of facilitating the description, the term “spatial band edge” is herein defined as ½d, wherein d is the separation between distinct pixels in the pertinent image. Ergo, the input and output image spatial band edges are defined herein as the band edges for the input and output image pixel densities (separations), respectively. In video cameras, the optical resolution can resolve spatial frequencies greater than the input image spatial band edge, i.e ½d where d is the pixel spacing in the input image sensor. These high spatial frequencies cause alias frequencies at spatial frequency k−½d where k is the spatial frequency of the optical image projected on the image sensor. These alias frequencies usually are not very disturbing in the picture but they increase the total amount of information that must be sent so they degrade the performance of compressed video systems. If the video image size is reduced by re-sampling at a lower pixel density, there is the possibility of introducing new alias components if there are signal components above the output image spatial band edge. In the present invention, the pre-filter is applied to the larger, i.e., “full,” input image before it is re-sampled at the lower output image pixel density. Thus the pre-filter serves both as an anti-alias filter and as a filter for reducing the high frequency components applied to the encoder. The pre-filter is applied to full pixel resolution image but with a 6 db attenuation frequency of about 0.7 of the output image spatial band edge. The amplitude response of this pre-filter at spatial frequency of the output image spatial band edge is about 0.25, which is adequate to suppress aliases. This same pre-filter will also suppress the alias components introduced by the camera. If the output pixel density is half the camera pixel density, then a filter that is 0.7 of the output image spatial band edge frequency for transmission is 0.35 of the input image spatial band edge frequency for the camera. Since most of the camera aliases will be at higher frequencies because of optical resolution limits, those above 0.35 input image spatial band edge will be effectively removed by the pre-filter. When the output image pixel density is less than the input image pixel density, camera induced aliases can be reduced without loss of resolution in the output image.
When the pixel density is reduced, if the new density is not a submultiple of the original density, then a poly-phase interpolation filter must be used to determine the values at new pixels that lie between the old pixels. The poly-phase filtering is done after the bandwidth limiting pre-filter described above. Alternatively the poly-phase filter may be merged with the bandwidth limiting filter whereby both bandwidth limiting and interpolation are done together. Alternatively, some of the bandwidth limiting can be done by each. The last alternative is the easiest to implement when the poly-phase filter is a finite impulse response filter since this filter will have the fewest taps for a given quality when it has a modest amount of lowpass in its frequency response.
Although the invention has been described herein relative to specific embodiments, various additional features and advantages will be apparent from the description and drawings. For example, the pre-filter means are described as implemented in the digital domain, but could be implemented in the analog domain with charge coupled devices (CCDs). The CCDs may be disposed in the image sensor in a video camera. Likewise, the narrow bandwidth channel and the compression/decompression processes could be performed in the analog domain via suitable analog devices. Thus the scope of the invention is defined by the following claims and their equivalents. | A method and apparatus is disclosed which minimizes the visual artifacts normally generated when images are compressed for transfer through very narrow band channels such as, for example, the Internet. To this end, the images are pre-filtered and then scaled down prior to compression using a two dimensional spatial impulse filter with good pulse fidelity rather than flat pass bands, rapid cutoff at high frequency and minimal impulse response width. The impulse filter preferably is operated at the 6 db point down about 0.6 to 0.9 of the output image spatial band edge, thereby removing visible aliases in the images while compromising between subjective sharpness and total picture entropy. | 7 |
FIELD OF THE INVENTION Field of the Invention
This invention relates to reducing the corrosion potential of components exposed to high-temperature water. As used herein, the term "high-temperature water" means water having a temperature of about 100° C. or greater, steam, or the condensate thereof. High-temperature water can be found in a variety of known apparatus, such as water deaerators, nuclear reactors, and steam-driven power plants.
BACKGROUND OF THE INVENTION
Nuclear reactors are used in electric power generation, research and propulsion. A reactor pressure vessel contains the reactor coolant, i.e. water, which removes heat from the nuclear core. Respective piping circuits carry the heated water or steam to the steam generators or turbines and carry circulated water or feedwater back to the vessel. Operating pressures and temperatures for the reactor pressure vessel are about 7 MPa and 288° C. for a boiling water reactor (BWR), and about 15 MPa and 320° C. for a pressurized water reactor (PWR). The materials used in both BWRs and PWRs must withstand various loading, environmental and radiation conditions.
Some of the materials exposed to high-temperature water include carbon steel, alloy steel, stainless steel, and nickel-based, cobalt-based and zirconium-based alloys. Despite careful selection and treatment of these materials for use in water reactors, corrosion occurs on the materials exposed to the high-temperature water. Such corrosion contributes to a variety of problems, e.g., stress corrosion cracking, crevice corrosion, erosion corrosion, sticking of pressure relief valves and buildup of the gamma radiation-emitting Co-60 isotope.
Stress corrosion cracking (SCC) is a known phenomenon occurring in reactor components, such as structural members, piping, fasteners, and welds, exposed to high-temperature water. As used herein, SCC refers to cracking propagated by static or dynamic tensile stressing in combination with corrosion at the crack tip. The reactor components are subject to a variety of stresses associated with, e.g., differences in thermal expansion, the operating pressure needed for the containment of the reactor cooling water, and other sources such as residual stress from welding, cold working and other asymmetric metal treatments. In addition, water chemistry, welding, crevice geometry, heat treatment, and radiation can increase the susceptibility of the metal in a component to SCC.
It is well known that SCC occurs at higher rates when oxygen is present in the reactor water in concentrations of about 1 to 5 parts per billion (ppb) or greater. SCC is further increased in a high radiation flux where oxidizing species, such as oxygen, hydrogen peroxide, and short-lived radicals, are produced from radiolytic decomposition of the reactor water. Such oxidizing species increase the electrochemical corrosion potential (ECP) of metals. Electrochemical corrosion is caused by a flow of electrons from anodic to cathodic areas on metallic surfaces. The ECP is a measure of the thermodynamic tendency for corrosion phenomena to occur, and is a fundamental parameter in determining rates of, e.g., SCC, corrosion fatigue, corrosion film thickening, and general corrosion.
Corrosion potential has been clearly shown to be a primary variable in controlling the susceptibility to SCC in BWR environments. FIG. 1 shows the observed and predicted crack growth rate as a function of corrosion potential for furnace-sensitized Type 304 stainless steel at 27.5 to 30 MPa√m in 288° C. water over the range of solution conductivities from 0.1 to 0.5 μS/cm. Data points at elevated corrosion potentials and growth rates correspond to irradiated water chemistry conditions in test or commercial reactors.
Corrosion (or mixed) potential represents a kinetic balance of various oxidation and reduction reactions on a metal surface placed in an electrolyte, and can be decreased by reducing the concentration of oxidants such as dissolved oxygen. FIG. 2 is a schematic of E (potential) vs. log |i| (absolute value of current density) curves showing the interaction of H 2 and O 2 on a catalytically active surface such as platinum or palladium. i 0 is the exchange current density, which is a measure of the reversibility of the reaction. Above i 0 , activation polarization (Tafel behavior) is shown in the sloped, linear regions. i L represents the limited current densities for oxygen diffusion to the metal surface, which vary with mass transport rate (e.g., oxygen concentration, temperature, and convection). The corrosion potential in high-temperature water containing oxygen and hydrogen is usually controlled by the intersection of the O 2 reduction curve (O 2 +2H 2 O+4e - →4OH - ) with the H 2 oxidation curve (H 2 →2H + +2e - ), with the low kinetics of metal dissolution generally having only a small role.
The fundamental importance of corrosion potential versus, e.g., the dissolved oxygen concentration per se, is shown in FIG. 3, where the crack growth rate of a Pd-coated CT specimen drops dramatically once excess hydrogen conditions are achieved, despite the presence of a relatively high oxygen concentration. FIG. 2 is a plot of crack length vs. time for a Pd-coated CT specimen of sensitized Type 304 stainless steel showing accelerated crack growth at ≈0.1 μM H 2 SO 4 in 288° C. water containing about 400 ppb oxygen. Because the CT specimen was Pd-coated, the change to excess hydrogen caused the corrosion potential and crack growth rate to drop.
In a BWR, the radiolysis of the primary water coolant in the reactor core causes the net decomposition of a small fraction of the water to the chemical products H 2 , H 2 O 2 , O 2 and oxidizing and reducing radicals. For steady-state operating conditions, approximately equilibrium concentrations are established for O 2 , H 2 O 2 , and H 2 in the water which is recirculated and for O 2 and H 2 in the steam going to the turbine. These concentrations of O 2 , H 2 O 2 , and H 2 are oxidizing and result in conditions that can promote intergranular stress corrosion cracking (IGSCC) of susceptible materials of construction. One method employed to mitigate IGSCC of susceptible material is the application of hydrogen water chemistry (HWC), whereby the oxidizing nature of the BWR environment is modified to a more reducing condition. This effect is achieved by adding hydrogen gas to the reactor feedwater. When the hydrogen reaches the reactor vessel, it reacts with the radiolytically formed oxidizing species homogeneously and on metal surfaces to reform water, thereby lowering the concentration of dissolved oxidizing species in the water in the vicinity of metal surfaces. The rate of these recombination reactions is dependent on local radiation fields, water flow rates and other variables.
The injected hydrogen reduces the level of oxidizing species in the water, such as dissolved oxygen, and as a result lowers the ECP of metals in the water. However, factors such as variations in water flow rates and the time or intensity of exposure to neutron or gamma radiation result in the production of oxidizing species at different levels in different reactors. Thus, varying amounts of hydrogen have been required to reduce the level of oxidizing species sufficiently to maintain the ECP below a critical potential required for protection from IGSCC in high-temperature water. As used herein, the term "critical potential" means a corrosion potential at or below a range of values of about -0.230 to -0.300 V based on the standard hydrogen electrode (SHE) scale. IGSCC proceeds at an accelerated rate in systems in which the ECP is above the critical potential, and at a substantially lower or zero rate in systems in which the ECP is below the critical potential (see FIG. 1). Water containing oxidizing species such as oxygen increases the ECP of metals exposed to the water above the critical potential, whereas water with little or no oxidizing species present results in an ECP below the critical potential.
Initial approaches to reduce the corrosion potential focused on relatively large additions of dissolved hydrogen, which proved capable of reducing the dissolved oxygen concentration in the water outside of the core from ≈200 ppb to <5 ppb, with a resulting change in corrosion potential from ≈+0.05 V she to ≦-0.25 V she . This approach is termed hydrogen water chemistry, and is in commercial use in domestic and overseas BWRs. Corrosion potentials of stainless steels and other structural materials in contact with reactor water containing oxidizing species can usually be reduced below the critical potential by injection of hydrogen into the feedwater. For adequate feedwater hydrogen addition rates, conditions necessary to inhibit IGSCC can be established in certain locations of the reactor. Different locations in the reactor system require different levels of hydrogen addition. Much higher hydrogen injection levels are necessary to reduce the ECP within the high radiation flux of the reactor core, or when oxidizing cationic impurities, e.g., cupric ion, are present.
It has been shown that IGSCC of Type 304 stainless steel (containing 18-20% Cr, 8-10.5% Ni and 2% Mn) and all other structural materials used in BWRs can be mitigated by reducing the ECP of the stainless steel to values below -0.230 V(SHE). An effective method of achieving this objective is to use HWC. However, high hydrogen additions, e.g., of about 200 ppb or greater in the reactor water, that may be required to reduce the ECP below the critical potential, can result in a higher radiation level in the steam-driven turbine section from incorporation of the short-lived N 16 species in the steam. For most BWRs, the amount of hydrogen addition required to provide mitigation of IGSCC of pressure vessel internal components results in an increase in the main steam line radiation monitor by a factor of five to eight. This increase in main steam line radiation can cause high, even unacceptable, environmental dose rates that can require expensive investments in shielding and radiation exposure control. Thus, recent investigations have focused on using minimum levels of hydrogen to achieve the benefits of HWC with minimum increase in the main steam radiation dose rates.
An effective approach to achieve this goal is to either coat or alloy the stainless steel surface with palladium or other noble metals. The presence of palladium on the stainless steel surface reduces the hydrogen demand to reach the required IGSCC critical potential of -0.230 V(SHE). The use of alloys or metal coatings containing noble metals permits lower corrosion potentials (e.g., ≈-0.5 V she ) to be achieved at much lower hydrogen addition rates. For example, U.S. Pat. No. 5,135,709 to Andresen et al. discloses a method for lowering the ECP on components formed from carbon steel, alloy steel, stainless steel, nickel-based alloys or cobalt-based alloys which are exposed to high-temperature water by forming the component to have a catalytic layer of a noble metal. Such approaches rely on the very efficient recombination kinetics of dissolved oxygen and hydrogen on catalytic surfaces (see the high i O for H 2 oxidation in FIG. 2, which causes most O 2 reduction curves to intersect at -0.5 V she ). This was demonstrated not only for pure noble metals and coatings, but also for very dilute alloys or metal coatings containing, e.g., <0.1 wt. % Pt or Pd (see FIGS. 3 to 5). FIG. 4 shows corrosion potential measurements on pure platinum, Type 304 stainless steel and Type 304 stainless steel thermally sprayed by the hyper velocity oxy-fuel (HVOF) technique with a powder of Type 308L stainless steel containing 0.1 wt. % palladium. Data were obtained in 285° C. water containing 200 ppb oxygen and varying amounts of hydrogen. The potential drops dramatically to its thermodynamic limit of ≈-0.5 V she once the hydrogen is near or above the stoichiometric value associated with recombination with oxygen to form water (2H 2 +O 2 →2H 2 O) . FIG. 5 shows corrosion potentials of Type 304 stainless steel doped with 0.35 wt. % palladium at a flow rate of 200 cc/min. in 288° C. water containing up to 5000 ppb oxygen and various amounts of hydrogen.
If the surface recombination rate is much higher than the rate of supply of oxidants to the metal surface (through the stagnant, near-surface boundary layer of water), then the concentration of oxidants (at the surface) becomes very low and the corrosion potential drops to its thermodynamic limit of ≈-0.5 V she in 288° C. water, even though the bulk concentration of dissolved oxygen remains high (FIGS. 3 to 5). Further, the somewhat higher diffusion rate of dissolved hydrogen versus dissolved oxygen through the boundary layer of water permits somewhat substoichiometric bulk concentrations of hydrogen to support full recombination of the oxidant which arrives at the metal surface. While some hydrogen addition to BWRs will still be necessary with this approach, the addition can be vastly lower than (as low as ≦1% of) that required for the initial hydrogen water chemistry concept. Hydrogen additions remain necessary since, while oxidants (primarily oxygen and hydrogen peroxide) and reductants (primarily hydrogen) are produced by radiolysis in stoichiometric balance, hydrogen preferentially partitions to the steam phase in a BWR. Also, no hydrogen peroxide goes into the steam. Thus, in BWR recirculation water there is some excess of oxygen relative to hydrogen, and then, in addition, a fairly large concentration of hydrogen peroxide (e.g., ≈200 ppb). Approaches designed to catalytically decompose the hydrogen peroxide before or during steam separation (above the core) have also been identified.
While the noble metal approach works very well under many conditions, both laboratory data and in-core measurements on noble metals show that it is possible for the oxidant supply rate to the metal surface to approach and/or exceed the recombination rate (see FIGS. 6 and 7). FIG. 6 shows the effect of feedwater hydrogen addition on the corrosion potential of stainless steel and platinum at several locations at the Duane Arnold BWR. At ≈2 SCFM of feedwater hydrogen addition, the corrosion potentials in the recirculation piping drop below ≈-0.25 V she . However, in the high flux (top of core) regions, even for pure Pt, the corrosion potential remains above ≈-0.25 V she at feedwater hydrogen levels of ≧15 scfm, where long-term operation is very unattractive due to the cost of hydrogen and the increase in volatile N 16 (turbine shine). FIG. 7 shows corrosion potential vs. hydrogen addition for Pd-coated Type 316 stainless steel in 288° C. water in a rotating cylinder specimen, which simulates high fluid flow rate conditions. The water contained 1.0 parts per million (ppm) O 2 . As the hydrogen level was increased above stoichiometry, the potential decreased, but only to about -0.20 V she . The oxygen supply rate in these tests had exceeded the exchange current density (i O ) of the hydrogen reaction (see FIG. 2), and activation polarization (Tafel response) of the hydrogen reaction began to occur, causing a shift to a mixed (or corrosion) potential which is in between the potentials measured in normal and extreme hydrogen water chemistry on noncatalytic surfaces.
At the point where the oxidant supply rate to the metal surface approaches and/or exceeds the recombination rate, the corrosion potential will rapidly increase by several hundred millivolts (e.g., to ≧-0.2 V she ). Indeed, even under (relatively small) excess hydrogen conditions, pure platinum electrodes in the core of BWRs exhibit corrosion potentials which are quite high, although still somewhat lower than (noncatalytic) stainless steel (see FIG. 6). At very high hydrogen levels (well above those typically used in the original hydrogen water chemistry concept), the corrosion potential on noble metal surfaces will drop to <-0.3 V she (see FIG. 6). However, the huge cost of the hydrogen additions combined with large observed increase in volatile radioactive nitrogen in the steam (i.e., N 16 , which can raise the radiation levels in the turbine building) make the use of very high hydrogen addition rates unpalatable.
SUMMARY OF THE INVENTION
The present invention is an alternative method for achieving the objective of low ECPs which result in slow or no crack growth in stainless steel and other metals. This is accomplished by coating the surfaces of IGSCC-susceptible reactor components with an electrically insulating material such as zirconia. In accordance with the present invention, the metal corrosion potential is shifted in the negative direction without the addition of hydrogen and in the absence of noble metal catalyst.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the observed and predicted crack growth rate as a function of corrosion potential for furnace-sensitized Type 304 stainless steel in 288° C. water.
FIG. 2 is a schematic of E (potential) vs. log i (absolute value of current density) curves showing the interaction of H 2 and O 2 on a catalytically active surface such as platinum or palladium.
FIG. 3 is a plot of crack length vs. time for a Pd-coated CT specimen of sensitized Type 304 stainless steel in 288° C. water containing about 400 ppb oxygen and 0.1 μM H 2 SO 4 .
FIG. 4 is a graph showing corrosion potentials of pure platinum (□), Type 304 stainless steel (◯) and Type 304 stainless steel thermally sprayed by the hyper velocity oxy-fuel (HVOF) technique with a powder of Type 308L stainless steel containing 0.1 wt. % palladium ( ).
FIG. 5 is a graph showing corrosion potentials of Type 304 stainless steel doped with 0.35 wt. % palladium at a flow rate of 200 cc/min. in 288° C. water containing various amounts of hydrogen and the following amounts of oxygen: (◯) 350 ppb; ( ) 2.5 ppm; and (□) 5.0 ppm.
FIG. 6 is a graph showing the effect of feedwater hydrogen addition on the corrosion potential of Type 304 stainless steel at the top of the core ( ), at the bottom of the core ( ), and in the recirculation piping ( ); and of platinum at the top (◯) and bottom (□) of the core.
FIG. 7 is a graph showing corrosion potential vs. hydrogen addition for Pd-coated Type 316 stainless steel in 288° C. water in a rotating cylinder specimen, which simulates high fluid flow rate conditions of 0.3 ( ), 1.5 (□) and 3.0 ( ) m/sec.
FIG. 8 is a schematic of electrochemical processes which generally lead to elevated corrosion potentials on the outside (mouth) of a crack and low corrosion potentials in the inside (tip) of the crack.
FIGS. 9A to 9D provide a schematic comparison of the corrosion potentials φ c which form under high radiation flux on various coated and uncoated components.
FIG. 10 is a schematic of an insulated protective coating, depicted as thermally sprayed zirconia powder.
FIGS. 11 and 12 are plots showing the corrosion potential of Type 304 stainless steel uncoated ( ) and coated (□) with yttria-stabilized zirconia by air plasma spraying versus oxygen and hydrogen peroxide concentration respectively.
FIGS. 13 and 14 are plots showing the corrosion potential versus oxygen concentration for uncoated Type 304 stainless steel ( ); Type 304 stainless steel coated with yttria-stabilized zirconia with thicknesses of 3 mils (□), 5 mils ( ) and 10 mils (◯); and pure zirconium ( ) after being immersed in pure water for 2 days and in water containing various water chemistry conditions for 3 months, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a technique for solving the problem of achieving low corrosion potentials in the high-flux, in-core region (or in other regions which may have very high oxidant supply rates from high concentrations and/or high fluid flow rates/convection). The technique entails the formation of an electrically insulating protective coating on SCC-susceptible surfaces of metal components of a water-cooled nuclear reactor. The insulated protective coating is designed to alter the balance between the rate of supply of oxidants to the surface and the rate of recombination on the surface by limiting the supply kinetics (by restricting the mass transport of reactants through a porous, insulated layer). The technique of the present invention is based on the following fundamental considerations.
The first consideration is that corrosion potentials are created only at metal-water interfaces. Thus, while on a metal coating the corrosion potential is formed at the interface of the metal coating with the bulk water, on a porous insulated coating, the corrosion potential is formed at the interface of the substrate metal and the water with which it is in contact (i.e., the water in the pores).
The influence of corrosion potential on stress corrosion cracking results from the difference in corrosion potential at the generally high potential crack mouth/free surface versus the always low potential (e.g., -0.5 V she ) within the crack/crevice tip. This potential difference causes electron flow in the metal and ionic flow in the solution, which induces an increase in the anion concentration in the crack.
FIG. 8 is a schematic of electrochemical processes which generally lead to elevated corrosion potentials on the outside (mouth) of a crack and low corrosion potentials in the inside (tip) of the crack. The potential difference Δφ c causes anions A - (e.g., Cl - ) to concentrate in the crack, but only if there is both an ionic path and an electron path.
FIGS. 9A to 9D provide a schematic comparison of the corrosion potentials φ c which form under high radiation flux: (A) on an uncoated (e.g., stainless steel) component (high φ c ); (B) on a component coated with a catalytic metal coating where the rate of supply of reactants to the surface is not too rapid (low φ c ); (C) on a component coated with a catalytic metal coating where the rate of supply of reactants to the surface approaches or exceeds the H 2 --O 2 recombination kinetics (moderate φ c ); and (D) on a component coated with an insulated protective coating (always at a low corrosion potential).
Thus, to influence stress corrosion cracking, the elevated crack mouth corrosion potential must form on a surface that is in electrical contact with the component of interest. If an insulating coating (see FIGS. 9 and 10) were applied to a metal component and some porosity or cracking in the coating is assumed to exist, the corrosion potential would be formed only at the metal component-water interface.
Thus, a crevice would be formed by the coating, but since it is electrically insulating, the crevice cannot represent an "electrochemical" crevice, but only a "restricted mass transport" geometry. The critical ingredient in "electrochemical" crevices is the presence of a conducting material in simultaneous contact with regions of high potential (e.g., a crack mouth) and regions of low potential (e.g., a crack tip). Thus, it would not help to have a component covered by an insulating layer, which layer is in turn covered by a metal layer (or interconnected metal particles) within which exists a crevice or crack. Under these conditions, the aggressive crevice chemistry could form in the outer metal layer, which in turn would be in contact with the component.
The second consideration is that if the insulated coating is impermeable to water, then obviously there can be neither corrosion potential formed on the underlying metal nor concern for stress corrosion cracking. Any pores or fine cracks in an insulating layer provide highly restricted mass transport and thus are equivalent to a very thick near-surface boundary layer of stagnant water. Since oxidants are always being consumed at metal surfaces, this very restricted mass transport (reduced rate of oxidant supply) causes the arrival rate of oxidants through the insulated coating to the substrate to decrease below the rate of their consumption. Under these mass transport limiting circumstances, the corrosion potential rapidly decreases to values ≦-0.5 V she , even for high oxidant concentrations and in the absence of stoichiometric excess hydrogen (or any hydrogen). Numerous observations consistent with this have been made, including low potentials on stainless steel surfaces at low oxygen levels (e.g., 1 to 10 ppb), as well as in (just inside) crevices/cracks, even at very high oxygen levels.
Thus, corrosion potentials -0.5 V she can be achieved even at high oxidant concentrations and, not only in the absence of stoichiometric excess hydrogen, but also in the absence of any hydrogen. This may prove to be a critical invention for BWR plants which are unable (because of cost or because of the high N 16 radiation levels from hydrogen addition) to add sufficient hydrogen to guarantee stoichiometric excess hydrogen conditions at all locations in their plant.
While various non-conducting materials could be used, zirconia (ZrO 2 ) is a good initial choice because it can be thermally sprayed and is very stable in high temperature water, both structurally (e.g., it is not prone to spalling and is not susceptible to environmentally assisted cracking) and chemically (e.g., it does not dissolve or react). Zirconia can be obtained in various particle sizes, so that there is flexibility in adjusting the thermal spray parameters. Alumina is also an option. The dissolution rate of alumina in 288° C. water is higher than that for zirconia, but is still very low. Additions of other oxides into the coating may also be advantageous. For example, ZnO has been shown to yield many benefits in BWRs, including reduced incorporation of Co 60 in films (thereby lowering the radiation level, e.g., in piping) and reduced susceptibility to SCC.
FIG. 10 is a schematic of an insulated protective coating, depicted as particles 4 of zirconia powder which have been thermally sprayed on a metal component surface 2. Due to the insulating nature of zirconia, there is no electrical connection between external (high oxidant) water and the metal component substrate. Thus, the insulated protective coating prevents an electrochemical crevice cell from being formed (see FIG. 8), while restricting mass transport of oxidants to the underlying metal substrate (see FIGS. 2 and 7) to sufficiently low rates such that the corrosion potential of the metal component is always low (i.e., -0.5 V she ).
Preliminary experimental data (shown in FIG. 11) were obtained in 288° C. pure water on a cylindrical stainless steel electrode coated with yttria-stabilized zirconia (YSZ) by air plasma spraying. A Cu/Cu 2 O membrane reference electrode was used to measure the corrosion potentials of the stainless steel autoclave, a platinum wire and the YSZ-coated stainless steel specimen. At oxygen concentrations up to ≈1 ppm (during BWR operation, the equivalent oxygen concentration (O 2 +0.5×H 2 O 2 ) is about 100 to 600 ppb), the corrosion potential of the YSZ-coated specimen remained at ≦-0.5 V she despite the high potentials registered on the stainless steel autoclave (+0.20 V she ) and the platinum electrode (+0.275 V she ). This is consistent with numerous observations of low potentials on stainless steel surfaces at low oxygen levels (e.g., 1 to 10 ppb) as well as inside crevices/cracks, even at very high oxygen levels.
Similar observations were obtained in hydrogen peroxide, where low potentials were observed on the YSZ-coated specimen at concentrations above 1 ppm (see FIG. 12). By contrast, uncoated stainless steel exhibited a high corrosion potential of ≈+0.150 V she . Low potentials were also observed on the YSZ-coated specimen in water containing 1 ppm O 2 when the specimen was rotated at 500 rpm, corresponding to 0.7 m/sec linear flow rate. This is not surprising, since the higher flow rates merely act to reduce the thickness of the stagnant boundary layer of liquid, a layer whose thickness is small relative to the zirconia coating. The success in maintaining low corrosion potentials under these conditions shows that the electrically insulating zirconia layer greatly reduces mass transport to the underlying metal surface such that, even in the absence of catalytic agents such as palladium, the cathodic (oxygen reduction) reaction is mass transport limited just as in uncoated specimens in solutions of very low dissolved oxygen content.
Further corroboration exists in the corrosion potential measurements on Zircaloy in 288° C. water, which apparently are always lower than -0.5 V she , even in aerated solutions. The relatively highly electrically insulating nature of the zirconia film causes the corrosion potential to be formed at the metal surface where the oxidant concentration is very low due to its restricted transport through the zirconia film.
Additional experimental data is presented in FIGS. 13 and 14. A coating made of yttria-stabilized zirconia powder was deposited in three different thicknesses (3, 5 and 10 mils) on the fresh metal surface of Type 304 stainless steel (1/8 inch in diameter and 2 inches long) by air plasma spraying. The corrosion potentials of the zirconia-coated electrodes, a pure zirconium electrode and uncoated Type 304 stainless steel were measured against a Cu/Cu 2 O/ZrO 2 reference electrode in 288° C. water containing various amounts of oxygen. After the corrosion potential measurement, test specimens were immersed in 288° C. water containing various water chemistry conditions for 3 months at open circuit.
In the initial tests, YSZ-coated stainless steel electrodes were mounted in the autoclave along with a zirconium electrode, an uncoated Type 304 stainless steel electrode and the reference electrode. All specimens were immersed in pure 288° C. water at a flow rate of 200 cc/min for 2 days. The corrosion potential was measured sequentially with incremental addition of oxygen, as shown in FIG. 13. At given oxygen levels up to 200-300 ppb, the YSZ-coated electrodes showed low potentials (<-0.5 V she ) essentially equivalent to those of the pure zirconium electrode, compared to the Type 304 stainless steel corrosion potential values measured at the same level of oxygen. Further increase of the oxygen concentration increased the corrosion potential of the YSZ-coated electrodes.
After the system was left in 288° C. water containing various water chemistry conditions for 3 months, the corrosion potential was again measured by increasing the oxygen concentration (see FIG. 14). This data indicates that the corrosion potential behavior of the YSZ-coated electrodes was retained for extended periods.
From the foregoing data, it is apparent that the application of a YSZ coating on the surface of Type 304 stainless steel appears is advantageous in maintaining a low corrosion potential (<-0.5 V she ) at high oxygen levels (up to about 300 ppb), even in the absence of hydrogen, by reducing mass transfer of oxygen to the metal surface and thereby mitigating SCC of the structural material. Since the oxygen concentration during operation of a BWR is about 200 ppb, SCC in BWR structural components could be mitigated by the application of a YSZ coating or any other electrically insulating protective coating on the surfaces of the structural material.
The foregoing method has been disclosed for the purpose of illustration. Variations and modifications of the disclosed method will be readily apparent to practitioners skilled in the art of water chemistry. All such variations and modifications are intended to be encompassed by the claims set forth hereinafter. | A method for mitigating crack initiation and propagation on the surface of metal components in a water-cooled nuclear reactor. An electrically insulating coating is applied on the surfaces of IGSCC-susceptible reactor components. The preferred electrically insulating material is yttria-stabilized zirconia. The presence of an electrically insulating coating on the surface of the metal components shifts the corrosion potential in the negative direction without the addition of hydrogen and in the absence of noble metal catalyst. Corrosion potentials ≦-0.5 V she can be achieved even at high oxidant concentrations and in the absence of hydrogen. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a pattern defect correction method of a photomask, and more particularly, to a method of correcting in high precision by a focused ion beam (referred to as FIB hereinafter) an opaque defect (pattern residue) and the like of a phase shift pattern generated informing a phase shift mask used in manufacturing an LSI.
2. Description of the Background Art
In manufacturing a semiconductor, the resolution R (μm) of lithography technique used in patterning interconnections is represented as:
R=k.sub.1 λ/NA, k.sub.1 =0.5
where λ is the light wavelength (μm) used for exposure, and NA is the numerical aperture of the lens. According to the above equation, the resolution of photolithography is decreased as the light wavelength becomes smaller, and also if the value of NA increases or if constant k 1 depending on the resist decreases. Using an i-line as the light for exposure (λ=0.365 μm) with numerical aperture NA=0.5 and constant k 1 =0.5, a resolution of approximately 0.4 μm is obtained. In order to improve the resolution, the light wavelength must be reduced or the value of the numerical aperture NA be increased. However, it is technically difficult to obtain a photolens meeting such conditions, and the depth of focus δ (=λ/2NA 2 ) will be reduced.
To overcome such problems, a phase shift exposure method is proposed in, for example, Japanese Patent Laying-Open No. 57-62052 and Japanese Patent Laying-Open No. 58-173744.
A conventional photomask that does not shift the phase, and a conventional photomask using a phase shift mask will be described hereinafter with reference to FIGS. 13A-13C and FIGS. 14A-14C.
In a conventional photomask which does not shift the phase, the electric field of light passing between the mask patterns 2 formed on a mask substrate 1 (FIG. 13A) is spatially separated from each other as shown in FIG. 13B. However it is not possible to focus an image of the mask patterns because the light intensity is distributed continuously as shown in FIG. 13C.
In the case of using a phase shift film, a phase shift pattern 3 formed of a SiO 2 film or the like is provided at every other portion between neighboring mask patterns 2, as shown in FIG. 14A. The phase of light passing between the mask patterns 2 will be displaced in phase by 180 degrees, so that the patterns of the electric field on the mask is distributed in inversion at every other pattern, as shown in FIG. 14B. Therefore, the light intensity on the mask shows a separated pattern, as shown in FIG. 14C. By using a phase shift mask with the above-described mechanism, the resolution can be reduced to approximately a half of the pattern width in comparison with the case of a photomask that does not shift the phase.
A method of correcting an opaque defect of a photomask using a conventional phase shift mask will be described hereinafter with reference to FIG. 15 and FIGS. 16A-16F.
Referring to FIG. 15, an opaque defect 13 is generated due to the material of a phase shifter remaining in a region between light shielding films 12 formed of a metal such as Cr or an intermetallic compound such as MoSi and not covered with the phase shifter on a mask substrate 11. The removal of the opaque defect 13 was carried out conventionally as shown in the steps of FIGS. 16A-16C and FIGS. 16D-16F. More specifically, an FIB is directed to scan only the region in the proximity of the opaque defect (the region XVIc in FIG. 15) to remove the opaque defect 13 by etching (FIG. 16B; FIG. 16E). When the etching process is stopped at the time the opaque defect 13 is completely removed, a recess 13a running along the configuration of the opaque defect 13 is seen due to the surface of the mask substrate 11 being overetched. The generation of such a recess 13a along the configuration of the opaque defect 13 on the surface of the mask substrate 11 is caused by the fact that the quartz used as the material of the mask substrate (11) and the SOG (Spin On Glass) used as the material of the phase shifter forming the opaque defect substantially have the same etching rate.
Because the correction method of a pattern defect of a photomask having a phase shift pattern was carried out as described above, a portion of the mask substrate was etched to result in a recess portion affected by the profile of the opaque defect in the defect region after the correction process. This will degrade the performance of the photomask.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a pattern defect correction method of a photomask that can correct in high accuracy a pattern defect such as an opaque defect in a phase shifter generated in forming a photomask including a phase shift pattern without the disadvantage of the mask substrate being etched.
A pattern defect correction method of a photomask of the present invention for achieving the above object includes the method of removing a pattern defect of a phase shifter generated in a region that is not covered with a light shielding film after the formation of a pattern of a predetermined phase shift mask including a light shielding film and a phase shifter on a mask substrate. According to this method, a planarization film is formed on the surface of a first region including the pattern defect on the mask substrate so as to cover at least the light shielding film and the pattern defect. Then, a FIB is directed on a second region on the mask substrate within the first region and including the pattern defect to etch away the planarization film and the pattern defect, followed by removing the remaining planarization film.
According to the pattern defect correction method of a photomask of the present invention, the planarization film and the pattern defect are removed simultaneously at substantially the same etching rate where the planarization film covers the pattern defect, whereby the etching process progresses maintaining a planar profile.
By setting the etching region larger than the area of the pattern defect, it is possible to monitor a change in the intensity of a secondary signal in the interface of the planarization film and the mask substrate to facilitate the detection of the end of an etching operation.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1J are sectional views of a photomask for showing the pattern defect correction steps according to a first embodiment of the present invention, in which FIGS. 1A-1E and FIGS. 1F-1J are taken along lines Ia--Ia and Ib--Ib, respectively, of FIG. 2.
FIG. 2 is a plan view showing the proximity of an opaque defect of a phase shift mask to which the pattern defect correction method according to the first embodiment of the present invention is applied.
FIG. 3 is a plan view showing the proximity of an opaque defect of a phase shift mask to which the pattern defect correction method of a photomask according to a second embodiment of the present invention is applied.
FIGS. 4A-4H are sectional views of a phase shift mask showing the steps of mask pattern defect correction according to the second embodiment of the present invention, in which FIGS. 4A-4D and FIGS. 4E-4H are taken along lines IVa--IVa and IVb--IVb, respectively, of FIG. 3.
FIG. 5 is a plan view showing the proximity of an opaque defect of a phase shift mask to which the mask defect correction method of a photomask according to a third embodiment of the present invention is applied.
FIGS. 6A-6J are sectional views of a photomask showing the steps of pattern defect correction of a photomask according to the third embodiment of the present invention, in which FIGS. 6A-6E and FIGS. 6F-6J are taken along lines VIa--VIa and VIb--VIb, respectively, of FIG. 5.
FIG. 7 is a plan view of the proximity of an opaque defect of a phase shift mask to which the pattern defect correction method of a photomask according to a fourth embodiment of the present invention is applied.
FIGS. 8A-8J are sectional views of the photomask showing the steps of pattern defect correction according to the fourth embodiment of the present invention, in which FIGS. 8A-8E and FIGS. 8F and 8J are taken along lines VIIIa--VIIIa and VIIIb--VIIIb, respectively, of FIG. 7.
FIG. 9 is a plan view of the proximity of an opaque defect of a phase shift mask to which the pattern defect correction method of a photomask according to a fifth embodiment of the present invention is applied.
FIGS. 10A-10J are sectional views of the photomask showing the steps of pattern defect correction according to the fifth embodiment of the present invention, in which FIGS. 10A-10E and FIGS. 10F-10J are taken along lines Xa--Xa and Xb--Xb, respectively, of FIG. 9.
FIG. 11 is a plan view of the proximity of an opaque defect of a phase shift mask to which the pattern defect correction method of photomask according to a sixth embodiment of the present invention is applied.
FIGS. 12A-12L are sectional views of the photomask according to the sixth embodiment of the present invention showing the steps of pattern defect correction, in which FIGS. 12A-12F and FIGS. 12G-12L are taken along lines XIIa--XIIa and XIIb--XIIb, respectively, of FIG. 11.
FIG. 13A is a sectional view of a conventional photomask that does not have the phase shifted,
FIG. 13B shows the electric field distribution on the main surface of the photomask thereof, and
FIG. 13C shows the light intensity distribution on the same main surface of the photomask.
FIG. 14A is a sectional view of a conventional phase shift mask,
FIG. 14B shows the electric field distribution on the main surface where a mask pattern 2 is formed on the phase shift mask thereof, and
FIG. 14C shows the light intensity distribution on the same main surface.
FIG. 15 is a plan view showing the proximity of an opaque defect of a conventional phase shift mask.
FIGS. 16A-16F are sectional views of the conventional phase shift mask of FIG. 15 showing the steps of opaque defect correction, in which FIGS. 16A-16C and FIGS. 16D-16F are taken along lines XVIa--XVIa and XVIb--XVIb, respectively, of FIG. 15.
FIG. 17 is a configuration diagram of a conventional device for detecting a secondary signal used in the embodiments of the present invention.
FIG. 18 is a plan view of the proximity of a clear defect of a phase shift mask to which the pattern defect correction method of the photomask according to a seventh embodiment of the present invention is applied.
FIGS. 19A-19E are sectional views of the photomask according to the seventh embodiment of the present invention showing the steps of pattern defect correction, respectively taken along lines XIXa--XIXa of FIG. 18.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the photomask pattern defect correction of the present invention will be described hereinafter with reference to the figures.
Referring to FIGS. 1A, 1F and FIG. 2, an opaque defect 13 which is a residue of the phase shift mask which should be removed is present between light shielding films 12 patterned having a gap adjacently on a mask substrate 11 formed of crystal and the like. The light shielding film 12 is formed of a metal such as Cr or an intermetallic compound such as MoSi. The opaque defect 13 which is a residue of the phase shifter is formed of a transparent material such as a SOG that is transparent with respect to exposure light of photography, similar to crystal forming the mask substrate 11. The etching rate of the light shielding film 12 and the opaque defect 13 are substantially equal with respect to the FIB.
According to an opaque defect correction method of the present embodiment, a resist resin 14 serving as a planarization film is applied in a planar manner all over the surface of the mask substrate 11 of the state shown in FIGS. 1A and 1F to cover at least both the light shielding film 12 and the opaque defect 13 to result in the state shown in FIGS. 1B and 1G. The etching rates of the resist resin forming the planarization film 14 and the phase shifter material forming opaque defect 13 are substantially the same.
The FIB is directed to scan an etching region 1c indicated by a dotted line in FIG. 2 to continue the etching process until the light shielding film 12 is exposed. This etching process is a physical etching called for example Ga + milling using Ga + as the irradiation ion of the FIB. The irradiation energy is 30 KeV and the beam current is approximately 200-300 pA. In this etching process, the secondary signal of a secondary electron, a secondary ion, light, an X ray and the like generated from the portion where Ga + milling progresses is monitored in real time, whereby a change in intensity of the secondary signal at the moment the surface of the light shielding film 12 is exposed is detected to set the end of the etching process.
The irradiation range of scanning by the FIB is reduced to the region Id indicated by the chain dotted line in FIG. 2 and the etching process further continued. By monitoring a change in intensity of the above-mentioned secondary signal, the moment the surface of the mask substrate 11 is exposed is detected, and the etching process terminated (FIGS. 1D and 1I).
Then, the resist resin 14 is removed using a parting agent or an oxygen plasma to result in the state shown in FIGS. 1E and 1J.
The method of monitoring a secondary signal in the above embodiment is similar to that disclosed in, for example, Japanese Patent Laying-Open No. 64-15922. This monitoring method will be described hereinafter with reference to FIG. 17. Referring to a secondary signal monitor of FIG. 17, an ion beam 502 from a metal ion source 501 is focused by an electrostatic lens 503 and polarized by an electrode 504, an aperture 506, and a polarizing electrode 505 to be directed onto a photomask 200. The secondary charged particles (a secondary electron, a secondary ion and the like) discharged from the specimen is captured by a detector 508, whereby a scanned ion image is displayed on a display 509. By comparing this scanned ion image with a proper pattern stored in advance, the position of an opaque defect can be detected. If the region where the opaque defect exists was detected using a transmission electron microscope and the like which is another defect scanning device, the data is stored in a memory 514. A controller 513 reads out that data to control the motor 512 driving a table 515, whereby the region where the defect exists is positioned at a location which is polarization-scanned by the ion beam.
By an instruction from the controller 513, the ion beam processing device operates to direct the ion beam to scan a region slightly greater than the region including the opaque defect.
A photomask pattern defect correction method according to a second embodiment of the present invention will be described hereinafter with reference to FIGS. 3, FIGS. 4A-4D, and FIGS. 4E-4H.
The present embodiment shows an example of a correction method where there is an opaque defect 13 in a region where a light shielding film 12 is not patterned on a mask substrate 11, as in FIG. 3. According to the present embodiment, a resist resin 14 serving as a planarization film is formed all over the mask substrate 11 of the state shown in FIGS. 4A and 4E having a thickness that covers at least the opaque defect 13 (FIGS. 4B, 4F). Then, a FIB is directed to scan the region IVc indicated by the broken line in FIG. 3. The resist resin 14 and the opaque defect 13 in the region IVc are etched. The moment the surface of the mask substrate 11 is exposed is detected by monitoring the secondary signal to stop the FIB irradiation, resulting in the state shown in FIGS. 4C and 4G. The remaining resist resin 14 is removed by a parting agent or an oxygen plasma (FIGS. 4D and 4H).
The present invention differs from the first embodiment only in that the need to specify again an etching region when the surface of the light shielding film 12 is exposed is eliminated because there is no light shielding film 12.
A third embodiment of the present invention will be described with reference to FIGS. 5, FIGS. 6A-6E, and FIGS. 6F-6J. The present embodiment is an opaque defect correction method where there is a pattern of a light shielding film 12 only at one side of the opaque defect 13, as shown in FIGS. 5, 6A and 6E.
The steps shown in FIGS. 6A-6E and FIGS. 6F-6J of the present embodiment are similar to the steps shown in FIGS. 1A-1E and FIGS. 1F-1J of the first embodiment, except that the cited range of the etching regions of VIc and VId differ from the etching regions of 1c and 1d of the first embodiment.
A fourth embodiment of the present invention will be described with reference to FIGS. 7, FIGS. 8A-8E, and FIGS. 8F-8J. Referring to FIGS. 7, 8A, and 8F, the present embodiment is an opaque defect correction where a phase shifter layer 11a is provided at a portion of the mask substrate 11 (the portion above the broken line in FIGS. 8A-8E) beneath the region of the light shielding film 12 with an opaque defect 13 on the mask substrate 11 20 in the region 11b between adjacent phase shifter layers 11a.
In the present embodiment, a resist resin 14 serving as a planarization film is applied all over the surface of the mask substrate 11 of the state of FIGS. 8A and 8F so that at least the surface of the light shielding film 12 is covered (FIGS. 8B, 8G). At this time, a recess 14a is generated in the resist region 14 above the region 11b between the phase shift layers 11a. A FIB is directed to scan the etching region VIIIc shown in FIG. 7 to carry out an etching process until the moment the exposure of the surface of the light shielding film 12 is detected (FIGS. C, 8H). Then the etching range is reduced from region 11b to an etching region VIIId included therein, whereby etching is further carried out until the upper face of the mask substrate 11 is exposed (FIGS. 8D, 8I). The resist resin 14 is then removed by a parting agent or an oxygen plasma and the like, resulting in the state of FIGS. 8E and 8J.
The thickness of the phase shifter layer 11a of the present embodiment is determined so that the phase of the light passing through the phase shifter layer 11a is offset by a half-wavelength with the phase of the light passing through region 11b. Therefore, the etching of region 11b requires a deep and precise etching process.
Although the profile at the location of recess 14a is maintained while the etching process proceeds, the surface of the mask substrate 11 in the region 11b can be exposed in a planar manner with almost no overetching of the mask substrate 11, because the etching rate of the resist resin 14 with respect to the FIB is greater than that of the mask substrate 11.
The phase shifter layer 11a is not limited to that described in the present embodiment which is formed of a portion of the mask substrate 11, and a newly formed SOG and the like may be used by a vapor deposition method or an application method.
A fifth embodiment of the present invention will be described hereinafter with reference to FIGS. 9, FIGS. 10A-10E, and FIGS. 10F-10J. The present embodiment is equivalent to the above-described fourth embodiment except that there is no light shielding film 12. Therefore, the steps of FIGS. 10A-10E and FIGS. 10F-10J are similar to those of FIGS. 8A-8E and FIGS. 8F-8J of the above-described fourth embodiment except for the fact that the switching from the etching region of Xc to the etching region of Xd is carried out at the moment the surface of the phase shifter layer 11a is exposed.
A sixth embodiment of the present invention will be described hereinafter with reference to FIG. 11, FIGS. 12A-12F, and FIGS. 12G-12L. The present embodiment is somewhat of an intermediate of the fourth embodiment and the fifth embodiment. More specifically, the present embodiment is an opaque defect correction in the case where there is a phase shifter 11a beneath the shield film 12, with the light shielding film 12 existing on the phase shifter 11a on only one side of the opaque defect 13.
According to the present embodiment, a resist resin 12 serving as a planarization film is applied all over the surface of the mask substrate 11 of the state of FIGS. 12A and 12G so as to cover at least the surface of the light shielding film 12 (FIGS. 12B, 12H) There is a recess 14a on the resist resin 12 on the region 11b. A FIB is directed to scan an etching region XIIc shown in FIG. 11 to carry out etching until the surface of the light shielding film 12 is exposed (FIGS. 12C, 12I). Next, the etching range is reduced to the region of XIId to carry out etching until the surface of the phase shifter 11a is exposed (FIGS. 12D, 12J). Then, the etching range is further reduced to a region of XIIe to carry out etching until the surface of the mask substrate in region 11b is etched (FIGS. 12E, 12K). Then the resist resin 14 is removed, resulting in the state shown in FIGS. 12F and 12L.
The steps of the present embodiment are similar to those of the fourth and fifth embodiment with the same effects, except that the reduction of the etching region is carried out in two stages.
A seventh embodiment of the present invention will be described with reference to FIGS. 18 and FIGS. 19A-19E. The present embodiment relates to a method of correcting a clear defect in comparison with the above-described first-sixth embodiments which are related to correcting an opaque defect. More specifically, the present embodiment is an example of a clear defect correction method where a phase shifter 15 is provided in a region between light shielding films 12 formed adjacently on a mask substrate 11 with a clear defect 16 which is a defect of the phase shifter material in the phase shifter 15, as shown in FIGS. 18 and 19A.
In the present embodiment, a resist resin 14 serving as a planarization film is applied all over the surface of the mask substrate 11 shown in FIG. 19A so as to cover at least the surface of the light shielding film 12 and the phase shifter 15 (FIG. 19B). Then, a FIB is directed to scan the region XIXb shown in the broken line in FIG. 18 to carry out etching (FIG. 19C). The etching process is continued in the same region even after the surface of the mask substrate 11 is exposed until a depth of δ from surface of the mask substrate 11 is reached (FIG. 19D). Then, the resist resin 14 is removed, resulting in the state shown in FIG. 19E.
According to the present embodiment where the thickness of the mask substrate 11 is made thinner by δ in the region XIXb, the phase of the light transmitting the mask substrate 11 in this region is made to be offset by a half-wavelength with respect to the phase of the light transmitting other regions. The performance as a phase shift mask can be obtained in regions where a clear defect occurs equivalent to a phase shifter 15.
According to the photomask pattern defect correction method of the above-described embodiments, planarization of a defected region with a planarization film allows etching to be carried out in uniform without being affected by the profile of the defect to easily correct the defect. Because it is easy to detect the moment the etching has reached the interface between the planarization film and the mask substrate, the termination of the etching process can be detected precisely. Therefore, correction of a defect can be carried out with high precision in the depth direction without the mask substrate being overetched.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | A pattern defect correction method of a photomask includes the steps of directing a focused ion beam to scan a small region including a pattern defect after a planarization film is formed on a region including a pattern defect of a phase shift mask to etch the small region. By monitoring a change in the intensity of a secondary signal, the end of an etching process is detected, followed by removal of the planarization film. According to this method, a pattern defect of a phase shift mask which is used in manufacturing an LSI can be corrected in high precision. | 6 |
BACKGROUND OF THE INVENTION
Electric switches having a frame with snap-in base retention means have been known heretofore. For example, Earl T. Piber U.S. Pat. No. 3,941,965, dated Mar. 2, 1976, and assigned to the assignee of this invention, shows a switch frame having straight depending legs for snap-in mounting and retaining the switch base therebetween. While that construction has been useful for its intended purpose, this invention relates to improvements thereover.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved electric switch.
A more specific object of the invention is to provide an electric switch frame with improved snap-in means for retaining the switch base thereto.
Another specific object of the invention is to provide an electric switch frame with improved snap-in base retention means that will accommodate switch bases having various tolerances.
Other objects and advantages of the invention will hereinafter appear.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the switch with part of the frame in cross-section to show the curved and tapered legs of the switch frame retaining the switch base therebetween;
FIG. 2 is a view similar to FIG. 1 of only the bushing and frame subassembly showing the relaxed shape of the legs prior to assembly of the switch base; and
FIG. 3 is a bottom view of the frame of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a toggle switch constructed in accordance with the invention. As shown therein, this switch is provided with a frame 2 molded of plastic insulating material or the like. This frame is generally rectangular in top view, and also in bottom view as shown in FIG. 3, and is provided with a collar 2a at the top having a hole 2b for retaining a bushing 4 which also is molded of plastic insulating material. This bushing has a tubular liner portion 4a that fits snugly down through and lines the hole in the frame and is non-rotatably keyed therein. The lower end 4b of this liner portion is formed or flared below a shoulder 2c near the lower end of the hole in the frame to rigidly secure the bushing to the frame.
This bushing is provided with snap-in means for mounting the switch in a hole in a mounting panel. This means comprises a frusto-conical skirt 4c at the upper end of the bushing having a key slot in one side. This skirt is integral with the bushing and flared downwardly and outwardly from the upper end of the bushing. Clearance space 4d is provided beneath this skirt in the outer wall around the bushing above collar 2a so that this skirt can be squeezed as it is pushed through the hole in the mounting panel and snaps out or spreads out again on the other side of the panel to abut the front of the panel around the hole and thus secure the switch to the panel. The rim of the hole in the mounting panel surrounds collar 2a and vertical ribs 2d spaced around this collar take up any free play between the panel and the collar.
To keep the bushing skirt tight against the front of the panel, the frame is provided with a pair of back-up elements or springs such as lateral wings 2e and 2f as shown in FIG. 1. These wings are integrally molded with the frame and taper outwardly so that they are resilient. In addition, these wings have ramped risers 2g and 2h at their ends so that the wings flex as the collar is pushed through the hole in the panel and then resiliently push against the rear surface of the panel to pull the flared edge of the collar tight against the front of the panel.
The inner surface of the bushing is provided with suitable constriction means for pivotally retaining a toggle lever 6 that extends therethrough into base 8 for actuating the switch contacts therein.
As shown in FIGS. 2 and 3, frame 2 is provided with means for snap-in mounting of base 8 thereon and for accommodating bases having sightly differing dimensional tolerances. This means comprises a pair of tapered and curved legs 2i and 2j extending down from the opposite ends of the frame and integrally molded therewith and adapted to be snap-in assembled on and to grip the left and right ends of the base. These legs are generally rectangular plates that taper to a thinner cross-section toward their lower ends while also curving inwardly toward one another. Each leg is provided with an inwardly-directed hook or shoulder, 2k and 2m, at its lower end that is adapted to snap beneath an undercut notch or portion, 8a-b, at the corresponding end of the base, this hook extending laterally all the way across the corresponding leg. Center notches 2n and 2p on the respective hooks of these legs are adapted to receive a tool for spreading the legs to facilitate assembly of the base therebetween. These hooks are provided with inwardly and upwardly slanted upper surfaces 2r and 2s for engaging the undercut notches on the base.
These legs are also provided with means for centering the base with respect to the frame even if some flashing from the molding process remains at the upper left and right corners of the base. This means comprises small lateral ridges 2t and 2u on the inner surfaces near the tops of the legs. These ridges tend to break off any flashing at the upper corners of the base as the base is pushed into place between the legs. These ridges space the left and right ends of the base slightly from the legs and provide clearance above these ridges for any flashing that remains at the upper corners of the base thereby to allow centering of the base relative to the frame.
As shown in FIG. 2, hooks 2k and 2m at the lower ends of the legs have upper surfaces 2r and 2s that slant upwardly as they extend inwardly. When the legs are spread part to receive the base therebetween, the legs straighten out partially and these slanted surfaces level off partially as shown in FIG. 1. Thus, the legs provide a bias inwardly against the base to pinch the base therebetween. These slanted surfaces on the hooks along with the unrolling of the curvature in the legs provide a lifting bias to the base to press the base tightly against the upper part of the frame. The tapering of the legs distributes the stresses evenly therealong so that the strain is more uniform. These legs do not unroll or straighten out completely when the base is snap-in assembled therebetween but retain some of their curvature as shown in FIG. 1. In this manner, these legs will accommodate bases having different dimensional tolerances of as much as 0.025 inch in height yet holding them rigidly in place.
Base 8 is provided with a compartment 8c in which the switch contacts are mounted.
As shown in FIG. 1, the base is provided with means for registering it laterally on the frame. This means comprises three pairs of narrow, low elongated ridges or flanges embracing the legs and cover portion of the frame between the flanges of these pairs thereof. These flanges include forward and rear flanges 8d and 8e, respectively, extending to the left from the left-hand end corners of the base and being elongated to extend from the top of the base 2/3 way toward notch 8a. Similar forward and rear flanges 8f and 8g, respectively, extend to the right from the right-hand end corners of the base and are elongated to extend from the top of the base 2/3 way toward notch 8b. The third pair of flanges include a rear upright flange 8h extending almost the length of the base along its upper, rear corner, and a similar flange, not shown, extending almost the length of the base along its upper, forward corner to confine the cover portion of the frame therebetween. The left and right end flanges confine the legs of the frame therebetween to prevent any lateral movement of the base.
While the apparatus hereinbefore described is effectively adapted to fulfill the objects stated, it is to be understood that the invention is not intended to be confined to the particular preferred embodiment of electric switch having a frame with improved snap-in base retention means disclosed, inasmuch as it is susceptible of various modifications without departing from the scope of the appended claims. | A toggle switch having a molded insulating frame including a pair of depending legs between which the insulating switch base is snap-in mounted and retained. The frame includes a bushing having a resilient collar for snap-in mounting of the switch in a hole in a mounting panel. This bushing pivotally retains the toggle lever for operating the switch contacts within the base. The legs of the frame are inwardly curved and tapered so that bases of varying tolerances may be retained thereby rigidly and securely. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to conduit rodding or fishing methods and devices used in the electrical construction and related industries. More specifically it relates to fish tape attachments having conduit lubricating means and flexible loops for freeing frictionally restrained fish tapes.
2. Description of the Prior Art:
In the electrical construction industry as well as others such as cable TV and telephone, it is necessary to insert conductors into protective conduits. These conduits are often made inaccessible by walls, ceilings, and floors of a building, or earth in underground construction prior to the installation of the conductors. In order to install the conductors, a long semi-flexible rod or ribbon made of steel or plastic, called a fish tape is commonly used. The fish tape is manually pushed through the conduit and attached to the conductors. The conductors are then attached and pulled back through the conduit with the fish tape. Several problems become evident with the use of this procedure and the fish tape. One problem is the stoppage of the fish tape while being pushed through the conduit due to frictional drag of the fish tape against the interior walls of the conduit. A short, very flexible fish tape spring-leader attachment has in the past been attached to the free end of the fish tape to assist in starting the tape around bends while being pushed through the conduit. Often, both the fish tape and spring-leader will become stuck while being pushed. Some fish tapes and leaders have been manufactured having loop structures designed to be hooked by a second fish tape. The second fish tape, with a hook structure on the free end is pushed from the opposite opening of the conduit by a second worker. This second fish tape is used to hook the loop structure of the stuck tape or leader and pull it the remainder of the way through the conduit.
The frictional forces responsible for sticking the fish tape are present between conductors sliding against interior conduit walls when being installed. Lubrication has in the past, been applied to the conductors prior to entering the conduit to reduce friction and consequently the pounds of pull needed to move the conductors through the conduit. Too much fiction results in a great deal of pulling pressure needed to move the conductors. This high pulling pressure can result in damaging the insulation on the conductor; the conductor, or both. The problem with applying lubricant to the conductors as they are entering the conduit is that the lubricant is usually wiped off onto the sides of the conduit before the conductors reach the bends, the location where lubrication is most needed. Also, conductors are often pulled manually making it desirable to reduce the amount of work needed to install the conductors. These procedures and apparatuses although somewhat effective, still have room for improvement.
Two separate searches were conducted to produce past art patents concerning conduit lubricating devices and methods, and fish tape leaders having hookable loops.
The first search was conducted in the following classes and subclasses for conduit lubricating devices and methods:
254/134.3FT, 134.3R, 134.7, 184/15,1 16, and 19.
The following patents represented devices which seemed most pertinent to my invention:
1. Pat. No. 4,137,623, was issued to Taylor on Feb. 6, 1979, for "Method and Apparatus for Dispensing Fluid in a Conduit".
2. Taylor was also issued Pat. No. 4,275,096, on Jun. 23, 1981, for a similar device.
3. On Oct. 9, 1984, Jonnes was issued Pat. No. 4,475,629, for "Method and Apparatus For Selectively Metering And Spreading Lubricant In A Conduit".
4. Pickett et al, was issued Pat. No. 4,569,420, on Feb. 11, 1986, for "Lubricating Method And System For Use In Cable Pulling".
The aforementioned devices are primarily concerned with lubricating the conduit prior to the passage of the electrical conductors after a fish tape or pull line has been installed through the conduit. No devices are provided for application of lubricant for the specific purpose of easing the initial installation of the fish tape or would they be suitable for such use. The above past art devices are uni-directional for lubricating the inner conduit walls, being effective only when pulled through a conduit since they are not structured in a manner that would allow them to be pushed. These devices are only useful after a pull line of some sort has been installed through the conduit.
The following past art patents represent devices concerned with fish tapes and fish tape attachments having loop structures and were found in the subsequent classes and subclasses; 254/134.3.
1. Wilson was issued Pat. No. 3,035,817, on May 22, 1962, for "Fish Tape Snagger".
2. Pat. No. 3,041,043, was issued to Harden, on June 26, 1962, for "Line Pull-Through Device".
3. On July 11, 1967, Blume was granted Pat. No. 3,330,533, for "Twisted Hook Terminal For Roding Ducts".
The above three patents teach conduit fishing or rodding devices with hookable structures. The hookable loop portion of the Wilson device is attached to the conductor attachment eye and must be removed before the conductors can be attached for pulling. If the loop structure were to be left on the eye of the fish tape or leader there would be less room to attach the conductors. Also the added bulk of the looped assemblage over the wires would pose a binding problem within the narrow limited space of the conduit. The Harden and Blume apparatuses would also need to be removed before pulling conductors through the conduit. These hookable loop structured devices are not suitable to be used as the wire pulling device. The worker apparently would have to anticipate getting stuck to use such a device. Most often he would try to push a standard fish tape through the conduit. If the fish tape got stuck, he would have to pull it out of the conduit, attach one of the aforementioned loop structured devices to it and push it back into the conduit. In any case, there is usually a second worker standing at the opposite end of the conduit waiting for the fish tape to exit so he can attach the conductors to be pulled through the conduit. Any delay in the installation of the fish tape causes a loss of time and a consequent loss of money in the form of wages.
I feel my invention not only overcomes the disadvantages presented in the previously mentioned past art patents but provides new and useful benefits not possessed by any related device.
SUMMARY OF THE INVENTION
In practice, I have developed attachments for use with fish tapes to reduce the problem of frictional adhering of the tape while being initially pushed through the conduit. My attachments also reduce friction between moving electrical conductors and the conduit walls. With my invention, installation time is saved by eliminating the necessity of continually attaching and removing the added accessories noted in some of the past art devices. The worker doesn't need to try to predict when he should take the time to attach a loop structure to his fish tape. My devices, attachable to the free end of any fish tape are bi-directional in that they can be effectively utilized by pushing or pulling through a conduit. The invention uses a pressure sensitive fluid absorbent outer jacketing for applying lubricant to conduit wall surfaces to reduce friction in the initial installation of the fish tape, while at the same time pre-lubricating the conduit walls for the conductor pulling process. The lubricant is applied on the exact area where the fish tape or the conductors slide against the interior conduit wall surfaces. The invention also provides flexible loops which can be easily hooked and pulled by a second fish tape in the event the invention becomes stuck in the conduit. The loops are placed so that they do not overlap or interfere with the conductor attachment eye on the fish tape, and yet the loops can be easily hooked by a second fish tape. The loops are left on during both the pushing and pulling processes without the problem of adding bulk to the conductors being pulled.
The pressure sensitive apparatus is provided in several embodiments. One embodiment is comprised of a section of absorbent, flexible sponge-like material affixed to a portion of a flexible rod between a conductor attachment eye and an end of my device structured for removable attachment to a fish tape. The sponge-like material is structured to absorb, releasably retain and then meter any approved fluid such as wire pulling lubricant onto particular sections of interior conduit wall surfaces. Permanently bound to the flexible rod in the sponge-like jacketing section are flexible loops. The loops are positioned to allow them to fold only partly into the area of the conductor attachment eye and slightly past the end of the sponge-like material adjacent the conductor attachment eye.
A second embodiment of my invention provides a fish tape attachment with an absorbent looped-fabric, jacketing a section of a spring rod. The absorbent material is similar to looped shag carpet floor covering. The jacketing material will absorb and meter the lubricant, and the loops intrinsic to the structure of the material provide the hookable loops of a suitable length.
Both embodiments are manufactured complete as leaders with spring rods attachable to the free end of a fish tape, however the fluid absorbent materials and loops are also provided as accessory attachment embodiments designed for in the field attachment to existing conventional fish tapes and spring leaders which the tradesman may already own. My accessory attachment embodiments have an inner core of heat shrinkable tubing to which the sponge-like material or looped carpet-like material is adhered. These embodiments are designed to be slipped over a typical spring leader or fish tape, positioned correctly and then gently heated with hot water or air to reduce the internal diameter of the shrink tubing tightly onto the fish tape.
Therefore, a primary object of my invention is to provide a fish tape attachment with means for lubricating a conduit for easier initial insertion of the fish tape, and a means for hooking and pulling a fish tape by a second fish tape should it become bound within the conduit.
A further object of my invention is to provide a fish tape attachment with hookable loops which do not connect to, or completely overlap the conductor attachment eye of the fish tape to allow the loops to be left on for both pushing and pulling modes.
Another object of my invention is to provide a fish tape attachment which acts as a swab to pickup pieces of debris which may be in the conduit.
A still further object of my invention is to provide an attachment means for my lubricating and flexible loop apparatuses for attachment to existing fish tapes and spring leaders.
Other objects and advantages of my invention will be disclosed by reading the following specification and subsequent comparison with the numbered parts shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 illustrates the complete looped carpet-like fabric material embodiment of the invention attached to a fish tape. The carpet-like material is shown partially covering the center flexible rod of the invention.
FIG. 2 illustrates the complete sponge-like material embodiment with connected loops attached to a fish tape. The sponge-like material is shown covering the entire length of the center flexible rod.
FIG. 3 illustrates my looped carpet-like accessory attachment embodiment in a perspective view attached directly to the free end of a fish tape.
FIG. 4 is a perspective exploded view of the component parts of the accessory sponge-like embodiment.
FIG. 5 is an assembled view of the accessory embodiment shown in FIG. 4.
FIG. 6 illustrates the sponge-like accessory embodiment attached to a standard spring leader in use within a conduit. Also shown is the end of a second fish tape with an open bent hook in the process of hooking the forward folded loops after the invention has become stuck and has pulled backward in the conduit a foot or so. Depicted by dotted lines is the position of the flexible loops as they would appear in the forward pushing mode.
FIG. 7 illustrates the complete sponge material embodiment with flexible rod attached to a fish tape. The invention is shown being forced against the interior longer radius wall surface of a bend in a conduit. Lubricant is shown being released out of the pressure sensitive material and spread onto the conduit wall.
DRAWING REFERENCE NUMBERS
10 complete looped fabric jacketed embodiment
12 complete sponge-like jacketed embodiment
14 inherent loops
16 flexible rod
18 conductor attachment eye
20 fish tape attachment terminal
22 attachment nut
24 absorbent jacket
26 heat shrinkable tubing
28 fish tape
29 free end of fish tape
30 conduit
31 long radius wall surface of bend
34 accessory attachment embodiment
36 fabric backing
38 loop assembly
40 central attachment loop
42 lubricant
44 movement directional arrows
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in general and FIG. 1 in particular where complete looped fabric jacketed embodiment 10 is shown attached to the free end of fish tape 29 by a strong metal or plastic fish tape attachment terminal 20 and metal attachment nut 22. This attachment method is shown in a cut-away view in FIG. 2 depicting fish tape attachment terminal 20 securely crimped with compression over the outside of flexible rod 16 at one end, and having a male threaded stud positioned oppositely. Attachment nut 22 has female threads in one opened end for cooperative threading with the threads of attachment terminal 20. Attachment nut 22 also has an unthreaded hollow inner section behind the threaded section which tapers to an aperture in the back of the nut 22. This aperture is sized for the insertion of the free end of fish tape 29. Attachment nut 22, prior to threading onto fish tape attachment terminal 20 is slipped over the end of fish tape 29, the free end of fish tape 29 is brought completely through nut 22 where it is hammered flat and wide before being pulled back into attachment nut 22 where it is restricted from pulling completely through the small aperture due to the newly widened end. Attachment nut 22 is then threaded onto fish tape attachment terminal 20 and tightened. This is just one example of a known method of attaching a leader to a fish tape 28 and other methods for round or plastic fish tapes are well known to those skilled in the art. Securely affixed to fish tape attachment terminal 20 is flexible rod 16, a resilient flexible cylindrically shaped elongated rod manufactured of any high strength yet flexible material such as plastic or metal. Flexible rod 16 as shown in the drawings is structured of a metal wound wire cable. Securely affixed at the opposite end of flexible rod 16 is conductor attachment eye 18 structured of any suitably strong material such as plastic or metal. As shown, conductor attachment eye 18 is manufactured of metal and is affixed by compression crimping, but could be affixed by welding or other suitable means. The plastic embodiment of conductor attachment eye 18 would be attached to flexible rod 16 with heat shrinking, adhesives, compression, sonic bonding, or combinations thereof. Conductor attachment eye 18 as shown in FIGS. 1, 2, and 6 has a smooth somewhat rounded terminal end which divides into two substantially parallel bars extending towards flexible rod 16 before joining together to form a hollow tube for which flexible rod 16 is slipped into and secured. Between the two parallel bars is the aperture which conductors are intended to be attached through.
The embodiment shown in FIG. 1 and the accessory attachment embodiment 34 shown in FIG. 3 use an outer material having a strong flexible fabric backing 36 such as heavy cloth or leather with a plurality of inherent loops 14 made of fabric or leather securely attached forming a looped carpet-like jacketing for attachment to the outer longitudinal surface of flexible rod 16 or the free end of a fish tape 29. Attachment of this carpet-like jacketing is accomplished by adhesives or other suitable means to flexible rod 16 starting adjacent conductor attachment eye 18 and extending toward the fish tape attachment terminal 20. The carpet-like jacketing is shown covering the outer surface of flexible rod 16 only partially in FIG. 1, but can cover all of the rod 16 as does the absorbent jacket 24 of a second embodiment shown in FIG. 2. The longer the jacketing material, the more of lubricant 42 will be able to be releasibly retained. The complete sponge-like jacketed embodiment 12 of FIG. 2 has absorbent jacket 24 securely attached to the outer surface of flexible rod 16. As shown in FIG. 2, 4, 5, 6, absorbent jacket 24 is manufactured of a flexible open cell plastic foam, but could be manufactured of any other suitably similar material such as sponge, rough surfaced suede leather, or a heavy fabric. Attachment of absorbent jacket 24 to flexible rod 16 is made by adhesives, vulcanizing, or other suitable means. Placement of absorbent jacket 24 begins adjacent conductor attachment eye 18 and extends toward fish tape attachment terminal 20. Both absorbent jacket 24 of complete sponge-like jacketed embodiment 12 and the carpet-like material of complete looped fabric jacketed embodiment 10 are designed to absorb large quantities of lubricant 42 such as wire pulling compound or other lubricants 42 deemed suitable for use in conduits and on the insulation of conductors. The absorbed lubricant 42 is releasibly held within the jacketing material until pressure is applied to the pressure sensitive material causing the release of a quantity of lubricant 42 onto the surface which is exerting the pressure. With the carpet-like material the fabric inherent loops 14 releasibly retain the lubricant 42 along with the fabric backing 36.
Securely affixed in the sponge-like jacketed area of embodiment 12 is an addendum loop assembly 38 consisting of a plurality of loops formed around a central attachment loop 40 shown best in FIG. 4. Loop assembly 38 can also be attached slightly beyond the end of the lubricant carrying material, behind the conductor attachment eye 18 as shown in FIG. 7. The placement and lengths of the plurality of loops relative to conductor attachment eye 18 is critical for proper utilization. The maximum forward folded distance of the loops is the beginning of the hole in conductor attachment eye 18, and a minimum forward folded distance being slightly past the forward end of absorbent jacket 24 or fabric backing 36. The minimum and maximum forward distances of the loops allow hooked fish tape 32 to move past the small conductor attachment eye 18 to hook inherent loops 14 or the loops of loop assembly 38 without having to move past the larger absorbent material area, which in the smaller conduits 30 is sometimes constricted as shown in FIG. 6. Loop assembly 38 is manufactured of a flexible non-resilient material having a tensile strength of at least 10 pounds. This low strength requirement is due to the fact that the loops are not designed to be used to pull the conductors which sometimes require hundreds of pounds of pulling pressure. Loop assembly 38 need only be strong enough to be hooked by a second hooked fish tape as shown in FIG. 6, and pulled the remainder of the distance through the conduit 30. This low strength requirement allows for the use of absorbent materials such as twine, string, or other fabric material such as used in complete looped fabric jacketed embodiment 10 for the manufacture of loop assembly 38. For a more durable loop assembly 38, non-absorbent materials such as flexible plastic, or somewhat absorbent leather, small flexible metal cable or chain is used. Loop assembly 38 manufactured of metal chain is very flexible, durable, and is easily attached by welding central attachment loop 40 to metal flexible rod 16 or by inserting central attachment loop 40 between flexible rod 16 and the tubular attachment end of conductor attachment eye 18 prior to compression crimping. It is conceivable that loop assembly 38 if manufactured of suitably strong materials could under some conditions also be used to pull wire. In FIG. 2 loop assembly 38, made of plastic, is shown attached through a two piece absorbent jacket 24 where attachment loop 40, sized just slightly larger in internal diameter than the external diameter of flexible 16, has been slipped over flexible rod 16 prior to affixing conductor attachment eye 18, and adhered with glue, sonic bonding or other suitable means. Absorbent jacket 24 has been installed on each side of loop assembly 38 and aids in retaining loop assembly 38 by creating a wall which central attachment loop 40 would have to expand over to be pulled off. As shown in FIG. 4, 5, 6, loop assembly 38 is made of a twine or string material with central attachment loop 40 having been tightly tied around absorbent jacket 24.
Both complete looped fabric jacketed embodiment 10 and complete sponge-like jacketed embodiment 12 are manufactured complete as attachable spring-type leaders for fish tapes, however the fluid absorbent materials and loops are also provided as accessory attachment embodiments 34 designed for in the field attachment to existing conventional spring leaders and the fish tapes 28 tradesman may already own. The accessory attachment embodiments 34 have an inner core of heat shrinkable tubing 26 to which the sponge-like absorbent jacket 24 or the fabric backing 36 with inherent loops 14 is adhered with glue, stitching or other suitable means. The heat shrinkable tubing 26 has an expanded internal diameter greater than the largest diametrical portion of the free end of fish tape 29, and a recovered internal diameter less than the smallest diametrical portion of the free end of fish tape 29 or flexible rod 16. These embodiments as shown in FIG. 3, and 4, are structured to be slipped over conductor attachment eye 18 of a spring leader or the terminal conductor attachment eye of a fish tape when the fish tape is intended to be used without a spring leader. The accessory attachment embodiment 34 is then positioned correctly and gently heated with hot water or air to reduce the diameter the heat shrinkable tubing 26 thus securing the unit onto the spring leader or fish tape. Accessory attachment embodiment 34 is then used in the same manner as complete looped fabric jacketed embodiment 10 and complete sponge-like jacketed embodiment 12. The heat shrinkable tubing 26, along with the adhered outer jacket is easily cut and removed with a knife to allow the absorbent material to be replace in the event of excessive wear.
In use, one of my embodiments 10, 12, or 34 is attached to the free end of a fish tape 29 and coated with a lubricant 42 making sure to saturate the absorbent jacket 24 material. The free end of the fish tape 29 is then inserted into an opening in conduit 30 and pushed. In the straight lengths of the conduit 30, the invention, attached at the free end of the fish tape 29 glides on the interior downward surface of the conduit 30 wall releasing only a small amount of the lubricant 42 in the path of the adjacent fish tape 28. Most of the lubricant 42 is retained in the pressure sensitive absorbent jacket material 24 until it reaches the long radius wall surface of a bend 31. As the lubricating embodiment enters the bend it is forced against the longer radius wall surface in the bend 31. The force creates pressure on the absorbent material causing it to release the lubricant 42 onto the area of highest frictional drag to the leader attachment and adjacent fish tape 28 in the bend. Both the leader and fish tape 28 are more able to move past this area and continue on through the conduit 30. As the lubricating leader moves through the conduit 30, it picks up small pieces of metal filings and other debris which might be in the conduit 30 and could damage the insulation on the conductors. If the leader becomes stuck in the conduit 30, the operator pulls back on the fish tape 28 a foot or so, the inherent loops 14 or the loops of add-on loop assembly 38 fold forward toward the conductor attachment eye 18 where the loops are easily hooked by a second fish tape and pulled the remainder of the distance through the conduit 30 as shown in FIG. 6. When the fish tape exits the conduit 30 the absorbent jacketing 24 is wiped off to remove the debris. Conductors are then attached through the conductor attachment eye 18 and the absorbent jacketing 24 is then recoated with lubricant 42. The fish tape 28 with my attached invention and conductors are then pulled back through the conduit 30. As the lubricated attachment enters a bend while being pulled, it is forced against the short radius wall surface of the bend releasing the lubricant 42 onto the area of very high resistance to movement of the conductors, the lubricant 42 allows the conductors to move easily through the bend.
Although I have described my invention in detail in the specification it is to be understood that modifications and changes may be practiced in the structure and method of use of my invention which do not exceed the intended scope of the appended claims. | A new method and apparatus for quickening in the insertion of a fish tape through a conduit by reducing the occurrence of frictional adhering. The apparatus provided in several embodiments uses flexible lubricant carrying materials having pressure sensitive fluid release characteristics affixed to the free end of a fish tape. The apparatus is saturated with a fluid lubricant prior to being inserted into an opening of the conduit and pushed. As the pressure sensitive material enters a bend in the conduit, pressure is applied to the pressure sensitive material by the long radius wall surface of the bend causing lubricant to be released. The possibility of frictional adhering of anything being pushed through the bend is greatly reduced. The apparatus moves past the well lubricated area and is immediately followed by the body of the fish tape. In the event frictional adhering does occur between the fish tape with attached lubricant spreading apparatus and the conduit, permanent hookable loops are provided to allow easy hooking and pulling of the apparatus by a second fish tape. | 7 |
This application is a continuation-in-part of U.S. patent application Ser. No. 11/148,178, filed Jun. 9, 2005, now U.S. Pat. No. 7,306,059, which is herein incorporated by reference in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates to thrust bearing assemblies, and more particularly to a hydrodynamic thrust bearing assembly having thrust pads individually mounted on resilient deflection elements, such as Belleville washers.
2. Background of the Invention
Most conventional downhole drilling motors use rolling element-type bearings, such as ball rollers or angular contact rollers. U.S. Pat. No. 5,074,681 to Turner et al. discloses an example of ball rollers. U.S. Pat. No. 5,248,204 to Livingston et al. discloses an example of angular contact rollers. Typically, these rolling element-type bearings are lubricated by the drilling fluid (mud) or by clean oil when encased in a sealed oil chamber. Due to the high loads, pressure, and abrasive conditions, bearing life is typically only several hundred hours.
Motors typically have a multiple number of bearings. The bearings can be resiliently supported on Belleville washers to equalize loading among bearings and to absorb shock. Rolling element type bearings are not tolerant of abrasives and thus wear quickly when exposed to mud lubrication. Once wear occurs, loads between the individual balls become uneven and wear rates accelerate. Indeed, rolling element balls taken from failed units are sometimes half their original diameter. For the oil-lubricated bearings, once the seals fail, wear occurs in a similar way.
Another type of bearing used in downhole drilling motors is a hydrodynamic or sliding surface type. U.S. Pat. No. 4,560,014 to Geezy discloses an example of this hydrodynamic bearing type, which uses rigidly mounted pads manufactured of industrial diamond. The diamond pads are mud-lubricated and slide against each other. These bearings, however, are extremely expensive and only marginally increase service life.
Other examples of hydrodynamic bearings are disclosed in the inventor's previous U.S. Pat. No. 5,441,347 to Ide and U.S. Pat. No. 5,620,260 also to Ide, both of which are incorporated herein by reference. These pad type hydrodynamic thrust bearings include a carrier and a plurality of bearing pads circumferentially spaced about the carrier. The pads may be provided with individual support structures and supported in the carrier, or may be integrally formed with the carrier.
SUMMARY OF THE INVENTION
An embodiment of the present invention provides a hydrodynamic thrust bearing assembly in which each thrust pad is individually mounted on a deflection element. Rather than mounting an entire bearing having fixed pads on a resilient member (e.g., spring), the present invention resiliently mounts the individual thrust pads, thereby avoiding costly finish-grinding/lapping of the complete bearing assembly.
An exemplary thrust bearing assembly according to an embodiment of the present invention comprises a rotating bearing runner having a wear resistant face and a stationary bearing carrier defining a plurality of cavities disposed annularly around the carrier. A deflection element is disposed in a cavity of the plurality of cavities and a pad is disposed over the deflection element. The pad is at least partially disposed within the cavity. The wear resistant face of the rotating bearing runner contacts the pad.
Another embodiment of the present invention provides a thrust bearing assembly for a downhole motor comprising a first stationary bearing carrier defining a first plurality of cavities disposed annularly around the first stationary bearing carrier, a second stationary bearing carrier defining a second plurality of cavities disposed annularly around the second stationary bearing carrier, and a rotating bearing runner disposed between the first stationary bearing carrier and the second stationary bearing carrier. The rotating bearing runner has a first wear resistant face and a second wear resistant face. Each cavity of the first plurality of cavities and the second plurality of cavities holds a deflection element and a pad disposed over the deflection element. The first wear resistant face is in contact with the pads of the first stationary bearing carrier. The second wear resistant face is in contact with the pads of the second stationary bearing carrier.
Another embodiment of the present invention provides a downhole drilling apparatus that includes a progressive cavity drive train. The apparatus comprises a housing structure, a stator, a rotor, and a thrust bearing assembly. The stator has a longitudinal axis. The rotor has a true center and is located within the stator. The stator and the rotor each have coacting helical lobes that are in contact with one another at any transverse section. The stator has one more helical lobe than the rotor such that a plurality of progressive cavities is defined between the rotor and the stator.
The rotor is adapted to rotate within the stator such that the true center of the rotor orbits the axis of the stator. The orbit has a predetermined radius and the orbiting motion of the rotor causes a progression of the progressive cavities in the direction of the axis of the stator. The thrust bearing assembly is coupled to the rotor and comprises a rotating bearing runner having a wear resistant face and a stationary bearing carrier defining a plurality of cavities disposed annularly around the carrier.
A deflection element is disposed in a cavity of the plurality of cavities and a pad is disposed over the deflection element. The pad is at least partially disposed within the cavity. The wear resistant face of the rotating bearing runner contacts the pad.
Another embodiment of the present invention provides a thrust bearing assembly in which pads disposed opposite to each other on opposite sides of a bearing carrier are rigidly connected to each other, such that the two pads move in unison.
For example, on a first side of a bearing carrier, a first pad mounted over a first deflection element can be rigidly connected to a second pad mounted over a second deflection element disposed on a second side of the bearing carrier opposite to the first side. In one implementation, the pads are rigidly connected by a pin that passes through the bearing carrier. The pin can be attached to the pads or can include integral or non-integral pad holders in which the pads are disposed. In one implementation, the pin has an integral first pad holder and is mechanically coupled to a second pad holder on the opposite side of the bearing carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view partly in section of the overall structure of a downhole drilling apparatus according to an embodiment of the present invention.
FIG. 2A is a sectional view of an exemplary thrust bearing assembly installed in a downhole motor, according to an embodiment of the present invention.
FIG. 2B is an enlarged view of a portion of the thrust bearing assembly of FIG. 2A .
FIG. 2C is a sectional view of the thrust bearing assembly of FIG. 2A prior to welding.
FIG. 2D is an enlarged sectional view of an exemplary thrust bearing assembly having rigidly connected opposing pads, in this case connected by a pin, according to an embodiment of the present invention.
FIG. 3A is a plan view of an exemplary bearing carrier, according to an embodiment of the present invention.
FIG. 3B is a sectional view of the bearing carrier of FIG. 3A along line 3 - 3 .
FIG. 3C is an isometric view of a section of the bearing carrier of FIG. 3A along line 3 - 3 .
FIG. 4A is a plan view of an exemplary runner, according to an embodiment of the present invention.
FIG. 4B is a sectional view of the runner of FIG. 4A along line 4 - 4 .
FIG. 4C is an isometric view of a section of the runner of FIG. 4A along line 4 - 4 .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of thrust bearing assemblies are described in this detailed description of the invention. In this detailed description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of embodiments of the present invention. One skilled in the art will appreciate, however, that embodiments of the present invention may be practiced without these specific details. In other instances, structures and devices are shown in block diagram form. Furthermore, one skilled in the art can readily appreciate that the specific sequences in which methods are presented and performed are illustrative and it is contemplated that the sequences can be varied and still remain within the spirit and scope of embodiments of the present invention.
An embodiment of the present invention provides a novel, longer life, higher capacity, lower cost hydrodynamic bearing that operates in, for example, a mud-lubricated or sealed oil bath-lubricated drilling motor bearing system. The pad wear surface can be made of a material that is harder than the particles typically found in the mud and that does not wear when maximum loads are kept in approximately the 1000 to 2000 psi range. Examples of suitable pad wear material include silicon carbide and tungsten carbide. Load equalization among individual pads within each bearing can be accomplished by resiliently mounting each thrust pad on deflection elements, such as Belleville washers. This resilient mounting differs from mounting the entire bearing, encompassing fixed pads, on a resilient element (spring), as has been done in the prior art. Indeed, resiliently mounting individual pads eliminates costly finish-grinding/lapping of the complete bearing assembly.
When designed to fit into existing motor bearing envelopes, thrust loading of approximately 1000 psi or less can be achieved. Tests conducted in mud lubrication at these loads have shown virtually no wear. In a preferred embodiment, the present invention includes a number of rotating disc members of abrasion-resistant hard wear surfaces and a number of stationary pad-type bearing members opposite one or both sides of the rotating member. The bearing members comprise pad carriers with a plurality of cavities for fitting hard ceramic wear pads on resilient elements, such as Belleville washers.
In an embodiment of a method for manufacturing a thrust bearing according to the present invention, the components are first loosely assembled. The stationary bearing carriers are then bolted or welded together after assembly with a preload (e.g., a slight compression) on the springs. This construction ensures that all components are held in position for proper alignment. Because of the difficulty in predicting precise loads downhole, the present invention can be designed with an overload protection blank runner that engages prior to bottoming of the Belleville washers. For example, a blank runner can be coupled to a bearing carrier of the thrust bearing assembly and configured to engage a blank overload stop. As used herein, the term “coupled” encompasses a direct connection, an indirect connection, or a combination thereof.
Illustrating one particular application of the present invention, FIG. 1 shows the overall structure of a progressive cavity drilling apparatus in which a hydrodynamic pad type thrust bearing of the present invention can be used. As shown, the apparatus includes a drill string 15 , a progressive cavity drive train, a drill bit drive shaft 16 , and a drill bit 26 . The drive train includes a progressive cavity device and a coupling for converting the motion of the rotor of the progressive cavity device, e.g., orbiting of the rotor and the rotational motion of the rotor, into rotation about a single axis at the same speed. This coupling, which is contained in the lower part of housing 10 and is not visible in FIG. 1 , is a joint assembly including one or more thrust bearing members of the present invention. The joint assembly can be, for example, either a mud-lubricated or sealed oil bath-lubricated drilling motor bearing system.
As illustrated in FIG. 1 , the progressive cavity device A has a stator, a rotor, a passageway 11 for fluid to enter between the stator and the rotor, and a passageway 20 for the fluid to exit therefrom. In the drawings, the housing 10 and its flexible lining 14 are held against movement so that they function as the stator in the device A and the shaft 12 functions as the rotor. The housing 10 is tubular and its interior communicates with inlet 11 in the top portion of the lining 14 to provide a passageway for fluid to enter the progressive cavity device A. Outlet 20 in the bottom portion of the lining 14 serves as the passageway for fluid to discharge from the progressive cavity device A. The shaft 12 is precisely controlled so as to roll within the lining 14 . The progressive cavity device A is attached to the lower end of a drill string 15 .
The lower end of the rotor shaft 12 includes a shaft connection 18 a . The shaft connection allows the rotor 12 to be directed to a stub shaft of the coupling. One end of the coupling is directly connected, by threading, splining, or the like, to the rotor shaft 12 . The other end of the coupling is similarly connected to a drill bit drive shaft 16 . Typically, the coupling includes separate stub shafts that are connected to the rotor shaft 12 and drive shaft 16 by connecting means such as threads, splines, and the like. Of course, a stub shaft could be integrally formed (connected) to either of these shafts, if desired. The drill bit drive shaft 16 is rotatably connected to a conventional drill bit 26 .
The progressive cavity train functions as a fluid motor of driving apparatus for driving the drilling apparatus shown in FIG.1 Thus, pressurized fluid, typically water carrying suspended particles commonly referred to as “mud,” is forced into the progressive cavity device. The rotor 12 responds to the flowing fluid to produce a rotor driving motion that is simultaneously a rotation, an oscillation, and an orbit. The coupling attached to the rotor 12 at connection point 18 a and aligned with the true center of the rotor described above converts this rotor driving motion into rotational driving motion substantially about single axis.
FIGS. 2A and 2B show sectional views of an exemplary thrust bearing assembly 150 installed in a downhole motor, according to an embodiment of the present invention. As shown, a drill motor shaft 104 is coupled to a drill bit (not shown) located below the thrust bearing assembly 150 . Drill motor shaft 104 is housed in drill casings 102 and 103 . Stationary bearing members 10 and 101 are fixed between the drill casings 102 and 103 . Stationary bearing members 10 are bearing carriers. Stationary bearing member 101 is a blank overload stop. Bearing carriers 110 and blank overload stop 101 are fixed in the drill string assembly via compressive forces on the top and bottom applied by drill casings 102 and 103 .
Rotating bearing runners 106 are locked to the rotating shaft 104 with compressive forces on the top and bottom by the threaded drill casing member 105 .
Wear resistant inserts 111 (e.g., made of silicon carbide and tungsten carbide) are fitted to rotating bearing runners 106 with adhesive. Optionally, wear resistant inserts 111 can be omitted if rotating bearing runners 106 have integral wear resistant faces.
For example, bearing runners 106 can be entirely made from a wear resistant material, such as silicon carbide and tungsten carbide.
Each stationary bearing carrier 110 includes one or more thrust pads. Each thrust pad can be resiliently mounted within an individual cavity. In one embodiment shown in FIG. 3A and discussed below, the individual thrust pads are disposed annularly around a carrier. As shown in the cross-sectional view of FIG. 2B , a pad 109 can be resiliently mounted on a deflection element 107 within a counterbore 115 of bearing carrier 110 . In this case, pad 109 is a hard ceramic disc and deflection element 107 is a resilient washer, such as a Belleville washer. A steel disc 108 can optionally be provided between the pad 109 and deflection element 107 to uniformly distribute the deflection element loads to the bottom of the pad 109 to eliminate any stress risers.
As shown in FIG. 2A , to provide overload protection, an exemplary thrust bearing assembly of the present invention can include a blank steel runner 100 that engages the blank overload stop 101 just prior to bottoming of the deflection elements 107 .
As shown in FIG. 2B , welds 152 at the base of each bearing carrier 110 lock the entire assembly together and hold the individual components in position. FIG. 2C illustrates a sectional view of bearing assembly 150 prior to this welding, showing blank overload stop 101 , blank steel runner 100 , stationary bearing carrier 110 , rotating bearing runners 106 , and a pad 109 (e.g., a ceramic wear disc) assembled together.
FIGS. 3A-3C illustrate an exemplary bearing carrier 110 for use in a thrust bearing assembly of an embodiment of the present invention. As shown in FIGS. 3A and 3C , bearing carrier 110 includes a bearing carrier housing having two groups of cavities annularly disposed around the carrier. The first group faces in one direction generally along the axis of the carrier 110 , and the second group faces in generally the opposite direction along the axis. A deflection element 107 is disposed in each cavity. A pad 109 (e.g., a wear resistant insert) is disposed over each deflection element 107 . Optionally, a load distribution washer 108 is disposed between the deflection element 107 and the pad 109 . Deflection element 107 is a resilient washer, such as a Belleville washer. Load distribution washer 108 is a steel disc, for example. Pad 109 is, for example, an abrasion resistant circular pad as shown. In one embodiment, deflection element 107 , load distribution washer 108 , and pad 109 are loosely assembled within cavity 115 , are held in place by the confines of cavity 115 and by bearing runner 106 (specifically, insert 111 , if provided), and are not attached to each other.
In an aspect of the present invention, as shown in FIGS. 2B , 3 B, and 3 C, pad 109 is at least partially disposed within cavity 115 . In this manner, pad 109 is constrained radially within cavity 115 , but is still free to move axially as deflection element 107 compresses and expands. Thus, each pad 109 can float axially within its cavity 115 as bearing runner 106 rotates and contacts pads 109 . Such independent axial movement provides load equalization among the individual pads within the bearing carrier 110 .
FIG. 2D illustrates an enlarged sectional view of an exemplary thrust bearing assembly having rigidly connected opposing pads, according to a further embodiment of the present invention. As shown in this example, the assembly includes a bearing carrier 10 , a first pad 109 a disposed on a first side of bearing carrier 110 , a second pad 109 b disposed on a second side of the bearing carrier 110 opposite to the first side and rigidly connected to the first pad 109 a through an opening 199 defined in the bearing carrier 110 , and one or more deflection elements 107 disposed between pad 109 a and bearing carrier 110 and/or between pad 109 b and bearing carrier 110 . The rigid connection between pads 109 a , 109 b enables the pads 109 a , 109 b to move in unison and to maintain a constant spacing between the pads 109 a , 109 b and between adjacent runners. Pad 109 a could, for example, be on the top or downthrust side of bearing carrier 110 , with pad 109 b on the bottom or upthrust side. The pads 109 a , 109 b move relative to the bearing carrier 110 .
The rigid connection between pads 109 a , 109 b can be accomplished in a number of ways. For example, pads 109 a , 109 b can be integrally formed with an interconnecting member between them, thereby forming a unitary part. As another example, a separate member could be attached to both pads 109 a and 109 b , for example, by welding or an adhesive.
In another embodiment, the pads 109 a , 109 b are disposed in pad holders, wherein the pad holders are connected to each other. For example, as illustrated in FIG. 2D , pad 109 a can be disposed in a pad holder 112 having an integral pin portion 191 extending therefrom. As shown, the pin portion 191 extends through the opening 199 in the bearing carrier 110 . Pin portion 191 is not fixed to the bearing carrier 110 and can move within opening 199 at least in a direction generally from pad 109 a to pad 109 b (e.g., a vertical direction in FIG. 2D ). The distal end of pin portion 191 is mechanically coupled to another pad holder 113 in which pad 109 b is disposed. In this manner, pad 109 a and pad holder 112 (with integral pin portion 191 ) are rigidly connected to pad holder 113 and pad 109 b.
By providing a rigid pad-to-pad connection, the pads 109 a , 109 b move together and maintain a constant spacing among the runners and pads. This spacing minimizes shock loading when loads change across the bearing carrier, e.g., when loads change from downthrust to upthrust and vice versa. Indeed, surprisingly, the gap provided by the rigid connection dramatically reduces the negative effect of a transitional shock.
FIGS. 4A-4C illustrate an exemplary bearing runner 106 for use in a thrust bearing assembly of an embodiment of the present invention. Bearing runner 106 rotates with the drill motor shaft. As shown best in FIG. 4B , bearing runner 106 includes a bearing runner housing with wear resistant, or abrasion resistant, rings 111 that are fitted to the runner, for example, by adhesive. Optionally, rings 111 can be omitted if bearing runner 106 has integral wear resistant faces.
Although embodiments of the present invention have been described in the context of downhole drilling motors, one of ordinary skill in the art would appreciate that the thrust bearing assemblies of the present invention are equally applicable to other applications for thrust bearings, such as in rock crushing equipment. Therefore, notwithstanding the particular benefits associated with applying the present invention to drilling motors, the present invention should be considered broadly applicable to any application in need of thrust bearings.
The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed.
Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible.
Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | A thrust bearing assembly comprising a rotating bearing runner and a stationary bearing carrier, the carrier defining a plurality of thrust pad sites annularly around the carrier, with a thrust pad disposed at a site and with the carrier constraining movement of the thrust pad in a direction generally radial to the longitudinal axis of the runner while allowing the thrust pad to move in a direction generally parallel to the longitudinal axis. An embodiment comprises a rotating bearing runner having a wear resistant face and a stationary bearing carrier defining cavities disposed annularly around the carrier. A deflection element (e.g., Belleville washer) is disposed in a cavity and a pad is disposed over the deflection element. The pad is at least partially disposed within the cavity. The wear resistant face contacts the pad. Another embodiment rigidly connects pads disposed on opposite sides of a stationary bearing carrier. | 5 |
TECHNICAL FIELD
[0001] This invention relates generally to a configuration for a luminaire using LEDs.
BACKGROUND
[0002] Light emitting diodes (LEDs) offer benefits over incandescent and fluorescent lights as sources of illumination. Such benefits include high energy efficiency and longevity. To produce a given output of light, an LED consumes less electricity than an incandescent or a fluorescent light. And, on average, the LED will last longer before failing.
[0003] The level of light a typical LED outputs depends upon the amount of electrical current supplied to the LED and upon the operating temperature of the LED. That is, the intensity of light emitted by an LED changes according to electrical current and LED temperature. Operating temperature also impacts the usable lifetime of most LEDs.
[0004] As a byproduct of converting electricity into light, LEDs generate heat that can raise the operating temperature if allowed to accumulate, resulting in efficiency degradation and premature failure. The conventional technologies available for handling and removing this heat are generally limited in terms of performance and integration. For example, most heat management systems are separated from the optical systems that handle the light output by the LEDs. The lack of integration often fails to provide a desirable level of compactness or to support efficient luminaire manufacturing.
[0005] A conventional lighting system utilizes Par 38 LED, incandescent, or high intensity discharge (e.g., metal halide) based replacements lamps with a medium Edison screw base. However, the conventional lighting systems do not deliver the efficacy, field changeable beam spreads, and shielding as part of the LED lamp module itself. The conventional lighting systems are beam spread specific (like conventional Par 38 incandescent light sources) and depend on the luminaire for shielding devices.
[0006] Accordingly, to address these representative deficiencies in the art, an improved technology for managing the heat and light LEDs produce is needed. A need also exists for an integrated system that can manage heat and light in an LED-based luminaire. An additional need exists for a compact lighting system having a design supporting low-cost manufacture. A capability addressing one or more of the aforementioned needs (or some similar lacking in the field) would advance LED lighting. It is also desirable to reduce energy consumption while producing the same light output and beam spreads.
SUMMARY
[0007] Exemplary embodiments described herein attempt to reduce energy consumption without limiting the light output and beam spreads. The exemplary embodiments may be useful for retail applications where a dimmable point source illumination is beneficial and minimal degradation due to damaging ultraviolet, infrared, and heat may be important to product shelf life. The packaging of a luminaire can include optic and shielding components, a printed circuit board, thermal management, and an electrical feed for connecting the luminaire as a monopoint or track lighting fixture. The electrical feed to a line voltage or a low voltage track can allow for electrical management of LEDs to provide for an appropriate constant current of the LEDs, which can also be pulse width modulated for dimming the LEDs and lowering the electrical voltage and power required for a cooling device.
[0008] In one aspect, a luminaire housing has a light source array positioned at a first end of the luminaire housing; a cooling device for cooling the light source array, the cooling device positioned at a second end of the housing; a heat sink region disposed between the light source array and the cooling device, wherein the cooling device is configured to direct air away from the heat sink region; and a shielding device substantially surrounding the light source along an edge of the first end of the luminaire.
[0009] In another aspect, a substantially cylindrical lighting assembly has a front end and a back end. The lighting assembly also has a plurality of light emitting diodes configured to emit light from the front end; a thermal management system for cooling the light emitting diodes from the back end; a printed circuit board connected to the light emitting diodes and the thermal management system; a refractor positioned on the light emitting diodes on the front end; and a shielding component positioned on the front end of the lighting assembly.
[0010] These and other aspects, objects, and features of the invention will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of exemplary embodiments exemplifying the best mode for carrying out the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 a shows a perspective view of a luminaire according to an exemplary embodiment.
[0012] FIG. 1 b shows a rear view of a luminaire according to an exemplary embodiment.
[0013] FIG. 1 c shows a side view of a luminaire according to an exemplary embodiment.
[0014] FIG. 1 d shows a frontal view of a luminaire according to an exemplary embodiment.
[0015] FIG. 2 shows a luminaire mounted to a track according to an exemplary embodiment.
[0016] FIG. 3 shows a mounted luminaire according to an exemplary embodiment.
[0017] FIG. 4 shows a cross-sectional view of a mounted luminaire according to an exemplary embodiment.
DETAILED DESCRIPTION
[0018] The invention may be better understood by reading the following description of non-limitative, exemplary embodiments with reference to the attached drawings wherein like parts of each of the figures are identified by the same reference characters.
[0019] The term “luminaire,” as used herein, generally refers to a system for producing, controlling, and/or distributing light for illumination. A luminaire can be a system outputting or distributing light into an environment so that people can observe items in the environment. Such a system could be a complete lighting unit comprising one or more LEDs for converting electrical energy into light; sockets, connectors, or receptacles for mechanically mounting and/or electrically connecting components to the system; optical elements for distributing light; and mechanical components for supporting or attaching the luminaire. Luminaires are sometimes referred to as “lighting fixtures” or as “light fixtures.” A lighting fixture that has a socket for a light source, but no light source installed in the socket, can still be considered a luminaire. That is, a lighting system lacking some provision for full operability may still fit the definition of a luminaire.
[0020] Referring to FIGS. 1 a to 1 c, an exemplary luminaire 100 is shown. Luminaire 100 combines a printed circuit board, optic and shielding devices, and thermal management in a single unit. The outer diameter of the luminaire 100 can be approximately the same as a conventional Par 38 light source. As a result, luminaire 100 can be used in retrofitting applications, such as where track lighting is used.
[0021] Luminaire 100 has a front trim bezel 110 . Optionally, bezel 110 can be removable to allow a user to change the optics or shielding devices in luminaire 100 . The bezel 110 can be attached to the luminaire 100 using a hinge or screwing means.
[0022] The optics can be configured to target a lumen output. For example, a plurality of LEDs, e.g., 24 LEDs, can be arranged in an array to provide a particular output, such as 900 lumens, 1200 lumens, or 1800 lumens. Some desired outputs may require more thermal management than other outputs.
[0023] A refractor (not shown) may be used in front of the LEDs to blend the luminous intensity so that the luminaire does not emit light that appears as a plurality of bright points. The refractor can have collimators for each of the LEDs. For example, if there are 24 LEDs, then 24 collimators can be imbedded in the refractor. The refractor collimator can be injection molded as a single piece. As a result, a user can change a single lens, rather than a refractor and individual collimators.
[0024] Referring to FIG. 1 d, a frontal view of an array of LEDs 160 in luminaire 100 is shown. In this exemplary embodiment, luminaire 100 has an optical component comprising 24 LEDs 160 . The LEDs are coupled to a printed circuit board (PCB) (shown in FIG. 4 ). The PCB is a circular array of individual LEDs 160 arranged in three concentric circles. In this particular example, 1 watt LEDs can be used, but it is intended that any type of LED can be used. Additionally, the LEDs can be MR-16 compatible or can be configured according to another standard. Bezel 110 can be removed to access the array of LEDs 160 . A shielding component 180 is positioned in front of the LEDs 160 . The shielding component 180 can be a cross blade baffle, a snoot, or any other shielding configuration. In this exemplary embodiment, shielding component 180 is a cross blade baffle that divides the optical component into four quadrants. Each quadrant is symmetric and has six LEDs 160 .
[0025] The optical component can be formed as a single injection molded component having a plurality of individual refractors embedded in the component. Each individual refractor can encompass an LED 160 . Each refractor can envelop and control the corresponding LED.
[0026] The ability to configure the optical components also allows various beam spreads based on the distribution of the LEDs in the luminaire. For example, the luminaire can provide various beam spreads, including, but not limited to, a 10 degree, 25 degree, or 50 degree beam spread. Because a user can change the optics and shielding components, such as the refractor and the LED configuration (which may include the number and spacing of LEDs), the user can change the beam spread as well. In one example, the user may adjust the beam spread to a narrower beam, e.g., 10 degrees, as may be desired in a retail application. The beam spreads are adjusted by field changing the removable optic component and replacing it with another optic component. Each beam angle has it's own optic component, which can be custom molded to give specifically desired beam angles.
[0027] Luminaire 100 has a shielding, shown as a cross-blade baffle 280 , 380 in FIGS. 2 and 3 below. Although a cross-blade baffle is shown in the exemplary embodiment, it is not intended to be limited to that configuration and may take the form of a snoot or other shielding configuration. The shielding can be used to block a viewer's direct view of the lens. The shielding has a matte surface and attempts to limit glare from the light produced by the luminaire 100 .
[0028] Luminaire 100 has an active cooling device 120 for thermal management. Luminaire 100 also has a plurality of radial fins 130 extending from a central axis to an outer perimeter of the luminaire 100 . In order to direct air away from the heat sink, the cooling device 120 circulates air around the heat sink fins 130 in a turbulent manner that increases the efficacy of the heat sink itself by moving the boundary layer air proximate to the fins 130 . The cooling device 120 produces pulses of air that are emitted from a series of jet nozzles that are positioned optimally with regard to the fins 130 . The air passes through the fins 130 and through a plurality of openings 140 along the perimeter of the luminaire. The housing of the luminaire 100 , including the bezel 110 and the fins 130 can be constructed from a thermally-conductive, rigid material such as a metal, e.g., aluminum. At lower outputs or currents, the luminaire may be used without the active cooling device and may use passive convective cooling. For higher outputs or currents, an active cooling device may be desirable for achieving the desired lamp life.
[0029] The luminaire 100 can be configured to replicate the light output of standard incandescent, metal halide, or halogen lamps, at generally the same or lower power, but with a greater lamp life. The exemplary configuration replicates a 90 W Par 38 incandescent lamp at a certain electrical configuration, which delivers the same or more candela at approximately half the power consumption and more than ten times the life expectancy. Due to the stringent energy codes in certain regions, this reduction in power density through the use of the luminaire 100 makes it a more cost effective and, at times, regulatory compliant solution for businesses and retailers. In another electrical configuration, the luminaire can replicate a 35 W Par 30 CMH lamp, thereby delivering the same or more candela at approximately the same power and with five times the life expectancy.
[0030] The form factor of this luminaire configuration allows it to reside in a variety of track heads as well as monopoint or multiple applications. In one exemplary embodiment, the outside diameter of the luminaire matches a conventional Par 38 light source. As a result, the luminaire can be used in many track lighting applications that require a Par 38 lamp. Although the luminaire is described and illustrated as a cylindrical device in the exemplary embodiments, it is understood that this shape is merely an example and is not intended to be limited to this shape.
[0031] Referring to FIG. 2 , a luminaire 200 can be slidably mounted or clamped on a track 270 . Luminaire 200 has a cooling device 220 that, at a certain level of output or current, pulls heat away from the metal core board of a driver (not shown) positioned at the center of the heat sink and directs the air through a plurality of radial fins and out openings along the perimeter of the luminaire 200 . A bezel 210 can be removed to access and change any optical components. Luminaire 200 can also have a shielding 280 . In one exemplary embodiment, the luminaire 200 has a quick-disconnect electrical feed that attaches to a track-mounted transformer 260 positioned on track 270 . The luminaire 200 has a feed 290 that can extend from the center-rear, shown as an aperture 150 in FIG. 1 b. The feed 290 has wires that connect to a metal point or track-mounted transformer 260 and electrically coupled with a twist-and-lock or other mating apparatus.
[0032] Referring to FIG. 3 , a luminaire 300 can be mounted as an adjustable monopoint, pendant, or surface-mounted downlight with a base 360 that can attach to a ceiling, shelf, or other surface. Luminaire 300 has a cooling device 320 that, at a certain level of output or current, pulls heat away from the metal core board of a driver (not shown) positioned at the center of the heat sink and directs the air through a plurality of radial fins and out openings along the perimeter of the luminaire 300 . A bezel 310 can be removed to access and change any optical components. Luminaire 300 can also have a shielding 380 . The luminaire 300 can have a quick-disconnect electrical feed 390 that can attach to the monopoint base 360 .
[0033] Referring to FIG. 4 , a cross-section of a mounted luminaire 400 is shown. An optional cooling device 420 and a cooling device control circuit 425 , such as cooling devices and circuits provided by Nuventix, can pull heat away from a heat sink 430 . In lower power or current conditions, the luminaire 400 can use passive cooling, as active cooling by a cooling device is not required. The heat sink 430 has a hollow center 435 to allow for wiring through the heat sink 430 to the optical component. A system control circuit 445 can be positioned in a track adapter 450 and control the power for the luminaire 400 (AC to DC) as well as control the dimming for a PCB 415 and cooling device 420 . A driver can be located remotely from the heat sink, such as in a track adapter for track head installations or in a junction box for monopoint installations.
[0034] As shown above in FIG. 1 d, a plurality of LEDs 460 are coupled to PCB 415 . A bezel 410 is removably fixed to the luminaire 400 , but can be removed to access a cross blade baffle 480 , or other shielding component.
[0035] The exemplary embodiments described herein provide for an LED luminaire with a longer lamp life than a conventional incandescent lamp. Additionally, the exemplary embodiment does not include ultraviolet, infrared, or heat radiating from the beam of light. Furthermore, these embodiments reduce energy consumption while producing the same light output and beam spreads as conventional 90 Watt Par 38 lamps. These LED luminaire described herein can be useful in applications such as art and museum lighting, or other high end retail lighting where ultraviolet light can deteriorate the product that is being illuminated.
[0036] Therefore, the invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art and having the benefit of the teachings herein. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit and scope of this invention as defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention as defined by the claims below. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. | A luminaire described herein reduces energy consumption without limiting the light output and beam spreads. This configuration is useful for retail applications where a dimmable point source illumination is beneficial and minimal degradation due to damaging UV, IR, and heat may be important to product shelf life. The luminaire combines a light source, a thermal management system, a printed circuit board, and optics and shielding components in a single unit to accomplish these objectives. The substantially cylindrical lighting assembly includes a plurality of LEDs configured to emit light from a front end; a thermal management system for cooling the LEDs from a back end; a printed circuit board electrically coupled to the LEDs and the thermal management system; a refractor positioned adjacent the LEDs on the front end; and a shielding component positioned along the front end of the lighting assembly. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Provisional U.S. Patent Application No. 60/612,474 filed on Sep. 23, 2004, and incorporated herein by reference. The present application is also a Continuation-In-Part of U.S. patent application Ser. No. 11/002,102 entitled “TECHNIQUE FOR SUBWOOFER DISTANCE MEASUREMENT”, filed on Dec. 3, 2004, and incorporated herein by reference. The present application is also a Continuation-In-Part of U.S. patent application Ser. No. 11/038,577, filed on Jan. 21, 2005, and incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for automatically equalizing a home theater or other audio system. In particular, the present invention is directed toward a technique for providing continuous or active adaptation of the equalization of a home theater or other audio system.
BACKGROUND OF THE INVENTION
Home theater systems, which once were expensive luxury items, are now becoming commonplace entertainment devices. Complete Home Theater systems, known as a Home Theater In a Box (HTIB), are available to consumers at reasonable prices. However, properly setting up such Home Theater systems can sometimes be problematic for the consumer.
Home theater systems provide a number of components, which may be located in various parts of the room. The components include the home theater receiver/amplifier, front stereo speakers (left and right), rear surround sound speakers (left and right), a center speaker, and a subwoofer. Various other combinations of speakers may also be used, including additional or fewer speakers. One such home theater system is described, for example, in U.S. Pat. No. 5,930,370, issued Jul. 27, 1999 to Ruzicka, incorporated herein by reference.
FIG. 1 depicts a diagrammatic view of the home theater surround sound speaker system (the surround sound system) 10 arranged in accordance with the principles of the present invention. The surround sound system 10 includes a source of a preferably amplified stereo signal, shown in FIG. 4 as television (“TV”) set 12 . The stereo audio source may be any of a number of audio signal sources. It should, thus, be noted that the source of a stereo audio signal is represented herein as television 12 , but the audio signal source may also be a stereo receiver, a car stereo, a portable compact disk or tape player, a portable boom-box type stereo, or any other source of a stereo signal.
Television 12 outputs an amplified audio signal to interconnect module 14 via a multi-conductor cable 16 . Multi-conductor cable 16 typically includes two conductor pairs for conducting the left and right channels of the stereo signal output by television 12 to interconnect module 14 . Interconnect module 14 receives the audio signals from television 12 and assembles the component left and right channel signals for selective distribution to particular component speakers of the surround sound system 10 .
The component speakers typically include a sub-woofer 18 , which receives full range left and right signals, but only reproduces the low frequency components of the audio signal. Interconnect module 14 also outputs an audio signal to front center speaker 20 . Front center speaker 20 receives both the left and right component signals of the stereophonic signal and reproduces the (L+R) summation signal. Preferably, front center speaker 20 is located in proximity to television 12 and projects the acoustic output of the (L+R) summation signal toward the listener 28 .
Interconnect module 14 also outputs the left channel signal to left satellite speaker 22 and right channel signal to right satellite speaker 24 . Left satellite speaker 22 and right satellite speaker 24 may be relatively small speakers and need only reproduce mid range and/or high frequency signals. Left and right satellite speakers are preferably oriented so that the primary axis of radiation of the speaker points upward along a vertical axis; however, other orientations of the satellite speakers may also provide satisfactory performance. Interconnect module 14 also outputs an audio signal to rear ambience speaker 26 . Rear ambience speaker 26 typically receives an audio signal in the form of a left channel minus right channel (L−R) or a right channel minus left channel (R−L) difference signal. As will become apparent throughout this detailed description, several embodiments of the invention described herein enable interconnect module 14 to generate a variety of signals to be output to left satellite speaker 22 , right satellite speaker 24 , and/or rear ambience speaker 26 . It should be noted at the outset that the term speaker refers to a system for converting electrical input signals to acoustic output signals where the system may include one or a number of crossover networks and/or transducers.
The components described in FIG. 1 typically are arranged to optimize the surround sound effect to enhance the listening experience of the viewer 28 . The viewer 28 typically faces television 12 which has front center speaker 20 arranged in proximity to television 12 so that center speaker 20 and television 12 radiate their respective audio and video output in the general direction of viewer 28 . The left satellite speaker 22 typically is arranged to the left side of viewer 28 while right satellite speaker 24 is arranged to the right side of viewer 28 , both satellite speakers typically being located nominally midway between the viewer 28 and television 12 . Rear ambience speaker 26 , which contributes to creating a spacious audio effect, is typically located behind viewer 28 . Rear ambience speaker 26 is depicted as a single speaker, but multiple rear speakers 26 may be included in the system.
One problem with these home theater systems is in adjusting the equalization of the system to compensate for room acoustics, speaker type, and other factors. Traditionally, a consumer adjusted equalization using a so-called graphic equalizer, where a number of narrow band-pass filters are provided, each with a corresponding slide switch. The consumer adjusts each slide switch to attenuate or amplify a particular frequency band. More modern systems may use electronic displays in place of the slide switches, but the overall functionality is the same.
The purpose of an equalizer is to provide an audio response that is generally “flat” across the entire frequency spectrum. Due to limitations in system and speaker design, as well as room acoustics and interaction of room acoustics with speaker design and placement, various frequency ranges in a system may be attenuated or accentuated, resulting in a sound reproduction which is not faithful to the original recording.
A “flat” response generally refers to the resulting frequency versus amplitude graph. If the system is properly equalized, the graph should look like a flat line though all frequency ranges. In reality, this goal is never entirely achieved due to limitations of audio components and room acoustics. However, with a graphic equalizer, it is possible to improve the response considerably such that the resulting sound is a more faithful reproduction of the original sound.
The problem with manually operated graphic equalizers is that the equalization is based upon the consumer setting the various frequency levels based upon what the consumer hears and what the consumer thinks will create the proper equalization for the system. This manual solution is a largely empirical approach, as many consumers cannot properly isolate various frequencies “by ear” and understand how to adjust the equalizer properly. In addition, as the music type and sound changes, as well as the acoustic properties of the room, the equalization set at one level may be inappropriate for another audio environment.
The early graphic equalizers generally had a fixed number of equalizer circuits, each adjusting a predetermined narrow band of frequencies. However, when attempting to equalize a system, it becomes readily apparent that certain frequency ranges may require finer incremental ranges of adjustment, whereas whole bands of frequencies can be adequately adjusted using a single circuit. Proving additional equalizer filter elements and switches to solve this problem is prohibitively expensive. The parametric equalizer helps solve this problem by allowing a limited number of equalizer elements to adjust audio levels in a flexible manner. Each level adjustment may be itself adjusted to control a different frequency range.
Thus, each band-pass filter in the equalizer may be adjusted for width. Frequency ranges that require a fine granularity of adjustment may be more precisely controlled using a number of narrow-band elements in the parametric equalizer. Large frequency ranges that can be adjusted as a group can be controlled with one single wide-band element in the parametric equalizer. In this manner, the parametric equalizer can provide a more sophisticated and correct equalization to the frequency spectrum with the same number or even fewer control elements than a typical prior art fixed-frequency element graphic equalizer. Again, however, if a consumer attempts to manually control equalization, the results are often less than optimal, as the results are based upon the ability of the consumer to discern different frequency ranges.
Equalization can be achieved in software as well as in hardware. For example, when decoding a digital data stream, such as from a CD, DVD, or other digital audio source, equalization may be applied to the data as part of the decoding process or in a separate step. Thus, the process of equalization, either using a fixed-bandwidth graphic equalizer or a variable-bandwidth parametric equalizer, can be achieved in software as well as in hardware, or in a combination of both.
Other systems are known in the art wherein home theater systems, particularly more low-end units, provide a limited number of pre-set equalization patterns for different music types and listening styles. Thus, a home theater system may provide pre-set equalization levels for rock music, jazz, classical, rap, or for movie or DVD playback or the like. The equalization takes place in software within the home theater system. These pre-set levels do not take into account the room acoustics and provide only limited choices to the consumer. The consumer can only select the equalization setup that sounds best for the given circumstances. The system is not optimized for the room acoustics, speakers, and other factors affecting audio playback.
More recently, one of the more popular features for home theater systems has been some form of automatic equalization setup to minimize adverse affects of speaker/room interactions. Most solutions, however, involve a one-time setup performed by the user when installing the system and/or prior to listening to music and/or watching a video or the like. An example of such a prior art equalization system is illustrated in U.S. Pat. No. 6,721,428, issued Apr. 13, 2004 to Allred et al. and incorporated herein by reference.
These prior art automatic equalization setup systems typically have three phases. First, the system is analyzed from a single position or multiple positions in the room, usually by generating an audio signal through the speakers, and then receiving the audio signal through a remote microphone or the like to produce a system response. Second, the results of such analysis are translated to a run-time equalization setup and saved. Run-time equalization refers to the process of equalizing the audio signal during the digital decoding stage. Third, the saved settings are used by the equalizer at run-time as an additional post-processing step to whatever other audio processor software is running at the time.
Examples of such other audio processor software include Dolby™ Digital™ AC-3, Digital Theater Systems (DTS), Pulse Code Modulation (PCM), bass management, delay control or the like. These various digital audio processing algorithms are known in the art and may be licensed from their respective producers, or comparable algorithms may be devised. The equalization algorithms of the Prior Art may thus be applied subsequent to the decoding step in the playback of a digital audio stream from a DVD, CD, or other audio source. Such audio processor software may include an existing equalization algorithm, which may receive an input based upon system response in the room.
The extent to which the system can be corrected for the speaker/room acoustics is largely determined by the complexity of the run-time equalization. For many low- to mid-level systems, the run-time equalization is simply the parametric or graphic equalizer already present in the software, and thus correction possibilities may be limited. Thus, it remains a difficulty in the prior art as to how to best fit a fixed-band graphic equalizer or parametric equalizer to a predetermined frequency response.
There are a number of prior solutions to the problem of fitting a fixed-band equalizer to a predetermined frequency response. One solution is a straightforward curve-fitting. For an n-band equalizer, the algorithm finds the n highest peaks and/or valleys in the frequency response and sets each band to correct the corresponding feature. Thus, if a particular frequency range is too high, it may be attenuated, and if a particular frequency range is too low, it may be boosted.
There are at least two problems with the curve-fitting technique. Quite often the peaks found in a system response (here, the term “system response” refers to the response of the speaker and room) are at least partially due to phase-response issues, which may not respond in the desired manner to a frequency-based solution. Applying a −3 dB equalization to a 3 dB peak may not flatten the response as intended.
The “phase response” of the speaker in the room is a function of frequency and is one part of the frequency response. The other part is the magnitude response (often inaccurately called the “frequency response”), which is the power level (Y-axis, usually in dB) plotted against frequency (X-axis in Hz).
A second problem with the curve fitting technique is the limited granularity of the underlying equalizer. For run-time equalizers with a limited range of center frequencies (either a graphic equalizer or a limited-implementation of a parametric equalizer), it may not be possible to exactly “center” on the peak or valley in system response. Thus, more or less of the frequency response is affected as desired. If a −3 dB attenuation is applied to a 3 dB peak, but due to the limitations of the system, applied at a frequency slightly away from this peak, adjacent frequencies may be unnecessarily attenuated, and the desired “peak” not properly flattened.
The second problem can be at least partially offset using a brute force approach. If the equalization software was provided with an enormous number of narrow-band parametric equalization elements, then individual peaks and valleys could be selectively eliminated in the system response. However, such an approach may be processor-, memory-, and hardware-intensive.
The first problem can be resolved by using an equalizer that targets both magnitude and phase, if the system designer is not limited to the use of an existing magnitude-only equalization algorithm already present in a product.
U.S. Pat. No. 6,721,426 to Allred et al. discloses an automatic loudspeaker equalizer. First digital data is provided for a tolerance range for a target response curve of sound level versus frequency for the loudspeaker. Second digital data is generated for an actual response curve of sound level versus frequency for the loudspeaker. The first digital data is compared with the second digital data, and it is determined whether the actual response curve is within the tolerance range. If the actual response curve is not within the tolerance range, digital audio filters are iteratively generated, and the digital audio filters are applied to the second digital data to generate third digital data for a compensated response curve. The frequency, amplitude and bandwidth of the digital audio filters are automatically optimized until the compensated response curve is within the tolerance range or a predetermined limit on the number of digital audio filters has been reached, whichever occurs first.
The iterative approach of Allred improves equalization of the audio system, resulting in a flatter system response. However, the iterative approach can take considerable time to achieve. In particular, in the system of Allred, only one equalization element is adjusted with each iteration. As a result, it will take at least as many iterations as equalization elements to properly adjust all equalization elements and insure each equalization adjustment does not introduce new artifacts into the equalization. For a consumer electronic system (e.g., Home Theater system), this solution may not be acceptable, as the process may continue on for some time. The consumer may get impatient or believe the process if not functioning properly and terminate the process prior to completion.
Thus, it remains a requirement in the art to provide an equalization technique that more accurately equalizes a home theater or other audio system while using a limited number of equalization elements and/or working within the parameters of an existing equalization algorithm. It remains a further requirement in the art to provide an equalization technique that optimizes the use of equalization elements for a given audio environment. It remains a further requirement in the art to provide an equalization technique that can optimize equalization settings without requiring a large number of iterative time-consuming processes.
SUMMARY OF THE INVENTION
Rather than basing the entire equalization setup on only one pass of the analysis phase, multiple passes are executed in the equalization setup and modification of the equalization is performed after each pass of the analysis phase. This modification allows the software to modify its initial settings to compensate for the unexpected effects of the original equalization. The number of passes can vary widely, as can the equalization adjustment or setting at each step.
After an initial pass, the equalization is adjusted, as in the Prior Art, based upon the location of peaks and valleys in the system response. This initial adjustment of equalization may tend to flatten most of the peaks and valleys to produce the desired uniform linear response. However, as noted above, this inexact application of equalization corrections may introduce other artifacts into the system response and/or may not sufficiently normalize equalization.
A second pass is then performed to measure the system response using the new equalization settings. The new peaks and valleys are measured, and the equalization adjusted to try to further flatten response. Any number of subsequent passes may be made to further normalize the equalization. However, in practice, the number of passes may be limited to reduce the amount of time needed for the equalization process.
The optimal number of iterations may be a tradeoff between test time and accuracy. For the most accurate results, one equalizer band per pass may be adjusted, so the number of iterations would be at least the number of equalization bands in the system. However, such a technique may take an excessive amount of time. In the preferred embodiment, two or three (or more) equalization bands are adjusted at the same time with each pass—the number of passes equals the number of total equalization bands in the equalizer divided by the bands set per pass. Thus, for example, with a nine-band equalizer, setting three bands per pass yields three passes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the home theater surround sound speaker system in accordance with the Prior Art.
FIG. 2 is a simplified block diagram of the equalization system of the present invention.
FIG. 3 is a graph illustrating initial system response before equalization correction is applied identifying peaks and valleys in the system response.
FIG. 4 is a graph illustrating initial system response, identifying peaks for equalization adjustment and illustrating application of a proximity range to determine which peaks and valleys will be equalized in a first pass.
FIG. 5 is a graph illustrating system response after a first pass of equalization adjustment is applied.
FIG. 6 is a graph illustrating system response after a second pass of equalization adjustment is applied.
FIG. 7 is a graph illustrating how artifacts can be introduced into the system response if the proximity range is not applied.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is a simplified block diagram of the equalization system of the present invention. The apparatus of FIG. 2 may be incorporated into a Home Theater system such as that illustrated in FIG. 1 , or an other type of audio system, including but not limited to a commercial audio systems, car audio systems, home stereo systems, and the like. For the sake of clarity, various elements that are not essential to the understanding of the invention are not illustrated.
Referring to FIG. 2 , a digital signal decoder 260 may receive data from a digital signal source and decode the data accordingly. Examples of such decoders, as noted above, include Dolby™ Digital™ AC-3 decoders, Digital Theater Systems (DTS) decoders, Pulse Code Modulation (PCM) decoders, and the like. Other types of decoders, including proprietary decoding systems, may also be used. Decoder 260 receives digital data from a digital signal source. For ordinary playback of audio, this digital sound source may include digital signal source 215 which may include a CD, DVD, HDTV digital audio track, digital radio, MP-3 data stream, or other digital audio data.
For setup and testing purposes, a digital testing signal 205 may be used to generate a sound pattern for various testing and setup purposes. As set forth in co-pending applications Ser. Nos. 11/002,102 and 11/038,577 cited previously, the test signal may comprise gated nose, a Maximum Length Sequence (MLS) or the like. In some embodiments, almost any source signal may be used for calibration, testing, and setup, including digital signal source 215 .
The output of digital signal decoder 260 may be fed to equalizer 210 . As previously noted, equalizer 210 may comprise a portion of digital signal decoder 260 . Moreover, all or part of both digital signal decoder 260 and equalizer 210 may comprise software or firmware components of the system, as opposed to dedicated hardware components. Thus, equalizer 210 may comprise a run-time equalizer that is executed subsequent to the process of digital signal decoder 260 .
Equalizer 210 may be provided with equalizer coefficients 270 to adjust the amplitude of each equalizer element. If equalizer 210 comprises a parametric equalizer, then these coefficients may also include center frequency and frequency ranges for each equalizer element. When initialized, the system may default to predetermined coefficients. These coefficients may be 0 coefficients (e.g., neither amplifying or attenuating any frequency band) or some other predetermined values. To reduce the amount of time for calibration and setup, the default coefficients may be selected to represent proper equalization for a “typical” consumer setting or other area.
The system may enter an equalization setup mode automatically when first powered up, or at the direction of the consumer (e.g., through infrared remote control, on-screen menu, or the like). Once the equalization calibration process begins, the digital testing signal 205 (or other signal) is fed to digital signal decoder 260 and equalizer 210 , which outputs a decoded and equalized digital audio signal to digital to analog converter (DAC) 220 . DAC 220 may then output an audio signal that may be amplified in amplifier 225 and then be reproduced in the room by speaker 230 .
For purposes of illustration, only one speaker 230 is shown in FIG. 2 . It will be appreciated by one of ordinary skill in the art that other numbers of speakers may be used, including, but not limited to left and right front speakers, center speakers, left and right rear speakers, surround sound speakers, subwoofers, and the like. Each speaker may be tested separately or in some combination. (Tests are typically done separately, except when testing the combination of a speaker and subwoofer)
Microphone 240 receives the audio signal from the room. As set forth in co-pending applications Ser. Nos. 11/002,102 and 11/038,577 cited previously, microphone 240 might also be used for other testing purposes, such as measuring speaker location and determining time delay. Thus, the same components in the system may be used for more than one purpose in setting up the system.
The output of microphone 240 may be fed to Analog to Digital Converter (ADC) 250 that in turn outputs a digital audio signal to frequency analyzer 280 . Frequency analyzer 280 may process the digital audio signal from ADC 250 and/or compare this signal with the source digital audio signal output from equalizer 210 . The result of this analysis is output as the system response 290 . System response 290 may be kept internal to the system; however, in some embodiments, system response 290 may be displayed on an on-screen display, LCD display or the like so that the consumer can better understand the process and view the results of the setup and calibration procedure.
As will be discussed in more detail in connection with FIGS. 3-5 , the system response may be analyzed by the system to determine which frequencies should be attenuated and which accentuated. The results of these decisions are used to alter the equalizer coefficients 270 .
After an initial system response 290 has been determined, equalizer coefficients 270 may be adjusted and the process repeated. If individual elements of equalizer 270 are adjusted one at a time, it may take a large number of repeated processes to properly calibrate equalizer 270 . Moreover, if the number of processes is limited (due to testing time considerations), the resulting calibration may not be optimal. Thus, for example, if there are seven elements in equalizer 270 , and seven processes are repeated, one for each equalizer element, then each element is adjusted only once.
In the present invention, a multiple number of equalizer elements may be adjusted in one process, and thus the overall testing time may be limited, while enhancing the adjustment of the equalizer elements. The optimal number of iterations may be a tradeoff between test time and accuracy. In the preferred embodiment, two or three (or more) equalization bands are adjusted at the same time with each pass—the number of passes equals the number of total equalization bands in the equalizer divided by the bands set per pass. Thus, for example with a nine-band equalizer, setting three bands per pass yields three passes.
In addition, each band can be re-adjusted to compensate for the subsequent adjustment of other adjacent bands. Thus, an equalizer band may be initially adjusted, the results tested, and the band adjustment then fine-tuned to improve the overall system response. Additionally, in the preferred embodiment a proximity range may be applied to the initial peaks to be adjusted, such that adjacent or proximal bands of the equalizer are not adjusted simultaneously, resulting in artifacts in the resultant system response.
Rather than basing the entire EQ setup on only one pass of the analysis phase, multiple analysis phases are executed with EQ setup and modification occurring after each analysis phase. This allows the software to modify its initial settings to compensate for unexpected effects of the original equalization. The number of passes can vary widely, as can the EQ adjustment or setting at each step. For example, one extreme might be:
Do (number of bands)
{
Analyze
Set one EQ band
While(unsatisfied)
{
Analyze
Tweak EQ band
}
}
At the other extreme:
Analyze Set all EQ bands Analyze Tweak all EQ bands
Or
Analyze Set half the EQ bands Analyze Set the other half
Additionally, when setting a plurality of bands at one time, it may be beneficial to ensure that those bands are orthogonal so that they do not affect each other. FIG. 3 is a graph illustrating an example of initial system response before equalization correction is applied. The X-axis represents frequency, on a logarithmic scale, while the Y-axis represents relative amplitude in dB. As previously discussed, an ideal system response may comprise a flat line at the 0 dB level, indicating that each frequency in the spectrum is reproduced faithfully and at the same level relative to all other frequencies in the spectrum.
As illustrated in the example system response of FIG. 3 , the overall response is anything but “flat”. Several peaks occur at different frequencies, representing frequencies that are overly amplified. Several valleys are illustrated that represent frequencies that are overly attenuated. In this example, major peaks 430 , 450 and 480 are located at approximately 100 Hz, 150 Hz, and 1500 Hz, respectively. Significant valleys 470 and 490 are present at approximately 600 Hz and 4000 Hz, respectively. The rest of the spectrum is relatively flat, or outside the range of human hearing or system (particularly speaker) range.
FIG. 4 is a graph illustrating initial system response, identifying peaks for equalization adjustment and illustrating peak width measurement as well as the proximity range applied in the present invention. In this example, when setting two bands between analysis phases, the first can be anywhere in the spectrum, but the second should be limited to anywhere in the spectrum except within a specified distance of the center frequency of the first, in order to prevent interference between the two corrections. Given the spectrum in FIGS. 3 and 4 , the first large peak 430 may be targeted at 100 Hz with the first equalizer band, but selection for the second band would ignore the next peak 450 at 150 Hz because of its “close” proximity to the 100 Hz peak 430 .
In this embodiment, a predetermined proximity range may be selected, for example, as four times (4×) the bandwidth of the first peak 430 . This range is represented in FIG. 4 by solid lines 410 and 460 . The bandwidth of the first peak 430 is illustrated by solid lines 420 and 440 . Bandwidth of a peak, such as peak 430 , may be determined by the width of the peak at a particular predetermined dB cutoff level such as −3 dB from the peak, or by the width at a particular percentage of the peak (in this example 70%, or 4 dB).
As second peak 450 is within the 4× range lines 410 and 460 , for the first adjustment of equalizer coefficients 270 , peak 450 will be ignored. Instead, the second equalizer band may target one of the smaller valleys 470 , 490 or the peak 480 . The use of the 4× proximity range prevents the adjustment of adjacent equalizer bands from interfering with each other and producing unexpected or undesirable results. Using this technique, each equalizer element can be adjusted once and still provide a reasonable equalization. Since more than one equalization element is adjusted during each stage, the overall numbers of cycles in the process is reduced.
In this example, a 4× proximity range is utilized. However, other ranges may be used within the spirit and scope of the present invention. For example, the proximity range may be selected as a logarithmic scale based upon peak (or valley) center frequency. Alternately, a fixed proximity range or selected one of a number of fixed proximity ranges may be used. The proximity range can also be determined based upon peak (or valley) amplitude or other indicia. The main feature of the proximity range is to prevent one equalization adjustment from altering or affecting an adjacent equalization adjustment.
In a subsequent cycle, peak 450 may be used to adjust another equalizer band to eliminate this peak. In each subsequent cycle, one or more equalizer elements may be adjusted until all the equalizer bands are optimized for the best system response (e.g., flat response or some other desirable response). In an alternative embodiment, the process may be repeated to fine-tune the equalizer band elements to provide an even better overall system response.
FIG. 5 is a graph illustrating system response after equalization is applied. As illustrated in FIG. 5 , peaks 430 and 480 have been largely attenuated, such that the overall system response is closer to the desirable flat response (in this example). Peak 450 and valleys 470 and 490 may be corrected in a subsequent cycle, provided they are not within the designated proximity range of one another. In this manner, more than one peak or valley may be corrected per cycle, without the corrections interfering with each other or otherwise creating new artifacts in the system response.
FIG. 6 is a graph illustrating system response after a second pass of equalization adjustment is applied. In this example, after peaks 430 and 480 have been attenuated in a first round of adjustment of equalization coefficients, a second round of testing and adjustment may be performed. In this example, only peak 450 is eliminated though adjustment of the equalizer coefficients. Valleys 470 and 490 are left for a subsequent adjustment cycle or cycles.
FIG. 7 is a graph illustrating how artifacts can be introduced into the system response if the proximity range is not applied. In FIG. 5 , the new extent of peak 450 after the first pass of equalization has been applied is illustrated. In FIGS. 3 and 4 , this peak is higher. If the proximity range were not applied in the first cycle of adjustment, and the system attempted to adjust equalizer coefficients 270 for the two adjacent peaks 430 and 450 , the net effect would be to over-attenuate peak 450 , resulting in a new valley 750 . Thus, a new valley is created, and the system will have to be “tweaked” further to eliminate this artifact.
While the present invention may be implemented in a number of embodiments, a number of fundamental features are present in one or more of these embodiments. Adjusting multiple equalizer bands during one process cycle is one feature of the present invention. In addition, the use of the proximity range to determine which frequency ranges, which may be adjusted in one cycle without causing adjacent equalizer band interference, is another feature. The use of multiple cycles of the calibration process to fine-tune the equalizer coefficients is yet another feature of the present invention. There are other features of the present invention that may be used alone or in combination with any of the aforementioned features of the present invention.
Note that multiple proximity ranges can be applied in each pass. Thus, in the example of FIG. 4 , a second proximity range could be applied to peak 480 . This second proximity range, may, for example, indicate that valleys 470 and 490 are not to be compensated in this pass, as they are within 4× the bandwidth (or other criteria) of peak 480 . Thus, valleys 470 and 490 would not be corrected until a subsequent pass, as is illustrated in the Example of FIG. 4 . The number of proximity ranges used in a given pass can vary and the width or formula used to determine the proximity range size can also be varied as previously noted.
While the preferred embodiment and various alternative embodiments of the invention have been disclosed and described in detail herein, it may be apparent to those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope thereof. | Multiple passes are executed in the setup of an equalizer, and modification of the equalization is performed after each pass of an analysis phase. After an initial pass, the equalization is adjusted, based upon the location of peaks and valleys in the system response. This initial adjustment of equalization may tend to flatten most of the peaks and valleys to produce the desired uniform linear response. Inexact application of equalization corrections may introduce other artifacts into the system response and/or may not sufficiently normalize equalization. A second pass is then performed to measure the system response using the new equalization settings. The new peaks and valleys are measured, and the equalization adjusted to try to flatten response further. A proximity range may be applied to each pass, to reduce the likelihood that adjustment of one equalizer coefficient will create artifacts in the resulting system response. | 7 |
This application claims priority under 35 USC § 119(e)(1) of provisional application No. 60/033,690 filed Dec. 19, 1996.
TECHNICAL FIELD OF THE INVENTION
The present invention pertains in general to protection circuitry and, more particularly, to a clamp circuit that can be utilized between the gate and drain or between the gate and source of an external power MOS transistor.
BACKGROUND OF THE INVENTION
In power applications involving an integrated circuit control element, an inductive load is typically driven by a power field effect transistor (FET). When the transistor is turned off, the inductive load will have a fly-back voltage associated therewith due to the inductive storage of energy therein. This fly-back will cause the voltage on the drain of an N-channel FET utilized for the driving element to rise to a relatively high level. These FETs can be damaged by flyback-induced voltage excursions that rise to a level above the junction breakdown of the FET.
In order to protect the FET, a clamp circuit is typically connected between the drain and gate of the FET. When the voltage on the drain of the FET rises to a sufficiently high level, current will conduct through the clamp, pulling the gate of the FET high and turning on the FET, this effectively preventing the fly-back voltage from pulling the drain above the clamp voltage. These clamp circuits utilized in the prior art circuits consisted of a series of zener diodes, each having a breakdown voltage that, when added together, comprise the overall threshold voltage for the clamp.
One disadvantage to prior art clamp circuits is the current level that must be accommodated by the clamp. Whenever the fly-back voltage pulls the drain of the FET high, current will flow from the drain to the gate, some passing through the driving circuit that drives the FET. This is a finite amount of current, which can be sufficiently high to require relatively robust components in the clamp. However, the design of a clamp circuit that will accommodate the necessary levels current require relatively large devices. This can become a disadvantage in that the clamp circuits are typically incorporated into the integrated circuit output that drives the FET.
SUMMARY OF THE INVENTION
The present invention disclosed and claimed herein comprises a clamp circuit for being disposed between the gate and one of the source/drain terminals of an external power transistor. The clamp circuit is operable to prevent a large voltage from being impressed across the gate oxide of the external transistor. The clamp circuit includes a threshold device having a high voltage side and a low voltage side for conducting current between the gate and the one of the source/drain terminals of the external transistor when the voltage thereacross exceeds a first threshold voltage. A current bypass device is associated with the threshold device for bypassing a portion of the current from the high voltage side to the low voltage side of the threshold device. This current bypass circuit is operable whenever the current through the threshold device exceeds a predetermined bypass current threshold.
In a further aspect of the present invention, the clamp circuit includes a blocking diode disposed in series with the threshold device to block current from passing from the low voltage side to the high voltage side of the threshold device. The threshold device includes one or more zener diodes oriented with the cathode thereof directed toward the high voltage side and the anodes thereof directed toward the low voltage side.
In a yet further aspect of the present invention, the current bypass circuit consists of a bypass transistor with the source/drain path thereof connected between the high voltage and low voltage sides of the threshold device. The gate of the bypass transistor is controlled by a gate control device that turns on the bypass transistor whenever the current to the threshold device exceeds the first threshold voltage. This gate control circuit is comprised of a resistor disposed in series with the threshold device, such that when the voltage thereacross rises above the threshold voltage of the transistor, the transistor conducts.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which:
FIG. 1 illustrates a prior art drain-to-gate clamp;
FIG. 2 illustrates a prior art gate-to-source clamp;
FIG. 3 illustrates the embodiment of the drain-to-gate clamp of the present invention;
FIG. 4 illustrates an alternate embodiment of the drain-to-gate clamp of the present invention;
FIG. 5 illustrates a schematic diagram of the gate-to-source clamp of the present invention; and
FIG. 6 illustrates one application of the drain-to-gate clamp and the gate-to-source clamp.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is illustrated a schematic diagram of a prior art drain-to-gate clamp. An integrated circuit is defined on one side of a phantom line 10, for driving an external power FET 12 through an output terminal 14, which output terminal 14 is connected to the gate of the FET 12. The drain of the FET 12 is connected to a node 16 and the source thereof is connected to ground. The node 16 is operable to drive one side of a load inductance 18, the other side of the load inductance 18 connected to a battery terminal 20.
The output terminal 14 is driven by a driver circuit 22. The driver circuit 22 is provided with two current sources, a first current source 24 for driving current to the output terminal 14 from a positive supply rail 26, which positive supply rail 26 is an internal power supply separate from the battery terminal 20, and a second current source 28 for sinking current from the output terminal 14. The driving circuit 22 receives an input signal on an input 30, which input signal has a high logic state and a low logic state. In the high logic state, the current source 28 is turned on and in the low logic state, the current source 24 is turned on. This driver circuit 22 is a conventional driver circuit.
The prior art clamp circuit is disposed between the output of the driver 22 and the output node 16, the output node 16 connected to an output terminal 32. The clamp is comprised of three zener diodes 34, 36 and 38, each having the cathodes thereof oriented toward the node 16, with the cathode of zener diode 36 connected to the anode of zener diode 34 and the cathode of zener diode 38 connected to the anode of zener diode 36. The cathode of zener diode 34 is connected to one side of a limit resistor 40, the other side thereof connected to the output terminal 32. The anode of zener diode 38 is connected to the anode of a Schottky diode 42, the cathode thereof connected to the output of driver 22.
In operation, when the voltage on node 16 rises to a level that exceeds the sum of the zener breakdown voltage of the zener diodes 34-38, current will flow through these diodes. This, of course, will forward bias diode 42. The limit resistor 40 provides some limitation on the current that can pass through the diodes 34-38 and the Schottky diode 42. However, it is noted that, when the FET 12 is turned off, current source 28 is turned on. This results in current path to ground from the output terminal 14. The current will pass through the diodes 34, 36, 38 and 42. Therefore, the diodes must be of sufficient size to handle this level of current.
Referring now to FIG. 2, there is illustrated a schematic of a prior art gate-to-source clamp. In this configuration, the output terminal 14 is illustrated as being driven by a current source 48, which is connected between the battery terminal 20 and the output terminal 14. In order to protect the gate of the transistor 14 from being pulled high in what is referred to as a "double battery condition", a zener diode 50 is connected between the output terminal 14 and ground, with the cathode of diode 50 connected to the output terminal 14. Therefore, the current through current source 48 will pass through zener diode 50. Again, the zener diode 50 must be of sufficient size to accommodate the current from the current source 48.
Referring now to FIG. 3, there is illustrated a schematic diagram of the drain-to-gate clamp of the present invention for one embodiment thereof, the FET 12 illustrated in phantom. The clamp utilizes the limit resistor 40, the zener diodes 34-38 and the Schottky diode 42, with the exception that they can be sized differently with respect to their power handling capability, as will be described hereinbelow. The cathode of the Schottky diode 42 is connected to a node 54, node 54 connected to one side of a resistor 56, the other side thereof connected to the output terminal 14. An N-channel transistor 58 has the gate thereof connected to the node 54, the source thereof connected to the output terminal 14 and the drain thereof connected to a node 60. The transistor 58 is oriented such that the body effect diode 61 is oriented with the cathode thereof connected to node 60 and the anode thereof connected to output terminal 14. Additionally, a drain-to-substrate diode 62 is formed with the cathode thereof connected to the node 60 and the anode thereof connected to the substrate. A Schottky diode 64 is connected between the drain output terminal 32 and the node 60, with the anode thereof connected to the drain output terminal 32 and the cathode thereof connected to the node 60.
In operation, the drain-to-gate clamp of FIG. 3 operates to bypass the zener diodes 34-38 and the Schottky diode 42 whenever the current through resistor 56 exceeds the V T voltage of the transistor 58. Transistor 58 will then turn on and current will pass through transistor 58. The portion of the current passing through transistor 58 is a function of the size of the resistor 56. The Schottky diode 64 is necessary to prevent the body diode 61 of transistor 58 from becoming forward biased during the normal "on" state of the external FET 12. Although not illustrated, this Schottky diode 64 could be directly incorporated into the transistor 58 by removing the drain NSD implant.
Referring now to FIG. 4, there is illustrated an alternate embodiment of the drain-to-gate clamp of FIG. 3, with the resistor 56 replaced by a current mirror. The current mirror is comprised of an N-channel transistor 66, having the source thereof connected to the output terminal 14, the drain thereof connected to the node 54 and the gate thereof connected to the gate of an N-channel transistor 68. Transistor 68 has the drain thereof connected to the gate and the source thereof connected to the output terminal 14. The source of transistor 68 is connected to the node 14, with the drain thereof connected to the output of a current source 72. This current source presents a fairly large impedance which will function substantially similar to the resistor 56.
Referring now to FIG. 5, there is illustrated a schematic diagram of a gate-to-source clamp in accordance with the present invention. The clamp is comprised of two zener diodes 74 and 76, with the anode of zener diode 74 connected to the cathode of zener diode 76. The anode of zener diode 76 is connected to a node 78 and the cathode of the zener diode 74 is connected to the cathode of a Schottky diode 80, the anode thereof connected to the output terminal 14. The node 78 is connected to one side of a resistor 82, the other side thereof connected to ground. An N-channel transistor 84 has the gate thereof connected to the node 78, the source thereof connected to ground and the drain thereof connected to the output terminal 14. A body effect diode 86 is associated with transistor 84 and oriented such that the anode thereof is connected to ground and the cathode thereof is connected to the output terminal 14. A drain-to-substrate diode 88 is connected between output terminal 14 and the substrate in association with the transistor 84 with the cathode thereof connected to the node 14.
In operation, the gate-to-source clamp will be non-conductive as long as the voltage is less than the combined zener breakdown voltages of the two zener diodes 74 and 76. When the voltage exceeds the sum of these two zener breakdown voltages, the diode 80 will conduct and pass current through the resistor 82. When the voltage across the resistor 82 equals or exceeds the V T threshold voltage of transistor 84, transistor 84 turns on and pulls current from node 14, bypassing diode 74 and 76. This, therefore, allows lower power diodes to be incorporated therein.
Referring now to FIG. 6, there is illustrated a block diagram of one application of the clamping circuits of the present invention. The transistor is configured such that, internal to the integrated circuit, a drain/gate clamp 90 is connected between the drain of transistor 12 and the gate thereof. A gate/source clamp 92 is connected between the gate and source of transistor 12. The drain/gate clamp 90 is similar as that described above with respect to FIGS. 3 and 4 and the gate/source clamp is that as described above with respect to FIG. 5.
Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | An external FET (12) has protection provided thereto for excessive voltages between the gate and drain and between the gate and source. A drain-to-gate clamp is provided with a plurality of series connected zener diodes (34), (36) and (38) which are connected in series with a Schottky diode (42). The current therethrough is sensed with a resistor (56) which turns on a bypass transistor (58) to shunt current around the zener diodes when an excess voltage causes them to break down. This will turn on the FET (12). The gate-to-source clamp is configured with two zener diodes (74) and (76) which are reversed biased. A series current sense resistor (82) senses the current through the diodes and turns on a transistor (84) when the current exceeds a predetermined level. This will effectively shunt current around the zener diodes (74) and (76). | 7 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.