description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
This invention relates to a deburring tool and more particularly a tool for machining the opening rims of bores which embodies a shaft and a cutter that radially protrudes from the shaft. In the deburring tool art it is known to provide a cutter body having a rockable cutter therein which is spring urged outwardly so as to protrude from a slot in the tool body. Such a type of tool is shown in U.S. Pat. No. 2,895,356. Another form of deburring tool that is known in the art and one which has diametrically opposed cutters is shown, for example, in U.S. Pat. No. 3,661,473. In this type of tool the tool part is longitudinally slit so that the cutting portions which are generally made part of the outer end of the tool may have some outward resiliency due to the spring action of the resulting fork-like end. It has been found that there are some difficulties with the first type of device particularly since it is relatively complicated and difficult to manufacture and further the recess in the shaft which receives the cutter and the pivoting shaft or axle upon which the cutter must rotate become difficult to manufacture and replacement of a worn cutter is complicated. In the second form of known deburring type tools the tool is suitable only for relatively small bore diameters since the resilient parts of the shaft formed by the fork or longitudinal slot structure tend to set up vibrations, and if strengthening is provided, then the two portions are not adequately resilient. Further since the cutting blades are integral with the head end of the tool and the fork limbs, there is no interchangeability of cutting edges and the tool body must effectively be re-ground when there is difficulty experienced. The instant invention provides a simpler tool which obviates the aforementioned difficulties and which is particularly suitable for large bore diameters.
SUMMARY OF THE INVENTION
The instant invention provides a deburring tool in which the cutter body protrudes from a diametric guide slot in the body and comprises a pair of cutter blades which are radially displaceable and are urged outwardly by a spring means which, for example, can be a simple helical compression spring. The guidance of the cutter body can be kept relatively simple by utilizing a four-cornered or alternately a cylindrical body in order to retain firm retention of the cutter body within the tool body itself, and in this way vibrations of the cutter are completely avoided, and further large forces can be exerted by the tool and exchangeability of worn cutters is readily provided.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the tool made in accordance with the invention;
FIG. 2 is a partial sectional view of the tool of the invention taken from the top thereof;
FIG. 3 is a sectional view taken on lines 3--3 of FIG. 2; and
FIG. 4 is a sectional view of a modified form of tool made in accordance with the invention taken in the same position as the showing of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The deburring tool comprises a shaft 11 which has formed at the end thereof a guide slot 12. Adjacent to the guide slot 12 from opposite ends thereof and bores 13, 13' so that there is an opening between these bores and the guide slot 12. At the bottom of each of the bores 13 is a smaller threaded bore 14, 14' which is adapted to receive a headed screw with a threaded stem which screw is designated 15 and 15'. The heads of these screws protrude laterally through the opening into the guide slot 12 for a purpose which will presently be described. Each of the screws 15 particularly the threaded shanks thereof are adapted to be locked in place by a deformable pressure pad 17, 17' and a set screw 16, 16' which are located in bores that intersect the threaded bores 14, 14'.
Two cutter blades with a cross section adapted to the shape of the guide slot 12 and designated 18 and 18' are provided with a groove respectively 19 and 19' which has an end wall 20 and 20' respectively. By referring to FIG. 3 it will be seen that the arrangement is such that when the cutter blades are properly inserted into their respective guide slots that the head of the set screw engages in the grooves 19 and 19' and the underside of these set screw heads 15 will abut the walls 20 and 20' respectively. This means that the set screw heads 15 and 15' limit the amount of outward radial movement of the cutter blades which are urged in a radially outward direction by a spring 21.
As will be seen by referring to FIG. 1, the guide slot 12 opens to the face 11' of the shaft 11. It will be apparent that the cutter blades 18, 18' may be arranged in the guide slot 12 through the end face 11' of the shaft 11 along with the spring means 21. In this position when the parts are properly assembled and the set screws 15, 15' are in place, a cover plate 22 may be placed over the end 11' of the shaft 11 and fastened into place by fastening screws 23. The cover plate 22 together with the guide slot 12 forms a complete guide recess for the cutter blades 18, 18'. As will be seen particularly by referring to FIG. 2, the cutter blades are preferably formed with a pair of cutting edges 24, 25 at the protruding ends of the bodies thereof, and these edges are inclined or at an angle to the general longitudinal extent of the cutter blades.
Surrounding the shaft 11 is a bushing 26 which is preferably made of a soft material such as bronze, and this bushing is secured to the shaft by a threaded ring 27 which is received on the threads 28 of the shaft 11. The threaded ring 27 may be secured from rotation about the threads by means of a set screw 29, and a soft pressure pad 30.
The deburring tool may be employed for entrance and exit deburring of bores. For this purpose the shaft 11 may be suitably clamped into a driving machine (not shown) which will effect the advance of the tool in one or the other of the axial directions of the shaft 11 and will further rotate the shaft 11. During a forward advance to the left as seen in the drawings, the cutter blades 18, 18' by their cutting edges 25, 25' will impact against the forward opening rim of the workpiece bore and deburr it as the shaft 11 rotates. It will be noted that the cutting edges 25, 25' are inclined against the direction of advance, and therefore, during further advance the pressure against these edges will be sufficient to force the cutter blades inwardly against the force of the spring 21 until the tool slides into the workpiece bore. The tool will thereupon traverse the workpiece bore and since the cutter blades are provided with rounded off end faces as at 31, 31' (see FIG. 3), they will merely rest under the pressure of the spring 21 against the inside of the workpiece bore without processing the same or in any way bothering the machine finish created therein. At the end of the workpiece bore with continued advance the cutter blades will again spring out of the recess 12 to the limit as adjusted by the heads 15, 15' of the set screws. In this way during the reverse run of the tool to the right as seen in the drawing, the cutting edges 24, 24' will engage the exit end of the workpiece bore and deburr the same.
It will be apparent that by merely removing the cover plate 22 the cutter blades 18, 18' can be exchanged and replaced or different length cutter blades may be inserted therein for deburring larger bore diameters. In the case of larger bore diameters the guide bushing 26 would also be removed and replaced with a larger bushing which corresponds to the larger workpiece bore diameter to be processed.
Referring to FIG. 4 there is shown in a sectional view a modified form of tool from that illustrated in the previous figures. In this case the shaft 11a has a guide slot 12a formed at the end thereof opening outwardly to the end face of the shaft, as in the previous embodiments, and has provision for a cover plate, such as 22, being secured thereon by fasteners received in the threaded holes 35. A pair of recesses 37, 38 open to the bottom wall 36 of slot 12a and aligned with the central section of the recesses and below the bottom wall 36, are a pair of threaded bores 14a. In the threaded bores 14a is received a screw 15a and located within the recesses 37, 38 are spring means 21a. The two cutter blades which are received in the slot 12a and which are designated 18a, each have protruding therefrom a stud 39 and, as will be seen by referring to FIG. 4, the spring means 21a bear against one end of the wall of the recesses 37, 38 and also against the stud 39 located on each of the cutter blades 18a. The spring forces each of the cutter blades radially outward to a position limited by the stud 39 engaging the screw 15a. It will thus be seen that this arrangement operates in exactly the same fashion as the arrangement disclosed above, the deburring tools being resiliently held radially outward against the stop means by spring means. | A cylindrical deburring tool is provided with a diametric guide slot extending through the body with a pair of cutter blades received in said guide slot for radial displacement therein and spring-biased apart to a position determined by an adjustable abutment means acting on each blade. | 8 |
BACKGROUND
The present disclosure relates to heating and cooling apparatus in general, and in particular, to a system that provides a heating or cooling “buffer” between a relatively continuous source of cooling or heating and an intermittent load (a user) of the heating or cooling.
Certain aircraft payloads, including directed energy weapons (DEWs), e.g., laser weapons, require substantial cooling at the lowest possible weight for sustained operation. This operation typically consists of relatively brief operating intervals, wherein relatively large “bursts” of cooling are required, interspersed with relatively long intervals in which the weapon is quiescent, and therefore, requires little or no cooling.
In one effort to address such cooling demands, so-called “Phase Change Heat Exchangers”PCHEXs) have been developed, such as are described in U.S. Pat. No. 7,106,777 to A. Delgado, Jr. et al., incorporated herein by reference, which enable the storage of cooling capacity in the form of solidified Phase Change Materials (PCMs). FIG. 1 is a functional block diagram of an existing PCHEX-cooled DEW system 100 that includes a Chemical Oxygen Iodine Laser (COIL) 102 , shown to the right of the dashed line 101 . In this DEW system, two fluids A and B, are supplied to a singlet oxygen generator 104 , where they react to form an excited oxygen in a metastable state. The excited oxygen is fed from the generator into a laser nozzle 106 , where it is reacted with two additional fluids C and D to effect lasing in a resonant cavity of the laser 102 and thereby produce a high energy beam of laser light 108 from the laser. Depleted laser fluids 110 are exhausted through a diffuser of the laser, and an un-reacted portion of the fluid A, which is heated by the reaction in the oxygen generator 104 and thus acts as a coolant fluid, is recirculated through a conditioner 112 and a PCHEX 114 for thermal conditioning, i.e., cooling. The cooled, reconditioned fluid A is then returned to the oxygen generator 104 .
The PCHEX 114 of the system shown to the left of the dashed line 101 includes conduits 116 that pass through a “foam” matrix, e.g., an expanded metal or ceramic matrix, having a PCM material, e.g., a paraffin wax, water/ice or eutectic solutions, disposed in the interstices thereof. When the heated reaction fluid A passes through the conduits, heat is transferred from the fluid to the PCM, thereby cooling the fluid and causing the PCM to melt, i.e., to change phase, at a relatively constant temperature. When substantially all of the PCM is melted, the cooling capacity of the PCHEX is deemed to be exhausted, and the PCM must then be cooled, e.g., by refrigerating the PCHEX, to a temperature below the PCM's melting point and causing the PCM to solidify before the PCHEX can be reused. Cooling to the PCHEX 114 is provided through same conduits 116 used for cooling of reaction fluid A.
The existing DEW heating/cooling solutions thus include:
1) Conventional refrigeration systems (e.g., Freon compression/expansion systems) that cool the system using electricity as the power source;
2) “Phase change” approaches, such as that described above and illustrated in FIG. 1 , which use a PCM material, such as ice, that melts to provide cooling, and in which the PCM is regenerated “offline”; and,
3) Multiple PCHEX units that are used sequentially, which effect the discharging of one unit while one or more additional exhausted units are being charged for re-use.
The foregoing approaches are all relatively heavy and/or do not provide optimal operational flexibility. For example, the existing PCHEX system described above charges and discharges through the same passageways, which in general, not only lacks a desired flexibility, but also prevents the use of different fluids for the two services. The latter drawback is a relatively important one for laser weapons, wherein the major coolant use is for laser diodes, in which water is used almost exclusively as the cooling medium of choice, whereas, the formation of ice requires the use of a material (e.g., a glycol solution) for cooling of the PCHEX that will remain a liquid below the freezing point of water. Additionally, these devices operate in either a “charge” mode (i.e., freezing the PCM using an external refrigeration system) or a “discharge” mode (i.e., thawing the PCM to cool the circulating DEW coolant).
Thus, while such systems are capable of performing the necessary cooling task satisfactorily, a strong need nevertheless exists for a more efficient, more operationally flexible, lower weight, higher capacity cooling system that has the ability to charge and discharge simultaneously, so that the DEW can operate in relatively large intermittent bursts but remain ready for further use as the PCHEX or other thermal storage method is recharged.
SUMMARY
In accordance with the present disclosure, a novel thermal buffer cooling system is provided for an intermittent, high-demand cooling load that is more efficient, lower in weight and higher in capacity than existing heating/cooling systems, and that has the ability to charge and discharge simultaneously, so that the cooling load can operate in intermittent, high-demand bursts and still remain ready for further use as the PCHEX or other thermal storage method is recharged on a relatively continuous but low-level basis.
In one exemplary embodiment, a thermal buffer for an intermittent thermal load, e.g., a directed energy weapon (DEW) system, includes a phase change heat exchanger (PCHEX), an apparatus for circulating a first working fluid of the thermal load through first conduits of the PCHEX cell in a first direction, such that heat is transferred between the first fluid and a PCM of the PCHEX in a second direction and causes a first phase change in the PCM, and an apparatus for circulating a second working fluid of a heat pump through second conduits of the PCHEX in a third direction opposite to the first direction, such that heat is transferred between the second fluid and the PCM in a fourth direction opposite to the second direction and results in a second phase change in the PCM opposite to the first phase change therein.
In another exemplary embodiment, a phase change heat exchanger (PCHEX) cell for a thermal buffer system comprises a plurality of generally parallel first and second conduits extending through a sealed housing and arranged in an alternating manner. Each of the conduits has opposite inlet and outlet ends. The inlet ends of the first conduits are disposed at an opposite end of the housing from the inlet ends of the second conduits. First and second headers are respectively coupled to the respective inlet ends of the first and second conduits. Each header has a fluid inlet and is disposed at an opposite end of the housing from the other header. First and second collectors are respectively coupled to the respective outlet ends of the first and second conduits. Each collector has a fluid outlet and is disposed at an opposite end of the housing from the other header. A thermally conductive matrix is disposed within the housing and between the conduits. The matrix is thermally coupled to exterior walls of the conduits and defines a plurality of interstitial voids therein. A phase change material (PCM) is disposed within and substantially fills the interstitial voids of the matrix.
A better understanding of the above and many other features and advantages of the novel heating and cooling system of the present disclosure may be obtained from a consideration of the detailed description of some exemplary embodiments thereof below, particular if such consideration is made in conjunction with the appended drawings, wherein like reference numbers are used to refer to like elements in the respective figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is functional block diagram of a DEW system incorporating a conventional PCHEX cooling system;
FIG. 2 is a functional block diagram of a DEW system incorporating an exemplary embodiment of a PCHEX thermal buffer cooling system in accordance with the present disclosure; and,
FIG. 3 is a schematic cross-sectional view of an exemplary embodiment of a PCHEX of the exemplary thermal buffer system.
DETAILED DESCRIPTION
In accordance with the present disclosure, a thermal buffer PCHEX cooling system provides intermittent bursts of cooling (or heating) to a load repetitively while being re-charged relatively continuously with the heat or cooling that is delivered. These two functions can occur synchronously or asynchronously and without interfering with each other.
FIG. 2 is a functional block diagram of a DEW system 200 incorporating an exemplary embodiment of a PCHEX thermal buffer cooling system 202 in accordance with the present disclosure, and FIG. 3 is a schematic cross-sectional view of an exemplary embodiment of a PCHEX 204 of the thermal buffer system 202 . As may be seen by reference to FIG. 2 , the portion of the DEW system to the right of the dashed line 201 comprises a COIL laser 102 and associated singlet oxygen generator 104 substantially similar to that described above and illustrated in FIG. 1 . However, it should be understood that the novel thermal buffer PCHEX system 200 of the present disclosure is not limited to such COIL DEW systems, but can be advantageously employed in other types of DEW systems, e.g., laser diode-driven DEWs, or indeed, in any thermodynamic system in which intermittent heating or cooling “burst” demands need to be met.
The thermal buffer system 202 shown to the left of the dashed line 201 of FIG. 2 comprises a PCHEX heat exchanger 204 described in more detail below, coupled to a conventional refrigeration unit, heating unit or a combination, reversible heating and cooling unit often referred to as a “heat pump” 206 . FIG. 3 is a schematic cross-sectional view of the exemplary PCHEX 204 of the system.
With reference to FIG. 3 , the exemplary PCHEX 204 comprises a plurality of “counter flow” fluid conduits 208 A and 208 B, through which a first coolant fluid 210 from a load, e.g., the DEW 102 of FIG. 2 , and a second refrigerant fluid 212 from, e.g., the refrigerating unit 206 of FIG. 2 , respectively flow. The respective coolant and refrigeration fluids 210 and 212 may comprise a gas, liquid or a two-phase mixture of gas and liquid. The conduits 208 A and 208 B are disposed in a closed housing 214 and respectively equipped with headers and collectors 209 A, 209 B and 211 A, 211 B at the respective opposite ends thereof. This separate header, collector and conduit arrangement enables the respective coolant and refrigerant “working” fluids 210 and 212 to flow in opposite directions through the PCHEX simultaneously and without intermingling with each other or the other internal components of the PCHEX described below.
The exemplary PCHEX 204 “cell” of FIG. 3 may include additional conduits 208 A and 208 B disposed on either side of those illustrated in the figure, preferably arranged in an alternating manner, and further, may include additional conduits that extend in a direction perpendicular to the common plane of those illustrated in FIG. 3 , which are also arranged in an alternating manner, and these may be disposed in either an in-line or a staggered arrangement relative to those of the figure. Additionally, as those of skill in the art will appreciate, multiple PCHEX “cells” such as that illustrated in FIG. 3 can be stacked in series on top of each other to provide additional cooling or heating capacity. Generally speaking, two identical stacked PCHEX cells 204 will provide about twice the cooling or heating rate and energy storage capacity of a single cell.
In the particular exemplary embodiment of FIG. 3 , substantially the entire internal volume of the PCHEX 202 external to the walls of the fluid conduits 208 A and 208 B is occupied by an expanded foam matrix 218 , which may comprise an expanded metal or ceramic, coupled to the external walls of the conduits and having interstices within which a suitable PCM 220 of a type described in more detail below is disposed. The interior walls of the fluid conduits may also have an expanded foam matrix disposed thereon, or alternatively, may incorporate a plurality of raised fins (not illustrated), both of which are adapted to transfer heat between the respective working fluids 210 and 212 and the PCM in a more efficient manner than conduits having bare walls.
In operation, heated coolant fluid 210 from a load, e.g., the DEW laser 102 of FIG. 2 , flows through the alternating coolant fluid conduits 208 A in a first direction, indicated by the broad arrows of FIG. 3 , causing heat to be transferred from the fluid to the PCM 220 , thereby cooling the coolant fluid and causing a solid portion of the PCM to melt into a liquid portion 220 M, as indicated by the lighter areas of FIG. 3 . Conversely, cooled refrigerant fluid 212 from the refrigerating unit 204 flows through the alternating refrigerant fluid conduits 208 B in a second direction opposite to the first, as indicated by the oppositely pointing broad arrows of FIG. 3 , causing heat to be transferred from the PCM, thereby warming the refrigerant fluid and causing a liquid portion of the PCM to solidify to a solid portion 220 S, as indicated by the dark areas of FIG. 3 .
In the following description of the exemplary PCHEX 204 cell, it is assumed that cooling is provided to the end user (e.g., the DEW laser 102 of FIG. 2 ) from a PCM 220 that expands on freezing (e.g., water-to-ice). The provision of separate passageways 208 A and 208 B in the PCHEX, both of which are in a relatively “close” thermal contact with the PCM due to the conductive matrix 218 , permits simultaneous thermal conditioning and thermal management. Since the thermal buffer system 202 is completely reversible in operation, the same system, equipped with a conventional heat pump, may be used for providing either heating or cooling, and one that can use a PCM that either expands or shrinks on cooling, requiring only the interchange of the direction of flow of the two working fluids 210 and 212 in the PCHEX, as appropriate to the particular situation. The rule for determining the flow direction of the fluids within the PCHEX is that a phase change of the PCM 220 that results in an expansion of its volume must occur with liquid disposed above it to prevent overpressure during the phase change process.
The PCHEX 204 of the thermal buffer system 202 thus may provide multiple layers or cells of a PCM 220 and thermally conductive foam 218 arranged between streams of the coolant fluid 210 for the DEW laser 120 and a refrigerant fluid 212 coming from a primary refrigerator unit 206 (e.g., a conventional refrigerator using Freon, or a functional equivalent, as a working fluid). In the particular embodiment of FIG. 3 , the DEW coolant fluid 210 enters at the top of the PCHEX at a temperature above the phase transition temperature of the PCM, and is cooled as it passes therethrough. As illustrated in FIG. 3 , a solid/liquid boundary 222 is defined in the PCM, which is farthest from the DEW coolant 210 at the top, where the heated fluid enters and is the hottest, and is closest to the DEW coolant temperature at the bottom of the PCHEX, from whence the coolant returns to the load 102 . The expanded foam 218 in the PCM provides the needed heat transfer capability within the PCM layer. As above, thermally conductive foam, fins or other types of extended surfaces may be used in the coolant and refrigerant layers as desired.
At the same time that the coolant fluid 210 is being cooled, the refrigerant fluid 212 (e.g., glycol, brine or Freon) enters the PCHEX 204 from the bottom and on the opposite side of each layer or cell of PCM 220 from the coolant fluid 210 , and at a temperature below that of the phase transition temperature of the PCM 220 . This flow removes heat from the PCM layer through the foam structure in that layer and causes the PCM to return to the solid form.
As an example, in one possible system, a DEW laser 120 may require 500 kW of cooling in bursts of up to 90 seconds each, while operating on the average only 5% of the time, i.e., a 5% “duty factor” (DF). Under these circumstances, the PCM 220 may be sized to provide in excess of
500 kW×90 sec=45 MJ of cooling capacity.
If the PCM 220 consists of ice (ΔH fusion =333.5 kJ/kg), this requires only
45 MJ/0.333.5 MJ/kg≈135 kg.
of ice to provide the required burst thermal capacity. Experience has shown that the weight of the PCHEX 204 can be approximately equal to that of the PCM 220 contained therein, giving a filled PCHEX weight of about 270 kg.
The exemplary 5% duty factor will require only
500 kW×5% DF=25 ≈kW 7 tons of refrigeration.
A practical 7 ton refrigerator for an aerospace application may weigh about 100 kg, and may require about 8 kW of electricity to operate, these values being dependent on the ambient temperature. This results in a total weight of about 370 kg for the exemplary thermal buffer system 202 and requires an amount of power that is manageable on many airborne and space platforms from a practicable standpoint.
By contrast, the direct supply of 500 kW from a refrigerator unit would require approximately 140 tons of refrigeration, would weigh over 1000 kg, and would require 150 kW of electricity to operate. This is clearly a case of overdesign, and results in a system that is much heavier and more difficult to implement than is necessary. This would also require the refrigerator unit to rapidly change output rates in a short timeframe (i.e. a few seconds), which is typically outside of the capabilities of typical refrigeration units.
During the course of a typical eight-hour “on station” period, a typical DEW system 200 may operate for a total of 1440 seconds, which would require over 5,920 kg of ice and a conventional PCHEX 114 of the type illustrated in FIG. 1 that weighs over 12,000 kg. Thus, this extreme also produces a much higher total weight than is necessary, given the intermittent operation of the DEW system.
Thus, as those of skill in the art will appreciate, the exemplary thermal buffer system 202 of the present disclosure provides an optimal blending of existing technologies (i.e., a modified PCHEX 204 and conventional refrigeration unit 206 ) to provide power- and weight-efficient heating or cooling to a payload that requires large bursts of cooling on a relatively infrequent and random basis, so as to minimize system weight while maximizing operational flexibility. It is therefore both lighter and makes better use of power sources typically available on aircraft, thereby providing reduced system costs, greater capability, and the ability to use smaller platforms, or alternatively, provides greater payload capabilities within fixed constraints (e.g., weight, platform type).
As those of skill in this art will by now appreciate, many modifications, substitutions and variations can be made in the constructions and methods of implementation of the thermal buffer system of the present disclosure without departing from its spirit and scope. In light of this, the scope of the present disclosure should not be limited to that of the particular embodiments illustrated and described herein, as they are only by way of some examples thereof, but instead, should be fully commensurate with that of the claims appended hereafter and their functional equivalents. | A thermal buffer for an intermittent thermal load, e.g., a directed energy weapon (DEW) system, includes a phase change heat exchanger (PCHEX), an apparatus for circulating a first working fluid of the thermal load through first conduits of the PCHEX cell in a first direction such that heat is transferred between the first fluid and a phase change material (PCM) of the PCHEX in a second direction and causes a first phase change in the PCM, and an apparatus for circulating a second working fluid of, e.g., a heat pump through second conduits of the PCHEX in a third direction opposite to the first direction such that heat is transferred between the second fluid and the PCM in a fourth direction opposite to the second direction and results in a second phase change in the PCM opposite to the first phase change therein. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a false twist device of the type embodying a number of friction disks which are coaxially arranged in sequence and thread guide elements helically distributed along the circumference of the false twist device, the thread guide elements extending into the space between the friction disks. Further, this invention pertains to a novel method of producing a textured yarn or the like.
The friction between the thread and the friction surface which is required for imparting twist to the thread is generated, on the one hand, by the coefficient of friction between the thread and the friction surface and, on the other hand, indirectly by the thread tension prevailing at the region of the false twist device. The thread tension directly generates the normal force required for the friction between the thread and the friction surface. Hence, there is generated a friction force between the thread and the friction surface of the false twist device owing to the twist- and thread travel speeds directed at right angles to one another, and which friction force is opposite the direction of travel of the thread and thus produces an additional thread tension.
On the other hand, there prevails the requirement that the maximum applicable thread tension should not become too great so that the individual filaments are not ruptured.
Now in order to at least partially compensate the aforementioned additional thread tension there is disclosed in German patent application 1,660,639 and Czechoslovakian patent 106,286 a false twist device embodying a number of coaxial successively arranged friction disks and thread guide elements extending into the space between the friction disks such that the thread guided by the thread guide elements contacts the disks at a uniform inclination with respect to the circumferential direction. Due to the inclination of the thread guided at the false twist device the friction force transmitted to the thread is resolved into a component imparting twist to the thread and a component which transfers or feeds the thread. This thread transfer component reduces the thread tension required following the false twist device.
The drawbacks of the aforementioned state-of-the-art devices are considered to be the following:
A. Due to the aforementioned resolution of the friction force with inclined arrangement of the thread at the friction disk the imparting of twist is reduced in relation to the circumferential speed of the twisting or friction disks, so that such must be brought to a higher rotational speed corresponding to the reduction in the imparted twist. This requires a correspondingly increased power consumption and furthermore increases the wear of the friction surface.
b. It is known that the last friction disks, and in particular the very last friction disk, viewed in the direction of travel of the thread or the like, imparts by far the greatest proportion of twist to the thread so that such experience an appreciably greater amount of wear, resulting in rapid changes in the friction properties and thus, in turn, in changes in the texturizing characteristics.
c. Moreover, the thread transfer component only can be changed at the expense of the twist imparting component, or vice versa, in such a manner that there can be hardly attained optimum conditions as concerns imparting the twist and the thread tension.
SUMMARY OF THE INVENTION
Hence, it is a primary object of the present invention to provide an improved method of producing a texturized thread or yarn and an apparatus for the performance thereof in a manner not associated with the previously discussed drawbacks and limitations of the prior art proposals.
Another and more specific object of the present invention aims at overcoming the aforementioned drawbacks and providing a false twist device by means of which it is possible to optimumly impart twist to the thread with as small as possible difference between the thread tension prevailing before the false twist device and after the false twist device.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the false twist device of this development comprises a number of friction disks coaxially arranged in sequence and thread guide elements distributed helically along the circumference of the false twist device. The thread guide elements extend into the space between the friction disks. In particular, these thread guide elements are arranged distributed along a helical configuration along the circumference of the false twise device in such a manner that a thread contacting the friction disks and guided by the guide element contacts the false twist device along a helix or helix line, the helix angle or helix increment of which decreases as viewed in the direction of thread transfer. Moreover, the thread guide elements can be pivotably arranged.
Not only is the invention concerned with the aforementioned apparatus aspects but deals with a method of producing a textured thread or the like which contemplates guiding the thread at the aforementioned friction disks under an angle which is less than 90° with respect to the circumferential direction of the disks. The thread is guided into contact with the successive arrangement of coaxially arranged friction disks such that the thread contacts the progressive friction disks under a decreasing angle with respect to the circumferential direction of such friction disks.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a simplified schematic view of a false twist device constructed according to the invention;
FIG. 2 is a cross-sectional view of the false twist device of FIG. 1, taken substantially along the line II--II thereof;
FIG. 3 illustrates a friction disk and shows the speed relations of a thread contacting the same;
FIG. 4 is a development view of the false twist device of FIG. 1 showing the travel of the thread or yarn;
FIGS. 5 and 6 respectively schematically show the forces acting upon a thread driven by a friction disk;
FIG. 7 is a variant embodiment of the thread guide element which can be used with the false twist device of FIG. 1;
FIG. 8 illustrates a detail of the false twist device of FIG. 7;
FIGS. 9 and 10 respectively illustrate modifications of the false twist device of FIGS. 1 and 2; and
FIG. 11 is a plan view of the arrangement of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
Describing now the drawings, in FIGS. 1 and 2 there is illustrated a false twist device 1 comprising a drive shaft 4 driven by a pulley 2 and a drive pulley 3 drivingly contacting such pulley 2. Arranged at a predetermined spacing from one another upon the drive shaft 4 are a number of friction disks 5 which are fixed in any suitable manner to the drive shaft 4 so that they cannot rotate relative thereto. The drive shaft 4 is rotatably supported in a support member 6 which, in turn, is mounted at a fixed support 7.
Additionally, a control disk 8 is rotatably arranged about the shaft 4 and, viewed in the direction of the axis of rotation X of the false twist device, slidingly supported upon a spacer ring 9 bearing upon the support member or bracket 6.
Thread guide elements 10 are rotatably provided in an circular arrangement about the axis X of the false twist element on the support member 6. In order to simplify the showing of the drawing not all of the thread guide elements have been illustrated. The thread guide elements 10 comprise a shaft 11 rotatably mounted at the support member 6 (only one such shaft 11 being fully shown in FIG. 1) and a head 12 mounted onto the lower end of the shaft 11 for rigidly supporting a thread guide pin 13. The upper end of the shaft 11 located above the support member 6 is inserted into an end portion of a lever 14 and clamped thereto by means of a fixing screw 20 or equivalent structure. The lower side 15 of the lever 14 is slidably supported by the upper side of the support member 6. In another end portion of the lever 14 there is inserted a pin 17 forming a right angle with the lever 14 and rigidly connected therewith.
The terms "upper" and "lower" as used in this disclosure are intended to mean the direction opposite to the thread transfer and the direction of thread transfer, respectively.
Continuing, control disk 8 is provided with slots 18 for slidingly guiding the pins 17 with narrow clearance or play. A handle 19 is provided on the control disk 8 for rotating such control disk and an opening 21 is also provided for the through-passage or transfer of the thread 22. By loosening the fixing screw 20 it is possible to rotate the shaft 11 in such a manner as to be able to alter the contact angle or angle of inclination α (FIG. 2) of the thread guide pin 13. The inclination angle α as used in the context of this disclosure, is the angle enclosed by the imaginary planes E abd F (FIG. 2). The plane E is arranged parallel to the axis of rotation X and contains the contacting point 23 (FIG. 3) of the thread 22 on a thread guide pin 13, whereas the plane F is a plane containing the axis of rotation X and the contact or contacting point 23.
The thread guide elements 10 are circumferentially distributed in such a manner that the angle β formed by two neighboring planes F is chosen to be larger for each subsequent thread guide pin 13 in a manner such that, considering the inclination angle α, the thread 22 contacting the friction disks 5 and guided by the thread guide pins 13 contacts the friction disks with a decreasing throughpassage angle δ (FIG. 4), and this configuration can be described as a helix or helix line with a helix angle or pitch which decreases in the direction of thread travel. The angle α can be chosen to be equal to 0° or greater.
As illustrated in FIG. 4, in the context of this disclosure the throughpassage angle δ is defined as that angle which, with the false twist device viewed in development and a corresponding development of the thread guided in contact thereat, is enclosed by the thread and the central circumferential line M U of the individual friction disks 5.
As best seen by referring to FIG. 3, the circumferential speed V UR imparted to the thread 22 by the friction disk 5 can be resolved into two velocity components, namely into a velocity or speed component V D producing the twist at the thread and emanating from the contact point 23 at the circumferential line M U , directed perpendicular to the thread 22 and extending between the thread and the friction disk 5, and a further component V F constituting a velocity or speed component and effective in the thread transfer direction and extending parallel to the thread 22. With the same diameter R of the friction disks 5 and if such rotate at the same speed then the component V D imparting the twist and the component V F assisting said transfer can be varied with the inventive thread travel arrangement in such a manner that:
a. On the one hand the transfer of feed component V F progressively assists the thread tension in the direction of thread travel from one friction disk to the next friction disk, and which thread tension is generated between a pair of conventional take-off rolls 24 provided downstream i.e. at the outfeed side of the false twist device and a pair of conventional delivery rolls 25 provided upstream i.e. at the infeed side of the false twist device; and
b. On the other hand, the effective twist imparted to the thread by the twist imparting component V D is increased from one disk to the next as seen in a direction opposite to the direction of thread travel or transfer. The advantages which can be realized by virtue thereof reside in the following:
1. The thread tension required
a. to overcome the sliding friction generated in the thread transfer direction between the thread and the friction disks, and
b. to generate the normal force between the thread and the friction disk,
is generated by the false twist device itself to such an extent that the ratio of the thread tensions before and after passing along the false twist device reaches values considerably lower thant the values previously achieved, and
2. The twist is no longer imparted substantially by the lowest disks, but is imparted more evenly throughout the entire false twist device.
As seen by referring to FIG. 5 the friction force R (= N.μ) generates at the assumed contact point 29 together with the thread guide pin 13 arranged at an angle of inclination α = 90° a reaction and a corresponding friction force R S .
The total torque or rotational moment M D available for imparting twist in the thread in the direction D thus is determined as follows:
M.sub.D = r (R - R.sub.S).
in order to maintain M D as large as possible, the surface of the pin 13 is accordingly chosen such that the friction R S is reduced to a negligible minimum.
In the arrangement of FIG. 6 there is illustrated an angle of inclination α which is less than 90°. In this arrangement there thus occurs a wedge action which, on the one hand, induces an additional normal force N' which is dependent upon the friction force (N' = R.cos α'.sin α'; α + α' = 90°, assuming R S is equal to O) and, on the other hand, since the thread 22 is a flexible structure and inasmuch as the thread guide pins 13 are arranged between the disks, brings about a wrapping of the thread in the direction U 22 along the surface O of the friction disk, which enlarges the surfaces transmitting the friction force on the friction disk 5 and the thread 22.
Due to the increased friction force it is possible to additionally counteract any slippage between the thread and the friction disk. The term "slippage" is intended to mean the difference between the maximum twist which can be imparted and the twist which has been effectively imparted. Thus, there is present the advantage that with friction conditions determined by the fiber material and the surface properties of the friction disk, the twisting device can be adapted to a large extent to the twist to be imparted.
The angles of inclination α less than 90° must be determined by tests in accordance with the twist which is to be imparted, the fiber material at the friction disk-surface properties.
The rotatability of the control disk 8 and therefore the pivotability of the thread guide pins 13 affords not only the advantage of being able to adapt the angle of inclination α, but also the advantage that the thread guide pins 13 can be pivoted during the threading-in process into a position, the so-called idling position, constituting negative angles of inclination. Consequently, there is the possibility of using the same element, typically a hand-held suction gun, for the threading-in process at the false twist device and at the other conventionally known elements of a false twist texturizing machine. A negative angle of inclination is present when the control disk 8 is rotated to such an extent in the direction of the arrow W until the largest of the angles of inclination α has reached a zero or negative value. After the thread has been engaged by the last element, for instance the take-up winding device, the thread guide elements are pivoted back into the operating position designated as that position having positive angles of inclination. Thus, undesirable thread tension peaks at the false twist device, possibly caused by the operation of the hand-held suction gun, are avoided.
To insure that the control disk 8 and thus the thread guide pins 13 are again reliably brought back into their operating position, the handle 19 can be brought into contact with a pre-threadable stop-screw 30 or equivalent structure which, in turn, is threaded into a holder 31 mounted at the support member 6. Furthermore, a coil spring 32 or equivalent device is connected with the handle 19 and the holder 31 and can insure for the aforementioned contact of the handle.
According to a variant embodiment of the invention the thread guide pins 13 can be arranged to be pivotable about the longitudinal axis in the zone of the guide pin where the thread is guided in any conventional manner, and the drive of the rotatable parts can be carried out by the action of the thread 22 itself or by any suitable drive device.
The advantage of this embodiment resides in the fact that the sliding friction between the thread 22 and the thread guide pins 13 is lower than for rigid pins in the direction of the thread transfer.
As shown in FIGS. 7 and 11, the thread guide pins can be replaced by thread guide disks 26 which are rotatable substantially in the axial direction of the false twist device.
This embodiment, as compared to that of FIGS. 1 and 2, differs in that the shaft 11 is provided with a head 27 at which there is provided a support member 28 upon which there is rotatably arranged the disk 26 about an axis parallel to the axis X.
Additionally, the disks 26, as shown in FIG. 7 with phantom lines, analogous to the thread guide pins 13, can be pivoted into the space between the friction disks.
Owing to this rocking or pivotability it is possible to alter the angle α" enclosed by the plane F and the plane E', as best seen by referring to FIG. 8. The plane E', analogous to the plane E, is parallel to the axis X of the false twist device, but contains the tangent T contacting the guide disk 26 extending through an intersection point S. The intersection point S, as viewed in the direction of the axis of the false twist device, constitutes the point of intersection at which the thread 22 is guided and which is formed by the circumferential lines resulting from the largest diameter of the disks 5 and 26. Since the thread cross-section is neglibibly small in relation to the diameter of the disks 5 and 26, the position of the plane E' corresponds to that of the plane E, so that the angle α" corresponds to the angle α.
The thread guide disks 26 are distributed along the circumference analogous to the distribution of the thread guide pins 13, i.e. in such a manner that the angle β determined by two neighboring planes F is chosen larger for each consecutive disk 26, so that analogous to the arrangement of the thread guide pins 13 the thread 22 forms a helix or helix line, the helical angle or pitch of which, as viewed in the direction of thread transfer, decreases. Also in this arrangement it is possible to select the angle α'" to be equal to 0° or greater.
The advantage of this modification of the invention resides in the fact that the friction R S is still further reduced.
Finally, with the arrangement of FIGS. 9 and 10 there should be illustrated that the contact angle or angle of inclination α, depending upon the twist to be imparted and the friction conditions between the thread 22 and the thread guide elements 13, can be chosen to be variably different. This is also true when there are used the disks 26.
While there is shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, tub may be otherwise variously embodied and practiced within the scope of the following claims. | A method of, and apparatus for, fabricating a textured yarn or the like comprising a false twist device containing a number of friction disks arranged in spaced coaxial relationship with respect to one another in succession and thread guide elements helically distributed along the circumference of the false twist device. The thread guide elements extend into the space between the disks and are helically arranged along the circumference of the false twist device in such a manner that a yarn contacting the disks and guided by the thread guide elements contacts the false twist device along a helix, the helix angle or pitch of which decreases in the direction of travel of the yarn. | 3 |
BACKGROUND OF THE INVENTION
This invention relates generally to the art of ceramics and more particularly to the art of producing objects with small orifices.
Various methods exist for producing objects with small orifices. U.S. Pat. No. 5,308,556 discloses a method of forming an extrusion die fabricated from sinterable ceramic or metal powders.
U.S. Pat. No. 4,769,097 shows a method whereby a member is fixed within a ceramic body. U.S. Pat. Nos. 3,389,215 and 3,213,337 involve sintering a ceramic with a metallic lead or electrode extending therethrough.
While the prior art devices may be suitable for their intended purposes, there is much room for improvement within the art of producing objects with small orifices.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to produce an object having a highly precise orifice diameter.
It is a further object of the invention to produce an object with a highly precise orifice diameter which can be made in an inexpensive and easy manner.
It is a further object of the invention to produce an object that can have the orifice produced prior to firing of the ceramic body.
These and other objects of the invention are achieved by an object with a small orifice comprising a casing with a bore therethrough and a ferrule made from a material having a controlled cross-sectional area and defining an orifice therethrough, wherein the ferrule is fixedly secured within the bore. The method of producing the object comprises providing a casing defining a bore therethrough, providing a ferrule made from a material having a controlled cross-sectional area and defining an orifice therethrough, placing the ferrule in the bore, and shrinking the casing around the ferrule to securely fix the ferrule in the casing, whereby the size of the orifice remains constant throughout the step of shrinking.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an object with a small orifice according to the invention before firing.
FIG. 2 is a perspective view of an object with a small orifice according to the invention after firing.
FIGS. 3A-3B are perspective views of an alternative embodiment of an object with a small orifice according to the invention.
DETAILED DESCRIPTION
According to this invention it has been found that objects with small orifices may be produced by first forming a ferrule with a small orifice and inserting one or more of such ferrules into an object to bond with that object upon further treatment. The following description will be given with particular emphasis to ceramic materials but the principle of the invention is applicable to a wide variety of material systems as which will become apparent from a reading of this disclosure with particular reference to the figures of drawing.
Producing objects with small orifices, such as spinnerets, requires a high degree of precise work because these objects are used in applications in which a precise amount of material flowing through an orifice within a specific tolerance of a specific size is required. Accordingly, objects with such small orifices are typically produced using highly precise methods such as micro-drilling or laser boring. However, these methods are expensive and can be cumbersome. These methods also produce rough surfaces in the capillary region. Furthermore, with ceramic spinnerets, the orifice must be made after firing of the ceramic because, otherwise, upon firing, the diameter of the orifice will shrink in a somewhat unpredictable manner. The present invention overcomes these deficiencies, as will be shown below.
FIG. 1 shows the preferred embodiment of an object 10 having a small orifice. Object 10 comprises a ceramic blank or casing 1, which may be made from toughened zirconia, having a bore 11. Casing 1 may be green or partially sintered. Bore 11, which will usually be cylindrical, can be created by conventional methods, and is preferably in the center of casing 1. Because bore 11 will shrink during firing, its precise pre-firing dimensions are not critical. In the preferred embodiment, what is important is that the diameter of bore 11 (which is also the inner diameter of casing 1) is larger than the outer diameter of ferrule 5. This is necessary to allow for insertion of ferrule 5 into bore 11. However, the diameter of bore 11 should only be slightly larger than the outer diameter of ferrule 5, so that when bore 11 shrinks and then expands upon cooling it will secure ferrule 5 therein.
Ferrule 5, which will usually be cylindrical, has an outer diameter less than the diameter of bore 11. The outer diameter of ferrule 5 will vary depending on the application and is generally not critical. Ferrule 5 will usually have a uniform diameter, and thus a uniform cross-sectional area. Ferrule 5 defines an orifice 2 therethrough, which may be in the range of 60-200 μm ±1 μm, depending on the precise dimensions required for the particular application contemplated. Orifice 2 is preferably in the center of ferrule 5. Ferrule 5 is made from a pre-fired ceramic or nonceramic material having a controlled cross-sectional area, the latter preferably being made by extrusion. A material having a controlled cross-sectional area is a material whose cross-sectional area does not change during the step of shrinking the casing around the ferrule. The ferrule material may include, but is not limited to, lava, steel, titanium, tungsten, polycrystalline ceramics, glass, graphite, and plastic.
Ferrule 5 can have various aspect ratios. The aspect ratio is the length of the orifice divided by the diameter of the orifice. Without the process of this invention, it is practically impossible to produce objects with orifices having consistent and precise aspect ratios.
In the method of making an object with a small orifice according to this invention, ferrule 5 is placed in bore 11. Because bore 11 is larger than ferrule 5, a gap 9 surrounds ferrule 5. As discussed above, it is preferred that bore 11 is only slightly larger than ferrule 5, allowing for a friction fit of ferrule 5 within bore 11.
In an alternative embodiment of the present invention, ferrule 5 can be made from plastic. Note that if ferrule 5 is made from plastic, firing is not used. In order to pre-shrink ferrule 5, a process such as cooling and shrinking ferrule 5 in liquid nitrogen is used. The shrunken ferrule 5 is inserted into bore 11, where it expands to fill and become fixedly secure within bore 11 upon warming to room temperature. Bore 11, ferrule 5, and orifice 2 are of the appropriate size for allowing orifice 2 to return to its original size upon expanding and becoming fixedly secured within bore 11.
In FIG. 2, the casing 1 and ferrule 5 combination has been fired to the required sintering temperature for the required time (e.g., for ceramic inserts, 1450° C. for four hours), and then allowed to cool. Accordingly, because casing 1 is not made from a material having a controlled cross-sectional area, casing 1 and its bore 11 shrink to where gap 9 disappears, or where substantially the entire inner surface 7 of casing 1 is in direct contact with ferrule 5, thus permanently and fixedly securing ferrule 5 within bore 11. Because ferrule 5 is made from a material having a controlled cross-sectional area, neither ferrule 5 nor its orifice 2 change in size during the firing of casing 1 and its subsequent cooling. After the firing and subsequent cooling, casing 1 becomes a support for ferrule 5.
Another embodiment of the present invention is shown in FIGS. 3A, 3B. As shown in FIG. 3A, toughened zirconia ferrule 5 can have a three part bore therethrough. The bore comprises two cylindrical portions, i.e., capillary orifice 2 and counter-bore orifice 4, having different diameters and joined together by a conical transition portion 3. The capillary portion 2 is formed during the extrusion of ferrule 5 to have a diameter of 0.250"-0.300." The green ferrule 5 is then machined so as to form counter-bore 4 and transition 3, since the diameters of these elements are not as critical. Machined ferrule 5 is then placed into a ceramic casing 1 as described above and the combination subjected to the firing and cooling processes, e.g., 1450°-1520° C. for four (4) hours. Finally, as shown in FIG. 3B, the final ferrule 5/casing 1 combination can then be placed into a bore in some other material such as steel, iron, or any other material. This embodiment is envisioned for such uses as the mounting of fuel injectors into cylinder heads where precise amounts of fuel, hence the need for controlled diameter orifices, are required to be injected into engine cylinders made from a metallic material.
Therefore, it is seen that the invention produces an object having a highly precise orifice diameter. It is also seen that the invention produces an object with a highly precise orifice diameter which can be made in an inexpensive and easy manner, thus overcoming the deficiencies of the prior art. Furthermore, it is seen that the invention produces an object that can have the orifice produced prior to firing of the ceramic body.
The above description is given in reference to a ferrule spinneret. However, it is understood that many variations are apparent to one of ordinary skill in the art from a reading of the above specification and such variations are within the spirit and scope of the instant invention as defined by the following appended claims. | An object with a small orifice has a highly precise orifice diameter which is produced prior to the firing of the object. A ferrule having an orifice is placed inside of a bore in a casing, preferably a ceramic casing. The casing is then shrunk around the ferrule, preferably by sintering, with the cross-sectional areas of both the ferrule and its orifice remaining constant during the shrinking step. Consequently, the ferrule is securely fixed within the casing without any gaps between the two. In an alternative method, the ferrule is pre-shrunk and placed inside the bore, where it expands to fill the bore. | 3 |
TECHNICAL FIELD
[0001] This document relates to a drive head for a wellhead.
BACKGROUND
[0002] Stuffing boxes are used in the oilfield to form a seal between the wellhead and a well tubular passing through the wellhead, in order to prevent leakage of wellbore fluids between the wellhead and the piping. Stuffing boxes may be used in a variety of applications, for example production with pump-jacks, and inserting or removing coiled tubing. Stuffing boxes may incorporate a tubular shaft mounted for rotation in the housing for forming a stationary seal with the piping in order to rotate with the piping. The tubular shaft in turn dynamically seals with the stuffing box housing. Designs of this type of stuffing box can be seen in the following patents: U.S. Pat. No. 7,044,217 and CA 2,350,047. in other designs, the stuffing box may instead form a dynamic seal directly against the piping without incorporating a rotating tubular shaft. Stuffing boxes may be used for rotating or reciprocating pumps.
[0003] Drive heads are used in tandem with stuffing boxes. In some cases the drive head sits above the stuffing box. In other cases the stuffing box is incorporated into the drive head or sits above the drive head, for example in FIG. 3 of U.S. Pat. No. 7,044,217.
[0004] Leakage of crude oil from a stuffing box is common in some applications, due to a variety of reasons including abrasive particles present in crude oil and poor alignment between the wellhead and stuffing box. Leakage costs oil companies money in service time, down-time and environmental clean-up. Leakage is especially a problem in heavy crude oil wells in which oil may be produced from semi-consolidated sand formations where loose sand is readily transported to the stuffing box by the viscosity of the crude oil. Costs associated with stuffing box failures are some of the highest maintenance costs on many wells.
SUMMARY
[0005] A drive head for a wellhead is disclosed, the drive head comprising: a rod drive; a pressure chamber; and a rod receiving part connected to the rod drive and enclosed within the pressure chamber.
[0006] A method is disclosed comprising: pressurizing a chamber mounted to a wellhead, in which the chamber encloses an upper end of a rod extending from the wellhead; and driving the rod using a rod receiving part enclosed within the chamber.
[0007] A drive head for a wellhead is disclosed, the drive head comprising: a stationary housing with a base, one or more sidewalk, and a top wall; and a rod drive connected to the stationary housing; the stationary housing defining a pressure chamber extending from an opening in the base to the top wall, in which the pressure chamber forms a dead end for a rod.
[0008] In various embodiments, there may be included any one or more of the following features: The rod drive is mounted within the pressure chamber. The rod drive is a hydraulic motor. The pressure chamber forms a casing for the hydraulic motor. A case drain is connected between the casing and a hydraulic fluid return line, which is also connected to the hydraulic motor. A rod is connected to the rod receiving part, the rod having an upper end enclosed within the pressure chamber. The pressure chamber is pressurized above a wellhead pressure. The pressure chamber is above 10 psi. The pressure chamber is above 100 psi. At least part of a top wall of the pressure vessel is removable. The rod receiving part further comprises a tubular shaft mounted for rotation, the tubular shaft having a threaded rod end coupler. The drive head is adapted for production of wellbore fluids. The drive head is adapted for a progressing cavity pump application. The rod is connected to a downhole pump. Downhole fluids are produced from the wellhead.
[0009] These and other aspects of the device and method are se out in the claims, which are incorporated here by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0010] Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:
[0011] FIG. 1A is a view of a progressing cavity pump oil well installation in an earth formation for production with a typical drive head, wellhead frame and stuffing box;
[0012] FIG. 1B is a view similar to the upper end of FIG. 1 but illustrating a conventional drive head with an integrated stuffing box extending from the bottom end of the drive head;
[0013] FIG. 2 is a side elevation section view of a drive head for a wellhead;
[0014] FIG. 3 is a side elevation view of the drive head of FIG. 2 ;
[0015] FIG. 4 is a perspective view of the drive head of FIG. 2 ; and
[0016] FIG. 5 is a hydraulic fluid schematic for operating the drive head of FIG. 2 .
[0017] FIG. 6 is a side elevation view of a drive head incorporating an electric rod drive.
DETAILED DESCRIPTION
[0018] Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims.
[0019] FIG. 1A illustrates a known progressing cavity pump installation 10 . The installation 10 includes a typical progressing cavity pump drive head 12 , a wellhead frame 14 , a stuffing box 16 , an electric motor 18 , and a belt and sheave drive system 20 , all mounted on a flow tee 22 . The flow tee is shown with a blowout preventer 24 which is, in turn, mounted on a wellhead 25 . The drive head 12 supports and drives a drive shaft 26 , generally known as a “polished rod”. The polished rod is supported and rotated by means of a polish rod clamp 28 , which engages an output shaft 30 of the drive head by means of milled slots (not shown) in both parts. The clamp 28 may prevent the polished rod from falling through the drive head and stuffing box, and may allow the drive head to support the axial weight of the polished rod. Wellhead frame 14 may be open sided in order to expose polished rod 26 to allow a service crew to install a safety clamp on the polished rod and then perform maintenance work on stuffing box 16 . Polished rod 26 rotationally drives a drive string 32 , sometimes referred to as a sucker rod, which, in turn, drives a progressing cavity pump 34 located at the bottom of the installation to produce well fluids to the surface through the wellhead.
[0020] FIG. 1B illustrates a typical progressing cavity pump drive head 36 with an integral stuffing box 38 mounted on the bottom of the drive head and corresponding to the portion of the installation in FIG. 1A that is above the dotted and dashed line 40 . An advantage of this type of drive head is that, since the main drive head shaft is already supported with hearings, stuffing box seals can be placed around the main shaft, thus improving alignment and eliminating contact between the stuffing box rotary seals and the polished rod. This style of drive head may also reduce the height of the installation because there is no wellhead frame, and also may reduce cost because there are fewer parts since the stuffing box is integrated with the drive head. A disadvantage is that the drive head must be removed to do maintenance work on the stuffing box. In addition, a stuffing box is still required above the drive head 36 to dynamically seal off the rod 30 from the ambient environment. Surface drive heads for progressing cavity pumps require a stuffing box to seal crude oil from leaking onto the ground where the polished rod passes from the crude oil passage in the wellhead to the drive head.
[0021] Referring to FIG. 2 , a drive head 50 is illustrated having a rod drive 52 , a pressure chamber 54 , and a rod receiving part 56 . Rod receiving part 56 is connected to the rod drive 52 and enclosed within the pressure chamber 54 . A rod 58 may be connected to the rod receiving part 56 . In use an upper end 60 of the rod 58 is enclosed within the pressure chamber 54 . Thus, the pressure chamber 54 forms a dead end for rod 58 . Because part 56 and upper end 60 are enclosed within the pressure chamber 54 during use, there is no need for a dynamic seal, such as provided by a stuffing box, between the rod 58 and the outer ambient environment 66 .
[0022] The lack of a dynamic seal between the outer ambient environment 66 and the pressure chamber 54 is advantageous because it allows pressure chamber 54 to be pressurized to a much greater extent than if chamber 54 terminated in a dynamic seal to the ambient environment 66 as is the case when a regular stuffing box is used. This is because static seals can be pressurized to a greater extent without leaking than dynamic seals. In fact, pressure chamber 54 may be pressurized above standard case pressures, for example if chamber 54 is pressurized to above 10 psi, above 100 psi, or even as high as above 500 psi in some cases. The pressure of chamber 54 may be equal or lower than pressure line 120 (FIG. 5 ) pressure if a hydraulic motor 53 is used, described further below. The relatively high pressure of chamber 54 works against wellhead fluid pressure and across the one or more seals 62 between the chamber 54 and the well 64 , reducing the amount of wellhead fluids that undesirably cross seals 62 and enter the chamber 54 . Chamber 54 may be pressurized above a wellhead pressure. By contrast with dynamic seals of a traditional stuffing box open to atmosphere 66 , if bottom seal 59 of drive head 50 fails, pressurized fluid leaks into the well 64 and not into the atmosphere 66 .
[0023] Referring to FIGS. 2 , 3 , and 4 , chamber 54 may be defined by a stationary housing 68 made up of one or more sidewalk 70 , a top wall 72 , and a base 74 . Sidewall 70 is illustrated as being cylindrical, although other shapes may be used for sidewall 70 . Top wall 72 may include an annular top cap 78 connected, for example threaded, to a top hat 80 for enclosing the upper end 60 of the rod 58 ( FIG. 2 ). At least part of top wall 72 may be removable, for example to allow a convenient method of servicing components within the chamber 54 . In other cases an interior 82 of chamber 54 is accessible via suitable means, such as a window in sidewall 70 . Chamber 54 may include one or more lifting lugs 76 for transporting the drive head 50 . Base 74 may house one or more seals 62 for sealing against rod 58 in use. Base 74 may connect to wellhead 6 . 4 directly or indirectly as shown, for example through a bottom spool 84 . other cases drive head 50 may be mounted upon a flow tee (not shown). Chamber 54 may extend from an opening 81 in the base 74 to the top wall 72 .
[0024] The pressurization advantages of chamber 54 are still realized if a stuffing box is used below chamber 54 . Bottom spool 84 is a form of stuffing box, although bottom spool 84 does not seal between wellhead fluid and outer ambient environment 66 like a normal stuffing box does. Thus, there is no dynamic seal on spool 84 between environment 66 and wellhead fluid. Bottom spool 84 may include one or more mechanisms for axially compressing seals 62 . For example, a biasing device such as spring 86 may be positioned between seals 62 and a ring 87 positioned between spool 84 and base 74 . Compression of spring 86 caused by bringing base 74 and spool 84 closer together increases sealing by seals 62 against rod 58 . other cases one or more bolts 88 may be mounted in spool 84 to provide lateral force into a wedge piston 90 whose tapered lateral end 92 contacts a wedge ring 93 that transfers lateral force into axial compression against seals 62 . Seals 62 positioned below bottom seals 59 of base 74 are advantageously used with drive head 50 in that they allow servicing of the drive head 50 without allowing leakage of well fluids. To service drive head 50 , a user may remove top hat 80 , coupler 96 , and top wall 72 in some cases, and remove a part or all of motor 53 . Poly seals 51 prevent excess production fluids from leaking past and contaminating the pressurized chamber 54 .
[0025] The rod receiving part 56 may comprise a tubular shaft 94 or rotating sleeve mounted for rotation. The tubular shaft 94 may have a threaded rod end coupler 96 , such as a hex driver with a PR thread as shown. One or more bearings or bushings (not shown) may be used to align the shaft 94 and facilitate smooth rotation. Shaft 94 may be connected to be driven by rod drive 52 by a suitable mechanism such as meshing with a lateral extension 100 of shaft 94 . Other mechanisms of torque transfer between rod drive 52 and rod 58 may be used.
[0026] The rod drive 52 may be connected to the chamber 54 , for example mounted within the pressure chamber 54 as shown. The rod drive 52 may be a suitable motor, such as a hydraulic motor 53 . The pressure vessel 54 may form a casing 55 for the hydraulic motor 53 . A case drain 98 may be connected to the casing 55 . Hydraulic pressure and return lines may connect to a pressure line input 102 and a return tine input 104 formed in housing 68 ( FIGS. 3 and 4 ). A relief valve 106 may be located on case drain 98 ( FIGS. 2-4 ). One or more fluid channels 111 may extend laterally from for example above top seal 57 of base 74 , in order to provide a leak path to allow fluid leaking from hydraulic motor 53 to preferentially collect in casing 55 . Fluid channel 111 also prevents crude oil from wellhead 64 from being forced into hydraulic motor 53 , where such oil may over pressure and damage motor 53 . Case drain 98 pressure may be set at a higher pressure than production fluid, so if hydraulic fluid is lost it goes downhole. If enough hydraulic fluid is lost, motor 53 will shut down.
[0027] Referring to FIGS. 2 , 3 , and 5 , a method of operation of hydraulic motor 53 will be described. Fluid from one or more hydraulic tanks 108 is pumped via pump 110 through a pressure line 112 ( FIG. 5 ). A return tank 109 may also be connected to pump 110 . A retarder 114 with a restriction 116 on bypass loop 117 may be located on line 112 to prevent or reduce backspin upon pump shut off. On pump shut off, the backspin generated by rod 58 and exerted upon motor 53 causes reverse flow of hydraulic fluid in line 112 , which cannot pass through check valve 118 , and instead flows through restriction 116 at a reduced flow rate, if at all. Restriction 116 acts as a break on backspin, and prevents the rod from damaging itself via unconstrained freewheeling. Restriction 116 also prevents or reduces the chance that hydraulic fluid contaminated with wellhead fluid is sent back to pump 110 or tank 108 .
[0028] Pressure line 112 ( FIG. 5 ) sends hydraulic fluid to motor 53 through pressure input 102 ( FIG. 3 ), where the pressure of the hydraulic fluid is used to perform work by rotating rod 58 ( FIG. 2 ). Rod 58 may connect to a downhole pump 34 for producing well fluids. Chamber 54 is pressurized by the motor case drain 98 , which is choked off via relief valve 106 . Once the work is accomplished by a given unit of fluid volume, the unit of fluid volume returns through return input 104 ( FIG. 3 ) and into return line 120 ( FIG. 5 ). Return line 120 cleans contaminants such as sand particles from return fluid by passing return fluid through a filter 122 , a check valve 124 . After filtration, the return fluid is deposited for re-use or further cleaning in a tank 126 , which may be the same as one of tanks 108 or 109 ( FIG. 5 ). If filter 122 becomes clogged, or in other events where fluid pressure in line 120 climbs beyond a predetermined level, a bypass valve 128 controlled by pressure from line 127 of line 120 bypasses return fluid past the filter 122 and into tank 126 .
[0029] Motor 53 also includes case drain 98 between the casing 55 ( FIG. 2 ) and hydraulic fluid return line 120 ( FIG. 5 ). The case drain line 98 has a line 123 that passes into a valve 130 that feeds case fluid back into return line 120 for recycling and re-use during normal pump 110 operation. Valve 130 is controlled by pressure from line 131 sent from pressure line 112 , so that the system operates as shown when pump 110 is not operating. Thus, free flow across valve 130 is allowed until the pressure line 112 pressure builds to a sufficient level to close valve 130 . When the pump 110 is shut off or pressure in line 112 reduces below a predetermined pressure, valve 130 opens to allow fluid connection between case drain 98 and return line 120 to reduce case pressure, Thus, during operation, the pressure in chamber 54 is allowed to grow to a predetermined pressure. In the event that valve 130 malfunctions and doesn't open, or another event causes an undesirable pressure increase in line 98 indicating a pressure state in pressure chamber 54 above a predetermined pressure, pressure from line 98 causes relief valve 106 to open, allowing case drain pressure to pass through bypass line 121 of line 98 and into return line 120 through check valve 132 . Running the case drain 98 to the return line 120 eliminates the need for an additional hose that would otherwise be used to keep the casing 55 at a low enough pressure to prevent dynamic seal leakage.
[0030] Drive head 50 may be used for production of wellbore fluids, such as production in a progressing cavity pumping application as shown. Drive head 50 may be adapted to be retrofitted into a wellhead 39 . In other cases drive head 50 may be adapted for an integral application, for example in the style shown in FIG. 1B . Connections between components may be accomplished by suitable mechanisms such as bolting, threading, clamping, and retaining. Although described above for a rotating rod embodiment, drive head 52 may be used in a reciprocating rod application as well.
[0031] It should be understood that various other components may be incorporated into drive head 50 . For example, various seals 89 may be provided at points between rod 58 and housing 68 , or between other components. Similarly, o-rings, gaskets, packing and other components may be used.
[0032] Referring to FIG. 2 , the one or more seals 62 may comprise packing 63 , packing 67 , or other suitable seals such as lip seals 65 or poly seals 51 . Seals 62 may be mechanical or non-mechanical seals. Different packing may be used for packing 63 and 67 . One or more rings such as brass rings may be located on either side of seals 62 . O-rings 89 or other suitable gaskets may be used throughout drive head 50 . In general, where the word seal is mentioned in this document, one or more seals may be provided to effectively operate as a single seal, for example observed in the stacking of packing seals 65 .
[0033] It should be understood that various other components such as blow out preventers may be provided with the drive head 50 for wellhead applications to be carried out. Drive head 50 may incorporate a lubrication system (not shown) for lubricating various components, such as the one or more seals 62 . Various components discussed herein may include sub-components, such as the plural sleeves that thread together to make up the top wall 72 of FIG. 2 . As well, components that are shown as being separate may be combined integrally, for example base 74 and side wall 70 . Connections between components, or the mounting of one component to another, may be done through intermediate parts. Figures may not be drawn to scale, and may have dimensions exaggerated for the purpose of illustration. Drive head 50 may have no rotating parts or dynamic seals on the exterior of drive head 50 . Non hydraulic drives may be used, for example if an electric motor is used as shown in FIG. 6 , although a pressurization system may be required to pressurize chamber 54 .
[0034] In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite article “a” before a claim feature does not exclude more than one of the feature being present. Each one of the individual features described here may he used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the | A drive head for a wellhead, the drive head comprising: a rod drive; a pressure chamber; and a rod receiving part connected to the rod drive and enclosed within the pressure chamber. A method comprising: pressurizing a chamber mounted to a wellhead, in which the chamber encloses an upper end of a rod extending from the wellhead; and driving the rod using a rod receiving part enclosed within the chamber. | 4 |
FIELD OF THE INVENTION
This invention relates, in general, to a chemical process and apparatus for the selective reduction of specific tar components of smoke generated by smoking articles such as cigarettes. More particularly, the present invention relates to the use of functionalized resin particles having a specific affinity for a targeted smoke component, such as tar, as a filter to selectively remove such component without coordinately removing desired nicotine and flavor components.
DESCRIPTION OF THE RELATED ART
The control of tar and nicotine in cigarette smoke is largely attributed to the use of filters which physically remove total particulate matter (TPM) from the mainstream smoke condensate. Thus, the grades of "full flavor", "light", and "ultralight" cigarettes are based on the effectiveness of their filters to eliminate the potential tar and nicotine as found in normal unfiltered cigarettes. This classification system relates to the Federal Trade Commission's (FTC) restrictions on the amount of "tar" the cigarettes may deliver to a smoker. A "full flavor" cigarette delivers 14 mg or more of tar; a "light" cigarette delivers between 8 and 14 mg of tar; and an "ultralight" cigarette delivers less than 7 mg of tar. The "ultralight" cigarette also has an air dilution filter tip to further reduce the tar in the mainstream smoke.
The latest technology is a "heat" cigarette, available from R. J. Reynolds under the trade designation "Eclipse" which employs a carbon core in the cigarette. Unlike traditional cigarettes, this new cigarette does not burn at 800° C. but instead heats the tobacco to less than 300° C. This low temperature avoids combustion which reduces tar formation and also the distillation of nicotine. The cigarette produces low levels of tar and nicotine in both the main and sidestream smoke. Toxicological and biological studies performed by Reynolds Tobacco Company have demonstrated that it is a safe smoking article. However, this cigarette does require some adjustment from the smoker.
In addition, numerous filter elements are disclosed in the art to be useful in reducing the levels of tar delivered to a smoker. For example, numerous patents exist describing filter elements that employ baffles and orifices to reduce tar and nicotine. U.S. Pat. No. 3,777,765 to Yoshinga discloses a filter apparatus consisting of a chamber for depositing smoke condensates. The smoke micelles route through this chamber and then exit through another porous barrier disk to become the mainstream smoke. U.S. Pat. No. 3,650,278 to Cook describes an adjustable tar removing filter for cigarettes having an adjustable needle valve that the smoker adjusts to the desired level of taste. U.S. Pat. No. 3,472,238 to Blount et al. describes yet another cigarette holder device with a disposable tar collecting cartridge. U.S. Pat. No. 5,617,882 to Bushuev et al describes a filter unit containing both organic and inorganic basalt fibers which it claims provides better tar trapping effectiveness than conventional filters.
Further, examples of liquids for chemical reaction in a filter are known. U.S. Pat. No. 3,943,940 to Minami proposes a chemical process in the smoking filter to remove nicotine from the smoke. An aqueous solution of potassium permanganate (KMnO 4 ) and chlorine is impregnated in the filter. Because the aqueous KMnO 4 solution is unstable, chlorine is added as a stabilizer. It is not clear to what extent permanganate contributes to the oxidation of nicotine since the water barrier filter is also removing nicotine from the smoke.
The potential of activated silica resin as a smoke adsorbent is also suggested in the art. For example, the use of activated silica in cigarette filters is disclosed in U.S. Pat. Nos. 1,808,707, 1,826,331 and 2,325,386. However, all of these patents describe a loose distribution of the resin particles in the filter proper for removing smoke condensates, and the results are not dramatic. U.S. Pat. No. 2,956,329 to Touey describes the manufacturing of a filamentous acetate filter containing up to 35.5% of silica gel, and reports the effective removal of 34% of the acetaldehyde from the smoke stream. U.S. Pat. No. 2,968,305 and British Pat. No. 795,420 to Barnett discloses a chamber and smoke labyrinth construction in a cigarette filter element for the placement of silica granules. Further, U.S. Pat. Nos. 2,834,354 and 2,872,928 both suggest that by incorporating silica gel bearing either deoxycholate or partially polymerized furfural into the cigarette filter it should be possible to remove heavy hydrocarbons such as benzopyrene from the smoke. However, in "Influence of Filter Additives on Smoke Composition" by M. L. Reynolds, Recent Advances in Tobacco Science, Vol. 4, pp. 47-67, 1978, it is discussed that the removal of polycyclic aromatic hydrocarbons (PAH) has been claimed in many patents, but has never been demonstrated to be successful.
Additionally, the use of ion exchange resins in filter elements has been suggested in the art. For example U.S. Pat. No. 2,739,598 to Eirich describes the manufacture of a copolymer of methyl acrylate and vinyl pyrrolidone as both anion and cation exchanger by embedding the polymers in a paper pulp. The impregnated paper is used as a cigarette filter to remove those ionic species from smoke. U.S. Pat. Nos. 2,754,829 and 2,815,760 to Hess disclose the use of cationic exchangers, and U.S. Pat. No. 3,093,144 to van Bururen discloses the use of both anionic and cationic resins to remove nicotine from tobacco smoke. U.S. Pat. No. 4,700,723 to Yoshikawa and Shimamura also discloses a fibrous ion-exchange resin that can be incorporated into a cigarette filter. However, their approach is one dimensional. The gas chromatograms of the smoke condensate following the resin treatment appear to show only a quantitative reduction of tar and nicotine. There is no consideration of specificity and the disclosure does not address specific trapping of targeted components.
In U.S. Pat. Nos. 2,920,629 and 2,920,630 to Kinnavy, a special cotton filter that is impregnated with a waxy salt of trimethyloctadecylammonium chloride (or a class of long chain alkyl-quaternary ammonium chloride) and sodium sterate is disclosed as being useful as a cigarette filter. The input is roughly 1 gm per 2 gm of cotton. When this is used as a tobacco smoke filter, it drastically reduces both tar and nicotine. The high input of a waxy substance with cotton fiber apparently creates a sticky, fatty, and oily filter that obliterates the potential of the long chain hydrocarbon to be capable of specific interactions with smoke components. Instead, it is made into a sticky filter pad for the nonspecific removal of tar and nicotine. U.S. Pat. No. 3,033,212 to Touey and Kiefer discloses a similar intent of incorporating a waxy sterate into a cellulose filter to prevent smoke condensates from being dislodged from the cigarette filter after entrapment.
In the advent of ultra low tar cigarettes, there is a need to increase flavor and nicotine while decreasing tar. U.S. Pat. No. 5,524,647 to Brackmann discloses using the upper portion of the tobacco plant to provide a higher than normal flavor to tar ratio. In addition, a cylinder of microfine filter element is used to reduce tar and nicotine. This biological approach tends to increase flavor and nicotine relative to tar levels.
U.S. Pat. No. 5,465,739 to Perfetti et al describe the incorporation of acids and bases into the filter elements to influence the nicotine content of tobacco in the mainstream smoke. Acid is used for removing more nicotine in the tobacco blends which has high nicotine content and base for those tobacco blends with low nicotine. The intent is for normalizing the tobacco blends to achieve a consistent product.
Recently increasing pressure to reduce cigarette tar has reached an all time high. The industry has responded by increasing the efficiency of filters to decrease tar and nicotine. Nevertheless, many smokers demand even further reductions in tar. However, the ability of existing cigarette design technology to respond to that demand, while still providing flavor, is limited. Conventional methods generally achieve a coordinated reduction of tar and nicotine from the mainstream smoke. The resultant "ultralight" cigarette may not be as flavorful. Consequently, a frustrated smoker may choose to smoke more cigarettes, or alter the filters in a number of ways. All of these known practices defeat the intent of reducing the tar and nicotine in the cigarette smoke. Moreover, because the delivery of tar and nicotine is highly dependent on the manner of smoking, issues of cigarette labeling and testing are being raised with manufacturers by the FTC. Clearly, there is a need for a new approach to control tar and nicotine in the mainstream smoke. This need is met by the invention disclosed herein. The invention represents a drastic departure from conventional cigarette filter design and engineering, and provides a filter capable of selectively removing tar, or virtually any other component, without coordinately removing other components, such as nicotine, below desired levels.
SUMMARY OF THE INVENTION
The present invention represents a new approach in the control of tar and nicotine in cigarette smoke. Although the separation of molecules according to affinity is a well-known chemical principle, the selective separation and removal of cigarette smoke constituents on a solid phase resin has not previously been effectively accomplished. Cigarette smoke condensate is both aqueous and organic, and is amenable to the characteristics of gas and liquid chromatography. However, it differs from traditional chromatography because the parameters have more constraints. For example, the puff composition, unlike the carrier gas or mobile phase of traditional chromatography, is not homogenous. Further, the time of flight of the smoke composition over the resin surface with each puff is very short. The total number of puffs per cigarette is also limited. Additionally, the binding affinity of the smoke components to the resin may involve complex interactions. In the first puff, the resin surface is unoccupied and therefore smoke components possessing both weak and strong interactions may have equal probability of landing on available binding sites. As smoking is continued, potential sites gradually disappear, and stronger binding molecules generated by each new puff begin to compete with all other existing molecules on the resin. The competition favors those that are specific and with high affinity and therefore the weaker binding components begin to be displaced by stronger binding molecules.
The present invention embodies the control of tar and nicotine via the incorporation of one or more resins with diverse functional groups which regulate the composition of the mainstream smoke as it exits the cigarette. In particular, the invention provides an improved use of silica, in the form of functionalized silica resins having a high capacity bonded phase for the selective removal of specific classes of tar components to achieve a desired balance in a cigarette that is still full of aroma and flavor, yet offers slightly more nicotine than unwanted tar to satisfy a smoker. Additionally, the present invention alleviates concerns that smokers can defeat the beneficial attributes of reduced tar by the manner in which they smoke. Because the affinity binding of the targeted smoke component to the resin is practically irreversible, the present invention generates a mainstream smoke that is true to the intended label. The smoker can no longer change the manner of smoking to effect the composition of the mainstream smoke.
The present invention thus has multifaceted attributes, including the ability of resins with distinctive characteristics to be designed to bring about adsorption of only that population of tar components with such specificity. As a result, nicotine and tar can be regulated independently through the use of high capacity bonded phase silica resins. For example, a silica resin functionalized with a broad spectrum bonded phase, such as an eighteen carbon (C-18) aliphatic hydrocarbon, a catch-all resin, is uniquely suited for the removal of aliphatics and hydrocarbons from smoke, yet allows some polar flavor components to be delivered to the smoker. The C-18 bonded silica filter provides a reduction of the volatile and semivolatile smoke components equal to the standard of clean smoke generated by the no bum cigarette known as Eclipse, while maintaining an acceptable level of nicotine. The process is simple, safe, and efficacious. Since no chemical is added to the tobacco rod, no new chemical species are generated.
Additionally, the present invention provides cigarettes capable of delivering an artificial flavor, e.g., menthol, into the smoke by incorporating the flavoring into the resin particles such that they are removed in a "reverse mode" by smoke constituents exhibiting greater affinity for the functional groups on the resin particles. Consequently, the new generation of cigarettes with desired advantages can even deliver menthol flavor continuously with every puff and even to the last puff.
BRIEF DESCRIPTION OF THE DRAWINGS AND TABLES
FIG. 1 depicts chromatograms of the mainstream vapor-phase smoke of various cigarettes collected in a methanol trap: the top panel is smoke from a cigarette treated with a combination of resins consisting of: 50 mg silica (100 μm and 60 Å), 100 mg C-18 resin (100 μm and 60 Å), 100 mg of C-18 resin (200 μm and 60 Å) and 100 mg 3-aminopropyl resin (200 μm and 60 Å); the bottom panel is the Eclipse regular flavor and the middle panel is the control Marlboro with the acetate filter removed.
FIG. 2 shows chromatograms of the mainstream vapor-phase smoke collected in methanol trap for cigarettes treated with various resin combinations of C-18, amino, and silica resins. From top to bottom: (1) Control of FIG. 1 (middle panel) diluted 1:4; (2) Resin 50/300 consisting of :50 mg 3 aminopropyl resin (100 μm and 60 Å) and 300 mg of C-18 resin (200 μm and 60 Å); and (3) 150 mg of C-18 resin (100 μm and 60 Å).
FIG. 3 illustrates the utility of the affinity C-1 resin in delivering menthol in the mainstream smoke.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a novel application of the principles of affinity chromatography in the design of cigarette filtration media to permit the planning and development of filter elements that selectively remove a class of targeted components of the smoke. The filter elements are comprised of functionalized resin particles wherein the ligands exhibit the desired specific affinities for the targeted component molecules. Useful resin particles include materials that are rigid, chemically stable, nontoxic and with very large resin surface areas which can be derivitized to permit the design and construction of useful functional groups. Suitable resins include methacrylate, and styrene, styrene divinylbenzene. Silica can also be used. However, silica is generally preferred because of its rigidity and its avoidance of swelling and shrinking over a broad range of humidity conditions.
The resin particles preferably have a particle size of from about 35 to 400 microns, and are preferably spherical or irregularly shaped and of high porosity. Non-porous resins are generally not preferred because they create draw resistance and have a reduced available surface area for the bonding of ligands.
The performance of the affinity resin is dependent upon its size, porosity and functional group capacity, which can be varied to maximize the efficiency or the specificity of the resulting filter. The efficiency of an affinity resin is measured by its ability to remove tar and nicotine from the smoke condensate. In general, the smaller the resin particle, the more efficient the resin. Spherical or irregular particulates create a resin filter column wherein the beads are stacking and overlapping. The interbead spacing of 40-60 μm resin is only ˜20-30 μm. This narrow and convoluted passage-way ensures the collision and adsorption of smoke micelles. Consequently, particles of such size provide a resin filter that is generally nonspecific, but which is highly efficient in removing tar and nicotine from the smoke condensate. However, the particle size and porosity is preferably selected so as not to increase pressure drop which increases draw resistance during smoking.
In general, specificity varies directly as the parameters of resin particle size, pore size, and resin capacity. The most selective resin therefore would generally have a large particle size (e.g., about 200 μm) a high porosity (e.g., about 1000 Å) and a high ligand loading capacity (e.g., at least about 1 milliequivalence per gram of resin). However, such a resin may be too fragile due to the thin walls created by the large pores in the particles. Accordingly, it is generally preferred that the selected resin be spherical or irregular particles having an average diameter of from about 35 to 400 microns, more preferably from 75 to 200 microns, and an average pore size ranging from about 60 to 1000 angstroms, more preferably from about 300 to 1000 angstroms. Additionally, the shape and size of the resin particles should be selected so as to enhance the interbead spacing to allow free flow of the smoke micelles.
To achieve a balance of efficiency and specificity, a preferred embodiment of the resin filter may employ a multicomponent resin cartridge. The first resin cartridge component preferably comprises a column from about 2-4 millimeters of a fine resin having an average particle diameter of from about 50 to 70 μm with a high porosity of from about 300 to 1000 Å to result in the gross reduction of tar and nicotine. The first component cartridge is preferably followed by a second component cartridge comprising a column of from about 5 to 10 millimeters in length of a relatively large bead resin, having an average particle diameter of from about 150 to 200 μm, with large pore size of at least about 300 Å and a high capacity loading of functionality for specificity.
Alternatively, it is envisioned that a honey combed, filigree-like, or even fiberous construction of nonparticulate materials bearing functional groups may be used as a substitute. The ultimate criteria is to achieve a high capacity of ligand bonding of at least 0.6 millimoles per gram of material.
The ligand attached to the resin beads are preferably selected to preferentially bond with the molecules targeted for removal from the smoke stream. Although the specific functional groups utilized may vary widely depending upon the targeted smoke component, selection of suitable functional groups are well within the purview of one skilled in the art based upon fundamental chemical principles. However, with regard to the generally desired reductions of tar, preferred functional groups that exhibit greater affinity for tar than for nicotine have been found to contain hydrocarbon groups of the general formula R 1 --(CH 2 ) n -where n is an integer from 1 to 40; and R 1 represents hydrogen, hydroxy, amine, amide, cyano, nitrate, nitro, thio, sulfide, sulfone, sulfoxide, I, Br, Cl, F or an alkyl or aryl organic substituent containing from about 1 to 40 carbon atoms, which may be straight or branched, saturated or unsaturated and optionally substituted with one or more substituents selected from O, N, S, or halides. For example, R 1 may be an alkyl group such as an alkane, alkene, alkyne, acid, alcohol, aldehyde, ester, ether, or ketone; or an aryl group such as a benzyl, naphthyl, anthryl, biphenyl, phenolic or heterocyclic group. Particularly useful functional groups have been found to be straight chain, alliphatic hydrocarbons of from 3 to 18 carbon atoms in length, with C-18 hydrocarbons, having been discovered to exhibit selectivity for a broad range of volatile organic smoke constituents in preference to nicotine. Additionally, aromatic functional groups such as benzene, naphthene and anthracene may be particularly useful in selectively removing volatile aromatic PAH components through chemical bonding known as π--π interaction.
In the practice of the invention, cigarette filters are formed of the functionalized particles by encasing a desired volume of the particles behind the tobacco rod of a conventional cigarette. The encasement may be formed in part by the cigarette filter paper overwrap, or the resin particles may be encased in a separate vapor permeable membrane to form a cartridge that may be affixed to the end of the cigarette, or included within the paper shell. The resin filter cartridges may be used alone or in conjunction with conventional acetate filters. In such embodiments the resin filters may be conveniently located between the tobacco rod and the conventional acetate filter element. Additionally, multiple resin filter cartridges may be serially connected to the tobacco rod and used to effectuate the desired selective removal of targeted molecules. In this manner, filter cartridges containing particles of varying functionality, size, porosity, etc. can be connected serially to remove specified amounts of targeted components. Furthermore, particles having different functionalities, size, porosity, etc. can be combined into a single filter cartridge as desired.
Accordingly, the preferred smoking article of the invention has incorporated therein at least about 15 mg of functionalized 35-200 μm silica gel particles right behind the tobacco rod and placed uniformly before the final monoacetate filter. The synthesis of the functionalized resin is illustrated below in Example 1, however, modifications necessary for the attachment of other functional groups will be readily apparent to the skilled artisan. The smoking article may be any brand of commercially available cigarettes, either filtered or unfiltered.
The following examples are illustrative of the present invention. The specific ingredients and processing parameters are presented as being typical, and various modifications can be derived in view of the disclosures as presented within the scope of the invention. Example 1 describes the basic strategies in the resin design. Examples 2-4, describes the solid phase affinity chemistry. The initial challenge to differentiate between nicotine and tar is borne out by the observation that nicotine is not retained by the reverse phase column. A specificity index is used to quantitate the differentiation and also to compare data between different groups of experiments. The resin experiments are recorded in the history of the mainstream smoke components in its passage through the compartments of resin, monoacetate filter and then collected onto a Cambridge filter pad. By studying the inter-relationship of the compartments, the molecular anatomy and the intricacies as well as the dynamics of the affinity smoke chemistry unfold. Additional confirmation of selectivity can be found in the Examples of amino and phenyl resins. The subtitles of selectivity are often difficult to recognize. This is due to the complexities in molecular recognition. Often it involves many functionalities and each contribute only a small percentage to the overall selectivity. The examples given are designed to provide the tools necessary to solve these intricate problems. Capacity and particle size parameters which enhance selectivity are discussed in Example 4. Example 5 validates the puff affinity technology by creating a low or ultralow tar cigarette that burns rather than heats the tobacco and achieves a clean vapour phase composition which is comparable to the industry standard of Eclipse. Additionally, menthol cigarettes have been a commercial favorite, and Example 6 demonstrates the reverse mode of affinity resin utility for delivering this flavor.
EXAMPLE 1
Silica is a very desirable solid phase sorbent and comes in various sizes and shapes. It can be either porous or nonporous, spherical or irregular, and with particle sizes that range from the very fine of 5 μm to the bead size of 1200 μm. Porous silica resin is the preferred material for the synthesis of a universal affinity precursor resin which possesses amino functionality. The arm of the precursor resin contains a 3 amino-propyl group which may be lengthened by reacting with various acyl-chlorides. For example, reaction with acetyl-chloride yields a resin containing a 5 carbon chain length functional group. In addition, more carbon chains may be extended to the amino arm by using fatty acids of different chain lengths.
The synthesis of the precursor resin began with selecting activated and porous silica resins with a mean diameter of either 50 μm, 100 μm or 200 μm. The fines of the resins were progressively removed by sedimentation and decantation in water and the resins were finally washed in methanol. The resins were dried in an vacuum oven overnight at 100° C. These resins were then used to make the following functionalized resins as follows:
3-amino-propyl resin: 20 gm of the washed and defined resins were treated with 10 ml of 3-aminopropylsilane in 100 ml of toluene. The resins were refluxed overnight to allow maximum incorporation of the propyl-amino group. The following day, the solvents were decanted and the resins were washed with 100 ml of toluene followed by three washes of methanol in a scintered disk funnel. The resins were thoroughly dried in a vacuum oven, and the capacity of the resin was determined by acid base titration. For the 200 μm resin, it was about 0.8 millimoles per gm; for the 60-120 μm resin, it was about 0.6 millimoles and the 40-60 μm resin was about 0.5 millimoles. These levels are at least about 10 times more than the capacity of resins typically used for High Pressure Liquid Chromatography (HPLC) applications, and they approach that of the ion-exchanger for deionizing water. In addition, the resin amino groups may be visualized by staining with ninhydrin and their lack of staining for the following resins.
C-1 resin: 2 gm of the washed and defined resins was treated with approximately 3 ml of chlorotrimethylsilane in 20 ml of toluene and refluxed for 2 hours. Following reaction, the C-1 resin was washed with toluene and followed by three washes with methanol and then dried.
C 5 or C 7 resin: Acetyl chloride or succinyl chloride was synthesized by reacting 5 ml of 2 M thionyl chloride in 10 ml of toluene with acetic acid or succinic acid. The acid chlorides were further purified by distillation. 2 gm of the 3-amino-propyl resin was then incubated overnight with the fresh acetyl chloride or succinyl chloride in pyridine. The next day, the resin was washed with methanol and dried.
Phenyl resin: Benzoyl chloride was synthesized by refluxing 5 ml of 2 M thionyl chloride in 10 ml of toluene with benzoic acid for 30 minutes. The residual thionyl chloride and toluene were removed by distillation. 2 gm of the 3-amino-propyl resin was then incubated at room temperature overnight with the fresh benzoyl chloride in pyridine. The next day, the resin was washed with methanol and dried.
C 18 resin: Pentadecanoyl chloride was synthesized by reacting 10 ml of 2 M thionyl chloride in 10 ml of toluene with 1.5 gm pentadecanoic acid. After 40 minutes of refluxing, the remaining thionyl chloride and toluene were removed by distillation. 4 gm of the 3-amino-propyl resin was then incubated overnight with the freshly prepared pentadecanoyl chloride in pyridine. The next day, the resin was twice washed with methylene chloride and then three times more with methanol and dried.
EXAMPLE 2
Chromatography of nicotine on C8 or C4 HPLC column under reverse phase condition showed that it was eluted in the void volume and was not retained by the column. This is due to the fact that nicotine is positively charged in an aqueous pH environment and does not bind to a resin which is specific for aliphatic carbon interaction. This fact makes it plausible to test if the nicotine present in the smoke condensate also behaves in the same manner. More specifically, the test may be conducted with C5 or C7 resins as manufactured under Example 1 in a "cigarette column." The resins used had an average particle size of 100 μm and a pore size of 60 angstroms. Table 1 shows the results of the experiments. The resins were placed between the filter and the tobacco rod of a conventional cigarette, and the cigarette was tested on a smoking machine. The control and resin treated cigarettes were smoked under standard FTC conditions. The puffing regimen consisted of 35±0.5 ml puff volume, a puff duration of 2 seconds and a puff frequency of 1 puff per 60 seconds. In measuring the semivolatiles of the cold trap experiments, the cigarettes were smoked to 12 mm from the overwrap. Smoke collection onto the Cambridge filter pad were extracted with 2-propanol. The determination of nicotine and propylene glycol was by capillary gas chromatography employing a HP5890 GC equipped with a 30 meter megabore carbowax column and flame ionization detector (FID). The semivolatiles were collected in an isopropanol cold trap maintained by dry ice at -70° C. and determined on a 30 meter DB624 capillary column equipped with a precolumn and also by FID detection. In the resin treated cigarette, the monoacetate filter was dislodged and removed from a commercial cigarette. The resins were weighed and placed right behind the tobacco rod from the open butt end of the cigarette. To insure even placement of the resin, the cigarette was kept in a vertical position, gently tapped, and a new and intact monoacetate filter reinserted. This experiment examined specific interactions between the smoke condensate and the resin. Therefore, the nonspecific trapping of smoke condensate was reduced in part by removing all the fines in the resins. The values of tar, nicotine, and propylene glycol, were all derived from the Cambridge filters.
Initially, the reduction of nicotine was compared to that of tar, however, any change in nicotine as a ratio to tar is insensitive because tar is at least ten times larger. In addition, tar is a poorly defined complex entity and its determination is not highly quantitative. The comparison should be to a specific indicator component of the tar such that both chemicals can be accurately determined. Propylene glycol is a suitable indicator since it is also a major component of the tar. However, it is chemically distinct from nicotine; that of a glycol versus an alkaloid. Both chemicals are slightly polar and yet both are soluble in organic solvents. In Table 1, the relative retention of nicotine by the two resins is compared to propylene glycol. In the control cigarette there is a basal ratio of nicotine to tar and it is 2.16. If the resin removes more propylene glycol than nicotine, this ratio will also increase proportionately. Therefore, by expressing the ratio of increase due to resin as a percentage of the control, a normalized quantitative comparison is achieved. This is defined as the specificity index.
TABLE 1______________________________________SPECIFICITY INDEX % of Control -Tar Nicotine Propylene Glycol Ratio Specificitymg mg mg Nic/PG Index______________________________________Control 12.54 0.8405 0.388 2.16 100%SuccinylC 7-30 mg 9.31 0.6062 0.200 3.03 140%C 7-45 mg 7.80 0.5057 0.181 2.79 129%C 7-45 mg 7.24 0.4220 0.162 2.60 120%C 7-60 mg 6.13 0.4022 0.105 3.83 177%AcetylC 5-30 mg 8.10 0.5406 0.215 2.51 116%C 5-45 mg 7.42 0.4409 0.138 3.19 147%C 5-45 mg 6.69 0.4068 0.100 4.07 188%______________________________________
The data of Table 1, as expected, does not appear to differentiate between C7 and C5 resins. The percent increase of nicotine to propylene glycol as a percentage of the control ratio reaches a high of approximately 180%. This indicates that the smoke condensate to resin interaction is akin to the HPLC column. Nicotine is subtly excluded from binding to the functional groups of C5 and C7 present on the "cigarette column."
EXAMPLE 3
In the present example, the nonspecific entrapment of the smoke condensate was further reduced by using a more open resin with a bead size of 200 μm. In Table 2, the distributions of nicotine in the three compartments of the Cambridge filter, cigarette acetate filter and the recovered resin are shown.
TABLE 2______________________________________DISTRIBUTION OF NICOTINE Nicotine Nicotine from from Acetate Nicotine Total Nicotine Cambridge Cigarette from RecoveredResin Type Filter Pad Fiber Resin in mg______________________________________Control 0.9167 0.6918 n/a 1.64Silica - 50 mg 0.8148 0.4386 0.1195 1.37Silica - 150 mg 0.7765 0.3383 0.2584 1.37Amino - 50 mg 0.8913 0.4766 0.1059 1.47Amino - 150 mg 0.8521 0.3768 0.3498 1.58C5 - 50 mg 0.9090 0.5246 0.1012 1.54C5 - 150 mg 0.8324 0.4316 0.3031 1.57Phenyl - 50 mg 0.8888 0.4844 0.0658 1.44Phenyl - 150 mg 0.9148 0.4541 0.2669 1.64______________________________________
As shown in Table 2, due to the large bead size of the resins, nicotine on the Cambridge filters did not diminish greatly even when the resin input was150 mg. The total nicotine recovered in each experiment is the sum total of all three compartments. The upper limit (1.64 mg) is shown in the control experiment. In all the resin experiments, the total nicotine recovered approaches this value except for silica. This is due, in part, to incomplete resins' recovery, but is largely due to inadequate extraction of nicotine from the silica by the isopropanol.
The recovery result of nicotine from the monoacetate fiber filter is most interesting. This conventional filter is a passive diffusion and capture device permitting certain population of smoke micelles to pass. The resin column at the level of 150 mg input is 0.5 cm long segregating the tobacco rod from the acetate filter. Since the resin column precedes the acetate filter, it has the first right to take up smoke micelles which would have been available to the monoacetate filter. The resins are 200 μm, with 60 Å pore size, and a theoretically calculated 92 μm inter-bead spacing. Statistically the resin would favor the uptake of the larger size micelle population. The removal of this population of smoke condensate reflects the observed lower recovery of nicotine in all the acetate filters of the resin treated cigarettes than the control. The decrease actually is quite significant and ranges from a low of 35% to a high of 51%. This creates an apparent paradox because nicotine content of the Cambridge filter fraction is almost unaffected as compared to the control. Accordingly, at the resin level, it must be replenishing the nicotine flight to the Cambridge filter with reprocessed micelles that are able to escape the acetate filter entrapment. Specifically, the resin is apparently behaving as a dynamic exchanger and functioning like an HPLC column in chromatographing nicotine with the mobile phase as the smoke condensate. This example illustrates the multidimensional physical-chemical dynamics of the filtration process of the invention in contrast to convention physical entrapment technologies.
Table 3 illustrates the comparative selectivity of the functional groups in the porous resin (200 μm and 60 Å). It shows the differential retention by the resins of propylene glycol and not for nicotine.
TABLE 3______________________________________DIFFERENTIAL REMOVAL OF PROPYLENE GLYCOL ANDNICOTINE BY RESIN % Control % Reduction Nico- Propylene Nico- PropyleneResin Type tine Glycol Tar tine Glycol Tar______________________________________Silica - 50 mg 88.9 55.4 89.5 11.1 44.6 10.5Silica - 150 mg 84.7 41.4 83.2 15.3 58.6 16.8Amino - 50 mg 97.2 63.4 97.2 2.8 36.6 2.8Amino - 150 mg 93.0 39.4 87.4 7.0 60.6 12.6C5 - 50 mg 99.2 80.2 102.8 0.8 19.8 -2.8C5 - 150 mg 90.8 51.9 92.3 9.2 48.1 7.7Phenyl - 50 mg 96.9 64.2 92.3 3.1 35.8 7.7Phenyl - 150 mg 99.8 54.3 92.3 0.2 45.7 7.7______________________________________
Table 3 again demonstrates the differential removal of nicotine and propylene glycol in this very porous resin. The low percentage nicotine reduction makes it easy to contrast the over 50% reduction of propylene glycol. The carbon backbone of propylene glycol is C3, and this apparently accounts for its retention by the C5 resin. The phenyl ring as a rigid planar structure viewed from its side, is actually four carbons long. Together with the amino-propyl arm, the phenyl resin may actually behave like a C7 resin. This also accounts for its selectivity towards the propylene glycol. The 3-amino-propyl resin appears to have a two fold interaction with propylene glycol. The first is the propyl group of the resin with the propylene backbone. Then the resin amino group can hydrogen bond with the glycol-OH. Amino HPLC column is selective for carbohydrates and involves hydrogen bonding between N--H and the cis glycol O--H of carbohydrates. The duality of interactions suggests that the amino resin may show a slight advantage towards propylene glycol in comparison to the C5 and phenyl-resin. Table 4 summarizes the results of the specificity index comparisons.
TABLE 4______________________________________AMINO RESIN SELECTIVITYParticle Nicotine/Propylene Specificity IndexSize Resin Glycol Ratio % of Control______________________________________200 μm Control 0.977 100%200 μm C5 - 50 mg 1.208 124% C5 - 150 mg 1.711 175%200 μm Phenyl - 50 mg 1.476 151% Phenyl- 150 mg 1.797 184%200 μm Amino - 50 mg 1.498 153% Amino - 150 mg 2.30 235%50 μm Control 1.87 100%50 μm Amino - 20 mg 2.69 144% Amino - 40 mg 3.60 193% Amino - 60 mg 3.87 207% Amino - 80 mg 3.72 199% Amino - 100 mg 4.44 237%______________________________________
Table 4 shows the comparison of specificity index for amino resins of two particle sizes to that of C5 and Phenyl resins. The nicotine and propylene glycol are both extracted from the Cambridge filter pads. Additional comparison data seen in Table 6 firmly establish higher selectivity of the amino resin towards propylene glycol.
Finally, the selectivity of the phenyl resin was investigated by comparing the volatile and semi-volatile major aromatic components of the cold trap collected smoke condensate such as benzene, toluene and phenol. The semivolatiles in the cigarette smoke were collected in cold traps (-76° C.) and analyzed by DB624 capillary column with FID detection in a gas chromatograph. Table 5 summarizes the comparisons and demonstrates the selectivity of the phenyl resin towards both benzene and toluene. It also illustrates the selectivity of the amino resin for phenol. Phenol or hydroxy-benzene is weakly acidic in an aqueous laden smoke condensate and therefore may form an ionic interaction with the weak basic amino resin. This explains the selectivity seen in Table 5 of phenol by the amino resin.
TABLE 5______________________________________PHENYL - RESIN SELECTIVITY Benzene Toluene Phenol % % %Resin Type Reduction Reduction Reduction______________________________________Amino-150 mg 43% 70% 78%Amino-150 mg 43% 52% 74%Phenyl-150 mg 68% 88% 64%Phenyl-150 mg 53% 79% 59%C5-150 mg 51% 76% 56%Silica-150 mg 38% 56% 60%______________________________________
All of the above data documents that "Affinity Smoke Chemistry" is valid and that the smoke components obey the principles governing the reverse phase column chromatography. This finding presents unique opportunities for the removal, or at least a reduction in, the level of all unwanted deleterious smoke components from the mainstream smoke of a cigarette.
EXAMPLE 4
The main constraint of smoke chromatography is the flow rate of the puff passing through the resin column. Total flow under the FTC condition is 35 ml per 2 seconds; thus the flow rate is 1.05 liters per minute. The linear velocity of the flow over a 0.5 cm resin column is 2.1 liters/cm/min. This flow rate hitherto is very foreign to any conditions of chromatography, and the resin needs some special treatment to increase the probability of successful encounters between the smoke components and the functional groups. One parameter that directly relates to specificity is the density of functional groups on the resin. When smoke components are accelerating at such a high velocity, the abundance of functional groups may encourage more frequent collision, meandering, probing and testing to result in only high affinity binding. Density of functional group loading in the resin is noted as its capacity. Table 6 examines the resin capacity as a function of the specificity index for nicotine and propylene glycol.
TABLE 6______________________________________SPECIFICITY AS A FUNCTION OF CAPACITYApprox. Capacity Specificity IndexParticle milliequivalent (% of ControlSize per Gm resin Resin Type Ratio NiC/PG)______________________________________ Control 100%Fiber Low 40 mg Glass Fiber, C-5 110% 60 mg, Glass Fiber, C-5 100%50 μm ˜0.1 meq 75 mg, Bead C-18 122% 100 mg, Bead C-18 130% 100 mg, Bead C-18 124%60 μm 0.5 meq 100 mg Bead, NH.sub.2 183% 130 mg, Bead NH.sub.2 197% 100 mg, Bead C-5 168% 130 mg, Bead C-5 164%100 μm 0.6 meq 50 mg, Bead NH.sub.2 203% 50 mg, Bead NH.sub.2 195% 45 mg, Bead C-5 147% 45 mg, Bead C-5 188%200 μm 0.8 meq 50 mg, Bead NH.sub.2 153% 150 mg, Bead NH.sub.2 235% 50 mg, Bead C-5 124% 150 mg, Bead C-5 175%40 μm 1.0 meq 60 mg, Bead NH.sub.2 207% 80 mg, Bead NH.sub.2 199% 100 mg, Bead NH.sub.2 237%______________________________________
As Table 6 illustrates, the higher the capacity, the better the specificity. At the low end when glass fibers are derivitized, the capacity is too low to measure and its specificity index is not very different from the control. The specificity factor increases dramatically when the capacity reaches 0.5 to 0.6 milliequivalent per gram resin. At 0.8 meq./gm to 1.0 meq/gm resin, it is at the maximum value. The selectivity of the amino resin follows the same trend when compared to resin capacity. Indeed the difference in specificity index between the amino and C-5 resins at the lower capacity of 0.5 meq is 20%, however, at 0.8 meq, the specificity indexes of the two resins now differ by 50%. This is consistent with the supposition that the higher the capacity, the easier it is to attain specificity.
The chromatography of smoke components on the resin is limited in time and space. Even at the optimum, the first and the last puff are less specific. When the smoke micelles of the first puff reach the resin surface, there is no competition and all components regardless of affinity can occupy a site on the resin. The last puff is equivalent to the final mobile phase load to the resin column with no additional washing. Each cigarette smoked according to the FTC method has a total of six to seven puffs. When the efficiency of the resin column is at its best, there is still roughly a minimum of 2/7 puffs or 30% error. Experimentally, this was investigated by extracting the resin after a smoking session and studying the specificity of binding for the intended design of the column. Table 7 examines the bound nicotine and propylene glycol (p.g.) on the amino resins.
TABLE 7______________________________________PARTICLE SIZE VS SELECTIVITYApprox. μg/mg resin RatioParticle Size Nicotine Propylene Glycol Nic/PG______________________________________60 μm 30 mg 14.52 12.52 1.16 40 mg 14.99 14.48 1.04 50 mg 12.99 10.18 1.27 60 mg 12.01 9.22 1.30 80 mg 9.31 6.53 1.43 100 mg 7.24 4.55 1.59100 μm 70 mg 5.50 8.83 0.62 100 mg 4.89 7.15 0.68 130 mg 3.47 4.89 0.71200 μm 50 mg* 2.12 6.24 0.34 150 mg* 2.33 4.81 0.48______________________________________ *Assuming total recovery
As Table 7 illustrates, the resin design selects propylene glycol and excludes nicotine. The ratio of nicotine to propylene glycol equal to 0.34 is found in the last row of the table in the 50 mg resin experiment. This ratio indicates high selectivity for propylene glycol and it approaches the theoretical error limit as previously discussed. Ultimately, the superiority of the resin is only recognized for its outcome at the level of the Cambridge filter. In Table 6, the specificity index of this 200 μm, 50 mg resin is 153%. To put this into perspective, the 50 mg resin column faces the most stringent of puffing competition and therefore those molecules that survive the test are very specific. However, because of the length and volume of the resin column, its overall performance is at a disadvantage. When the resin column is increased to 150 mg, the ratio of bound nicotine/p.g. (Table 7) drops to 0.48. However, there is an overwhelming increase in column performance as measured by the specificity index of 235% (Table 6).
The ratio of nicotine/propylene glycol data of Table 7 classifies the resins as a function to particle size roughly into two classes; the 60 μm resins are not specific while the 100 and 200 μm resin columns are more specific. This correlation to particle size can be explained in terms of nonspecific entrapment by the small particle size resins which act like a physical filter. Whereas, with the large particles, the molecules are free to collide, explore, and thus result in specific binding.
EXAMPLE 5
A practical application of the affinity smoke chemistry is to test a C-18 resin of high porosity and particle size of 100-200 μm. The C-18 resin is the most popular reverse phase media in HPLC chromatography because the long aliphatic side-chain has the broadest selectivity. It is a "catch-all" resin. Conversely, many polar flavor molecules of alcohol and aldehyde and some flavor molecules including nicotine show weak interactions with the C-18 resin. Again the resins were placed behind the tobacco rod in tandem and kept in place by a thin layer of glass wool. A hollow acetate filter of 0.5 cm in length was removed from an Eclipse cigarette and used to support the glass wool which indirectly prevented the resin from shifting. Similarly, two hollow acetate filters were used to support the control cigarette as it was tested in the smoking machine. FIG. 1 shows the comparative GC evaluations of the vapor-phase smoke collected in methanol traps of: the resin treated cigarettes, the control cigarettes and the full flavored Eclipse cigarettes. FIG. 1 middle panel, the control chromatogram illustrates many volatile and semivolatile smoke components. A total of about 100 vapor phase smoke components of a burning cigarette have been described in the monograph of "Chemical and Biological Studies On New Cigarette Prototypes That Heat Instead of Burn Tobacco" (R. J. Reynolds Tobacco Company, 1988). Several components in the chromatogram have been assigned identity and these are: benzene at 7.43 mins, internal standard (I.S.) methyl-cyclohexane at 9.48 mins., toluene at 12.76 mins., propylene glycol at 17.2 mins., phenol at 28.8 mins., glycerol at 30.3 mins., quinoline(I.S.) at 36.0 mins. and nicotine at 39.32 mins. The Eclipse vapor phase chromatogram (bottom panel) in comparison to the unfiltered control cigarette is very simple. The most prominent species are: nicotine, glycerol, toluene, and benzene. However, many other smoke components between toluene and glycerol are clearly visible. Also observed are the volatiles that appear at the beginning of the chromatogram, before the benzene peak at 7.4 minutes. At the end of the chromatogram between 45-57 minutes a large number of low level components are indicated. The simple and clean vapor phase chromatogram of Eclipse is therefore a standard for purity of cigarette smoke.
In FIG. 1, top panel, the vapor phase chromatogram of the C-18 puff affinity resin treated cigarette is shown. The resin composition consists of: 50 mg silica (100 μm and 60 Å), 100 mg C-18 resin (100 μm and 60 Å) 100 mg C-18 resin (200 μm and 60 Å) and 100 mg 3 aminopropyl resin (200 μm and 60 Å), and thus contains silica, C-18 and amino functionalities. From a visual examination of the chromatogram, it is readily apparent that the resin treated vapor phase is also relatively simple and clean. In particular, the multitude of semivolatiles and volatiles appearing between the I.S.(methyl-cyclohexane) and glycerol as seen in the control chromatogram are all absent, except for propylene glycol and a trace of toluene and phenol. The resins also have significantly decreased the highly retentive components which are eluted after 54 minutes. There are a few volatile species including benzene at the beginning of the chromatogram. At room temperature these components are very volatile and a small amount may even come off the resin during the smoking session and be retained in the cold trap. In contrast, there is a significant amount of nicotine still present in the smoke even after passage through such a broad spectrum specificity resin.
FIG. 2 (middle panel) shows the vapor phase chromatogram of the combination resin consisting of: 50 mg 3 aminopropyl resin (100 μm and 60 Å) and 300 mg of C-18 resin (100 μm and 60 Å). The total areas of all the vapor phase components were summed and compared to the total integrated areas of the control (FIG. 1, middle panel). The relative areas of the resin treated smoke components were 19.7% of the control integrated areas. Therefore, the control methanol trap vapor phase content was diluted 1:4 and then subjected to GC analysis. The resultant chromatogram (FIG. 2 top panel) is compared to the resin treated GC vapor phase chromatogram. The diluted control serves as a barometer in determining the efficient removal of any smoke component by the C-18 resin. The resin vapor phase profile should resemble the 1:4 diluted control chromatogram, if all smoke components is removed proportionately and non-specifically. Obviously, this is not the case, as the following smoke components of known identity illustrate. The most prominent component is nicotine and it is enhanced by two fold; the resin treated nicotine content is 0.4 mg whereas the 1:4 diluted control is 0.2 mg. Glycerol is even removed less by the C-18 resin and it is four and half times more than the diluted control. By contrast, the removal of toluene and propylene glycol are nearly complete. They are respectively: 7.6% and 22.7% that of the 1:4 diluted control. Benzene is relatively neutral, in that the resin treated content is 75% of the diluted control. Phenol in the resin treated is 51% that of the diluted control. These quantitative comparsion results illustrate that the C-18 and the amino resins are actively removing smoke components on the basis of structural and chemical characteristics. By design, nicotine and other flavor smoke components that possess a positive charge, or which are very polar, are deferentially less removed by the resins. Hence, many of the tobacco specific alkolides such as nornicotine, anatabine, and anabasin will also be differentiated by the C-18 resin. Their exact locations have not been assigned, however, they should reside near quinolin and nicotine. Indeed, several candidate species are clearly visible between 32-46 minutes which like nicotine appear to be significantly less removed than the 1:4 diluted control. As revealed in FIG. 3, the flavor components of menthol and vanillin are eluted in this region of the chromatogram. In provisional taste tests by a knowledgeable smoker, the resin treated cigarette is still flavorful.
The chromatograms of FIG. 1 top and bottom panels further illustrate that the C-18 resin vapor phase is comparable both in simplicity and in the total amount of components to that of the Eclipse. This experiment affirms the uniqueness of the affinity resin technology. The implication is that the cigarette smoke is also safe. This is not surprising since both PAH and nitrosoamines are highly retentive on the C-18 resin in HPLC chromatography. The total tar of the resin treated cigarette as evaluated by spectrophotometry is also decidedly low, only at about 3.5-4.0 mg. The nicotine content is between 0.3-0.4 mg which is about 3-4 times more than the full flavored Eclipse of 0.1 mg.
Similar results were obtained with different combination resins incorporating several large and small particle size resins of 100-200 μm. The capacity of the 100 μm and 200 μm resins were both 0.8 milli-equivalents of C-18 loading per gm of silica. The pressure drops of these resins were measured and shown in Table 8.
TABLE 8______________________________________PRESSURE DROP MEASUREMENTSResin or Filter Pressure drop______________________________________Monoacetate Filter 20 mm 2%300 mg 200 μm 3%Resin 50/300 (50 mg 100 μm 4%300 mg 200 μm)Resin A (135 mg 100 μm 5%200 mg 200 μm)150 mg 100 um 6%200 mg 100 um 7%Resin S0 (150 mg 100 μm 8%200 mg 200 μm)Resin S08 (150 mg 100 μm 8%200 mg 200 μm)______________________________________
The low tar delivery of the resin treated cigarette is not a result of non-specific physical trapping or to a high pressure drop. The 1:4 dilution of control smoke experiment clearly shows that it is due to differential binding. Further, the potential of this technology to produce different marketable cleaner cigarettes is illustrated in FIG. 2. As FIG. 2 (bottom panel) shows, a 150 mg of 100 μm C-18 resin treated cigarette produces a vapor phase GC chromatogram comparable to that of the diluted control, differing primarily in that the nicotine content is almost doubled at 0.8 mg and the tar content is 14 mg. This is equivalent to a full flavored low tar cigarette, except that it has a much cleaner vapor phase smoke. For the 50/300 resin treated cigarette (middle panel), the nicotine content is 0.4 mg. It is equivalent to an ultra low tar cigarette with a higher than normal nicotine and flavor content. These experiments demonstrate the range of cigarette products that can be manufactured by simply adjusting the amount of C-18 resins in the filter.
EXAMPLE 6
The displacement of nicotine by other strong binding smoke components in the puff affinity resin has been illustrated in many of the above experiments. These results suggest that extrinsic flavor can be delivered by a flavor cartridge to the smoker. The flavor can be delivered in large doses or made to release slowly. In the experiment, 50 mg of C-1 resin was loaded by melting 4.2 mg of menthol and 9.6 mg of vanillin in-situ. The resins were carefully placed behind the tobacco rod of a Marlboro cigarette as in the above experiments. The flavor cartridge immediately transformed the full flavored cigarette into a menthol cigarette. FIG. 3 shows the mainstream smoke GC chromatogram of the smoke trapped on a Cambridge filter and extracted by 2-propanol. The menthol delivered is 1.19 mg or 28.2% of the input, however, only a small percentage of vanillin is delivered. This shows the selectivity of the resin binding towards vanillin and not menthol. For vanillin delivery, another bonded phase resin would have to be selected or empirically determined. The menthol delivered by the affinity technology is a controlled release. The flavor is released in each puff; from the first to the last puff. In the monoacetate loaded menthol, the flavor is chronically released because there is no chemical binding. The delivery is most abundant in the first puff and then quickly diminishes with every puff such that in the last few puffs, there is no menthol.
In a limited number of experiments, the loading and delivery of menthol has been further investigated. By melting the menthol in-situ on a smaller cartridge of 30 mg, the percentage delivery was increased to 34.4%. When the menthol was loaded in alcohol and dried by vacuum evaporation, only 4% of the loaded menthol was found on the Cambridge filter. This indicated that most of the menthol was not available for the smoke micelles to displace. Presumably, the menthol must have been lodged in the interior of the resin where the pores of 0.6 μm were limited in accessibility to the smoke micelles of 0.1-1.0 μm. This further suggests that all the affinity experiments thus far are a surface phenomenon. A resin with much larger pores, such as a 5 μm pore size may be used by making available additional interior resin surface.
A low tar menthol cigarette can also be manufactured by adding the menthol cartridge to the C-18 affinity resin. When the flavor cartridge preceded the C-18 affinity resin cartridge, most of the menthol was removed by the C-18 resin. By placing the flavor cartridge (30 mg C-1 resin) behind the C-18 affinity resin, 18.25% of the menthol now become available. The decrease of menthol delivery from 34.4% to 18.25% may reflect the importance of moisture when the resins were located next to the tobacco rod versus far away from it.
The examples provided above are illustrative of the present invention and numerous modifications will be apparent to the skilled artisan. Accordingly, the present invention is not intended to be limited by the foregoing examples, but rather, is defined by the claims which follow and their equivalents. | A smoking article capable of delivering a regulated smoke composition to a smoker, includes: a) a combustible filler wrapped in a combustible sheath; and b) at least one affinity chromatographic filter unit designed to preferentially remove specific targeted components from the smoke disposed within the sheath adjacent the combustible filler. The filter unit includes a mass of silica or resin particles having chemically bonded to their surfaces functional groups which exhibit preferential affinity for the targeted components and which reversibly bind the targeted components to elute components having a lower affinity than a previously bound component. | 0 |
This is a division, of application Ser. No. 08/347,864 filed Dec. 1, 1994 now U.S. Pat. No. 5,639,693.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device which comprises a plurality of semiconductor elements, such as computers, semiconductor image sensors, etc., and a process for fabricating the same.
2. Description of the Related Art
Examples of the known technology for this field include the methods illustrated in FIGS. 8 to 10. Referring to a prior art device illustrated in FIG. 8, a plurality of semiconductor chips 1 are adhered and fixed on a single alumina substrate 2, and the plurality of semiconductor chips 1 are electrically connected one another by gold-wire bonding 18 between the pads 5 on the semiconductor chips 1 and the copper interconnection 6 on the alumina substrate 2. According to another prior art technology with reference to FIG. 9, the active plane of the semiconductor chip 1 having a solder bump 19 previously formed thereon is opposed to the alumina substrate 2 having thereon a copper interconnection 6, and the plane is heated to about 220° C. to melt and adhere the copper interconnection 6 to the solder bump 19. In this manner, the desired electrodes of the plurality of semiconductor chips 1 are electrically connected to obtain the semiconductor device. In another prior art device with reference to FIG. 10, a semiconductor chip 1 having thereon a gold bump 21 is opposed to a tin lead 20 being adhered to a polyimide film 13, and is heated together with the polyimide film to about 400° C. to eutectically join the gold bump 21 on the semiconductor chip 1 with the tin lead. Thus, a plurality of semiconductor chips 1 have been electrically connected by any of the aforementioned processes.
The prior art processes described above are provided for electrically connecting a plurality of semiconductor chips one another, however, following problems were found yet to be solved. In the method of wire bonding the plurality of semiconductor elements with reference to FIG. 8, the use of a wire bonding machine creates several problems. Due to the limitations of the wire bonding machine, a long distance w is necessary for drawing the wire. Thus, at least a distance of 2 w is necessary between two adjacent semiconductor elements, and, moreover, a height of h is required for drawing out the wire. Consequently, the semiconductor device composed of a plurality of semiconductor elements becomes voluminous and thick. Furthermore, since about 0.25 seconds per wire is necessary for the connection, the total process consumes considerable time. This leads to the increase in production cost. Referring to the process comprising connecting a plurality of semiconductor elements via the solder bumps with reference to FIG. 9, the elements are pulled and connected one another by the surface tension of the solder. With increasing size of the semiconductor element, however, warping and thermal deformation occur on the semiconductor elements to generate bumps which cannot be brought into contact with the neighboring bumps. Another prior art process with reference to FIG. 10 is unfeasible to connect the semiconductor elements having a large number of pads, because the capacity of producing the leads is limited to about 400 pins. Moreover, none of the aforementioned processes with reference to FIGS. 8, 9, and 10 can achieve the connection of semiconductor elements having a pitch between pads as short as about 0.1 mm or even narrower.
SUMMARY OF THE INVENTION
The present invention aims to solve the aforementioned problems by a process for fabricating a semiconductor device, which comprises mechanically joining a semiconductor element to an alumina substrate or a polyimide film by adhesion fixing or by using a joint chip, and then electrically connecting the semiconductor elements by forming an electrically conductive coating by means of PVD or CVD on the periphery of the joining portion between the semiconductor elements and patterning the resulting coating as desired by using a processing apparatus such as an excimer laser.
The process according to the present invention as described above implements connection in an extremely small area because it does not need a long distance or height as required in case of effecting wire bonding. Thus, the process enables the fabrication of a compact and thin semiconductor device. Moreover, since the process obviates the need of connecting wires one by one, the connection process consumes less time. This enables the fabrication of semiconductor devices at a low cost. The present process also enables the fabrication of large area semiconductor devices because it can be conducted without any limitations concerning the problems of warping and deformation which affect the process in case of using solder bumps. It is also possible to connect semiconductor elements comprising a considerable number of pads. The use of a processing machine such as an excimer laser in patterning allows connection of very narrowly pitched semiconductor elements, because an excimer laser enables patterning to a pitch as fine as about 0.02 mm. The use of such a processing machine also results in the fabrication of low-cost semiconductor devices, because it allows the fabrication of compact and thin semiconductor devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an upper view of a semiconductor device according to the present invention;
FIG. 2 is a cross section view along line A-A' of a semiconductor device according to the present invention;
FIG 3. is an enlarged upper view of the connecting portion of a semiconductor device according to the present invention;
FIG. 4 is an enlarged cross section view along line B-B' of the connecting portion of a semiconductor device according to the present invention;
FIG. 5 is a cross section view of another semiconductor device according to the present invention;
FIG. 6 is an upper view of a mask for use in the excimer laser according to the present invention;
FIG. 7 is a scheme showing the irradiation state of an excimer laser according to the present invention;
FIG. 8 is a cross section view of a prior art semiconductor device;
FIG. 9 is a cross section view of another prior art semiconductor device;
FIG. 10 is a cross section view of a yet other prior art semiconductor device; and
FIG. 11 is an upper view of a semiconductor device comprising five semiconductor elements being connected according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the attached drawings, examples according to the present invention are described below.
FIG. 1 is the upper view of the semiconductor device of an example according to the present invention. FIG. 2 is the cross section view along line A-A' of the semiconductor device of an example according to the present invention. A semiconductor chip 1 is adhered and fixed using an epoxy-based adhesive 11 to a predetermined position on an alumina substrate 2 having thereon a previously formed copper interconnection 6. A polyimide film 4 about 2 μm in thickness is formed on the surface of said alumina substrate 2 except for the portions corresponding to pads 5 on the semiconductor chip 1 and electrically conductive electrodes 6. An aluminum film 3 for wiring is formed at a thickness of 0.3 μm on the polyimide film 4 to electrically connect between the pads 5 and the copper.
The fabrication process of the present example is described below. First, a semiconductor chip 1 was adhered and fixed using an epoxy-based adhesive 11 to an alumina substrate 2 having thereon a previously formed copper interconnection. A polyimide film 4 was formed thereafter at a thickness of about 2 μm on the entire surface of said alumina substrate 2 by spray coating. The portions of the polyimide film 4 corresponding to the pads 5 on the semiconductor chip 1 and the copper wiring on the alumina substrate 2 were removed by irradiating a laser beam in 5 pulses using an excimer laser operated at an output energy of 300 mJ/cm 2 to perforate holes having an aperture of 0.05×0.05 mm in size. Subsequently, the resulting alumina substrate 2 was placed inside a vacuum chamber (not shown in the figure) of a sputtering apparatus, and after evacuating the inside of the vacuum chamber to have a pressure of about 1×10 -5 Torr, Ar gas was introduced therein to control the inner pressure to about 7×10 -3 Torr. Thereafter, an aluminum film as a target material was deposited at a thickness of about 0.3 μm by applying a sputtering power of about 500 W for a duration of 10 minutes. After forming the aluminum film, referring to FIG. 7, a laser beam 24 emitted from an excimer laser 16 (2 pulses; the laser was operated at 300 mJ/cm 2 ) was reduced to a half by transferring it through a mirror 23 and a lens 17, and was irradiated to the aluminum film using a mask for an excimer laser comprising an aluminum mask pattern 15 formed on a quartz glass 14 at a line width of about 0.04 mm as shown in FIG. 6. In this manner, the aluminum film was removed from portions to which the laser beam was irradiated after being transmitted through the mask having no mask pattern 15 thereon to leave over aluminum electrodes 3. Thus was obtained a semiconductor device comprising a plurality of semiconductor chips 1 electrically connected to one another.
Another example according to the present invention is described below referring to FIG. 3 (an enlarged upper view of the connecting portion) and FIG. 4 (an enlarged cross section view along line B-B' of the connecting portion). Semiconductor elements 7 each comprising on both sides thereof a silicon oxide film 12 and an aluminum pattern 8 formed on the silicon oxide film 12. The aluminum pattern 8 comprises lines formed at a line width of 30 μm and spaced at a distance of 20 μm. The semiconductor elements were each 30 mm in outer width and 60 mm in outer length. Two such semiconductor elements 7 were mechanically joined by adhering glass joint chips 10 to the end portions thereof using an epoxy-based adhesive 11, provided that the glass joint chips 10 have each a trapezoidal cross section and that they were attached in such a manner that the wider plane may correspond to the side of the semiconductor element 7. This step was repeated 4 times to join five semiconductor elements.
FIG. 11 shows the upper view of a complete semiconductor device obtained by joining five semiconductor elements.
After finishing the mechanical joining, the periphery of the joining portions of each of the semiconductor elements 7 was coated with a polyimide film 4 by spray coating, and holes each 0.015 mm in diameter were perforated using an excimer laser 16 at the portions corresponding to the aluminum pattern. After finishing the perforation of holes in the polyimide film 4, aluminum was deposited on the side inner than the polyimide film 4 to a thickness of 0.3 μm using a sputtering apparatus in the same manner as in the foregoing example. Then, the step of forming aluminum electrodes 3 each 0.02 mm in width was effected by removing the aluminum film from the unnecessary portions in the same manner as in the foregoing example, by irradiating laser beam in two pulses using an excimer laser at an output energy of 300 mJ/cm 2 through a quartz glass mask for excimer lasers (not shown in the figure) corresponding to the aluminum pattern 8. This step was repeated on both sides of four places to obtain a semiconductor device comprising a plurality of semiconductor elements being joined to about 300 mm in total length. In the present example, the glass joint chips 10 were used to increase the mechanical strength of the semiconductor device. However, the mechanical joining can be effected using, if necessary, an adhesive alone. Furthermore, the joining can be effected via the cross sections of the joining portions alone. Although glass joint chips 10 were used in the present example, silicon joint chips 10 obtained by processing silicon wafers into a trapezoidal shape by means of anisotropic etching using potassium hydroxide and the like may be used in the place thereof.
Another example is described below with reference to FIG. 5 (cross section view). A semiconductor chip 1 was adhered and fixed on a polyimide film 13 having a thickness of 0.05 to 0.125 mm via an adhesive film 22 provided previously on the polyimide film 13. Upon completing adhesion, the polyimide film 13 and the adhesive film 22 provided at the position corresponding to the pads 5 on the semiconductor chip 1 were removed by irradiating laser beam in 20 pulses using an excimer laser operated at an output energy of 500 mJ/cm 2 . In this manner, holes 9 were perforated at an aperture size of 0.05×0.05 mm. Subsequently, an aluminum film was deposited at a thickness of about 0.3 μm on the substrate by using a sputtering apparatus in the same manner in the foregoing example. Aluminum electrodes 3 each having 0.05 mm in width were formed by removing the aluminum film from the unnecessary portions using the laser beam emitted in two pulses from an excimer laser operated at an output energy of 300 mJ/cm 2 transmitted through the portions having no mask patterns thereon. A semiconductor device comprising the aluminum electrodes 3 formed with 0.05 mm in width and a plurality of semiconductor chips connected on the polyimide film was fabricated in this manner.
The description above was made specifically on an example comprising aluminum electrodes 3 spaced at a distance of 0.02 mm and having a minimum pattern width of 0.02 mm. However, the present fabrication process can be effectively applied to the formation of aluminum electrodes being spaced at a distance of 0.01 mm and having a pattern width of about 0.01 mm. It was also found that no defects such as a change in resistance value and disconnection occurred on the aluminum electrodes formed on the electric connecting portions in weathering tests performed under severe environments such as high temperature and extreme humidity conditions. Although aluminum electrodes were used for the electric connection, other electrode materials such as copper, nickel, and chromium can be used as well. In the example of the present invention, the deposition of the film was conducted by sputtering. However, PVD apparatuses for use in vacuum deposition, ion plating, etc., or those used in plasma-assisted CVD as well as in photochemical vapor deposition can be used in the deposition of films.
The description above was made specifically to a case using an excimer laser for the processing. However, the same effects were obtained by using other processing methods, for example, a process employing laser apparatuses such as YAG laser and the like, or a process using an ion beam.
As described in the foregoing Examples, the present invention enables a connection at a pitch width of 0.02 mm. This pitch width is extremely narrow as compared with any other achieved in the prior art processes, and it allows the fabrication of a compact and thin semiconductor device, because the area necessary for the connection can be reduced. Furthermore, since the process obviates the need of connecting wires one by one, the connection process consumes less time. This consequently enables the fabrication of semiconductor devices at a low cost. The present process also enables the fabrication of large area devices because it can be carried out without any limitations concerning the warping and deformation which affect the process in case of using solder bumps. Furthermore, since it is not required to produce leads, it is also possible to connect semiconductor elements comprising a considerable number of pads. | A semiconductor device comprises at least two semiconductor elements connected together at a connecting region of the semiconductor elements. At least one joint chip is adhered to the connection region of the semiconductor elements for connecting the semiconductor elements together. The joint chip has a trapezoidal cross-section defining a first surface and a second surface wider than the first surface. The second surface of the joint chip is adhered to the connection region of the semiconductor elements. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 10/052,927 filed on Nov. 7, 2001 now U.S. Pat. No. 6,642,252, which claims the benefit of U.S. Provisional Application No. 60/246,392, filed Nov. 7, 2000; all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to processes for the preparation of acid derivatives that are inhibitors of serine proteases such as Factor VIIa, Factor IXa, Factor Xa, Factor FXIa, tryptase, and urokinase. In particular, this invention relates to processes for prepartion of 1-aminoisoquinolines and related analouges, which are key intermediates for the synthesis of the acid derivatives. These acid derivatives are useful as anticoagulants in treating and preventing cardiovascular diseases, as anti-inflammatory agents, and as metastasis inhibitors in treating cancer.
BACKGROUND OF THE INVENTION
Early preparation of 1-aminoisoquinoline involved direct treatment of isoquinoline with an alkali amide such as sodium amide and potassium amide (NaNH 2 , KNH2) via a Chichibabin type of reaction (for a review on Chichibabin reaction, see: McGill, C. K. and Rappa, A. Advances in Heterocyclic Chemistry , 1988, 44, 1-79). While this reaction is straight foreword for simple isoquinolines, it does not work well with those isoquinolines that have functional groups imcompatible with harsh condition using alkali amide (Rewinkel, J. B. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 685).
A more general approach to 1-aminoisoquinolines involves transformation of 1-hydroxyisoquinolines. In this approach the 1-hydroxy group was first converted to a better leaving group such as halides and phenoxides, followed by an aminolysis (Sanders, G. M., et al. Recl. Trav. Chim. Pays - Bas . 1974, 93, 198; Nuvole, A. and Pinna, G. A. J. Heterocyclic Chem . 1978, 15, 1513; Rewinkel, J. B. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 685; Rewinkel, J. B. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 2837; Zhang, P. et al. Bioorganic & Medicinal Chemistry Letters , 2002, 12, 1657; Choi-Sledeski, Y. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 2539). The 1-hydroxyisoquinolines starting materials used in this method were obtained by: (1) thermolysis of cinnamoyl azides (Choi-Sledeski, Y. M. et al. Bioorganic & Medicinal Chemistry Letters, 1999, 9, 2539); (2) oxidation of isoquinolines to isoquinoline N-oxides using peracids followed by rearrangement (Ochiai, K. Pharm Bull . 1957, 5, 606); or less commonly, transformation of 2-(β-carbamylvinyl)benzonitriles (Gabriel, Chem. Ber . 1916, 49, 1612). Direct transformation of isoquinoline N-oxides to 1-haloisoquinolines has also been reported (Rewinkel, J. B. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 685; Rewinkel, J. B. M. et al. Bioorganic & Medicinal Chemistry Letters , 1999, 9, 2837). This approach, however, suffered from long reaction sequences, use of hazardous reagents such as peracides and intermediates such as acyl azides.
Reaction of 2-methylbenzonitrile with 1-(t-butoxy)-N,N,N′,N′-tetramethylmethanediamine to give 2-(2-dimethylaminovinyl)benzonitrile has been reported (Fisher, U. et al. Helvetica Chimica Acta , 1990, 73, 763).
SUMMARY OF THE INVENTION
The present invention is directed to a process for preparing an amino isoquinoline of the structure:
which comprises
(a) reacting a cyanostyrene compound of the structure:
with lithium hexamethyl disilane to form the aminoisoquinoline; or (b) reacting a cyanostyrene of the structure:
with 2,4-dimethoxylbenzylamine to form an isoquinoline of the structure
and reacting the isoquinoline with anisole to form the aminoisoquinoline.
This invention is also directed to a process for making a benzylamino isoquinoline compound of the structure:
which comprises preparing an aminoisoquinoline
and employing the aminoisoquinoline to prepare the benzylaminoisoquinoline compound.
This invention is also directed to a process for preparing a compound of formula (I):
or a pharmaceutically-acceptable salt, hydrate or prodrug thereof, wherein:
W is selected from C 2-10 alkyl, C 2-10 alkenyl, substituted C 2-10 alkyl, substituted C 2-10 alkenyl, —C(═O)NR 4 R 5 , —OR 6 , —CO 2 R 4 , —C(═O)R 4 , —SR 4 , —S(O) p R 4 , —NR 4 R 5 , —NR 4 SO 2 R 5 , —NR 4a SO 2 NR 4 R 5 , —NR 4 CO 2 R 5 , —NR 4 C(═O)R 5 , —NR 4a C(═O)NR 4 R 5 , —SO 2 NR 4 R 5 , heterocyclo, heteroaryl, aryl, and cycloalkyl;
ring B is phenyl or pyridyl;
X 2 is N, CH, or C, provided that X 2 is C when R 1 and R 2 join to form a fully unsaturated ring;
L is —(CR 18 R 19 ) s —Y—(CR 18a R 19a ) t ;
Y is selected from —C(═O), —C(═O)NR 13 —, —NR 13 C(═O)—, —NR 13 CR 14 R 15 —, —CR 14 R 15 —NR 13 —, and —CR 13 R 14 —CR 15 R 16 —;
Z is a 5 to 7-membered monocyclic or 8 to 11-membered bicyclic aryl, heteroaryl, heterocyclo, or cycloalkyl, wherein each Z group is optionally substituted with up to two R 20 and/or up to one R 21 , except Z is not phenyl substituted with phenyloxy when W is methoxy, s is 0 and Y is —CH 2 —CH 2 —;
R 1 and R 2 (i) are independently selected from hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, heteroaryl, aryl, heterocyclo, and cycloalkyl; or (ii) are taken together to form an aryl, heteroaryl, cycloalkyl, or heterocyclo, provided that R 1 and R 2 do not together form pyrazole when W is methoxy and Z is biphenyl; and when R 1 and R 2 individually or together form a heteroaryl, aryl, heterocyclo, or cycloalkyl, said cyclic group is optionally substituted with up to three R 26 ;
R 3 is hydrogen, alkyl, substituted alkyl, heteroaryl, aryl, heterocyclo, cycloalkyl, or alkyl substituted with —OC(═O)R 24 or —OC(═O)OR 24 , wherein R 24 is alkyl, substituted alkyl, or cycloalkyl, provided that R 3 is not phenyl when W is methoxy;
R 4 , R 4a , R 5 and R 6 are (i) independently selected from hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, heteroalkyl, substituted heteroalkyl, aryl, heteroaryl, heterocyclo, and cycloalkyl; or alternatively, (ii) R 4 and R 5 may be taken together to form a five-to-seven membered heteroaryl or heterocyclo, except when W is —S(O) p R 4 , then R 4 is not hydrogen;
R 8 and R 26 (i) are at each occurrence independently selected from hydrogen, OR 30 , NR 31 R 32 , NR 31 SO 2 R 32a , alkyl, alkenyl, substituted alkyl, substituted alkenyl, halogen, haloalkyl, haloalkoxy, cyano, nitro, alkylthio, —C(═O)H, acyl, —CO 2 H, alkoxycarbonyl, sulfonamido, sulfonyl, and phenyl, or (ii) two of R 8 and/or two of R 26 may be taken together to form a fused benzo ring, a fused heteroaryl, a fused cycloalkyl, or a fused heterocyclo other than a five or six membered heterocyclo having as its heteroatoms two oxygen atoms, provided further that when two R 26 form a fused benzo ring, then Z is not phenyl substituted in the para position with cyano or a five-membered heterocycle or heteroaryl;
R 13 , R 14 , R 15 , R 16 , R 18 , R 18a , R 19 , and R 19a are selected from hydrogen, lower alkyl, hydroxy, and lower alkyl substituted with hydroxy or halogen;
R 20 and R 21 are independently selected at each occurrence from hydrogen, halogen, alkyl, substituted alkyl, haloalkyl, haloalkoxy, cyano, nitro, —C(═O)NR 22 R 23 , —OR 22 , —CO 2 R 22 , —C(═O)R 22 , —SR 22 , —S(O) q R 22a , —NR 22 R 23 , —NR 22 SO 2 R 23 , —NR 22 CO 2 R 23 , —NR 22 C(═O)R 23 , —NR 22 C(═O)NR 23 R 33 , —SO 2 NR 22 R 23 , —NR 22 SO 2 NR 23 R 33 , five or six membered heterocyclo or heteroaryl, phenyl, and four to seven membered cycloalkyl, wherein when R 20 and/or R 21 independent of each other comprise a cyclic group, each cyclic group in turn is optionally substituted with up to three of C 1-4 alkyl, C 1-4 alkoxy, halogen, hydroxy, haloalkyl, haloalkoxy, amino, alkylamino, and/or cyano;
R 22 , R 23 and R 33 are independently selected from hydrogen, alkyl, and substituted alkyl;
R 22a is alkyl or substituted alkyl;
R 30 at each occurrence is selected from hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, cycloalkyl, and phenyl;
R 31 and R 32 at each occurrence are independently selected from hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, and cycloalkyl;
R 32a is alkyl, substituted alkyl, alkenyl, substituted alkenyl, or cycloalkyl;
m is 0, 1 or 2 when ring B is phenyl and 0 or 1 when ring B is pyridyl;
p and q are independently 1 or 2; and
s and t are independently 0, 1 or 2;
which comprises
(a) reacting a cyanostyrene of the structure:
with lithium hexamethyl disilane to form an aminoisoquinoline of the structure:
or (b) reacting the cyanostyrene with 2-4-dimethoxylbenzylamine to form an isoquinoline of the structure:
and reacting the isoquinoline with anisole to form the aminoisoquinoline, and employing the aminoisoquinoline to form the compound of formula (I).
Also included within the scope of the invention are novel intermediates utilized in the process.
DETAILED DESCRIPTION OF THE INVENTION
The following are definitions of terms used in this specification. The initial definition provided for a group or term herein applies to that group or term throughout this specification, individually or as part of another group, unless otherwise indicated.
The term “alkyl” refers to straight or branched chain hydrocarbon groups having 1 to 12 carbon atoms, preferably 1 to 8 carbon atoms. Lower alkyl groups, that is, alkyl groups of 1 to 4 carbon atoms, are most preferred.
When numbers appear in a subscript after the symbol “C”, the subscript defines with more specificity the number of carbon atoms that a particular group may contain. For example, “C 1-6 alkyl” refers to straight and branched chain alkyl groups with one to six carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-pentyl, and so forth.
The term “substituted alkyl” refers to an alkyl group as defined above having one, two, or three substituents selected from the group consisting of halo, alkenyl, alkynyl, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, —CO 2 -alkyl, —C(═O)alkyl, —S(O) 2 (alkyl), keto (═O), aryl, heteroaryl, heterocyclo, and cycloalkyl, including phenyl, benzyl, phenylethyl, phenyloxy, and phenylthio. The substituents for “substituted alkyl” groups may also be selected from the group consisting of —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, and —NR′SO 2 ′R″, wherein each of R′ and R″ is independently selected from hydrogen, alkyl, cycloalkyl, and alkyl substituted with one to two of alkenyl, halogen, haloalkyl, haloalkoxy, cyano, nitro, hydroxy, alkoxy, alkylthio, amino, alkylamino, phenyl, benzyl, phenyloxy, and benzyloxy. Alternatively, R′ and R″ may together form a heterocyclo or heteroaryl ring. When a substituted alkyl includes an aryl, heterocyclo, cycloalkyl, or heteroaryl substituent, said ringed systems are as defined below and thus may have zero, one, two, or three substituents, also as defined below.
When the term “alkyl” is used in conjunction with another group, e.g., arylalkyl, hydroxyalkyl, etc., the term defines with more specificity a particular substituent that a substituted alkyl will contain. For example, arylalkyl refers to a substituted alkyl group having from 1 to 12 carbon atoms and at least one aryl substituent, and “lower arylalkyl” refers to substituted alkyl groups having 1 to 4 carbon atoms and at least one aryl substituent.
The term “alkenyl” refers to straight or branched chain hydrocarbon groups having 2 to 12 carbon atoms and at least one double bond. Alkenyl groups of 2 to 6 carbon atoms and having one double bond are most preferred.
The term “alkynyl” refers to straight or branched chain hydrocarbon groups having 2 to 12 carbon atoms and at least one triple bond. Alkynyl groups of 2 to 6 carbon atoms and having one triple bond are most preferred.
The term “alkylene” refers to bivalent straight or branched chain hydrocarbon groups having 1 to 12 carbon atoms, preferably 1 to 8 carbon atoms, e.g., {—CH 2 —} n , wherein n is 1 to 12, preferably 1-8. Lower alkylene groups, that is, alkylene groups of 1 to 4 carbon atoms, are most preferred. The terms “alkenylene” and “alkynylene” refer to bivalent radicals of alkenyl and alkenyl groups, respectively, as defined above.
When reference is made to a substituted alkylene, alkenylene, or alkynylene group, these groups are substituted with one to three substitutents as defined above for alkyl groups. A ringed substituent of an alkyl, alkenyl, alkynyl, alkylene, alkenylene, or alkynylene may be joined at a terminal atom or an available intermediate (branch or chain) atom and thus may comprise, for example, the groups:
and so forth.
The term “alkoxy” refers to an alkyl group as defined above having one, two or three oxygen atoms (—O—) in the alkyl chain. For example, the term “alkoxy” includes the groups —O—C 1-2 alkyl, —C 1-6 alkylene-O—C 1-6 alkyl, —C 1-4 alkylene-O—C 1-4 alkylene-O—C 1-4 alkyl, O—C 1-4 alkylene-O—C 1-4 alkylene-O—C 1-4 alkyl, and so forth.
The term “alkylthio” refers to an alkyl group as defined above bonded through one or more sulfur (—S—) atoms. For example, the term “alkylthio” includes the groups —S—C 1-2 alkyl, —S 1-6 alkylene-S—C 1-6 alkyl, etc.
The term “alkylamino” refers to an alkyl group as defined above bonded through one or more nitrogen (—NR—) groups. The term alkylamino refers to straight and branched chain groups and thus, for example, includes the groups —NH(C 1-12 alkyl) and —N(C 1-6 alkyl) 2 .
When a subscript is used with reference to an alkoxy, alkylthio or alkylamino, the subscript refers to the number of carbon atoms in the group in addition to heteroatoms. Thus, for example, monovalent C 1-2 alkylamino includes the groups —NH—CH 3 , —NH—CH 2 —CH 3 , and —N—(CH 3 ) 2 . A lower alkylamino comprises an alkylamino having from one to four carbon atoms.
When reference is made to a substituted alkoxy or alkylthio, the carbon atoms of said groups are substituted with one to three substituents as defined above for alkyl groups. When reference is made to a substituted alkylamino, the carbon and/or nitrogen atoms of these groups are substituted with one to three substitutents appropriately selected from the group of substituents recited above for alkyl groups. Additionally, the alkoxy, alkylthio, or alkylamino groups may be monovalent or bivalent. By “monovalent” it is meant that the group has a valency (i.e., power to combine with another group), of one, and by “bivalent” it is meant that the group has a valency of two. Thus, for example, a monovalent alkoxy includes groups such as —O—C 1-12 alkyl and —C 1-6 alkylene-O—C 1-6 alkyl, whereas a bivalent alkoxy includes groups such as —O—C 1-12 alkylene- and —C 1-6 alkylene-O—C 1-6 alkylene-, etc.
The term “heteroalkyl” is used herein to refer saturated and unsaturated straight or branched chain hydrocarbon groups having 2 to 12 carbon atoms, preferably 2 to 8 carbon atoms, wherein one, two or three carbon atoms in the straight chain are replaced by a heteroatom (O, S or N). Thus, the term “heteroalkyl” includes alkoxy, alkylthio, and alkylamino groups, as defined above, as well as alkyl groups having a combination of heteroatoms selected from O, S, or N. A “heteroalkyl” herein may be monovalent or bivalent, and for example, may comprise the groups —O—(CH 2 ) 2-5 NH—(CH 2 ) 2 — or —O—(CH 2 ) 2-5 NH—CH 3 , etc. A “substituted heteroalkyl” has one to three substituents appropriately selected from those recited above for alkyl groups.
The term “acyl” refers to a carbonyl group
linked to an organic radical including an alkyl, alkenyl, alkynyl, substituted alkyl, substituted alkenyl, or substituted alkynyl group, as defined above.
The term “alkoxycarbonyl” refers to a carboxy or ester group
linked to an organic radical including an alkyl, alkenyl, alkynyl, substituted alkyl, substituted alkenyl, or substituted alkynyl group, as defined above.
The term “halo” or “halogen” refers to chloro, bromo, fluoro and iodo.
The term “haloalkyl” means an alkyl having one or more halo substituents, e.g., including trifluoromethyl.
The term “haloalkoxy” means an alkoxy group having one or more halo substituents. For example, “haloalkoxy” includes —OCF 3 .
The term “sulfonyl” refers to a sulphoxide group (i.e., —S(O) 1-2 —) linked to an organic radical including an alkyl, alkenyl, alkynyl, substituted alkyl, substituted alkenyl, or substituted alkynyl group, as defined above. The organic radical to which the sulphoxide group is attached may be monovalent (e.g., —SO 2 -alkyl), or bivalent (e.g., —SO 2 -alkylene, etc.)
The term “sulfonamide” refers to the group —S(O) 2 NR′R″, wherein R′ and R″ may be hydrogen or alkyl, alkenyl, alkynyl, substituted alkyl, substituted alkenyl, or substituted alkynyl, as defined above. R′ and R″ may be monovalent or bivalent (e.g., —SO 2 —NH-alkylene, etc.)
The term “aryl” refers to phenyl, biphenyl, 1-naphthyl and 2-naphthyl, with phenyl being preferred. The term “aryl” includes such rings having zero, one, two or three substituents selected from the group consisting of halo, alkyl, alkenyl, alkynyl, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, cycloalkyl, heterocyclo, heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, —NR′SO 2 ′R″, and/or alkyl substituted with one to three of halo, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, cycloalkyl, heterocyclo, heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, and/or —NR′SO 2 ′R″, wherein each of R′ and R″ is independently selected from hydrogen, alkyl, alkoxy, hydroxyalkyl, and arylalkyl, or R′ and R″ together form a heterocyclo or heteroaryl ring. When an aryl is substituted with a further ring, said ring may in turn be substituted with one to three of halogen, haloalkyl, haloalkoxy, cyano, nitro, hydroxy, alkoxy, alkylthio, amino, alkylamino, phenyl, benzyl, phenyloxy, and benzyloxy.
The term “cycloalkyl” refers to fully saturated and partially unsaturated hydrocarbon rings of 3 to 9, preferably 3 to 7 carbon atoms. The term “cycloalkyl” includes such rings having zero, one, two, or three substituents, preferably zero or one, selected from the group consisting of halo, alkyl, alkenyl, alkynyl, nitro, cyano, oxo (═O), hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, keto, ═N—OH, ═N—O-alkyl, heteroaryl, heterocyclo, a five or six membered ketal (i.e. 1,3-dioxolane or 1,3-dioxane), a four to seven membered carbocyclic ring, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, —NR′SO 2 ′R″, and/or alkyl substituted with one to three of halo, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, a four to seven membered carbocyclic ring, heterocyclo, heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, and/or —NR′SO 2 ′R″, wherein each of R′ and R″ is independently selected from hydrogen, alkyl, alkoxy, hydroxyalkyl, and arylalkyl, or R′ and R″ together form a heterocyclo or heteroaryl ring. When a cycloalkyl is substituted with a further ring, said ring may in turn be substituted with one to three of halogen, haloalkyl, haloalkoxy, cyano, nitro, hydroxy, alkoxy, alkylthio, amino, alkylamino, phenyl, benzyl, phenyloxy, and benzyloxy.
The term “heterocyclo” refers to substituted and unsubstituted non-aromatic 3 to 7 membered monocyclic groups, 7 to 11 membered bicyclic groups, and 10 to 15 membered tricyclic groups which have at least one heteroatom (O, S or N) in at least one of the rings. Each ring of the heterocyclo group containing a heteroatom can contain one or two oxygen or sulfur atoms and/or from one to four nitrogen atoms, provided that the total number of heteroatoms in each ring is four or less, and further provided that the ring contains at least one carbon atom. The fused rings completing the bicyclic and tricyclic groups may contain only carbon atoms and may be saturated, partially saturated, or unsaturated. The nitrogen and sulfur atoms may optionally be oxidized and the nitrogen atoms may optionally be quaternized. The heterocyclo group may be attached at any available nitrogen or carbon atom. The heterocyclo ring may contain zero, one, two or three substituents selected from the group consisting of halo, alkyl, alkenyl, alkynyl, nitro, cyano, oxo, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, keto, ═N—OH, ═N—O-alkyl, aryl, heteroaryl, cycloalkyl, a five or six membered ketal (i.e. 1,3-dioxolane or 1,3-dioxane), —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, —NR′SO 2 ′R″, and/or alkyl substituted with one to three of halo, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, cycloalkyl, heterocyclo, heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, and/or —NR′SO 2 ′R″, wherein each of R′ and R″ is independently selected from hydrogen, alkyl, alkoxy, hydroxyalkyl, and arylalkyl, or R′ and R″ together form a heterocyclo or heteroaryl ring. When a heterocyclo is substituted with a further ring, said ring may in turn be substituted with one to three of halogen, haloalkyl, haloalkoxy, cyano, nitro, hydroxy, alkoxy, alkylthio, amino, alkylamino, phenyl, benzyl, phenyloxy, and benzyloxy.
Exemplary monocyclic groups include azetidinyl, pyrrolidinyl, oxetanyl, imidazolinyl, oxazolidinyl, isoxazolinyl, thiazolidinyl, isothiazolidinyl, tetrahydrofuranyl, piperidinyl, piperazinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolodinyl, 2-oxoazepinyl, azepinyl, 4-piperidonyl, tetrahydropyranyl, morpholinyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiamorpholinyl sulfone, 1,3-dioxolane and tetrahydro-1,1-dioxothienyl and the like. Exemplary bicyclic heterocyclo groups include quinuclidinyl.
The term “heteroaryl” refers to substituted and unsubstituted aromatic 5 or 6 membered monocyclic groups, 9 or 10 membered bicyclic groups, and 11 to 14 membered tricyclic groups which have at least one heteroatom (O, S or N) in at least one of the rings. Each ring of the heteroaryl group containing a heteroatom can contain one or two oxygen or sulfur atoms and/or from one to four nitrogen atoms provided that the total number of heteroatoms in each ring is four or less and each ring has at least one carbon atom. The fused rings completing the bicyclic and tricyclic groups may contain only carbon atoms and may be saturated, partially saturated, or unsaturated. The nitrogen and sulfur atoms may optionally be oxidized and the nitrogen atoms may optionally be quaternized. Heteroaryl groups which are bicyclic or tricyclic must include at least one fully aromatic ring but the other fused ring or rings may be aromatic or non-aromatic. The heteroaryl group may be attached at any available nitrogen or carbon atom of any ring. The heteroaryl ring system may contain zero, one, two or three substituents selected from the group consisting of halo, alkyl, alkenyl, alkynyl, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, cycloalkyl, heterocyclo, a further monocyclic heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, —NR′SO 2 ′R″, and/or alkyl substituted with one to three of halo, nitro, cyano, hydroxy, alkoxy, alkylthio, —CO 2 H, —C(═O)H, CO 2 -alkyl, —C(═O)alkyl, phenyl, benzyl, phenylethyl, phenyloxy, phenylthio, cycloalkyl, heterocyclo, heteroaryl, —NR′R″, —C(═O)NR′R″, —CO 2 NR′R″, —NR′CO 2 ′R″, —NR′C(═O)R″, —SO 2 NR′R″, and/or —NR′SO 2 ′R″, wherein each of R′ and R″ is independently selected from hydrogen, alkyl, alkoxy, hydroxyalkyl, and arylalkyl, or R′ and R″ together form a heterocyclo or heteroaryl ring. When a heteroaryl is substituted with a further ring, said ring may in turn be substituted with one to three of halogen, haloalkyl, haloalkoxy, cyano, nitro, hydroxy, alkoxy, alkylthio, amino, alkylamino, phenyl, benzyl, phenyloxy, and benzyloxy.
Exemplary monocyclic heteroaryl groups include pyrrolyl, pyrazolyl, pyrazolinyl, imidazolyl, oxazolyl, isoxazolyl, thiazolyl, thiadiazolyl, isothiazolyl, furanyl, thienyl, oxadiazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, triazinyl and the like.
Exemplary bicyclic heteroaryl groups include indolyl, benzothiazolyl, benzodioxolyl, benzoxaxolyl, benzothienyl, quinolinyl, tetrahydroisoquinolinyl, isoquinolinyl, benzimidazolyl, benzopyranyl, indolizinyl, benzofuranyl, chromonyl, coumarinyl, benzopyranyl, cinnolinyl, quinoxalinyl, indazolyl, pyrrolopyridyl, furopyridinyl, dihydroisoindolyl, tetrahydroquinolinyl and the like.
Exemplary tricyclic heteroaryl groups include carbazolyl, benzidolyl, phenanthrollinyl, acridinyl, phenanthridinyl, xanthenyl and the like.
The term “carbocyclic” refers to optionally substituted aromatic or non-aromatic 3 to 7 membered monocyclic and 7 to 11 membered bicyclic groups, in which all atoms of the ring or rings are carbon atoms.
When the term “unsaturated” is used herein to refer to a ring or group, the ring or group may be fully unsaturated or partially unsaturated.
The term “metal ion” refers to alkali metal ions such as sodium, potassium or lithium and alkaline earth metal ions such as magnesium and calcium, as well as zinc and aluminum.
Whenever a bond appears in a formula as a dashed-double bond, i.e., with one bond appearing as a dash as in
it should be understood that such bonds may be selected from single or double bonds, as appropriate given the selections for adjacent atoms and bonds. For example, in formula I, above, when X 2 is N or CH, the bonds linking R 1 to X 2 and X 2 to C 6 are single bonds; and when X 2 is C, one of the bonds linking X 2 to an adjacent atom is a double bond, i.e., either a bond to R 1 or to C 6 is a double bond.
It should be understood that one skilled in the field may make various substitutions for each of the groups recited in the claims herein, without departing from the spirit or scope of the invention. For example, one skilled in the field may replace a W group recited in the claims with a cyano, halogen, or methyl group. The linker group “L” recited in the claims may be replaced with the group —(R′) u —Y′—(R″) v — wherein Y′ is a Y group recited in formula (I), is a bond, or is selected from —C(═O)—, —[C(═O)] 2 —, —O—, —NR—, —C(═NR)—, —S(O) 1-2 —, —NRC(═O)NR—, —NRSO 2 —, or —SO 2 NR—, wherein R is selected from hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, a heterocyclo or carbocyclic ring, and so forth, R′ and R″ may comprise substituted or unsubstituted alkylene, alkenylene, or alkynylene, and u and v may be 0-4. Additionally, the acid group —CO 2 R 3 may be joined to the phenyl or pyridyl ring B with a linker such as a methylene group or replaced with other acid functional groups such as —SO 3 H, —P(═O)(OR) 2 , —SO 2 NHC(═O)R, —C(═O)NHSO 2 R, —C(═O)NHOH, —[C(═O)] 2 OR, or tetrazole, wherein R is hydrogen, alkyl, substituted alkyl, cycloalkyl, and so forth.
It should be further understood that for compounds of formula (I), the linker group “L” is inserted into the formula (I) in the same direction set forth in the text. Thus, for example, if L is recited as —CH 2 —Y—, this means the —CH 2 — group is attached to Z, and the Y group is attached to the C 6 carbon atom i.e., to which X 2 is attached, as in:
Likewise, when Y is recited as —NR 13 C(═O)—, the carbonyl group C(═O) is attached to the C 6 carbon atom and the nitrogen group —NR 13 — is attached to Z, as in many Examples herein. Conversely, when Y is recited as —C(O)NR 13 —, this means the carbonyl group C(═O) is attached to Z and the nitrogen group —NR 13 — is attached to the C 6 carbon atom.
Throughout the specification, groups and substituents thereof may be chosen by one skilled in the field to provide stable moieties and compounds.
The compounds of formula (I) form salts which are also within the scope of this invention. Unless otherwise indicated, reference to an inventive compound is understood to include reference to salts thereof. The term “salt(s)” denotes acidic and/or basic salts formed with inorganic and/or organic acids and bases. In addition, the term “salt(s) may include zwitterions (inner salts), e.g., when a compound of formula I contains both a basic moiety, such as an amine or a pyridine or imidazole ring, and an acidic moiety, such as a carboxylic acid. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, such as, for example, acceptable metal and amine salts in which the cation does not contribute significantly to the toxicity or biological activity of the salt. However, other salts may be useful, e.g., in isolation or purification steps which may be employed during preparation, and thus, are contemplated within the scope of the invention. Salts of the compounds of the formula (I) may be formed, for example, by reacting a compound of the formula (I) with an amount of acid or base, such as an equivalent amount, in a medium such as one in which the salt precipitates or in an aqueous medium followed by lyophilization.
Exemplary acid addition salts include acetates (such as those formed with acetic acid or trihaloacetic acid, for example, trifluoroacetic acid), adipates, alginates, ascorbates, aspartates, benzoates, benzenesulfonates, bisulfates, borates, butyrates, citrates, camphorates, camphorsulfonates, cyclopentanepropionates, digluconates, dodecylsulfates, ethanesulfonates, fumarates, glucoheptanoates, glycerophosphates, hemisulfates, heptanoates, hexanoates, hydrochlorides (formed with hydrochloric acid), hydrobromides (formed with hydrogen bromide), hydroiodides, 2-hydroxyethanesulfonates, lactates, maleates (formed with maleic acid), methanesulfonates (formed with methanesulfonic acid), 2-naphthalenesulfonates, nicotinates, nitrates, oxalates, pectinates, persulfates, 3-phenylpropionates, phosphates, picrates, pivalates, propionates, salicylates, succinates, sulfates (such as those formed with sulfuric acid), sulfonates (such as those mentioned herein), tartrates, thiocyanates, toluenesulfonates such as tosylates, undecanoates, and the like.
Exemplary basic salts include ammonium salts, alkali metal salts such as sodium, lithium, and potassium salts; alkaline earth metal salts such as calcium and magnesium salts; barium, zinc, and aluminum salts; salts with organic bases (for example, organic amines) such as trialkylamines such as triethylamine, procaine, dibenzylamine, N-benzyl-β-phenethylamine, 1-ephenamine, N,N′-dibenzylethylene-diamine, dehydroabietylamine, N-ethylpiperidine, benzylamine, dicyclohexylamine or similar pharmaceutically acceptable amines and salts with amino acids such as arginine, lysine and the like. Basic nitrogen-containing groups may be quaternized with agents such as lower alkyl halides (e.g., methyl, ethyl, propyl, and butyl chlorides, bromides and iodides), dialkyl sulfates (e.g., dimethyl, diethyl, dibutyl, and diamyl sulfates), long chain halides (e.g., decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides), aralkyl halides (e.g., benzyl and phenethyl bromides), and others. Preferred salts include monohydrochloride, hydrogensulfate, methanesulfonate, phosphate or nitrate.
Prodrugs and solvates of the inventive compounds are also contemplated. The term “prodrug” denotes a compound which, upon administration to a subject, undergoes chemical conversion by metabolic or chemical processes to yield a compound of the formula I, and/or a salt and/or solvate thereof. Various forms of prodrugs are well known in the art. For examples of such prodrug derivatives, see:
a) Design of Prodrugs, edited by H. Bundgaard, (Elsevier, 1985) and Methods in Enzymology, Vol. 42, p. 309-396, edited by K. Widder, et al. (Acamedic Press, 1985);
b) A Textbook of Drug Design and Development, edited by Krosgaard-Larsen and H. Bundgaard, Chapter 5, “Design and Application of Prodrugs,” by H. Bundgaard, p. 113-191 (1991); and
c) H. Bundgaard, Advanced Drug Delivery Reviews, 8, 1-38 (1992), each of which is incorporated herein by reference.
Compounds containing a carboxy group can form physiologically hydrolyzable esters which serve as prodrugs by being hydrolyzed in the body to yield formula I compounds per se. For example, in compounds of formula (I), prodrugs comprise compounds wherein the upper ring substituent —CO 2 R 3 is a group that will hydrolyze in the body to compounds where said substituent is —CO 2 H. Such prodrugs are preferably administered orally since hydrolysis in many instances occurs principally under the influence of the digestive enzymes. Parenteral administration may be used where the ester per se is active, or in those instances where hydrolysis occurs in the blood. Examples of physiologically hydrolyzable esters of compounds of formula (I) include C 1-6 alkylbenzyl, 4-methoxybenzyl, indanyl, phthalyl, methoxymethyl, C 1-6 alkanoyloxy-C 1-6 alkyl, e.g. acetoxymethyl, pivaloyloxymethyl or propionyloxymethyl, C 1-6 alkoxycarbonyloxy-C 1-6 alkyl, e.g. methoxycarbonyloxymethyl or ethoxycarbonyloxymethyl, glycyloxymethyl, phenylglycyloxymethyl, (5-methyl-2-oxo-1,3-dioxolen-4-yl)-methyl and other well known physiologically hydrolyzable esters used, for example, in the penicillin and cephalosporin arts. Such esters may be prepared by conventional techniques known in the art.
Compounds of formula (I) and salts thereof may exist in their tautomeric form, in which hydrogen atoms are transposed to other parts of the molecules and the chemical bonds between the atoms of the molecules are consequently rearranged. It should be understood that the all tautomeric forms, insofar as they may exist, are included within the invention. Additionally, inventive compounds may have trans and cis isomers and may contain one or more chiral centers, therefore existing in enantiomeric and diastereomeric forms. The invention includes all such isomers, as well as mixtures of cis and trans isomers, mixtures of diastereomers and racemic mixtures of enantiomers (optical isomers). When no specific mention is made of the configuration (cis, trans or R or S) of a compound (or of an asymmetric carbon), then any one of the isomers or a mixture of more than one isomer is intended. The processes for preparation can use racemates, enantiomers or diastereomers as starting materials. When enantiomeric or diastereomeric products are prepared, they can be separated by conventional methods for example, chromatographic or fractional crystallization.
The compounds of the instant invention may, for example, be in the free or hydrate form, and may be obtained by methods exemplified by the following descriptions.
METHODS OF PREPARATION
The process of the instant invention is readily carried out as described in Scheme A, wherein R a , R b and R c are each independently selected from the group consiting of hydrogen, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, heteroalkyl, substituted heteroalkyl, aryl, heteroaryl, heterocyclo, cycloalkyl, halogen, haloalkyl, haloalkoxy, cyano, nitro, —C(═O)NR 22 R 23 , —OR 22 , —CO 2 R 22 , —C(═O)R 22 , —SR 22 , —S(O) q R 22a , —NR 22 R 23 , —NR 22 SO 2 R 23 , —NR 22 CO 2 R 23 , —NR 22 C(═O)R 23 , —NR 22 C(═O)NR 23 R 33 , —SO 2 NR 22 R 23 , and —NR 22 SO 2 NR 23 R 33 , R 22 and R 23 are defined as above; and n is 1-3.
Compound 10 was prepared according to J. Med. Chem ., 1999, 42, 3510-3519, from 2-methyl-4-nitroaniline. A mixture of compound 10 and 1-(1,1-dimethylethoxy)-N,N,N′,N′-tetramethyl-methanediamine in dry DMF (10 mL) was stirred at 70° C. for 2 h under N 2 . After cooling to rt, the reaction mixture was treated with hexane, and the solid was collected by filtration and washed with hexane to give compound 11 as black crystals. Compound 11 was converted to compound 13 in two alternate ways.
In one approach, compound 11 was converted to 13 by adding 1N LiHMDS to a solution of 11 in dry THF under N 2 . The reaction mixture was stirred at 65° C. for 2 h. After cooling to rt, 12 N HCl was added and the reaction mixture stirred at 50° C. for 1 h. After cooling to rt, the mixture was neutralized with sat'd NaHCO 3 , the product extracted with EtOAc, and the organic layer washed with water and sat'd NaCl. The product was concentrated and purified to give compound 13 as a yellow solid.
Alternatively, compound 11 was converted to 13 by first mixing compound 11 and 2,4-dimethoxylbenzylamine in DMF and stirring the mixture at 140° C. for 3 h. The solvent was removed by vacuum distillation and residue treated with EtOAc. The orange solid was collected by filtration and washed with hexane to give compound 12. To a solution of compound 12 in anisole was added TFA. The reaction mixture was stirred at 90° C. for 1 h and the solvent removed under reduced pressure. The residue was treated with sat'd NaHCO 3 (30 mL) and the product collected by filtration and washed with water to afford compound 13.
Compound 13 (366 mg, 1.93 mmol) and 2,4-dimethoxybenzaldehyde were heated for 16 h at 125-130° C. with a stream of nitrogen passing in and out of the reaction flask, and sampling of the reaction mixture at 80° C. indicated conversion to compound 14.
To a solution of 14 and 2,4-dimethoxybenzaldehyde above in THF was added sodium triacetoxyborohydride. The reaction was stirred for 22 h and additional sodium triacetoxyborohydride (1.23g, 5.8 mmol) was added. After 40 h, the reaction was concentrated to an oil which was taken up in EtOAc, water, and dilute sodium bicarbonate. The EtOAc was washed with water (3×), dried (sodium sulfate), and concentrated to an oily residue, which was chromatographed to give 140 mg of compound 15a as a glassy residue and 228 mg of compound 15b as an amorphous solid.
Hydrogenation of compound 15b in EtOAc and MeOH in the presence 10% Pd/C for 1 h at one atmosphere afforded compound 16 as an amorphous solid. Compound 16 was coupled to a substrate and deprotected to produce compounds of formula (I). | This invention relates to novel processes for the preparation of amino isoquinolines, benzylamino isoquinolines, and acid derivatives useful as serine protease inhibtors. | 2 |
FIELD OF THE INVENTION
The present invention relates to image transfer techniques and apparatus for use in electrophotography.
BACKGROUND OF THE INVENTION
Liquid toner images are developed by varying the density of pigmented solids in a developer material on a latent image bearing surface in accordance with an imaged pattern. The variations in density are produced by the corresponding pattern of an electric field extending outward from the latent image bearing surface, which is configured by the different latent image and background voltages on the latent image bearing surface and a voltage on a developer plate or roller.
In general, developed liquid toner images are neither solid nor homogeneous. Typically, a liquid toner developer contains about 1.5% to 2% solids and a developed image contains about 15%-25% solids. The developed image has a higher density closer to the latent image bearing surface and a "fluffy", i.e. loosely bound, region furthest away from the latent image bearing surface.
In order to improve transfer of a clean developed image from the latent image bearing surface to a substrate it is most desirable to ensure that, before transfer, the pigmented solids adjacent background regions are substantially removed and the density of pigmented solids in the developed image is increased, thus compacting or rigidizing the developed image. The compacting or rigidizing of the developed image increases the image viscosity and enhances the ability of the image to maintain its integrity under the stresses encountered during image transfer. It is also desirable that excess liquid be removed from the latent image bearing surface before transfer.
It is known in the prior art, as described in U.S. Pat. No. 3,955,533, to employ a reverse roller spaced about 50 microns from the latent image bearing surface to shear off the carrier liquid and pigmented solids in the region beyond the outer edge of the image and thus leave relatively clean areas above the background.
The technique of removing carrier liquid is known generally as metering. An alternative metering technique, described in U.S. Pat Nos. 3,767,300 and 3,741,643, employs an air knife, but has not been particularly successful due to sullying of the background as a result of turbulence and consequent mixing of the background inversion layer with the surface layer of the carrier liquid.
In U.S. Pat. No. 3,957,016, the use of a positive biased metering roller is proposed wherein the metering roller is maintained at a voltage intermediate the image and background voltages to clean the background while somewhat compacting the image.
In the prior art it is known to effect image transfer wherein the image is brought into contact with a substrate backed by a charged roller. Unless the image is rigidized before it reaches the nip of the latent image bearing surface and the roller, image squash and flow may occur. This is particularly true if the substrate is a non-porous material, such as plastic.
In the prior art, liquid toner images are generally transferred to substrates by electrophoresis, whereby the charged image moves from the latent image bearing surface to the substrate through the carrier liquid under the influence of an electric field produced by a high voltage, associated with the substrate, which is of opposite polarity to the charge on the image particles.
The voltage and thus the field strength available for electrophoretic transfer are limited by the danger of electrical breakdown which can occur at both the input and output edges of the nip, due to the minimum of the Paschen curve being at about 8 microns. Thus, according to the Paschen curve, the voltage difference at the nip cannot exceed about 360 volts, if possible damage to the image and possible damage to the latent image bearing surface due to electrical breakdown are to be avoided.
Electrophoretic compaction of images prior to transfer thereof is described in U.S. Pat. No. 4,286,039 which shows a metering roller followed by a negatively biased squeegee roller. The squeegee roller is operative both for compacting of image and for removing excess liquid. The voltage that can be applied to the squeegee roller is also limited by the danger of electrical breakdown. The breakdown problem is least serious at the input to the squeegee roller since the meniscus present there acts to increase the minimum effective air gap. In the image areas, the breakdown problem is more severe since the fields produced by the squeegee roller and by the latent image bearing surface add. The problem is most severe at the exit edge of the squeegee roller at which a meniscus is substantially not present.
In U.S. Pat. No. 4,684,238 an unmetered image is initially transferred to an intermediate transfer member and is then metered by a metering roller having a voltage opposite to the charge on the toner particles making up the image. No discussion of the problem of electrical breakdown is presented.
SUMMARY OF THE INVENTION
The present invention seeks to provide improved apparatus for image transfer.
There is thus provided in accordance with a preferred embodiment of the present invention an image bearing surface and an image receiving surface arranged for relative movement along a pathway whereby portions of the image bearing surface and the image receiving surface sequentially come into propinquity for image transfer therebetween and subsequently move out of propinquity following image transfer therebetween, potential impression means associated with at least one portion of at least one of the image bearing surface and the image receiving surface for impressing a potential on the at least one portion, and means for energizing the potential impression means only when the at least one portion is located at a predetermined location along the pathway, thereby to provide desired image transfer enhancement.
Further in accordance with a preferred embodiment of the present invention, the potential impression means includes a plurality of electrical conductors associated with at least one of the image bearing surface and the image receiving surface.
Still further in accordance with a preferred embodiment of the present invention, the potential impression means includes means for impressing a potential of a first polarity opposite to the polarity of the charge on the image particles.
Further in accordance with a preferred embodiment of the present invention, the potential impression means includes means for impressing a first potential on the at least one portion when the at least one portion is located at a first predetermined location and for impressing a second potential on the at least one portion when the at least one portion is located at a second predetermined location.
Still further in accordance with a preferred embodiment of the present invention, the potential impression means includes means for simultaneously impressing a first potential on a first portion of the at least one surface and a second potential on a second portion of the at least one surface.
Additionally in accordance with a preferred embodiment of the present invention, the potential impression means includes means for impressing a first potential on a first portion of the at least one surface when the first portion is located at a first predetermined location and for impressing a second potential on the first portion when the first portion is located at a second predetermined location and simultaneously impressing the second potential on the second portion when it is located at the second predetermined location and the first potential on the second portion when it is located at the first location.
Further in accordance with a preferred embodiment of the present invention, the potential impression means includes means for simultaneously impressing a first potential on a first portion of the at least one surface when the first portion is located at a first predetermined location and a second potential on a second portion of the at least one surface when the second portion is located at a second predetermined location, and means for simultaneously impressing the second potential on the first portion when the first portion is located at the second predetermined location and the first potential on a third portion when it is located at the first location.
Further in accordance with a preferred embodiment of the present invention, the first and second potentials are of opposite polarity.
Still further in accordance with a preferred embodiment of the present invention, the plurality of electrical conductors include first and second arrays of electrical conductors arranged on the image receiving surface and the means for electrically energizing include first means for selectably energizing at least one electrical conductor of the first array for providing a desired potential at a first predetermined location, and second means for selectably energizing at least one electrical conductor of the second array for providing desired heating of the image receiving surface at a second predetermined location.
Additionally in accordance with a preferred embodiment of the present invention, the apparatus for image transfer also includes means for removing excess liquid from the image bearing surface.
Further in accordance with a preferred embodiment of the present invention, the potential impression means provides a desired electrical field at a desired location for producing electrophoretic image transfer thereat.
Still further in accordance with a preferred embodiment of the present invention, energization of the electrical conductors provides desired resistance heating of the image just prior to transfer thereof.
Further in accordance with a preferred embodiment of the present invention, the image bearing surface is arranged to support a liquid toner image thereon, including image regions and background regions, and the apparatus for image transfer also includes means for removing pigmented toner particles from the background regions defined on the image bearing surface.
Additionally in accordance with a preferred embodiment of the present invention, the means for removing includes a roller with a potential intermediate that of the image regions and the background regions.
Additionally in accordance with a preferred embodiment of the present invention, the potential impression means includes means for impressing a potential of a first polarity, the same as that of the polarity of the charge on the image particles, on at least one conductor in a first region and for impressing a potential of a second polarity, opposite to to that of the polarity of the charge on the image particles, on at least one conductor in a second region.
Further in accordance with a preferred embodiment of the present invention, the plurality of electrical conductors include first and second arrays of electrical conductors arranged on the image receiving surface and the means for electrically energizing include first means for selectably energizing at least one electrical conductor of the first array for providing a desired potential at a first given location on the image receiving surface and second means for selectably energizing at least one electrical conductor of the second array for providing desired heating of the image receiving surface at a second given location.
Still further in accordance with a preferred embodiment of the present invention, the image transfer apparatus also includes second transfer means for image transfer from the image receiving surface to a substrate.
Throughout the specification and claims, the term "potential impression means" will be used in a very broad sense to mean any apparatus for applying an electrical potential which results in the presence of an electric field and thus, includes. inter alia, conductors, partially conducting dielectrics and other materials or devices which perform the indicated function.
Throughout the specification and claims, the terms "rigidization" and "compacting" will be used interchangeably to indicate an increase in cohesiveness of the image produced in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a simplified sectional illustration of electrophotographic apparatus constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 2 is a simplified sectional illustration of electrophotographic apparatus constructed and operative in accordance with another preferred embodiment of the present invention;
FIG. 3A is a simplified conceptual sectional illustration of image transfer apparatus constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 3B is a simplified conceptual sectional illustration of image transfer apparatus constructed and operative in accordance with another preferred embodiment of the present invention;
FIG. 4 is a simplified sectional illustration of part of an intermediate transfer member constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 5 is a simplified sectional illustration of part of an intermediate transfer member constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 6 is an illustration of part of the apparatus of FIG. 3A and illustrating the supply of potential to the intermediate transfer member;
FIG. 7 is a pictorial illustration of the arrangement of conductors on the intermediate transfer member employed in the apparatus of FIG. 6;
FIG. 8 is a simplified side view illustration of the arrangement of electrical supply apparatus in association with an intermediate transfer member;
FIG. 9 is a side view illustration taken along lines IX--IX in FIG. 8 for one embodiment of the invention;
FIG. 10 is a simplified illustration of electrical supply apparatus useful in the arrangement of FIG. 8;
FIG. 11 is a simplified sectional illustration of electrophotographic apparatus constructed and operative in accordance with another preferred embodiment of the present invention;
FIG. 12 is a simplified conceptual sectional illustration of image rigidization apparatus constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 13 is a simplified conceptual sectional illustration of image rigidization apparatus constructed and operative in accordance with another preferred embodiment of the present invention; and
FIG. 14 is a simplified sectional illustration of electrophotographic apparatus constructed and operative in accordance with yet another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is now made to FIG. 1 which illustrates electrophotographic imaging apparatus constructed and operative in accordance with a preferred embodiment of the present invention. This and other embodiments of the invention are described for the case of liquid toner systems with negatively charged particles, and positively charged photoconductors. For positively charged toner, the polarities of the voltages given would be reversed.
In a preferred embodiment of the invention the toner of example 1 of U.S. Pat. No. 4,794,651 can be used, but a variety of liquid toner types are useful in the practice of the invention.
As in conventional electrophotographic systems, the apparatus of FIG. 1 comprises a drum 10 arranged for rotation about an axle 12 in a direction generally indicated by arrow 14. The drum 10 is formed with a cylindrical photoconductive surface 16.
A corona discharge device 18 is operative to generally uniformly charge the photoconductor surface 16 with a positive charge. Continued rotation of the drum 10 brings the charged photoconductor surface 16 into image receiving relationship with an exposure unit including a lens 20, which focuses a desired image onto the charged photoconductor surface 16, selectively discharging the photoconductor surface, thus producing an electrostatic latent image thereon.
Continued rotation of the drum 10 brings the charged photoconductor surface 16 bearing the electrostatic latent image into a development unit 22 including development electrodes 24, which is operative to apply a liquid toner to develop the electrostatic latent image.
In accordance with a preferred embodiment of the invention, following application of toner thereto, the photoconductor surface 16 passes a typically positively charged rotating roller 26, preferably rotating in a direction indicated by an arrow 28. Typically the spatial separation of the roller 26 from the photoconductor surface 16 is about 50 microns. Preferably the charge on roller 26 is intermediate the voltages of the latent image areas and of the background areas on the photoconductor surface. Typical voltages are: roller 26: 200 V, background area: 50 V and latent image areas: up to 1000 V.
It is appreciated that roller 26 may rotate in the direction opposite to that indicated by arrow 28 and function as a metering roller and reduce the thickness of liquid on the photoconductor surface 16.
Alternatively, the metering function may be eliminated at this stage or carried out downstream by an appropriate technique.
In any event, the liquid which passes the roller 26 should be relatively free of pigmented particles except in the region of the latent image.
Downstream of roller 26 there is preferably provided a rigidizing roller 30. The rigidizing roller 30 is preferably formed of a resilient polymeric material, such as conductive resilient polymeric materials as described in either or both of U.S. Pat. Nos. 3,959,574 and 3,863,603 and is preferably maintained in non-contacting spatial relationship with the photoconductive surface 16.
According to one embodiment of the invention, roller 30 is lightly urged against the photoconductive surface 16 as by a spring mounting (not shown). Rotation of the photoconductive surface 16 produces hydrodynamic forces on roller 30 which push it slightly away from the photoconductive surface 16, so that it typically lies at a separation of 15 microns from the photoconductive surface.
According to an alternative embodiment of the present invention, the roller 30 may be mounted at a fixed separation from photoconductive surface 16. In such a case, to take account of surface irregularities, the roller 30 lies at a separation of about 50 microns from the photoconductive surface. The surface of roller 30 typically moves in the same direction as the photoconductive surface so as not to substantially remove liquid from the image. Preferably the nip between the roller 30 and the photoconductive surface 16 is kept wet so as to minimize problems of electrical discharge. Various constructions of rigidizing rollers which reduce problems of electrical discharge are described hereinbelow.
In an embodiment of the invention, the biased squeegee described in U.S. Pat. No. 4,286,039, the disclosure of which is incorporated herein by reference, is used as the roller 30. A negative voltage of between several hundred to 2000 volts can be used and some breakdown is experienced. Roller 30 is negatively charged to a potential of at least several hundred and up to 2000 volts with the same sign as the charge on the pigmented toner particles, so that it repels similarly charged pigmented particles and causes them to more closely approach the image areas of the photoconductor surface 16, thus compressing and rigidizing the image.
Downstream of rigidizing roller 30 there is provided an intermediate transfer member 40, which rotates in a direction opposite to that of photoconductor surface 16, as shown by arrow 41, and is operative for receiving the toner image therefrom and for transferring the toner image to a receiving substrate 42, such as paper.
Various types of intermediate transfer members are known and are described, for example in U.S. Pat. No. 4,684,238 and in assignee's copending U.S. patent application entitled METHOD AND APPARATUS FOR IMAGING USING AN INTERMEDIATE TRANSFER MEMBER filed Jan. 4, 1989, the disclosures of which are incorporated herein by reference. Particularly beneficial constructions of intermediate transfer members in accordance with the present invention are described in detail hereinbelow.
Transfer of the image to intermediate transfer member 40 is preferably aided by providing electrification of the intermediate transfer member 40 to a voltage of polarity to that of the charged particles, although other methods known in art may be employed. Subsequent transfer of the image to substrate 42 is preferably aided by heat and pressure, although other methods known in the art may be employed.
It has been noted that when the negatively biased squeegee roller of U.S. Pat. No. 4,286,039, with high negative voltage, is utilized as the roller 30, the positive voltage on the intermediate transfer member required to transfer the image thereto is sharply reduced, typically from about 1000 volts or more to about 500 volts. It is believed that this reduction is possibly due to a discharge of the charges in the image area of the image bearing surface and a charging of the background areas of the image bearing surface.
Following transfer of the toner image to the intermediate transfer member, the photoconductive surface 16 is engaged by a cleaning roller 50, which typically rotates in a direction indicated by an arrow 52, such that its surface moves in a direction opposite to the movement of the adjacent photoconductive surface 16 which it operatively engages. The cleaning roller 50 is operative to scrub clean the surface 16. A cleaning material, such as toner, may be supplied to the cleaning roller 50, via a conduit 54. A wiper blade 56 completes the cleaning of the photoconductive surface. Any residual charge left on the photoconductive surface 16 is removed by flooding the photoconductor surface with light from a lamp 58.
Reference is now made to FIG. 2 which illustrates electrophotographic imaging apparatus constructed and operative in accordance with another preferred embodiment of the present invention. The apparatus of FIG. 2 shares many common elements with that of FIG. 1. These elements are indicated by identical reference numerals, and for the sake of conciseness are not described herein a second time.
The embodiment of FIG. 2 differs from that of FIG. 1 in that the rigidizing roller 30 is eliminated and further in that a belt-type, instead of roller type, intermediate transfer member 70 is employed. Belt-type intermediate transfer members are well known in the art and are described, inter alia, in U.S. Pat. Nos. 3,893,761; 4,684,238 and 4,690,539, the disclosures of which are incorporated herein by reference.
It will be appreciated that the belt-type intermediate transfer member may be employed in the apparatus of FIG. 1 and that the rigidizing roller 30 may be omitted in the embodiment of FIG. 1 or added to the embodiment of FIG. 2.
Intermediate transfer member 70 is preferably charged so as to provide electrophoretic transfer of the image from the photoconductive surface 16 thereto. Within given limits, the efficiency of electrophoretic transfer of the image can be enhanced by increasing the potential difference between the photoconductive surface 16 and the intermediate transfer member 70. Increase in the potential difference between the photoconductive surface 16 and the intermediate transfer member 70 is limited, however, by the danger of electrical breakdown, which increases with an increase in potential difference.
The interrelationship between the minimum voltage difference at which breakdown occurs across a gap and the gap separation is given by the well-known Paschen curve. In air, the minimum breakdown voltage for a gap between two surfaces typically occurs, for a gap separation of about 8 microns, at a voltage difference of about 360 V. The breakdown voltage increases significantly for gaps either smaller or larger than the indicated gap, and when dielectric liquids such as Isopar or liquid developer, are present in the gap.
In accordance with a preferred embodiment of the invention, means are provided for significantly reducing or eliminating electrical breakdown in the vicinity of the photoconductive surface 16, which breakdown could damage the photoconductive surface and/or the image. In this connection reference is made to FIGS. 3A and 3B, which illustrate conceptually an intermediate transfer member 40 having a limited charged region or regions.
FIG. 3A conceptually illustrates an intermediate transfer member 40 which is provided with an arrangement of electrical conductors whereby, at any given time, for any given rotational state of the intermediate transfer member, only an angularly delimited portion of the intermediate transfer member is energized to a sufficiently high voltage as to define a significant potential difference relative to the photoconductor surface 16.
In the illustrated embodiment, the energized portion, is selected so as to roughly correspond with the region of the nip 62 between the intermediate transfer member and the photoconductor surface 16. According to one embodiment of the invention the energized portion corresponds to the region which is filled with a liquid, which is delineated by adjacent radii 61, thus substantially reducing or eliminating electrical discharge thereat. According to a more generalized concept of the invention, the energized portion is not necessarily limited to the region filled with a liquid but is limited to a region in which the gap does not have a separation for which the breakdown voltage is less than the potential difference between the energized portion and the photoconductor surface 16, taking into account the nature of the material disposed in the gap. Even more generally, small amounts of breakdown may be allowed.
In the embodiment of FIG. 3A a voltage difference across the gap of 1000 V to 2000 V should be maintained for best results, although lesser or greater voltage differences may also be employed.
FIG. 3B illustrates a further development of the structure illustrated in FIG. 3A. Here electrical voltages are supplied to the conductors in the intermediate transfer member 40 such that two different potentials are applied to the surface of the intermediate transfer member in adjacent regions 64 and 66 as illustrated.
This arrangement has particular utility in providing an intermediate transfer member 40 which serves both to rigidify the image prior to transfer and then to transfer the rigidified image from the photoconductor surface 16 to the intermediate transfer member 40.
In such an arrangement, where the pigmented particles are normally negatively charged the image areas on the photoconductor surface positively charged, and the directions of rotation of the photoconductor surface 16 and of the intermediate transfer member 40 as indicated in FIG. 3B, portion 64 will be energized to a negative potential, typically -200 V to -2000 V, to provide image compression or rigidization by urging the pigmented particles towards the image areas on the photoconductor surface, while portion 66 will be energized to a positive potential, typically +300 V to +2500 V, thus drawing the image electrophoretically from the photoconductor surface 16 through the solvent in the meniscus 68 onto the surface of intermediate transfer member 40 in portion 66. The lower positive voltage on portion 66 can be used for a relatively high negative voltage on portion 64.
One possible, but not definitive explanation of why good transfer is achieved with low positive voltage on portion 66 and high negative voltage on portion 64 is that charge transfer from the intermediate transfer member 40 to the photoconductive surface takes place, with subsequent at least partial neutralization of the charge on the drum.
Normally, between portions 66 and 64 there may be defined a region on the photoconductor surface of intermediate potential so as to prevent unwanted electrical discharge between portions 64 and 66. The outer boundaries of regions 64 and 66 are normally defined so as to avoid electrical breakdown between regions 64 and 66 and the photoconductor surface 16, as described above in connection with FIG. 3A.
Reference is now made to FIG. 4, which is a signified and not necessarily to scale sectional illustration of an intermediate transfer member particularly useful in the apparatus shown in FIG. 2. The intermediate transfer member, generally indicated by reference numeral 70, typically comprises a high tensile strength substrate 72, such as Kapton, typically of thickness 10 microns, on which is preferably provided a resilient layer 74.
A resistive heating layer 76, typically formed of nickel-chrome alloy, is preferably formed onto resilient layer 74 and is coupled to a source of electrical current for providing desired heating of the intermediate transfer member 70 to assist in image transfer therefrom onto an image receiving substrate. Disposed over heating layer 76 is an insulative layer 78, typically formed of polyurethane of thickness 5 microns.
Supported on insulative layer 78 is a generally parallel array 80 of generally uniformly spaced selectably energizable electrical conductors 82. The elongate axes of the conductors 82 are generally perpendicular to the direction of movement indicated by arrow 84 of the intermediate transfer member 70 when in operation, as shown, for example, in FIG. 2.
Conductors 82 are typically of thickness 35 microns and of width 500 microns and are separated by 250 microns. They are typically embedded in a layer 86 of conductive material, such as a silicone-polyurethane copolymer loaded with 2% Degussa Printex XE-2, manufactured by Degussa AG of Frankfurt. West Germany, having a thickness about 100 microns over the conductors 82 and a resistivity of about 10 +5 ohm-cm. Disposed over layer 86 is a release layer 88, such as Syl-Off manufactured by Dow Corning, and having a typical thickness of 10 microns.
Reference is now made to FIG. 5, which illustrates an intermediate transfer member which is identical to that shown in FIG. 4 except that the resistive heating layer 76 is not continuous but is rather formed of a generally parallel array 90 of generally uniformly spaced selectably energizable electrical conductors 92. The elongate axes of the conductors 92 are generally perpendicular to the direction of movement indicated by arrow 84 of the intermediate transfer member 70 when in operation as shown. For example, in FIG. 2.
The provision of array 90 instead of a continuous resistive heating area permits the heating of the intermediate transfer member 70 to be spatially selective, for example, to permit heating of the intermediate transfer member only along that portion of its route which extends from the photoconductor surface 16 to the substrate 42 (FIG. 2).
Heating of the image carried on the intermediate transfer member 70 along this portion of its route enables enhancement of the cohesiveness of the image to be realized without possible heat damage to the photoconductor surface 16 as described in Assignee's copending U.S. patent application 272,323 filed Nov. 21, 1988, the disclosure of which is incorporated herein by reference, and also permits heating of the image to be terminated with a desired level of precision to enhance transfer of the image from the intermediate transfer member to the substrate. Enhancement of image transfer in this manner is described and claimed in Assignee's copending U.S. patent application filed Jan. 4, 1989 and entitled Method & Apparatus for Imaging Using an Intermediate Transfer Member, the teaching of which is hereby incorporated herein by reference.
This selective heating will be most effective if the heat capacity of the intermediate transfer member is relatively low, so that the heating and cooling can occur as described in the above-identified U.S. patent application.
It will be appreciated that although the intermediate transfer members having one or more arrays of selectably energizable conductors have been described and shown in FIGS. 4 and 5 in the context of belts, the structure thereof may be applied equally to intermediate transfer members in the form of rollers, such as those employed in the apparatus of FIG. 1. In addition, some of the layers of the structures of FIGS. 4 and 5 can be omitted, as may be appropriate if, for example, heating is not desired.
Reference is now made to FIGS. 6-10, which illustrate the use of selectably energizable conductors in roller configurations. FIGS. 6 and 7 illustrate an intermediate transfer member roller 40 having at least one array 80 of selectably energizable conductors in operative engagement with a substrate 42 and a drum 10. An electrical energizing shoe 100 applies electrical power to the array 80. The shoe 100 may comprise one or more brushes or contacts contacting one or more groups of conductors.
FIG. 7 illustrates a preferred arrangement of the array 80 on a roller 40. It is seen that the conductors 82 are circumferentially offset adjacent the edge of the roller 40. The purpose of this offset is to enable energizing shoe 100 to be located outside of the nip between roller 40 and drum 10 yet nevertheless apply a desired voltage to the conductors 82 located in the nip for enhancing transfer thereat while minimizing electrical breakdown as described hereinabove.
FIG. 8 illustrates an arrangement by which a shoe assembly of the type illustrated in FIG. 10 may be mounted in tension in operative engagement with a roller 92. The roller 92 is similar to roller 40, illustrated in FIG. 7, except that the conductors 82 no longer are required to be offset as shown in FIG. 7. The shoe assembly is held in tensioned contact with roller 92 and contacts 112, 114 and 116 of a shoe 110 (FIG. 10) are in contact with the extremities of conductors 82. The diameter of drum 10 is reduced at a region facing the extremities of conductors 82, as shown in FIG. 9, to provide clearance of shoe 110.
Accordingly, as seen in FIG. 10, shoe portion 112 may be maintained at -2000 Volts, shoe portion 114 may be maintained at 0 Volts and shoe portion 116 may be maintained at +500 Volts. An electrical connector 120 (shown in FIG. 8) may provide the desired voltages to respective connectors 122,124 and 126 which are electrically coupled to shoe portions 112, 114 and 116 respectively.
It may be appreciated that an intermediate transfer member of the type illustrated in FIG. 5, having two arrays 80 and 90 of conductors, may receive electrical power via shoe assemblies 110 arranged at opposite ends of the roller 92, as illustrated in FIG. 9.
Reference is now made to FIG. 11, which illustrates electrophotographic imaging apparatus generally similar to that shown in FIG. 1 with the following principal exception: the use of an intermediate transfer member is abandoned in favor of direct transfer from the photoconductor surface 16 to a substrate 130, such as paper. The direct transfer is effected by the provision of guide rollers 132, 134 and 136, which guide a continuous web of substrate 130, and a drive roller 138, which cooperates with a support web 140. A suitable charging device, such as a corona discharge device 142, charges the substrate at a transfer location, for effecting electrophoretic transfer of the image from the photoconductor surface 16 to the substrate 130.
According to a preferred embodiment of the invention, the apparatus of FIGS. 1 or 11 may be constructed and operative with a rigidizing roller 30 (FIG. 1, 11-13) which includes a generally parallel array 150 of generally uniformly spaced selectably energizable electrical conductors 152. The elongate axes of the conductors 152 are generally perpendicular to the direction of movement of the rigidizing roller 30 in operation as shown, for example, in FIG. 12. wherein the motion of the rigidizing roller is indicated by an arrow 154.
Conductors 152 are typically of thickness 35 microns and of width 500 microns and are separated by 250 microns. There is defined a general region 155 between the rigidizing roller 30 and the photoconductor surface 16, delimited by imaginary radii 156, in which the chance of electrical breakdown is low due to the presence thereat of a meniscus of the dielectric toner carrier. In this region conductors 152 are charged to a voltage opposite to that of the pigmented toner particles, typically -500 to -2000 Volts. This arrangement compresses the toner particles of the image, thus rigidizing the image on the photoconductor surface, for resulting enhancement of transfer therefrom. It should be understood that the roller 30 of FIG. 12 can also act as a squeegee roller, substantially removing most of the liquid from the image and further physically compressing the image.
FIG. 13 illustrates a further development of the apparatus of FIG. 12 in which roller 30 serves as a metering, background removal and rigidizing roller. In this arrangement, two regions 160 and 162 are defined and opposite voltages are applied to the conductors 152 in those regions much in the same way as described above and illustrated in FIG. 3B.
This arrangement has particular utility in providing a background removal and rigidifying roller 30 which serves both to remove background from the image and to rigidify the image prior to transfer.
In such an arrangement, where the pigmented particles are normally negatively charged and the image areas on the photoconductor surface are positively charged, and the directions of rotation of the photoconductor surface 16 and of the roller 30 which is spaced from surface 16, are as indicated in FIG. 13, region 160 will be energized to a positive potential, typically +200 Volts, to draw pigmented particles away from the background areas of the photoconductor surface 16. Region 162 will be energized to a negative potential, typically -200 V to -2000 V, to provide image rigidization by urging the pigmented particles towards the image areas on the photoconductor surface.
Normally, between regions 160 and 162 there may be a region on the roller 30 of intermediate potential, so as to prevent unwanted electrical discharge between regions 160 and 162. The outer boundary, of region 162 will normally be defined so as to avoid electrical breakdown between region 162 and the photoconductor surface 16.
Metering of excess liquid from the photoconductive surface 16 is achieved by counter rotation of roller 30 in a direction indicated by an arrow 164, as is well known in the art.
Reference is now made to FIG. 14 which illustrates electrophotographic imaging apparatus which is substantially similar to that illustrated in FIG. 11 with the following exception; roller 30 is replaced by a non-rotating rigidizing element 170 having an electrically charged region 172 which is located interiorly of the edges of element 170, such that electrical breakdown is prevented.
Region 172 is selected such that the gap separation between the element 170 and the photoconductor surface 16 is such that when the gap is filled with dielectric toner carrier liquid during operation, no electrical discharge takes place at the operating voltages, which are preferably in the range of -200 to -2000 Volts for the element 170 within region 172, when the photoconductor surface 16 is charged to 1000 Volts at the image region and 50 Volts at the background region. The rigidizing element is preferably hydrodynamically shaped so that rotation of the roller will cause it to be spaced about 15 microns from the surface of the photoconductor, when it is lightly urged towards the photoconductor. Alternatively it may be kept at a fixed spacing from the photoconductor of the order of 50 microns.
Alternatively, a larger portion of the element 170 can be electrified, and the upstream end to the element shaped to provide a meniscus of insulating carrier liquid, until the spacing in air of the element 170 and the photoconductor are large enough to prevent breakdown or corona.
It will be appreciated that the signs of the various voltages have been given for an example using negatively charged toner particles. The invention is equally applicable to the use of positively charged toner particles with a negatively charged photoconductor, appropriate changes being made in the signs of the stated voltages.
It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims which follow: | Apparatus for image transfer including an image bearing surface and an image receiving surface arranged for relative movement along a pathway whereby portions of the image bearing surface and the image receiving surface sequentially come into propinquity for image transfer therebetween and subsequently move out of propinquity following image transfer therebetween, potential impression device associated with at least one portion of at least one of the image bearing surface and the image receiving surface for impressing a potential on the at least one portion, and device for energizing the potential impression device only when the at least one portion is located at a predetermined location along the pathway, thereby to provide desired image transfer enhancement. | 6 |
This application is a division of application Ser. No. 189,402 filed Sept. 19, 1980 now U.S. Pat. No. 4,285,867.
BACKGROUND OF THE INVENTION
This invention relates to novel 4-[2-hydroxy-4-(substituted)phenyl]-naphthalen-2(1H)-ones and 2-ols, to derivatives thereof, to processes for preparation of said compounds, and intermediates therefor. The naphthalen-2(1H)-one and 2-ol products are useful as CNS agents, especially as non-narcotic analgesics, antiemetics and antidiarrheals.
Despite the current availability of a number of analgesic agents, the search for new and improved agents useful for the control of broad levels of pain and accompanied by a minimum of side-effects continues. The most commonly used agent, aspirin, is of no practical value for the control of severe pain and is known to exhibit various undesirable side-effects. Other analgesic agents, such as meperidine, codeine, and morphine, possess addictive liability. The need for improved and potent analgesic agents is, therefore, evident.
Compounds having utility as analgesics, tranquilizers, sedatives, antianxiety agents and/or as anticonvulsants, diuretics and antidiarrheal agents are described in Belgian Pat. Nos. 870,404 and 870,402, both granted Mar. 12, 1979. Belgian Pat. No. 870,404 describes 3-[2-hydroxy-4-(substituted)phenyl]cycloalkanones and cycloalkanols; and Belgian Pat. No. 870,402 discloses certain 2-(acyclic substituted)phenols; namely, 2-(hydroxyalkyl)-4-(substituted)phenols and 2 -(oxoalkyl-4-(substituted)phenols.
U.S. Pat. No. 3,576,887, issued Apr. 27, 1971, discloses a series of 1-(1'-hydroxy)alkyl-2-(o-hydroxyphenyl)cyclohexanes which exhibit central nervous system depressant properties.
U.S. Pat. No. 3,974,157 describes 2-phenylcyclohexanones which can be substituted in the phenyl ring with up to two alkyl, hydroxy or alkoxy groups as intermediates for preparation of 1-(aminoalkyl)-2-phenylcyclohexanols useful as analgesics, local anesthetics and antiarrhythmics.
Chemical Abstracts 85, 176952f (1976) discloses a number of 3-phenyl- and 3-phenylalkylcyclohexanones as intermediates for 2-aminomethyl-3-phenyl (or phenylalkyl)cyclohexanones which exhibit analgesic, sedative, antidepressant and anticonvulsant activities.
Our concurrently filed application, D.P.C. (Ph) 6302, entitled "Pharmacologically Active 2-Hydroxy-4-(Substituted)Phenyl Cycloalkanes, Derivatives and Intermediates Therefor" describes 2-hydroxy-4-(substituted)cycloalkanones and cycloalkanols in which the 4- (or 5)-position of the cycloalkyl moiety is substituted with hydroxy or a substituted alkyl group.
SUMMARY OF THE INVENTION
The compounds of this invention have the formula ##STR3## wherein
A when taken individually is hydrogen;
B when taken individually is hydroxy, or alkanoyloxy having from one to five carbon atoms,
A and B when taken together are oxo;
R 1 is hydrogen, benzyl, or R 1 ' wherein R 1 ' is alkanoyl having from one to five carbon atoms, P(O)(OH) 2 and mono- and disodium and potassium salts thereof, --CO(CH 2 ) 2 COOH and the sodium and potassium salts thereof, and --CO(CH 2 ) p NR 4 R 5 wherein p is 0 or an integer from 1 to 4, each of R 4 and R 5 when taken individually is hydrogen or alkyl having from one to four carbon atoms; R 4 and R 5 when taken together with the nitrogen to which they are attached form a 5- or 6-membered heterocyclic ring (piperidino, pyrrolo, pyrrolidino, morpholino and N-alkylpiperazino having from one to four carbon atoms in the alkyl group);
R 2 when taken individually is hydrogen,
R 3 when taken individually is hydrogen, methyl, hydroxy, hydroxymethyl, OR 1 ' or --CH 2 OR 1 ';
R 2 and R 3 when taken together are oxo, methylene or alkylenedioxy having from two to four carbon atoms;
W is hydrogen, pyridyl or ##STR4## wherein W 1 is hydrogen, chloro or fluoro;
when W is hydrogen, Z is
(a) alkylene having from five to thirteen carbon atoms; or
(b) --(alk 1 ) m --O--(alk 2 ) n -- wherein each of (alk 1 ) and (alk 2 ) is alkylene having from one to thirteen carbon atoms; each of m and n is 0 or 1; with the provisos that the summation of carbon atoms in (alk 1 ) plus (alk 2 ) is not less than five or greater than thirteen; and at least one of m and n is 1;
when W is other than hydrogen, Z is
(a) alkylene having from three to eight carbon atoms; or
(b) --(alk 1 ) m --O--(alk 2 ) n -- wherein each of (alk 1 ) and (alk 2 ) is alkylene having from one to eight carbon atoms; each of m and n is 0 or 1; with the provisos that the summation of carbon atoms in (alk 1 ) plus (alk 2 ) is not less than three or greater than eight; and at least one of m and n is 1.
Also included in this invention as noted above are the pharmaceutically acceptable acid addition salts of those compounds of formula I which contain a basic group. Typical of such compounds are those wherein the W variable is pyridyl and/or OR 1 represents a basic ester moiety. In compounds having more than one basic group present, polyacid addition salts are, of course, possible. Representative of such pharmaceutically acceptable acid addition salts are the mineral acid salts such as the hydrochloride, hydrobromide, sulfate, phosphate, nitrate; organic acid salts such as the citrate, acetate, sulfosalicylate, tartrate, glycolate, malate, malonate, maleate, pamoate, salicylate, stearate, phthalate, succinate, gluconate, 2-hydroxy-3-naphthoate, lactate, mandelate and methanesulfonate.
Compounds having the above formula, and the pharmaceutically acceptable acid addition salts thereof, are effective as CNS agents, especially as analgesics in mammals, including humans; and/or as anti-emetics in mammals, including man.
Compounds of formula I wherein A is hydrogen and B is hydroxy contain asymmetric centers at the 2-, the 4-, the 4a-, and 8a- and the 6-positions and may of course, contain additional asymmetric centers in the --Z--W-- substituent of the phenyl ring. Cis-relationship between the 2- and 4-position substituents of the bicyclic moiety is favored, as is trans-relationship between the 4a- and 8a-hydrogens, and between the 4-hydrogen and the 4a-hydrogen because of their quantitatively greater biological activity. For the same reason, trans-relationships at the 4-, 4a- and the 4a-, 8a-positions is favored for compounds wherein A and B when taken together represent oxo. The 6-substituted compounds of formula I exhibit potent biological activity regardless of whether the stereochemistry at said position is axial or equatorial.
In addition to the compounds of formula I, various intermediates useful in the preparation of said compounds are also included in this invention. The intermediates have formula II-IV below: ##STR5## wherein
R 6 is hydrogen or C 1-4 alkyl; ##STR6##
R 2 and R 3 are as previously defined. Also included in this invention are the ketoacids and the ketoaldehydes corresponding to formula III and which are obtained by cleavage of the enolic lactone or lactol, respectively.
It is noted that formula I compounds wherein R 1 is benzyl are not pharmacologically active for the purposes disclosed herein but are useful as intermediates to formula I compounds wherein R 1 is hydrogen.
For convenience, the above formula depicts the racemic compounds. However, formulae I-IV are considered to be generic to and embracive of the racemic modifications of the compounds of this invention, the diastereomeric mixtures, and pure enantiomers and diastereomers thereof. The utility of a racemic mixture, a diastereomeric mixture as well as of the pure enantiomers and diastereomers is determined by the biological evaluation procedures described below.
Favored because of their greater biological activity relative to that of other compounds described herein are the compounds of formula I wherein A and B together are oxo; A and B when taken individually are hydrogen and hydroxy, respectively; R 2 is hydrogen, R 1 is hydrogen or alkanoyl; R 3 is hydrogen or hydroxymethyl; and Z and W have the values shown below:
______________________________________ Z m n W______________________________________alkylene having from 7 -- -- Hto 11 carbon atomsalkylene having from 4 to 7 carbon atoms -- -- ##STR7##(alk.sub.1).sub.mO(alk.sub.2).sub.n 0,1 1 ##STR8##______________________________________
each of (alk 1 ) and (alk 2 ) is alkylene having from one to seven carbon atoms with the proviso the summation of carbon atoms in (alk 1 ) plus (alk 2 ) is not less than four or greater than seven;
(alk.sub.1).sub.m --O--(alk.sub.2).sub.n 0,1 1 H
each of (alk 1 ) and (alk 2 ) is alkylene having from one to eleven carbon atoms with the proviso the summation of carbon atoms in (alk 1 ) plus (alk 2 ) is not less than seven or greater than eleven.
Preferred compounds of formula I are those compounds of formula I wherein
each of R 1 and R 2 is hydrogen;
Z is --C(CH 3 ) 2 (CH 2 ) 6 and W is hydrogen;
Z is C 4-7 alkylene and W is phenyl;
Z is --O--alkylene having 7 to 9 carbon atoms and W is hydrogen;
Z is --O--alkylene having from 4 to 5 carbon atoms and W is phenyl;
A is hydrogen and B is hydroxy (cis- and trans- forms);
A and B taken together are oxo;
R 3 =hydroxy or hydroxymethyl.
Especially preferred are the compounds of formula I wherein R 1 , R 2 , R 3 , Z and W are as defined for the preferred compounds, A and B taken individually are hydrogen and hydroxy, respectively and which have formula I' ##STR9##
Additionally, the favored and preferred intermediates of formulae II-IV are those compounds having said formulae which serve as intermediates for the favored and preferred compounds of formula I.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention having formula I are prepared by Grignard reaction of the appropriate 2-bromo-5-(Z--W--substituted)phenol, the hydroxy group of which is protected, with the appropriate hexahydronaphthalen-2(1H)-one of formula IV. The reaction is stereoselective and is illustrated in the following reaction sequence by the conversion of a compound of formula IV-A (formula IV wherein R 2 +R 3 =ethylenedioxy) to a compound of formula I-A. Preparation of 2-bromo-5-(Z--W--substituted)phenol reactants is described in U.S. Pat. No. 4,147,872, issued Apr. 3, 1979. ##STR10##
Suitable protecting groups are those which do not interfere with subsequent reactions and which can be removed under conditions which do not cause undesired reactions at other sites of said compounds or of products produced therefrom. Representative of such protective groups are methyl, ethyl and preferably benzyl or substituted benzyl wherein the substituent is, for example, alkyl having from one to four carbon atoms, halo (Cl, Br, F, I) and alkoxy having from one to four carbon atoms; and dimethyl-t-butylsilyl. The ether protecting, or blocking, groups can be removed through the use of hydrobromic acid in acetic acid or hydrobromic acid, 48% aqueous. The reaction is conducted at elevated temperatures and desirably at the reflux temperature. However, when Z is --(alk 1 ) m --O--(alk 2 ) m --, acids such as polyphosphoric acid or trifluoroacetic acid should be used to avoid cleavage of the ether linkage. Other reagents such as hydriodic acid, pyridine hydrochloride or hydrobromide, or lithio n-alkyl mercaptides in hexamethylphosphoramide can be used to remove protecting ether groups such as methyl or ethyl groups. When the protecting groups are benzyl or substituted benzyl groups, they can be removed by catalytic hydrogenolysis. Suitable catalysts are palladium or platinum, especially when supported on carbon. Alternatively they can be removed by solvolysis using trifluoroacetic acid. A further procedure for removing benzyl comprises treatment with n-butyllithium in a reaction-inert solvent at room temperature. The dimethyl-t-butylsilyl group is removed by mild hydrolysis.
The exact chemical structure of the protecting group is not critical to this invention since its importance resides in its ability to perform in the manner described above. The selection and identification of appropriate protecting groups can easily and readily be made by one skilled in the art. The suitability and effectiveness of a group as a hydroxy protecting group are determined by employing such a group in the herein-illustrated reaction sequences. It should, therefore, be a group which is easily removed to regenerate the hydroxy groups. Methyl and benzyl are favored protecting groups since they are readily removed.
The protected 2-bromo-5-(Z-W substituted) phenol is then reacted with magnesium in a reaction-inert solvent and generally in the presence of a promoter, e.g., cuprous salts such as the chloride, bromide and iodide (to promote 1,4-addition) with an appropriate compound of formula IV. Suitable reaction-inert solvents are cyclic and acyclic ethers such as, for example, tetrahydrofuran, dioxane and dimethyl ether of ethylene glycol (diglyme). The Grignard reagent is formed in known manner, as, for example, by refluxing a mixture of one molar proportion of the bromo reactant and two molar proportions of magnesium in a reaction-inert solvent, e.g. tetrahydrofuran. The resulting mixture is then cooled to about 0° C. to -20° C., and cuprous iodide added followed by the appropriate formula IV compound at a temperature of from about 0° C. to -20° C. The amount of cuprous iodide used is not critical but can vary widely. Molar proportions ranging from about 0.2 to about 0.02 moles per mole of bromo reactant afford satisfactory yields of compounds of formula I wherein the phenolic hydroxy group is protected (formula I, R 1 =a protecting group; A+B=oxo, remaining groups as defined above).
The protected formula I compound is then treated with an appropriate reagent, if desired, to remove the protecting group. The benzyl group is conveniently removed by methods described above. If the protecting group is an alkyl group (methyl or ethyl) it is removed by the above-mentioned methods or by treatment with, for example, pyridine hydrochloride. The ketal group of formula I-A compounds is restored to oxo, if desired, by treatment with acid to provide a compound of formula I-B.
However, in most instances in the processes for preparing compounds of formula I, the protecting groups are retained throughout the overall process and not removed until the penultimate or ultimate process step is reached.
The compounds having formula I-C are prepared from the corresponding protected compounds of formula I-A by reduction. Sodium borohydride is favored as reducing agent in this step since it not only affords satisfactory yields of the desired product, but retains the protecting group on the phenolic hydroxy group, and reacts slowly enough with hydroxylic solvents (methanol, ethanol, water) to permit their use as solvents. Temperatures of from about -40° C. to about 30° C. are generally used. Lower temperatures, even down to -70° C., can be used to increase selectivity of the reduction. Higher temperatures cause reaction of the sodium borohydride with the hydroxylic solvent. If higher temperatures are desired, or required for a given reduction, isopropyl alcohol or the dimethyl ether of diethylene glycol are used as solvents. Sometimes favored as reducing agent is potassium trisec-butyl borohydride since it favors stereoselective formation of the 2-beta-hydroxy derivative. The reduction is conducted in dry tetrahydrofuran at a temperature below about -50° C. using equimolar quantities of the ketone compound and reducing agent.
Reducing agents such as lithium borohydride, diisobutylaluminum hydride or lithium aluminum hydride which can also be used require anhydrous conditions and non-hydroxylic solvents, such as 1,2-dimethoxyethane, tetrahydrofuran, diethyl ether, dimethyl ether of diethylene glycol.
The deprotected compounds of formula I, except those of formula I-E, wherein A is hydrogen and each of B and OR 1 is hydroxy can, of course, be obtained directly by catalytic reduction of the corresponding protected compounds (formula I, A+B=oxo, R 1 =benzyl) over palladium-on-carbon, or by chemical reduction of the unprotected compounds (formula I, A+B=oxo, R 1 =H) using the reducing agents described above. In practice it is preferred to produce the deprotected compounds of formula I (A=H, B=OH) by reduction of the corresponding benzyl protected compounds of formula I (A+B=oxo, R 1 =benzyl) as described above since it permits stereochemical control of the reduction and formation of the 2-beta hydroxy epimer (see conversion I-A to I-C) as the major product and thus facilitates separation and purification of the epimeric 2-hydroxy derivatives. The ketal group at the 6-position, if present, is converted to oxo by treatment with aqueous acid. Debenzylation of formulae I-E compounds is accomplished by reaction with n-butyllithium in hexane in order to avoid reduction of the 6-methylene group.
Compounds of formula I-C serve as intermediates for compounds of formula I-D through I-G. Reduction of the oxo group by methods such as those described above affords the corresponding dihydroxy compound I-D.
Compounds of this invention wherein R 2 and R 3 taken together are methylene (I-E) are readily prepared from the corresponding oxo compounds (I-C) via the Wittig reaction with methylene triphenylphosphorane or other appropriate methylide. The usual procedure comprises generating the Wittig reagent; that is, the methylide, in situ and, immediately following generation of the methylide, reacting it with the appropriate oxo compound. A convenient procedure for generating the methylide comprises reacting sodium hydride with dimethyl sulfoxide (sodium dimsyl) at a temperature of from about 50° C.-80° C., usually until evolution of hydrogen ceases, followed by reacting the resulting solution with methyl triphenyl phosphonium bromide at a temperature of from about 10° C. to about 80° C. To the thus-produced solution of the ylide is then added the appropriate oxo compound and the mixture stirred at temperatures ranging from about room temperature to 80° C. The methylene compound this produced is isolated by known procedures.
Other methods of generating the methylide are, of course, known and can be used in lieu of the above-described procedure. Typical procedures are described by Maercker, Organic Reactions, 14, 270 (1965). In the oxo compounds having formula I-C, the phenolic hydroxy group can be protected by groups other than benzyl if desired as, for example, by conversion to an alkanoyloxy derivative or to an ether such as, for example, a tetrahydropyranyl ether. However, protection of the phenolic hydroxy group is not absolutely necessary if sufficient base is present to convert the phenolic hydroxy group to an alkoxide.
The methylene derivatives of formula I-E are reduced to corresponding methyl derivatives (I-F) by catalytic hydrogenation. Simultaneous removal of the benzyl protecting group also occurs.
Conversion of the methylene derivatives (I-E) to hydroxymethyl derivatives (I-G) is accomplished by hydroboration-oxidation. Borane in tetrahydrofuran is favored for the hydroboration step since it is commercially available and gives satisfactory yields of the desired hydroxymethyl compound. The reaction is generally conducted in tetrahydrofuran or diethylene glycol dimethyl ether (diglyme). The borane product is not isolated but is directly oxidized with alkaline hydrogen peroxide to the hydroxymethyl compound.
Compounds of formulae I-D, I-F and I-G wherein the 2-hydroxy group and the R 3 substituent (OH, CH 3 , CH 2 OH) have the beta configuration are resolved into their diastereomers by formation of the corresponding d-mandelates by reaction with d-mandelic acid. When R 3 is OH or CH 2 OH, the bis-d-mandelate derivative is formed. A convenient method of preparing the d-mandelates comprises reacting said formulae I-D, I-F and I-G compounds with an excess of d-mandelic acid in benzene in the presence of p-toluenesulfonic acid monohydrate at the reflux with continuous removal of water. The diastereomeric mandelates thus prepared are separated via column chromatography on silica gel. Hydrolysis of the esters using potassium carbonate in methanol-tetrahydrofuran-water affords the entantiomeric I-D, I-F and I-G compounds.
Esters of formula I compounds wherein only group OR 1 is acylated are prepared by reacting formula I compounds wherein A together with B represent oxo and R 3 is other than hydroxy or hydroxymethyl with the appropriate alkanoic acid or acid of formula HOOC--(CH 2 ) p --NR 2 R 3 in the presence of a condensing agent such as dicyclohexylcarbodiimide followed by reduction of the oxo group to OH. Alternatively, they are prepared by reaction of a formula I compound with the appropriate alkanoic acid chloride or anhydride, e.g., acetyl chloride or acetic anhydride, in the presence of a base such as pyridine. The monoacylated product is then subjectedto further reactions, if desirable, such as reduction of A+B=oxo to the corresponding alcohol.
Diesters of formula I compounds in which each of B and OR 1 groups is hydroxy and R 3 is other than hydroxy or hydroxymethyl are prepared by acylation according to the above-described procedures. Compounds in which only the B-hydroxy group is acylated are obtained by mild hydrolysis of the corresponding diacyl derivative, advantage being taken of the greater ease of hydrolysis of the phenolic acyl group. Formula I compounds in which only the phenolic hydroxy group is esterified are obtained by borohydride reduction of the corresponding formula I ketone (A+B=oxo) which is esterified at the phenolic hydroxy group. The thus-produced formula I compounds in which only one OH group is acylated can then be acylated further with a different acylating agent to produce a diesterified compound of formula I in which the ester groups represented by B and OR 1 are different.
Diesters of compounds wherein each of OR 1 and B is hydroxy and R 3 is hydroxy or hydroxymethyl are also prepared by acylation of the appropriate trihydroxy containing derivative with at least three equivalents of an appropriate acylating agent, e.g., acid chloride, acid anhydride or acid plus condensing agent, as described above. The order of acylation of the hydroxy groups appears to be R 3 (═CH 2 OH)>OR 1 >B. This observation permits acylation of R 3 in the presence of OR 1 and B as OH. Diesters of formula I compounds in which each of OR 1 and R 3 is alkanoyloxy are prepared by acylating the appropriate formula I compound wherein A+B is oxo and each of OR 1 and R 3 is hydroxy. The oxo (A+B) group is then reduced, if desired, by means of sodium borohydride. The hydroxy group thus produced can be acylated with a different acylating agent to produce a mixed ester containing product. Similarly, diesters of formula I compounds wherein each of OR 1 , B is alkanoyloxy and R 3 is hydroxy are obtained by acylation of formula I compounds wherein R 2 +R 3 is HO and each of OR 1 and B is hydroxy. Borohydride reduction of R 2 +R 3 as oxo affords the desired diesters.
Acylation of a formula I compound wherein OR 1 and B is hydroxy and R 3 is OH or --CH 2 OH with one equivalent of an acylating agent affords a mixture of esters wherein OR 1 and/or R 3 are acylated. The products are separated chromatographically on silica gel.
Pharmaceutically acceptable acid addition salts of compounds of this invention are readily prepared by well known procedures. A typical procedure comprises reacting the appropriate formula I compound and appropriate acid, generally in stoichiometric amounts, in a reaction-inert solvent, e.g. methanol, and recovering the resulting salt by a suitable method, e.g., filtration, precipitation by addition of a nonsolvent such as ether, or evaporation of the solvent. When more than one basic group is present, diacid salt formation becomes possible.
In the above sequence the oxo (or alkylenedioxy) group can be converted to other values of R 2 and R 3 as defined herein at any step of the sequence if desired. It is generally advantageous for reasons of economy to carry out the sequence as illustrated and to convert the alkylenedioxy group to other values of R 2 and R 3 as shown in Sequence A.
The required compound of formula IV-A is prepared according to the following reaction sequence. ##STR11##
In this sequence an appropriate 3-carboxycyclohex-3-enone is ketalized using an alkyleneglycol having from two to four carbon atoms according to procedures described above. The ketalized product is then esterified under non-acid conditions such as by using dimethyl sulfate in the presence of potassium carbonate. The unsaturated ester (VIII) is then converted to ketone II-A by reaction with metallated acetone dimethylhydrazone. The reaction comprises metallating the dimethylhydrazone of acetone by reaction with a suitable lithiating agent such as n-butyllithium or lithium diisopropylamide in a reaction-inert solvent such as tetrahydrofuran at 0° C. or lower. The lithiated acetone dimethylhydrazone is then reacted with a solution of cuprous iodide-diisopropylsulfide in tetrahydrofuran or other reaction-inert solvent at a temperature of -78° C. to -50° C. The temperature of the reaction mixture is gradually warmed to about 0° C. over a period of one half to one hour and then cooled to about -78° C. The cuprate thus prepared is then reacted with the unsaturated ester VIII to produce the dimethylhydrazone of the ester of II-A. Oxidative hydrolysis of the dimethylhydrazone using, for example, aqueous sodium periodate at pH 7, or by means of cupric chloride in water-tetrahydrofuran at pH 7 affords the ester of II-A. Hydrolysis (saponification) of the ester provides II-A.
Ketone II-A is transformed to the enolic lactone III-A by treatment with sodium acetate in acetic anhydride at an elevated temperature, e.g., reflux. Other dehydrating conditions can, of course, be used.
The enol lactone is then treated with diisobutylaluminum hydride in a reaction-inert solvent at a temperature -20° C. or lower. Other useful reducing agents are lithium tri-sec-butyl hydride, 9-borobicyclo[3.3.1]nonane, and lithium tri-tert-butoxyaluminohydride. The keto aldehyde thus produced, and which is in equilibrium with the corresponding lactol (III-B) is then cyclized by intramolecular aldol condensation using a secondary amine, preferably pyrrolidine, and acetic acid as catalysts to provide the bicyclic ketone (IV-A).
Alternatively, the compound of formula IV-A is preferably produced by reaction of decahydro-2,6-naphthalenedione monoethylene ketal with lithium diisopropylamide in a reaction-inert solvent, e.g. tetrahydrofuran, at an initial temperature of about -50° C. to -78° C. followed by warming to ambient temperature. The mixture is then cooled to -10° C. to +10° C. and treated with diphenyldisulfide. Oxidation of the 3-alpha-phenylthiodecahydro-2,6-naphthalenedione 6-monoethylene ketal thus produced with a peracid such as m-chloro-peroxybenzoic acid at 0° C. to 20° C. in a reaction-inert solvent (CH 2 Cl 2 ) affords the corresponding phenylsulfenyl derivative. Said compound can be produced in a single step by reacting decahydro-2,6-naphthalenedione monoethylene ketal with an alkylphenylsulfinate in the presence of an alkali metal hydride at about 0° C. in diglyme.
Treatment of the phenylsulfinyl derivative with a solid base (CaCO 3 ) in toluene at 110° C. produces the compound of formula IV-A.
Also of value as CNS agents, anticonvulsants, antiemetics, analgesics and antidiarrheal agents in the same manner as compounds of formula I above, are compounds of formula I wherein A is hydrogen and B is hydrogen, amino or acetamido; and R 1 , R 2 , R 3 , Z and W are as defined in formula I above.
Compounds of this invention wherein B is amino are prepared from the corresponding compounds wherein A and B taken together represent oxo. One procedure comprises converting the appropriate oxo compound (ketone) of formula I to the corresponding oxime or oxime derivative; e.g., an alkyl ether or an acetyl derivative, followed by reduction of the oxime or derivative thereof to the desired amine. Of course, when R 2 and R 3 taken together represent oxo, said oxo group must be protected to avoid reaction at that site. The ketal (R 2 +R 3 =alkylenedioxy) group is a preferred protecting group because of the ease of preparation of said compounds and the relative ease of removal of said group to regenerate the oxo group.
The oximes of compounds of formula I wherein A and B taken together represent oxo, and R 2 and R 3 taken together are other than oxo, are prepared by reacting said compounds with hydroxylamine hydrochloride in a solution of methanol-water at room temperature. In practice, it is preferred to use an excess of hydroxylamine, up to as much as a three fold excess. Under such conditions the preparation of the desired oxime derivative is complete in 1 to 2 hours. The product is isolated by addition of the reaction mixture to water followed by basification to pH 9.5 and extraction with a water-immiscible solvent such as ethyl acetate.
When O-methylhydroxylamine hydrochloride is employed in place of hydroxylamine hydrochloride, the reaction provides the O-methyloxime derivative. When using O-methylhydroxylamine, it is preferred to extend the reaction time to 6 to 12 hours. Isolation of the product is carried out in the same manner as previously described for the oxime derivative.
Preparation of the O-acetyloxime compounds is accomplished by acetylation of the corresponding oxime with an equimolar amount of acetic anhydride in the presence of an equimolar amount of pyridine. The use of an excess of the anhydride and pyridine aid in the completion of the reaction and an excess of two to three fold of each is preferred. The reaction is best conducted in an aprotic hydrocarbon solvent such as benzene or toluene at room temperature overnight. On completion of the reaction, water is added and the product is separated in the hydrocarbon layer. Alternatively, O-acetyl derivatives can be prepared by treating the requisite oxo compound with O-acetylhydroxylamine hydrochloride under reaction conditions similar to those described above for preparation of the oxime derivatives.
The oxime or oxime derivative is then reduced catalytically using, for example, Raney nickel, palladium-on-charcoal or platinum oxide at an initial hydrogen pressure of about 2-3 atmospheres at ambient temperature in a reaction-inert solvent such as C 1-4 alkanol, or lithium aluminum hydride in a reaction-inert solvent such as tetrahydrofuran at reflux temperature.
A still further procedure comprises the Gabriel synthesis in which potassium phthalimide is reacted with a 4-halo, e.g. 4-iodo- or 4-bromo derivative of a compound of formula I (B=I, Br) and the resulting phthalimide derivative hydrolyzed with a base such as sodium or potassium hydroxide or hydrazine. The 4-halo compound of formula I is prepared by reaction of the corresponding hydroxy compound of formula I-C with phosphorous halide or hydrogen halide.
A favored procedure for preparing amino compounds of formula I comprises condensation of the appropriate formula I compound wherein A and B taken together represent oxo with the ammonium salt of a lower alkanoic acid and subsequent reduction of the in situ generated imine. In addition to lower alkanoic acid ammonium salts, ammonium salts of inorganic acids can also be used in this procedure.
A further favored procedure comprises reaction of the appropriate compound of formula I wherein B is alpha-hydroxy with equimolar quantities of phthalimide, triphenylphosphine and diethylazodicarboxylate.
In practice, a solution of the ketone (A+B=O) in a lower alkanol such as methanol is treated with an ammonium salt of an alkanoic acid such as acetic acid and the cooled reaction mixture treated with the reducing agent sodium cyanoborohydride. The reaction is allowed to proceed at room temperature for several hours, and is subsequently hydrolyzed and the product isolated.
Although stoichiometric proportions of ketone and ammonium alkanoate are required, it is advantageous to use up to a ten fold excess of ammonium alkanoate in order to ensure rapid formation of the imine. It is also advantageous to conduct the reduction at ambient temperature and to use two moles of sodium cyanoborohydride per mole of ketone reactant in order to maximize yield of the final product. Reaction is complete in 2-3 hours.
Reduction of the imine can, of course, be carried out with other reducing agents such as palladium-on-charcoal. In practice, a solution of the appropriate ketone in a lower alkanol, such as methanol or isopropanol, is treated with an ammonium alkanoate, such as ammonium acetate, and 10% palladium-on-charcoal, and the resulting suspension shaken in a hydrogen atmosphere at temperatures of about 25°-50° C. until the theoretical amount of hydrogen has been absorbed. It is preferred that a 10 fold excess of the ammonium alkanoate be employed to ensure complete reaction in a reasonable time period. The amount of the catalyst can vary from 10% to 50% on a weight basis, of the starting ketone. The initial pressure of the hydrogen is not critical, and a pressure from one to fifty atmospheres is preferred to shorten the reaction time. Employing the aforementioned parameters, the reaction time will vary between 2 to 6 hours. Upon completion of the reductive amination reaction, the spent catalyst is filtered and the filtrate concentrated to dryness.
The amino compounds produced by the above procedures are isolated by taking advantage of their basic nature which permits convenient separation from non-basic by-products and reactants. In general, an aqueous solution of the product is extracted over a range of gradually increasing pH so that non-basic materials are removed at the lower pH's and the product at a pH of about 9. The extracting solvents, e.g. ethyl acetate, diethyl ether, are back-washed with brine and water, dried and evaporated to give the product.
Formula I compounds wherein each of A and B is hydrogen are prepared from corresponding compounds wherein A and B taken together are oxo. The process comprises converting the oxo group to a hydrazone (or semicarbazone) and then decomposing said hydrazone (or semicarbazone) by alkali such as sodium or potassium hydroxide to produce the desired compound wherein each of A and B is hydrogen. The process is readily carried out by heating a mixture of the appropriate compound of formula I wherein A and B taken together are oxo and R 2 and R 3 taken together are other than oxo with hydrazine hydrate in a reaction inert solvent such as ethylene glycol or triethyleneglycol at 100° C. Solid potassium (or sodium) hydroxide is then added and the mixture heated at an elevated temperature, e.g. 150°-200° C. It is then cooled, acidified and the product recovered, e.g. by extraction with ether, or other known method.
Esters of formula I compounds in which the amino group and/or hydroxy groups (OR 1 , B, R 3 ) are acylated are prepared by acylation with the appropriate alkanoic acid or amino acid in the presence of a condensing agent such as dicyclohexylcarbodiimide or by reaction with the appropriate alkanoic acid chloride or anhydride, e.g. acetyl chloride or acetic anhydride, in the presence of a base such as pyridine.
When B is amino, further opportunity for formation of pharmaceutically acceptable acid addition salts exists and, when more than one basic group is present, to formation of poly-acid addition salts according to procedures described herein.
The analgesic properties of the compounds of this invention are determined by tests using nociceptive stimuli.
TESTS USING THERMAL NOCICEPTIVE STIMULI
(a) Mouse Hot Plate Analgesic Testing
The method used is modified after Woolfe and MacDonald, J. Pharmacol. Exp. Ther., 80, 300-307 (1944). A controlled heat stimulus is applied to the feet of mice on a 1/8-inch thick aluminum plate. A 250 watt reflector infrared heat lamp is placed under the bottom of the aluminum plate. A thermal regulator, connected to thermistors on the plate surface, programs the heat lamp to maintain a constant temperature of 57° C. Each mouse is dropped into a glass cylinder (61/2-inch diameter) resting on the hot plate, and timing is begun when the animal's feet touch the plate. The mouse is observed at 0.5 and 2 hours after treatment with the test compound for the first "flicking" movements of one or both hind feet, or until 10 seconds elapse without such movements. Morphine has an MPE 50 =4-5.6 mg./kg. (s.c.).
(b) Mouse Tail Flick Analgesic Testing
Tail flick testing in mice is modified after D'Amour and Smith, J. Pharmacol. Exp. Ther., 72, 74-79 (1941) using controlled high intensity heat applied to the tail. Each mouse is placed in a snug-fitting metal cylinder, with the tail protruding through one end. This cylinder is arranged so that the tail lies flat over a concealed heat lamp. At the onset of testing an aluminum flag over the lamp is drawn back, allowing the light beam to pass through the slit and focus onto the end of the tail. A timer is simultaneously activated. The latency of a sudden flick of the tail is ascertained. Untreated mice usually react within 3-4 seconds after exposure to the lamp. The end point for protection is 10 seconds. Each mouse is tested at 0.5 and 2 hours after treatment with morphine and the test compound. Morphine has an MPE 50 of 3.2-5.6 mg./kg. (s.c.).
(c) Tail Immersion Procedure
The method is a modification of the receptacle procedure developed by Benbasset, et al., Arch. int. Pharmacodyn., 122, 434 (1959). Male albino mice (19-21 g.) of the Charles River CD-1 strain are weighed and marked for identification. Five animals are normally used in each drug treatment group with each animal serving as its own control. For general screening purposes, new test agents are first administered at a dose of 56 mg./kg. intraperitoneally or subcutaneously, delivered in a volume of 10 ml./kg. Preceding drug treatment and at 0.5 and 2 hours post drug, each animal is placed in the cylinder. Each cylinder is provided with holes to allow for adequate ventilation and is closed by a round nylon plug through which the animal's tail protrudes. The cylinder is held in an upright position and the tail is completely immersed in the constant temperature waterbath (56° C.). The endpoint for each trial is an energetic jerk or twitch of the tail coupled with a motor response. In some cases, the endpoint may be less vigorous post drug. To prevent undue tissue damage, the trial is terminated and the tail removed from the waterbath within 10 seconds. The response latency is recorded in seconds to the nearest 0.5 second. A vehicle control and a standard of known potency are tested concurrently with screening candidates. If the activity of a test agent has not returned to baseline values at the 2-hour testing point, response latencies are determined at 4 and 6 hours. A final measurement is made at 24 hours if activity is still observed at the end of the test day.
TEST USING CHEMICAL NOCICEPTIVE STIMULI
Suppression of Phenylbenzoquinone Irritant-Induced Writhing
Groups of 5 Carworth Farms CF-1 mice are pretreated subcutaneously or orally with saline, morphine, codeine or the test compound. Twenty minutes (if treated subcutaneously) or fifty minutes (if treated orally) later, each group is treated with intraperitoneal injection of phenylbenzoquinone, an irritant known to produce abdominal contractions. The mice are observed for 5 minutes for the presence or absence of writhing starting 5 minutes after the injection of the irritant. MPE 50 's of the drug pretreatments in blocking writhing are ascertained.
TESTS USING PRESSURE NOCICEPTIVE STIMULI
Effect on the Haffner Tail Pinch Procedure
A modification of the procedure of Haffner, Experimentelle Prufung Schmerzstillender. Deutch Med. Wschr., 55, 731-732 (1929) is used to ascertain the effects of the test compound on aggressive attacking responses elicited by a stimulus pinching the tail. Male albino rats (50-60 g.) of the Charles River (Sprague-Dawley) CD strain are used. Prior to drug treatment, and again at 0.5, 1, 2 and 3 hours after treatment, a Johns Hopkins 2.5-inch "bulldog" clamp is clamped onto the root of the rat's tail. The endpoint at each trial is clear attacking and biting behavior directed toward the offending stimulus, with the latency for attack recorded in seconds. The clamp is removed in 30 seconds if attacking has not yet occurred, and the latency of response is recorded as 30 seconds. Morphine is active at 17.8 mg./kg. (i.p.).
TESTS USING ELECTRICAL NOCICEPTIVE STIMULI
The "Flinch-Jump" Test
A modification of the flinch-jump procedure of Tenen, Psychopharmacologia, 12, 278-285 (1968) is used for determining pain thresholds. Male albino rats (175-200 g.) of the Charles River (Sprague-Dawley) CD strain are used. Prior to receiving the drug, the feet of each rat are dipped into a 20% glycerol/saline solution. The animals are then placed in a chamber and presented with a series of 1-second shocks to the feet which are delivered in increasing intensity at 30-second intervals. These intensities are 0.26, 0.39, 0.52, 0.78, 1.05, 1.31, 1.58, 1.86, 2.13, 2.42, 2.72 and 3.04 mA. Each animal's behavior is rated for the presence of (a) flinch, (b) squeak and (c) jump or rapid forward movement at shock onset. Single upward series of shock intensities are presented to each rat just prior to, and at 0.5, 2, 4 and 24 hours subsequent to drug treatment.
Results of the above tests are recorded as percent maximum possible effect (%MPE). The %MPE of each group is statistically compared to the %MPE of the standard and the predrug control values. The %MPE is calculated as follows: ##EQU1##
The compounds of this invention, when used as analgesics via oral or parenteral administration, are conveniently administered in composition form. Such compositions include a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practics. For example, they can be administered in the form of tablets, pills, powders or granules containing such excipients as starch, milk sugar, certain types of clay, etc. They can be administered in capsules, in admixtures with the same or equivalent excipients. They can also be administered in the form of oral suspensions, solutions, emulsions, syrups and elixirs which may contain flavoring and coloring agents. For oral administration of the therapeutic agents of this invention, tablets or capsules containing from about 0.01 to about 100 mg. are suitable for most applications.
The physician will determine the dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient and the route of administration. Generally, however, the initial analgesic dosage in adults may range from about 0.1 to about 750 mg. per day in single or divided doses. In many instances, it is not necessary to exceed 100 mg. daily. The favored oral dosage range is from about 1.0 to about 300 mg./day; the preferred dose is from about 1.0 to about 50 mg./day. The favored parenteral dose is from about 0.1 to about 100 mg./day; the preferred range from about 0.1 to about 20 mg./day.
This invention also provides pharmaceutical compositions, including unit dosage forms, valuable for the use of the herein described compounds as analgesics and other utilities disclosed herein. The dosage form can be given in single or multiple doses, as previously noted, to achieve the daily dosage effective for a particular utility.
The compounds (drugs) described herein can be formulated for administration in solid or liquid form for oral or parenteral administration. Capsules containing drugs of this invention are prepared by mixing one part by weight of drug with nine parts of excipient such as starch or milk sugar and then loading the mixture into telescoping gelatin capsules such that each capsule contains 100 parts of the mixture. Tablets containing said compounds are prepared by compounding suitable mixtures of drug and standard ingredients used in preparing tablets, such as starch, binders and lubricants, such that each tablet contains from 0.10 to 100 mg. of drug per tablet.
Suspensions and solutions of these drugs, particularly those wherein R 1 (formula I) is hydroxy, are often prepared just prior to use in order to avoid problems of stability of the suspensions or solution (e.g. precipitation) of the drug upon storage. Compositions suitable for such are generally dry solid compositions which are reconstituted for injectable administration.
By means of the above procedures, the analgesic activity of several compounds of this invention is determined. The compounds have the formula shown below: ##STR12##
The following abbreviations are used in the Tables: PBQ=phenylbenzoquinone-induced writhing; TF=tail flick; HP=hot plate; RTC=rat tail clamp; and FJ=flinch jump.
TABLE I______________________________________Analgesic Activity - MPE.sub.50, mg./kg. Route = Subcutaneous.A B R.sub.2 R.sub.3 PBQ RTC______________________________________O H H 3.19 -- H OH H H 1.46 13.4 H OH H H 1.24 -- H OH H OH 0.55 2.3 H OH H OH 3.22 6.9 H.sup.(c) OH H CH.sub.2 OH 0.054 0.22 H OH H CH.sub.2 OH 2.81 6.8 H OH O 1.44 5.6 H.sup.(a) OH H CH.sub.2 OH 0.018 0.06 H.sup.(b) OH H CH.sub.2 OH 1.58 10______________________________________ .sup.(a) Pure enantiomer A .sup.(b) Pure enantiomer B .sup.(c) Analgesic activity by oral administration: PBQ = 0.25; RTC = 0. mg./kg
The antiemetic properties of the compounds of formula I are determined in unanesthetized unrestrained cats according to the procedure described in Proc. Soc. Exptl. Biol. and Med., 160, 437-440 (1979).
The compounds of the present invention are active antiemetics via oral and parenteral administration and are conveniently administered in composition form. Such compositions include a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice. For example, they may be administered in the form of tablets, pills, powders or granules containing such excipients as starch, milk sugar, certain types of clay, etc. They may be administered in capsules, in admixtures with the same or equivalent excipients. They may also be administered in the form of oral suspensions, dispersions, solutions, emulsions, syrups and elixirs which may containing flavoring and coloring agents. For oral administration of the therapeutic agents of this invention, tablets or capsules containing from about 0.01 to about 100 mg. are suitable for most applications.
The physician will determine the dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient and the route of administration. Generally, however, the initial antiemetic dose of drug is administered in an amount effective to prevent nausea. Such dosage in adults may range from 0.01 to 500 mg. per day in single or divided doses. In many instances, it is not necessary to exceed 100 mg. daily. The favored oral dosage range is from about 0.01 to about 300 mg./day; the preferred range is from about 0.10 to about 50 mg./day. The favored parenteral dose is from about 0.01 to about 100 mg./day; the preferred range from about 0.01 to about 20 mg./day.
Their antidiarrheal utility is determined by a modification of the procedure of Neimegeers et al., Modern Pharmacology-Toxicology, Willem van Bever and Harbans Lal, Eds., 7, 68-73 (1976). In general, the dosage levels and routes of administration for use of these compounds as antidiarrheal agents parallels those with respect to their use as analgesic agents.
The compounds (drugs) described herein can be formulated for administration in solid or liquid form for oral or parenteral administration. Capsules containing compounds of formulae I or II are prepared by mixing one part by weight of drug with nine parts of excipient such as starch or milk sugar and then loading the mixture into telescoping gelatin capsules such that each capsule contains 100 parts of the mixture. Tablets are prepared by compounding suitable mixtures of drug and standard ingredients used in preparing tablets, such as starch, binders and lubricants, such that each tablet contains from 0.01 to 100 mg. of drug per tablet.
In addition to these uses, the herein-described compounds also exhibit activity as tranquilizers, sedatives, anticonvulsants, diuretics and as antianxiety agents.
EXAMPLE 1
3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2(1H)-one
A solution of 5.20 g. (13.4 mmole) of 1-bromo-2-benzyloxy-4-(1,1-dimethylheptyl)benzene in 27 ml. of tetrahydrofuran is slowly added to 641 mg. (26.7 mmole) of magnesium metal. After a 5 minute initiation period of rate of addition is adjusted such that reflux is just maintained. The reaction mixture is stirred 30 minutes longer while cooling to 25° C. It is then cooled to -15° C. and 127 mg. (0.668 mmole) of cuprous iodide is added. The resultant mixture is stirred 5 minutes and then a solution of 1.8 g. (12.2 mmole) of trans-4a,5,6,7,8,8a-hexahydro-naphthalen-2(1H)-one in 10 ml. of tetrahydrofuran is added over a 10 minute period. Half way through the addition of the naphthalenone another 127 mg. (0.668 mmole) portion of cuprous iodide is added. The reaction mixture is stirred 5 minutes longer and then added to 250 ml. of cold, saturated ammonium chloride and 250 ml. of ether. The ether extract of the quenched reaction is washed once with 250 ml. of saturated ammonium chloride, dried over magnesium sulfate and evaporated to an oil. The crude oil is purified via column chromatography on 150 g. of silica gel eluted with 10 ml. fractions with 15% ether-petroleum ether to yield 3.45 g. (62%) of the title compound as an oil.
IR (CHCl 3 ): 1724, 1626 and 1582 cm -1 .
MS (m/e): 460 (M.sup.⊕), 440, 375, 369, 363, 351 and 91.
PMR (CDCl 3 ): delta 0.88 (m, terminal methyl), 1.28 (s, gem dimethyls), 5.12 (s, benzylic methylene), 6.90 (dd, J=8 and 2 Hz, ArH), 6.90 (d, J=2 Hz, ArH), 7.12 (d, J=8 Hz, ArH) and 7.42 (s, PhH).
In like manner, the following compounds are prepared by substituting equivalent amounts of the appropriate 1-bromo-2-benzyloxy-4(substituted)benzenes for 1-bromo-2-benzyloxy-4-(1,1-dimethylheptyl)benzene.
__________________________________________________________________________ ##STR13## Z W Z W__________________________________________________________________________C(CH.sub.3).sub.2 (CH.sub.2).sub.4 H O(CH.sub.2).sub.7 H(CH.sub.2).sub.8 H OCH(CH.sub.3)(CH.sub.2).sub.9 HC(CH.sub.3).sub.2 (CH.sub.2).sub.6 H OCH(CH.sub.3)(CH.sub.2).sub.5 H(CH.sub.2).sub.7 H OC(CH.sub.3).sub.2 (CH.sub.2).sub.5 HC(CH.sub.3).sub.2 (CH.sub.2).sub.8 H OC(CH.sub.3).sub.2 (CH.sub.2).sub.7 HCH(CH.sub.3)CH(CH.sub.3)(CH.sub.2).sub.5 H O(CH.sub.2).sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.2 H(CH.sub.2).sub.11 H O(CH.sub.2).sub.4 C.sub.6 H.sub.5(CH.sub.2).sub.3 C.sub.6 H.sub.5 O(CH.sub.2).sub.6 C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.5 C.sub.6 H.sub.5 OC(CH.sub.3).sub.2 (CH.sub.2).sub.3 C.sub. 6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH(CH.sub.3)CH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5 O(CH.sub.2).sub.4 4FC.sub.6 H.sub.4(CH.sub.2).sub.8 C.sub.6 H.sub.5 OCH(CH.sub.3)(CH.sub.2).sub.3 4FC.sub.6 H.sub.4CH(CH.sub.3)(CH.sub.2).sub.3 4-FC.sub.6 H.sub.4 OCH(CH.sub.3)(CH.sub.2).sub.5 4FC.sub.6 H.sub.4CH(C.sub.2 H.sub.5)(CH.sub.2).sub.4 4-FC.sub.6 H.sub.4 O(CH.sub.2).sub.7 4ClC.sub.6 H.sub.4CH(O.sub.2 H.sub.5)(CH.sub.2).sub.2 4-ClC.sub.6 H.sub.4 OCH(C.sub.2 H.sub.5)(CH.sub.2).sub.3 4ClC.sub.6 H.sub.4(CH.sub.2).sub.5 H O(CH.sub.2).sub.3 C.sub.6 H.sub.5(CH.sub.2).sub.13 H O(CH.sub.2).sub.8 4-FC.sub.6 H.sub.4O(CH.sub.2).sub.5 H OC(CH.sub.3).sub.2 (CH.sub.2).sub.5 4-ClC.sub.6 H.sub.4O(CH(CH.sub.3)CH.sub.2 C.sub.6 H.sub.5 O(CH.sub.2).sub.13 HCH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4 (CH.sub.2).sub.4 OCH.sub.2 C.sub.6 H.sub.5(CH.sub.2).sub.4 4-pyridyl (CH.sub.2).sub.6 O C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.3 4-pyridyl CH(CH.sub.3)(CH.sub.2).sub.2 O C.sub.6 H.sub.5CH(C.sub.2 H.sub.5)CH.sub.2 4-pyridyl CH(CH.sub.3)(CH.sub.2).sub.5 O C.sub.6 H.sub.5(CH.sub.2).sub.7 4-pyridyl (CH.sub.2).sub.6 O 4-FC.sub.6 H.sub.4CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 4-pyridyl (CH.sub.2).sub.6 O 4-ClC.sub.6 H.sub.4CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 3-pyridyl (CH.sub.2).sub.3 OCH(CH.sub.3) 2-pyridylCH(CH.sub.3)(CH.sub.2).sub.3 2-pyridyl (CH.sub.2).sub.4 O 4-pyridyl(CH.sub.2).sub.3 O(CH.sub.2).sub.4 H (CH.sub.2).sub.3 O(CH.sub.2).sub.4 4-pyridyl(CH.sub.2)O(CH.sub.2).sub.7 H CH.sub.2 CH(CH.sub.3)O(CH.sub.2).sub.2 4-pyridylC(CH.sub.3).sub.2 (CH.sub.2).sub.2 O(CH.sub.2).sub.2 H O(CH.sub.2).sub.5 3-pyridyl(CH.sub.2).sub.7 O H O(CH.sub.2).sub.7 2-pyridyl(CH.sub.2).sub.11 O H OCH(CH.sub.3)(CH.sub.2).sub.3 2-pyridylCH(CH.sub.3)(CH.sub.2).sub.6 O H CH.sub.2 O(CH.sub.2).sub.5 C.sub.6 H.sub.5CH(CH.sub.3)CH.sub.2 O(CH.sub.2).sub.4 C.sub.6 H.sub.5 CH(CH.sub.3)CH.sub.2 OCH.sub.2 4-ClC.sub.6 H.sub.4(CH.sub.2).sub.3 OCH(CH.sub.3) C.sub.6 H.sub.5 CH.sub.2 O(CH.sub.2).sub.5 4-FC.sub.6 H.sub.4__________________________________________________________________________
EXAMPLE 2
1,2-alpha,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-naphthalen-2-beta-ol and the 2-alpha isomer
To a -5° C. solution of 2.40 g. (5.24 mmole) of 3,4-alpha,4-beta,5,6,7,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2(1H)-one in 15 ml. methanol and 5 ml. tetrahydrofuran is added 199 mg. (5.24 mmole) of sodium borohydride. The reaction is stirred 30 minutes and then added to 250 ml. saturated sodium chloride and 250 ml. ether. The ether extract is washed once with 250 ml. saturated sodium chloride, dried over magnesium sulfate and evaporated. The crude residue is purified via column chromatography on 100 g. of silica gel eluted in 12 ml. fractions with 2:1 pentane:ether to yield in order of elution 0.572 g. (24%) of the 2-alpha isomer of the title compound and 1.53 g. (64%) of the title compound.
Title Compound:
IR (CHCl 3 ): 3333, 1618 and 1575 cm -1 .
MS (m/e): 462 (M.sup.⊕), 447, 377, 354, 285, 269 and 91.
PMR (CDCl 3 ): delta 0.85 (m, terminal methyl), 1.28 (s, gem dimethyl), 3.0 (bm, benzylic H), 3.75 (bm, carbinol H), 5.07 (s, benzylic methylene), 6.9 (m, ArH) and 7.36 (s, PhH).
2-alpha Isomer of the Title Compound:
IR (CHCl 3 ): 3571, 3425, 1616 and 1575 cm -1 .
MS (m/e): 462 (M.sup.⊕), 377, 354, 285, 269 and 91.
PMR (CDCl 3 ): delta 0.87 (m, terminal methyl), 1.27 (s, gem dimethyl), 4.18 (m, carbinol H), 5.05 (s, benzylic methylene), 6.85 (m, ArH), 7.07 (d, J=8 Hz, ArH) and 7.38 (m, ArH).
The remaining compounds of Example 1 are reduced in like manner to provide compounds having the formula shown below wherein Z and W are as defined in Example 1. ##STR14##
The isomeric alcohols are produced in each instance.
EXAMPLE 3
1,2-alpha,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-naphthalen-2-beta-ol
A mixture of 1.48 g. (3.19 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-decahydro-4beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2-beta-ol and 300 mg. of 5% Pd/C/50% H 2 O in 15 ml. of ethanol is stirred under one atmosphere of hydrogen gas for one hour. The reaction mixture is filtered through diatomaceous earth with ethyl acetate and the filtrate evaporated to an oil. The crude oil is purified via column chromatography on 40 g. of silica gel eluted in 10 ml. fractions with 2:1 pentane:ether to yield 875 mg. (74%) of the title compound.
MP: 127°-128° C. (pentane).
IR (CHCl 3 ): 3333, 1618 and 1582 cm -1 .
MS (m/e): 372 (M.sup.⊕), 354, 287 and 269.
PMR (CDCl 3 ): delta 0.82 (m, terminal methyl), 1.28 (s, gem dimethyl), 2.72 (m, benzylic methine), 3.82 (m, carbinol methine), 6.8 (m, ArH) and 7.08 (d, J=8 Hz, ArH).
Analysis: Calc'd for C 25 H 40 O 2 : C, 80.59; H, 10.82. Found: C, 80.57; H, 10.62.
Similarly, debenzylation of the remaining beta-naphthaleneols of Example 2 according to the above procedure provides the corresponding products having the formula shown below wherein Z and W are as defined in Example 2. ##STR15##
EXAMPLE 4
1,2-beta,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-naphthalen-2-alpha-ol
Using the procedure of Example 3, 500 mg. (1.08 mmole) of 1,2-beta3,4-alpha,4a-beta,5,6,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethyl-heptyl)phenyl-naphthalen-2-alpha-ol is reduced to give 200 mg. (50%) of the title compound.
MP: 120°-122° C. (pentane).
IR (CHCl 3 ): 3333, 1626 and 1570 cm -1 .
MS (m/e): 372 (M.sup.⊕), 357, 354, 287 and 269.
PMR (CDCl 3 ): delta 0.86 (m, terminal methyl), 1.28 (s, gem dimethyl), 3.00 (m, benzylic methine), 4.28 (m, carbinol methine), 6.84 (m, ArH) and 7.03 (d, J=8 Hz, ArH).
Analysis: Calc'd. for C 25 H 40 O 2 : C, 80.59; H, 10.82. Found: C, 80.47; H, 10.51.
Debenzylation of the remaining alpha naphthalenols of Example 2 by the above procedure provides the following compounds wherein Z and W are as defined in Example 2. ##STR16##
EXAMPLE 5
3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Octahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-naphthalen-2(1H)-one
Using the procedure of Example 3, reduction of 1.00 g. (2.18 mmole) of 3,4-alpha,4a-beta,5,6,7,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-naphthalen-2(1H)-one, the title product of Example 1, gives 606 mg. (76%) of the title compound as an oil.
IR (CHCl 3 ): 3571, 3333, 1712, 1626 and 1587 cm -1 .
MS (m/e): 370 (M.sup.⊕), 352, 285 and 273.
PMR (CDCl 3 ): delta 0.82 (terminal methyl), 1.22 (s, gem dimethyl), 5.45 (s, OH), 6.8 (m, ArH) and 7.03 (d, J=8 Hz, ArH).
By means of the above procedure the remaining compounds of Example 1 are reduced to give corresponding compounds of the formula wherein Z and W are as defined in Example 1. ##STR17##
EXAMPLE 6
1,4-Dioxa-7-carboxyspiro[4.5]dec-7-ene
A mixture of 89.8 g. (0.641 mole) of 3-carboxy-cyclohex-3-enone and 615 mg. (3.17 mmole) of p-toluenesulfonic acid monohydrate in 920 ml. of benzene and 362 ml. of ethylene glycol is heated at reflux with a Dean-Stark trap for 3.5 hours. The cooled reaction mixture is diluted with 1.5 l. water and 3.2 ml. 1 N sodium hydroxide. The quenched reaction mixture is then extracted with two 2 l. portions of ether. The combined ether extract is washed with 750 ml. of saturated sodium chloride, dried over magnesium sulfate and evaporated to 91.1 g. of crude oil. The crude product is purified via column chromatography on 1.75 kg. of silica gel eluted with 30% ether-dichloromethane to give the title compound. Crystallization of the title compound from diisopropyl ether gives 49.2 g. (42%) of the title compound.
MP: 72°-73° C. (diisopropyl ether).
IR (CCl 4 ): 2874, 2817, 1678 and 1637 cm -1 .
MS (m/e): 184 (M.sup.⊕), 169, 139 and 86.
PMR (CDCl 3 ): delta 1.8 (bt, methylene), 2.3-2.7 bm, methylenes), 4.0 (s, ethylene), 7.0-7.2 (bm, olefinic H) and 10.8 (bs, COOH).
Analysis: Calc'd. for C 9 H 12 O 4 : C, 58.70; H, 6.57. Found: c, 58.39; H, 6.50.
Repetition of the above procedure but replacing ethylene glycol with an equivalent amount of 1,3-butylene glycol affords the corresponding 1,5-dioxa-8-carboxy-2-methylspiro[5.5]undec-8-ene.
EXAMPLE 7
1,4-Dioxa-7-carbomethoxyspiro[4.5]dec-7-ene
To a refluxing slurry of 66 g. (0.523 mole) of powdered potassium carbonate in 450 ml. of acetone are added simultaneously a solution of 83.0 g. (0.45 mole) of 1,4-dioxa-7-carboxyspiro[4.5]dec-7-ene in 450 ml. of acetone and a solution of 56.8 g. (0.45 mole) of dimethylsulfate in 450 ml. of acetone. The reaction mixture is refluxed 45 minutes longer and then filtered. The filtrate is evaporated to yield the crude title compound. Distillation of the crude product yields 87.7 g. (98%) of the title compound.
BP: 95° C. (2 torr).
IR (CCl 4 ): 2919, 2816, 1703 and 1642 cm -1 .
MS (m/e): 198 (M.sup.⊕), 183, 166, 139 and 86.
PMR (CDCl 3 ): delta 1.7 (bt, methylene), 2.4 (m, methylenes), 3.7 (s, methyl), 4.0 (s, ethylene) and 7.0 (bm, olefinic H).
Analysis: Calc'd. for C 10 H 14 O 4 : C, 60.17; H, 6.83. Found: C, 60.53; H, 7.11.
Repetition of this procedure but using an equivalent amount of diethylsulfate in place of dimethylsulfate affords the corresponding ethyl ester.
EXAMPLE 8
1,4-Dioxa-7-carbomethoxy-8-(2-oxopropyl)spiro[4.5]decane
To a -78° C. solution of 74 ml. (0.575 mole) of acetone dimethylhydrazone in 1.9 l. of tetrahydrofuran is added dropwise 288 ml. (0.575 mole) of butyllithium (2 M in hexane). To the resultant cloudy solution is added dropwise a solution of 54.8 g. (0.288 mole) of cuprous iodide and 167 ml. (1.15 mole) of diisopropyl sulfide in 500 ml. of tetrahydrofuran. The resultant suspension is warmed to -23° C. for 20 minutes, 0° C. for 5 minutes and the resultant solution cooled to -78° C. To the above prepared cuprate solution is added dropwise 44.6 g. (0.225 mole) of 1,4-dioxa-7-carbomethoxyspiro[4.5]dec-7-ene. The resultant mixture is stirred 15 minutes at -78° C. and then added to 4 l. of saturated ammonium chloride solution (pH adjusted to 8 with ammonium hydroxide). The reaction quench is extracted with 1 l. of ether and the extract washed with four 2 l. and one 1 l. portion of pH 8 saturated ammonium chloride. The organic extract is dried over magnesium sulfate and evaporated to yield 67 g. of intermediate hydrazone of the title compound. To the 67 g. of crude intermediate dissolved in 3 l. tetrahydrofuran and 625 ml. of pH 7 buffer is added a solution of 45.2 g. (0.339 mole) of cupric chloride in 1 l. of water. The hydrolysis mixture is stirred at 25° C. for 22 hours and then added to pH 8 saturated ammonium chloride solution and ether. The ether extract is washed with pH 8 saturated ammonium chloride until colorless, dried over magnesium sulfate and evaporated to an oil.
The above procedure is repeated on a scale of 42.5 g. (0.214 mole) of 1,4-dioxa-7-carbomethoxyspiro[4.5]dec-7-ene. The combined crude product from each preparation (113 g.) is purified via column chromatography on 3 kg. of silica gel eluted with 75% ether-petroleum ether to give 80.3 g. (71.2%) of the title compound as an oil.
IR (CHCl 3 ): 1730 and 1715 cm -1 .
HRMS (m/e): No M.sup.⊕, 224.1071 (C 17 H 17 O 4 ), 198, 157, 139 and 99.
PMR (CDCl 3 ): delta 1.5-2.0 (m), 2.12 (s, methyl ketone), 2.2-3.0 (m), 3.62 (s, methyl ester) and 3.92 (s, ethylene).
EXAMPLE 9
1,4-Dioxa-7-carboxy-8-(2-oxopropyl)spiro[4.5]decane
To a solution of 80.2 g. (0.313 mole) of 1,4-dioxa-7-carbomethoxy-8-(2-oxopropyl)spiro[4.5]decane in 500 ml. methanol and 1.6 l. tetrahydrofuran is added a solution of 36.1 g. (0.90 mole) of sodium hydroxide in 300 ml. of 5:16 methanol:tetrahydrofuran. The reaction mixture is stirred 30 minutes and then diluted with 500 ml. water and saturated with sodium chloride. The reaction mixture is cooled to 0° C., 500 ml. of ether added and acidified to pH 5 with concentrated hydrochloric acid. The quenched reaction is extracted once with 2 l. ether, the pH lowered to 3.5 and extracted with 1.5 l. ether and the pH lowered to 2.0 and extracted with two 1.5 l. portions of ether. The combined extract is dried over magnesium sulfate and evaporated to yield 72.5 g. (96%) of the title compound as an oil.
IR (CHCl 3 ): 2836 (broad) and 1702 cm -1 .
HRMS (m/e): 242.1185 (M.sup.⊕, calc'd for C 17 H 18 O 5 : 242.1149), 224, 185, 184, 139, 99 and 86.
PMR (CDCl 3 ): delta 1.4-2.0 (m), 2.12 (s, methyl ketone), 2.2-3.4 (m), 3.95 (s, ethylene) and 9.97 (bs, COOH).
EXAMPLE 10
Trans-4a,5,8,8a-tetrahydro-(1H,6H)-3-methyl-2-benzopyran-1,7-dione-7-Ethylene Ketal
A mixture of 72.5 g. (0.299 mole) of 1,4-dioxa-7-carboxy-8-(2-oxopropyl)spiro[4.5]decane and 14.3 g. (0.174 mole) of sodium acetate in 690 ml. of acetic anhydride is heated at reflux for 12 hours and stirred at 25° C. for 5.5 hours. The reaction mixture is poured onto 585 g. ice and 440 g. of sodium acetate, diluted with 200 ml. ether and slowly neutralized with 454 g. of solid sodium bicarbonate. The organic extract is dried over magnesium sulfate and evaporated. The crude residue is vacuum distilled to yield an oil which is dissolved in 100 ml. ether and washed twice with 100 ml. saturated sodium bicarbonate, once with 100 ml. saturated sodium chloride, dried over magnesium sulfate and evaporated to yield 63.0 g. (94%) of the title compound as an oil.
IR (CCl 4 ): 1770, 1695 and 1667 cm -1 .
HRMS (m/e): 224.1055 (M.sup.⊕, calc'd. for C 12 H 16 O 4 : 224.1044), 195, 180, 153, 126, 99 and 86.
PMR (CDCl 3 ): delta 1.2-2.0 (m), 1.93 (bs, vinyl methyl), 2.0-3.0 (m), 3.99 (s, ethylene) and 4.90 (bs, vinyl H).
EXAMPLE 11
Trans-4a,5,8,8a-tetrahydro-naphthalen-2(1H),6(7H)-dione-6-Ethylene Ketal
To a -78° C. solution of 50.4 g. (0.225 mole) of trans-4a, 5,8,8a-tetrahydro-(1H,6H)-3-methyl-2-benzopyran-1,7-dione 7-ethylene ketal in 504 ml. toluene is slowly added 236 ml. (0.236 mole) of diisobutylaluminum hydride (1 M in hexane). The reaction is allowed to stir 15 minutes at -78° C. and then a small portion of methanol is slowly added to remove any excess diisobutylaluminum hydride. The quenched reaction is added to 3 l. ether and washed successively with three 800 ml. portions of 50% saturated sodium potassium tartrate and one 800 ml. portion of saturated sodium chloride. The combined tartrate washes are extracted with 1.6 l. dichloromethane and 1.6 l. ether followed by washing of the combined extracts with 800 ml. saturated sodium chloride. All organic extracts are combined, dried over magnesium sulfate and evaporated to give a quantitative yield of intermediate ketoaldehyde. To the above prepared crude ketoaldehyde dissolved in 890 ml. benzene is added 16.0 g. (0.225 mole) of pyrrolidine and 9.2 g. (0.153 mole) of acetic acid. The reaction is stirred 4 hours at 25° C. and then diluted with 2 l. ether and washed with 600 ml. water, 600 ml. saturated sodium chloride, dried over magnesium sulfate and evaporated to an oil. This crude oil is purified via column chromatography on 1 kg. of silica gel eluted with 10% hexane-ether to give 10.6 g. (23%) of the title compound as an oil.
IR (CHCl 3 ): 1677 and 1615 cm -1 .
HRMS (m/e): 208.1100 (M.sup.⊕, calc'd. for C 12 H 16 O 3 : 208.1095), 180, 152, 99 and 86.
PMR (CDCl 3 ): delta 1.2-3.4 (m), 4.00 (bs, ethylene), 5.98 (dd, J=10 and 3 Hz, vinyl H) and 6.71 (dd, J=10 and 2 Hz, vinyl H).
Following the procedure of Examples 7-10 and the above procedure, 1,5-dioxa-8-carboxy-2-methyl-spiro[5.5]undec-8-ene is converted to trans-4a,5,8,8a-tetrahydro-(1H,6H)-2-benzopyran-1,7-dione 1,3-butylene ketal.
EXAMPLE 12
3,4-alpha-4a-beta,5,8,8a-alpha-Hexahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2(1H),6(7H)-dione 6-Ethylene Ketal
Using the procedure of Example 1, 23.3 g. (60 mmole) of 1-bromo-2-benzyloxy-4-(1,1-dimethylheptyl)-benzene and 10.0 g. (48.1 mmole) of trans-4a,5,8,8a-tetrahydro-naphthalen-2(1H),6(7H)-dione 6-ethylene ketal are reacted together to give 9.94 g. (40%) of the title compound as an oil.
IR (CHCl 3 ): 1712, 1613 and 1575 cm -1 .
HRMS (m/e): 518.3390 (M.sup.⊕, calc'd. for C 34 H 46 O 4 : 518.3392), 433, 273, 243, 153, 140 and 91.
PMR (CDCl 3 ): delta 0.82 (m, terminal methyl), 1.23 (s, gem dimethyl), 3.83 (bs, ethylene ketal), 5.05 (s, benzyl ether methylene), 6.84 (d, J=2 Hz, ArH), 6.84 (dd, J=8 and 2 Hz, ArH), 7.08 (d, J=8 Hz, ArH) and 7.37 (s, PhH).
The following compounds are prepared in like manner but using the appropriate 1-bromo-2-benzyloxy-4-(substituted)benzene in place of 1-bromo-2-benzyloxy-4-(1,1-dimethylheptyl)benzene.
__________________________________________________________________________ ##STR18## Z W Z W__________________________________________________________________________C(CH.sub.3).sub.2 (CH.sub.2).sub.4 H O(CH.sub.2).sub.7 H(CH.sub.2).sub.8 H OCH(CH.sub.3)(CH.sub.2).sub.9 HC(CH.sub.3).sub.2 (CH.sub.2).sub.6 H OCH(CH.sub.3)(CH.sub.2).sub.5 H(CH.sub.2).sub.7 H OC(CH.sub.3).sub.2 (CH.sub.2).sub.5 HC(CH.sub.3).sub.2 (CH.sub.2).sub.8 H OC(CH.sub.3).sub.2 (CH.sub.2).sub.7 HCH(CH.sub.3)CH(CH.sub.3)(CH.sub.2).sub.5 H O(CH.sub.2).sub.2 C(CH.sub.3).sub.2 (CH.sub.2).sub.2 H(CH.sub.2).sub.11 H O(CH.sub.2).sub.4 C.sub.6 H.sub.5(CH.sub.2).sub.4 C.sub.6 H.sub.5 O(CH.sub.2).sub.6 C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub. 5 C.sub.6 H.sub.5 OC(CH.sub.3).sub.2 (CH.sub.2).sub.3 C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5 OCH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5CH(CH.sub.3)CH(CH.sub.3)(CH.sub.2).sub.3 C.sub.6 H.sub.5 O(CH.sub.2).sub.4 4FC.sub.6 H.sub.4(CH.sub.2).sub.7 C.sub.6 H.sub.5 OCH(CH.sub.3)(CH.sub.2) 4FC.sub.6 H.sub.4CH(CH.sub.3)(CH.sub.2).sub.3 4-FC.sub.6 H.sub.4 OCH(CH.sub.2)(CH.sub.2).sub.6 4FC.sub.6 H.sub.4CH(C.sub.2 H.sub.5)(CH.sub.2).sub.4 4-FC.sub.6 H.sub.4 O(CH.sub.2).sub.8 4ClC.sub.6 H.sub.4CH(C.sub.2 H.sub.5)(CH.sub.2).sub.2 4-ClC.sub.6 H.sub.4 OCH(C.sub.2 H.sub.5)(CH.sub.2).sub.3 4ClC.sub.6 H.sub.4CH(CH.sub.3)(CH.sub.2).sub.3 4-ClC.sub.6 H.sub.4 (CH.sub.2).sub.4 OCH.sub.2 C.sub.6 H.sub.5(CH.sub.2).sub.4 4-pyridyl (CH.sub.2).sub.6 O C.sub.6 H.sub.5CH(CH.sub.3)(CH.sub.2).sub.3 4-pyridyl CH(CH.sub.3)(CH.sub.2).sub.2 O C.sub.6 H.sub.5CH(C.sub.2 H.sub.5)CH.sub. 2 4-pyridyl CH(CH.sub.3)(CH.sub.2).sub.5 O C.sub.6 H.sub.5(CH.sub.2).sub.7 4-pyridyl (CH.sub.2).sub.6 O 4-FC.sub.6 H.sub.4CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 4-pyridyl (CH.sub.2).sub.6 O 4-ClC.sub.6 H.sub.4CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 3-pyridyl (CH.sub.2).sub.3 OCH(CH.sub.3) 2-pyridylCH(CH.sub.3)(CH.sub.2).sub.3 2-pyridyl (CH.sub.2).sub.4 O 4-pyridyl(CH.sub.2).sub.3 O(CH.sub.2).sub.4 H (CH.sub.2).sub.3 O(CH.sub.2).sub.4 4-pyridyl(CH.sub.2)O(CH.sub.2).sub.7 H CH.sub.2 CH(CH.sub.3)O(CH.sub.2).sub.2 4-pyridylC(CH.sub.3).sub.2 (CH.sub.2).sub.2 O(CH.sub.2).sub.2 H O(CH.sub.2).sub.5 3-pyridyl(CH.sub.2).sub.7 O H O(CH.sub.2).sub.7 2-pyridyl(CH.sub.2).sub.11 O H OCH(CH.sub.3)(CH.sub.2).sub.3 2-pyridylCH(CH.sub.3)(CH.sub.2).sub.6 O H CH.sub.2 O(CH.sub.2).sub.5 C.sub.6 H.sub.5CH(CH.sub.3)CH.sub.2 O(CH.sub.2).sub.4 C.sub.6 H.sub.5 CH(CH.sub.3)CH.sub.2 OCH.sub.2 4-ClC.sub.6 H.sub.4(CH.sub.2).sub.3 OCH(CH.sub.3) C.sub.6 H.sub.5 CH.sub.2 O(CH.sub.2).sub.5 4-FC.sub.6 H.sub.4(CH.sub.2).sub.5 O H (CH.sub.2).sub.3 O C.sub.6 H.sub.5(CH.sub.2).sub.9 O(CH.sub.2).sub.4 H (CH.sub.2).sub.3 O(CH.sub.2).sub.5 C.sub.6 H.sub.5__________________________________________________________________________
EXAMPLE 13
1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-Octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one 6-Ethylene Ketal and Its 2-alpha Isomer
Using the procedure of Example 2 9.8 g. (18.9 mmole) of 3,4-alpha,4a-beta,5,8,8a-alpha-hexahydro-4-beta-[2-benzyloxy-4-(1,1-dimethyheptyl)phenyl]-naphthalen-2(1H),6(7H)-dione 6-ethylene ketal, the title product of Example 12, is reduced to 1.5 g. (15%) of the 6-alpha isomer of the title compound, 1.75 g. (18%) of mixture and 4.0 g. (41%) of the title compound. Title Compound:
IR (CHCl 3 ): 5597, 3448, 1618 and 1582 cm -1 .
HRMS (m/e): 520.3580 (M.sup.⊕, calc'd. for C 34 H 48 O 4 : 520.3548), 435, 244, 243, 154, 153, 140 and 91.
PMR (CDCl 3 ): delta 0.81 (m, terminal methyl), 1.22 (s, gem dimethyl), 3.2 (m, benzylic methine), 3.8 (m, carbinol methine and ethylene ketal), 5.02 (s, benzylic methylene), 9.0 (m, ArH), 7.07 (d, J=8 Hz, ArH) and 7.35 (s, PhH). 2-alpha Isomer of the Title Compound:
IR (CHCl 3 ): 3448, 1613 and 1578 cm -1 .
HRMS (m/e): 520.3496 (M.sup.⊕, calc'd. for C 34 H 48 O 4 : 520.3548), 435, 323, 244, 243 and 91.
PMR (CDCl 3 ): 0.82 (m, terminal methyl), 1.22 (s, gem dimethyl), 3.4 (m, benzylic methine), 3.80 (bs, ethylene ketal), 4.12 (m, carbinol methine), 5.02 (s, benzylic methylene), 6.88 (m, ArH), 7.07 (d, J=8 Hz, ArH) and 7.38 (m, PhH).
Reduction of the remaining compounds of Example 12 in like manner affords their corresponding isomeric 2-hydroxynaphthalen-6(7H)-ones of the formula ##STR19## wherein Z and W are as defined in Example 12.
EXAMPLE 14
1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-Octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-2-beta-hydroxy-naphthalen-6(7)-one
A mixture of 2.0 g. (3.85 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one 6-ethylene ketal, the title compound of Example 13, in 50 ml. tetrahydrofuran and 25 ml. 1 N hydrochloric acid is heated at 70° C. for 4 hours. The reaction is cooled and added to 250 ml. saturated sodium chloride-300 ml. ether. The ether extract is washed twice with 250 ml. portions of saturated sodium bicarbonate, dried over magnesium sulfate and evaporated to yield 1.9 g. (100%) of the title compound as an oil.
IR (CHCl 3 ): 3425, 1709, 1608 and 1575 cm -1 .
HRMS (m/e): 476.3278 (M.sup.⊕, calc'd. for C 32 H 44 O 3 : 476.3285), 371, 259, 233, 200, 147 and 91.
PMR (CDCl 3 ): delta 0.84 (m, terminal methyl), 1.22 (s, gem dimethyl), 3.2 (m, benzylic methine), 3.85 (m, carbinol methine), 5.05 (s, benzylic methylene), 6.9 (m, ArH), 7.03 (d, J=8 Hz, ArH) and 7.38 (s, PhH).
Acid treatment of the remaining compounds of Example 13 affords the corresponding 2-hydroxynaphthalen-6(7H)-ones.
EXAMPLE 15
1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-Octahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-2-beta-hydroxy-naphthalen-6(7H)-one
Following the procedure of Example 3 330 mg. (0.692 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one is reduced to give 218 mg. of the title compound.
MP: 160°-161° C. (acetonitrile).
IR (CHCl 3 ): 3571, 3333, 1706, 1621 and 1582 cm -1 .
HRMS (m/e): 386.2844 (M.sup.⊕, calc'd. for C 25 H 38 0 3 : 386.2817), 368, 301, 283 and 110.
PMR (100 MHz, CDCl 3 ): delta 0.84 (bt, J=6 Hz, terminal methyl), 1.24 (s, gem dimethyl), 3.08 (m, benzylic methine), 3.32 (bd, J=4 Hz, OH), 3.82 (m, carbinol methine), 6.7 (m, ArH), 6.96 (d, J=8 Hz, ArH) and 8.1 (bs, OH).
Following the procedure of Example 14 and the above procedure the tabulated compounds of Example 13 are converted to compounds having the formula shown below wherein Z and W are as defined in Example 13: ##STR20##
EXAMPLE 16
1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-alpha-Decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-naphthalen-2-beta,6-alpha-diol
Following the procedure of Example 2, reduction of 500 mg. (1.05 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one, the title product of Example 14, gives a quantitative yield of the title compound as an oil.
PMR (CDCl 3 ): delta 0.84 (m, terminal methyl), 1.25 (s, gem dimethyl), ˜3.0 (m, benzylic methine), 3.8 (bm, carbinol methine), 5.02 (s, benzylic methylene), 6.95 (m, ArH), 7.10 (d, J=8 Hz, ArH) and 7.40 (s, PhH).
EXAMPLE 17
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-naphthalen-2-beta,6-beta-diol
To a 25° C. solution of 400 mg. (0.84 mmole) of the title product of Example 14, 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one in 2 ml. of tetrahydrofuran is added 5.04 ml. (2.52 mmole) of potassium tri-sec-butylborohydride (0.5 M) in tetrahydrofuran). The reaction is stirred 30 minutes, cooled to 0° C. and then oxidized with 10 ml. tetrahydrofuran, 30 ml. 1 N sodium hydroxide and 6 ml. 30% hydrogen peroxide. After 30 minutes the reaction is added to 250 ml. saturated sodium chloride and 300 ml. ether. The ether extract is washed once with 250 ml. saturated sodium chloride, dried over magnesium sulfate and evaporated to an oil. This crude oil is purified via column chromatography on 100 g. of silica gel eluted in 10 ml. fractions with 1 l. of 50% ether-hexane and then 100% ether to yield 283 mg. (71%) of the title compound as an oil.
R f =0.23 (0.25 mm silica gel; ether).
Reduction of the remaining compounds of Example 14 according to the above procedure affords the corresponding 2-beta,6-beta-naphthalenediols.
EXAMPLE 18
1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-naphthalen-2-beta,6-alpha-diol
Following the procedure of Example 3, catalytic reduction of 502 mg. (1.05 mmole) of crude 1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2-beta,6-alpha-diol gives 300 mg. (74%) of the title compound as a foam.
PMR (100 MHz, CDCl 3 ): delta 0.83 (m, terminal methyl), 2.84 (m, benzylic methine), 3.47 and 3.87 (m, carbinol methines), 6.80 (m, ArH) and 6.99 (d, J=8 Hz, ArH).
HRMS (m/e): 388.2781 (M.sup.⊕, calc'd. for C 25 H 40 O 3 : 388.2973), 370, 352, 303, 285 and 267.
EXAMPLE 19
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-naphthalen-2-beta,6-beta-diol
Following the procedure of Example 3, 283 mg. (0.592 mmole) 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-naphthalen-2-beta,6-beta-diol is reduced to provide 145 mg. (63%) of the title compound.
MP: 91°-2° C. (diisopropyl ether).
PMR (100 MHz, CDCl 3 ): delta 0.85 (m, terminal methyl), 1.20 (s, gem dimethyl), 280 (m, benzylic methine), 3.80 (bm, carbinol methine), 4.03 (m, carbinol methine), 6.85 (m, ArH) and 7.12 (d, J=8 Hz, ArH).
HRMS (m/e): 388.2985 (M.sup.⊕, calc'd. for C 25 H 40 O 3 : 388.2973), 370, 352, 303, 285 and 267.
In like manner, the compounds of Examples 16 and 17 are reduced to provide compounds of the formula below wherein Z and W are as defined in said Examples. ##STR21##
EXAMPLE 20
1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-Octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-6(7H)-methylene-naphthalen-2-beta-ol
To a 15° C. mixture of triphenylphosphorous methylide [from 2.25 g. (6.30 mmoles) of methyltriphenylphosphonium bromide and 151 mg. (6.30 mmole) of sodium hydride] in 7 ml. of dimethyl sulfoxide is added a solution of 1.0 g. (2.10 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-hydroxy-naphthalen-6(7H)-one, the title compound of Example 14, in 3 ml. of dimethyl sulfoxide and 5 ml. of tetrahydrofuran. The reaction mixture is stirred 20 minutes and then added to 250 ml. of water, 200 ml. ether and 100 ml. pentane. The organic extract is washed with two 125 ml. portions of water, dried over magnesium sulfate and evaporated. Triphenylphosphine oxide is removed from the crude product by crystallization in ether-pentane. The title compound is obtained upon evaporation of the filtrate in quantitative yield as an oil.
R f =0.22 (0.25 mm silica gel; 50% ether-hexane).
PMR (CDCl 3 ): delta 0.82 (m, terminal methyl), 1.23 (s, gem dimethyl), 3.02 (m, benzylic methine), 3.7 (m, carbinol methine), 4.43 (m, vinyl methylene), 5.02 (s, benzylic methylene), 6.85 (m, ArH), 7.04 (d, J=8 Hz, ArH) and 7.33 (s, Ph).
By means of the above procedure the remaining compounds of Example 14 are converted to their 6-methylene derivatives.
EXAMPLE 21
1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-alpha-Decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6-alpha-hydroxymethyl-naphthalen-2-beta-ol and Its 6-beta-Isomer
To a 0° C. solution of 925 mg. (210 mmole) 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6(7H)-methylene-naphthalen-2-beta-ol, the title compound of Example 20, in 10 ml. of tetrahydrofuran is added 4.2 ml. (4.20 mmole) of borane tetrahydrofuran complex (1 M in tetrahydrofuran). The reaction is stirred 45 minutes and then oxidized by the addition of 6.3 ml. (12.6 mmole) of 2 N sodium hydroxide and 1.08 ml. (12.6 mmole) of 30% hydrogen peroxide. After stirring 30 minutes the reaction mixture is added to 500 ml. saturated sodium chloride and 300 ml. ether. The organic extract is washed once with 250 ml. of saturated sodium chloride, dried over magnesium sulfate and evaporated to an oil. Purification of the crude product via column chromatography on 100 g. of silica gel eluted with 2:1 ether:hexane gives in order of elution 275 mg. (27%) of the title compound and 670 mg. (65%) of the 6-beta-isomer of the title compound.
Title Compound:
HRMS (m/e): 492.3605 (M.sup.⊕, calc'd. for C 33 H 48 O 3 : 492.3597), 407, 389, 384, 299 and 91.
6-beta-Isomer of the Title Compound:
HRMS (m/e): 492.3555 (M.sup.⊕, calc'd. for C 33 H 48 O 3 : 492.3597), 407, 389, 384, 299 and 91.
EXAMPLE 22
1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-Decahydro-4-beta-[4-(1,1-dimethylheptyl-2-hydroxy-phenyl]-6-alpha-hydroxymethyl-naphthalen-2-beta-ol
Catalytic reduction of 270 mg. (0.548 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,6-beta,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)-phenyl]-6-alpha-hydroxymethyl-naphthalen-2-beta-ol according to the procedure of Example 3 gives 178 mg. (81%) of the title compound as a foam.
HRMS (m/e): 402.3109 (M.sup.⊕, calc'd. for C 26 H 42 O 3 : 402.3129), 384, 317, 299 and 147.
PMR (270 MHz, CDCl 3 ): delta 0.94 (t, J=7 Hz, terminal methyl), 1.39 (s, gem dimethyl), 3.11 (m, benzylic methine), 3.70 (m, hydroxymethylene), 4.19 (m, carbinol methine), 6.27 (s, OH), 7.43 (bs, ArH), 7.59 (bd, J=8 Hz, ArH) and 7.80 (d, J=8 Hz, ArH).
EXAMPLE 23
1,2-alpha,3,4-alpha-4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-6-beta-hydroxymethyl-naphthalen-2-beta-ol
Reduction of 660 mg. (1.34 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6-beta-hydroxymethyl-naphthalen-2-beta-ol according to the method of Example 3 gives 421 mg. (78%) of the title compound as an oil.
HRMS (m/e): 402.3109 (M.sup.⊕, calc'd. for C 26 H 42 O 3 : 402.3129), 384, 317, 299, 161 and 147.
PMR (270 MHz, CDCl 3 ): delta 0.96 (t, J=7 Hz, terminal methyl), 1.35 (s, gem dimethyl), 3.07 (m, benzylic methine), 4.00 (m, hydroxymethylene), 4.22 (m, carbinol methine), 6.20 (s, OH), 7.43 (bs, ArH), 7.59 (bd, J=8 Hz, ArH) and 7.76 (d, J=8 Hz, ArH).
By means of the procedure of Example 21 and of the above procedure, the 6-methylene derivatives of Example 20 are converted to corresponding 6-hydroxymethyl derivatives having the formula wherein Z and W are as defined in Example 20. ##STR22##
EXAMPLE 24
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta[2-Benzyloxy-4-(1,1-dimethyl-heptyl)phenyl]-2-beta-(d-Mandeloyloxy)-6-beta-(d-Mandeloyloxy)methyl Naphthalene
A mixture of 940 mg. (1.91 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6-beta-hydroxymethylnaphthalene-2-beta-ol, 912 mg. (6.00 mmole) of d-mandelic acid and 38 mg. (0.2 mmole) of p-toluenesulfonic acid monohydrate in 15 ml. of benzene is heated at reflux for 11 hours. Water is removed via a soxhlet extractor filled with 3A molecular sieves. The reaction is cooled and diluted in 250 ml. ether--250 ml. saturated sodium bicarbonate. The organic extract is dried over magnesium sulfate and evaporated to yield an oil. The crude oil is purified via column chromatography on 200 g. of silica gel eluted with 50% ether-hexane to yield, in order of elution, 481 mg. (crystallized from diisopropyl ether) (33%) of diastereomer A and 352 mg. (24%) of diastereomer B as an oil.
Diastereomer A of Title Compound:
MP: 148°-149° C. (from diisopropyl ether).
[alpha] D 20 ° =+17.84° (c=0.419, 20:1 CH 3 OH:CHCl 3 ).
PMR (CDCl 3 , 100 MHz): delta 0.82 (m, terminal methyl), 1.24 (s, gem dimethyl), 2.95 (m, benzylic methine), 3.42 and 3.44 (d, J=6 Hz, OH), 4.08 (m, methylene), 4.85 (m, methine), 4.94 and 5.10 (d, J=6 Hz, methines), 5.08 (s, benzylic methylene), 6.92 (m, ArH), 7.27 (s, PhH) and 7.40 (m, PhH),
Analysis: Calc'd. for C 49 H 60 O 7 : C, 77.33; H, 7.95. Found: C, 77.40; H, 8.14.
Diastereomer B of Title Compound: [alpha] D 20 ° =+51.34° (c=1.073, 20:1 CH 3 OH:CHCl 3 ).
PMR (CDCl 3 , 100 MHz): 0.80 (m, terminal methyl), 1.20 (s, gem dimethyl), 2.90 (m, benzylic methine), 3.28 and 3.43 (d, J=6 Hz, OH), 4.07 (m, methylene), 4.83 (m, methine), 4.99 (s, benzylic methylene), 5.05 and 5.09 (d, J=6 Hz, methines), 6.84 (m, ArH), 7.28 (s, PhH), and 7.31 (m, PhH).
EXAMPLE 25
1,2-alpha,3,4-alpha-4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[2-Benzyloxy-4-(1,1-dimethylheptyl)phenyl]6-beta-Hydroxymethyl-naphthalen-2-beta-ol (Enantiomer A)
A mixture of 590 mg. (0.776 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-2-beta-(d-mandeloyloxy)-6-beta-(d-mandeloyloxy)methylnaphthalene, diastereomer A, and 429 mg. (3.11 mmole) of potassium carbonate in 7 ml. methanol--2 ml. tetrahydrofuran--1 ml. water is stirred 20 hours at 25° C. The reaction is added to 250 ml. ether--250 ml. saturated sodium bicarbonate. The organic extract is dried over magnesium sulfate and evaporated to give a quantitative yield of the title compound.
HRMS (m/e): 492.3614 (M + , calc'd. for C 33 H 45 O 3 : 492.2277), 407, 299 and 91.
In like manner, 596 mg. (0.784 mmole) of the B diastereomer of the above reactant affords a quantitative yield of the B enantiomer of the title compound as an oil.
EXAMPLE 26
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[2-Hydroxy-4-(1,1-dimethylheptyl)phenyl]-6-beta-hydroxymethyl-2-beta-naphthalenol, Enantiomer A
Using the procedure of Example 3, 2.54 g. (5.17 mmole) of 1,2-alpha-3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6-beta-hydroxymethyl-2-beta-naphthalenol, diastereomer A, gives 2.0 g. (97%) of the title compound.
MP: 115°-116° C. (from ethyl acetate-hexane).
Analysis: Calc'd. for C 26 H 42 O 3 : C, 77.56; H, 10.52. Found: C, 77.66; H, 10.19.
[alpha] D 20 ° C. =-28.68° (c=1.55, CH 3 OH).
PMR (CDCl 3 , 100 MHz): delta 0.81 (m, terminal methyl), 1.19 (s, gem dimethyl), 2.70 (m, benzylic methine), 3.36-3.98 (m), 5.58 (bs, OH) and 6.56-7.06 (m, ArH).
HRMS (m/e): 402.3167 (M.sup.⊕, calc'd. for C 26 H 42 O 3 : 402.3123) 384, 317, 249, 161 and 147.
Similarly, 356 mg. (0.784 mmole) of enantiomer B affords 306 mg. (97% yield) of the B enantiomer of the title compound as a glass.
[alpha] D 20 ° C. =+27.98° (c=1.047, CH 3 OH).
PMR (CDCl 3 , 100 MHz): delta 0.81 (m, terminal methyl), 1.19 (s, gem dimethyl), 2.70 (m, benzylic methine), 3.36-3.98 (m), 5.58 (bs, OH) and 6.56-7.06 (m, ArH).
HRMS (m/e): 402.3154 (M.sup.⊕, calc'd. for C 26 H 42 O 3 : 402.3123) 384, 317, 300 and 299.
EXAMPLE 27
1,2-alpha,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-6-methylnaphthalen-2-beta-ol
Catalytic hydrogenation of 1.0 g. (2.11 mmole) of 1,2-alpha,3,4-alpha,4a-beta,5,8,8a-alpha-octahydro-4-beta-[2-benzyloxy-4-(1,1-dimethylheptyl)phenyl]-6(7H)-methylenenaphthalen-2-ol, the title compound of Example 20, according to the procedure of Example 3, affords the title compound as a mixture of the isomeric 6-methyl derivatives.
The remaining 6-methylene compounds of Example 20 are reduced in like manner to the corresponding 6-methyl derivatives.
EXAMPLE 28
General Hydrochloride Salt Formation
Excess hydrogen chloride is passed into a methanol solution of the appropriate compound of formula I having a basic group and ether added to the resulting mixture to insure maximum precipitation of the salt.
In this manner, compounds of formula I described herein which have a basic group are converted to their hydrochloride, hydrobromide, sulfate, nitrate, phosphate, acetate, butyrate, citrate, malonate, maleate, fumarate, malate, glycolate, gluconate, lactate, salicylate, sulfosalicylate, succinate, pamoate, tartrate and embonate salts.
EXAMPLE 29
1,2-alpha,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Decahydro-2-beta-Acetoxy-4-beta-[2acetoxy-4-(1,1-dimethylheptyl)phenyl]-naphthalene
A solution of 2.0 g. of 1,2,3,4-alpha,4a-beta,5,6,7,8,8a-alpha-decahydro-[4-(1,1-dimethylheptyl)-2-hydroxy)phenyl]-naphthalen-2-beta-ol in 20 ml. of pyridine is treated at 10° C. with 20 ml. acetic anhydride and the mixture stirred for 18 hours under nitrogen. It is then poured onto ice/water and acidified with dilute hydrochloric acid. The acidified mixture is extracted with ethyl acetate (2×100 ml.), the extracts combined, washed with brine and dried (MgSO 4 ). Evaporation under reduced pressure gives the title product as an oil.
Similarly, substitution of anhydrides of propionic, butyric and valeric acid for acetic anhydride affords the corresponding ester derivatives.
Reduction of the 2-oxo group by means of sodium borohydride according to the procedure of Example 2 affords the corresponding 2-hydroxy derivatives, both isomers being formed.
EXAMPLE 30
3,4-alpha,4a-beta,5,6,7,8,8a-alpha-Octahydro-4-beta-[2-acetoxy-4-(1,1-dimethylheptyl)phenyl]-naphthalen-2(1H)-one
Repetition of the procedure of Example 29 but using 10 ml. each of pyridine and acetic anhydride and 3,4-alpha,4a-beta,5,6,7,8,8a-alpha-octahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]naphthalen-2(1H)-one (2.0 g.) as reactant affords the title compound as an oil.
Replacement of acetic anhydride by propionic, butyric or valeric acid anhydrides affords the corresponding alkanoyl derivatives.
Sodium borohydride reduction of the 2-oxo group according to the procedure of Example 2 affords an isomeric mixture of the corresponding 2-hydroxy derivatives.
EXAMPLE 31
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-2-beta-acetoxy-4-beta-[2-acetoxy-4-(1,1-dimethylheptyl)-phenyl]-6-beta-acetoxymethyl-naphthalene
Following the procedure of Example 29, 2.0 g. of 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-6-beta-hydroxymethylnaphthalen-2-beta-ol is acetylated using 30 ml. each of acetic anhydride and 30 ml. of pyridine to give the title product.
Substitution of acetic anhydride by valeric acid anhydride provides the corresponding trivaleryl derivative.
EXAMPLE 32
1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-Decahydro-4-beta-[4-(1,1-dimethylheptyl)-2-hydroxyphenyl]-6-beta-(4-morpholinobutyryloxymethyl)naphthalen-2-beta-ol hydrochloride
Dicyclohexylcarbodiimide (1.0 mmole) and 4-N-piperidylbutyric acid hydrochloride (1.0 mmole) are added to a solution of 1,2-alpha,3,4-alpha,4a-beta,5,6-alpha,7,8,8a-alpha-decahydro-4-beta-[4-(1,1-dimethyl-heptyl)-2-hydroxyphenyl]-6-beta-hydroxymethylnapthalen-2-beta-ol (1.0 mmole) in methylene chloride at room temperature. The mixture is stirred for 18 hours, then cooled to 0° C. and filtered. Evaporation gives the title product. Also produced are the corresponding ester wherein acylation has occurred at the phenolic hydroxy group and the diester wherein the phenolic hydroxy group and the 6-hydroxymethyl group are esterified.
PREPARATION A
Methyl 3-benzyloxybenzoate
A mixture of 1564 g. (10.2 mole) of methyl 3-hydroxybenzoate, 1407.6 g. (10.2 mole) potassium carbonate and 1285.2 g. (10.2 mole) benzyl chloride in 5 l. of acetone is heated at reflux for 22 hours. The reaction mixture is then cooled, filtered and the filtrate evaporated. The residue is crystallized in a small volume of pentane to give a quantitative yield of the title compound.
MP: 74°-77° C. (Pentane).
IR (CHCl 3 ): 1724, 1587, 1486, and 1449 cm -1 .
MS (m/e): 242 (M + ), 211 and 91.
PMR (CDCl 3 ): delta 3.95 (s, methyl), 5.10 (s, methylene), 7.2 (m, ArH), 7.35 (m, PhH) and 7.65 (m, ArH).
Analysis: Calc'd. for C 15 H 14 O 3 : C, 74.38; H, 5.78. Found: C, 74.58; H, 6.09.
PREPARATION B
3-Benzyloxybenzene-2-propanol
To a 0° solution of 2.2 mole of methyl magnesium iodide in 1.5 l. ether is added a solution of 200 g. (1.06 mole) of methyl 3-benzyloxybenzoate in 500 ml. ether and 500 ml. tetrahydrofuran. The reaction mixture is stirred for 3 hours and then added to 1.5 l. ice cold saturated ammonium chloride and 2 l. ether. The organic extract is dried over magnesium sulfate and evaporated to an oil. Crystallization of the crude oil in petroleum ether gives 186 g. (93%) of the title compound.
MP: 45°-48° C. (Petroleum ether).
IR (CHCl 3 ): 3509, 3333, 1587, 1570, 1475 and 1443 cm -1 .
MS (m/e): 242 (M + ), 225 and 91.
PMR (CDCl 3 ): delta 1.85 (s, gem dimethyl), 2.05 (s, OH), 5.1 (s, benzylic methylene), 7.2 (m, ArH) and 7.45 (bs, PhH).
PREPARATION C
2-(3-Benzyloxyphenyl)-2-chloropropane
A mixture of 200 g. (0.826 mole) of 3-benzyloxy-benzene-2-propanol in 50 ml. of hexane and 1 1. of concentrated hydrochloric acid is shaken for 15 minutes in a 2 1. separatory funnel. The organic layer is removed and washed with saturated sodium bicarbonate. The neutralized organic extract is dried over magnesium sulfate and evaporated to give a quantitative yield of the title compound as an oil.
PMR (CDCl 3 ): delta 1.98 (s, gem dimethyl), 5.03 (s, benzylic methylene), 6.8-7.7 (m, ArH) and 7.38 (bs, PhH).
2-(3-Benzyloxyphenyl)-2-bromopropane
In a similar manner 5.0 g. (20.6 mmole) of 3-benzyloxybenzene 2-propanol and 200 ml. of 35% hydrobromic acid gives a quantitative yield of the title compound as an oil.
PMR (CDCl 3 ): delta 2.14 (s, gem dimethyl), 5.00 (s, benzylic methylene), 6.6-7.5 (m, ArH) and 7.33 (bs, PhH).
PREPARATION D
1-Benzyloxy-3-(1,1-dimethylheptyl)benzene
To a 0° C. mixture of 10.1 mmole of n-hexyl magnesium bromide in 5 ml. of hexane is added dropwise a solution of 2.0 g. (7.69 mmole) of 2-(3-benzyloxyphenyl)-2-chloropropane in 14 ml. of hexane. The reaction mixture is stirred 5 minutes longer and then added to 500 ml. of saturated ammonium chloride and 300 ml. ether. The organic extract is dried over magnesium sulfate and evaporated to an oil. The oil is purified via column chromatography on 150 g. of silica gel eluted with hexane to yield 841 mg. (35% ) of the title compound as an oil.
IR (CHCl 3 ): 1600, 1575, 1481, 1471 and 1447 cm -1 .
MS(m/e): 310 (M + ), 225 and 91.
PMR (CDCl 3 ): delta 0.84 (terminal methyl), 1.28 (s, gem dimethyl), 5.04 (s, benzylic methylene), 6.7-7.6 (m, ArH) and 7.42 (bs, PhH).
PREPARATION E
2-Benzyloxy-1-bromo-4-(1,1-dimethylheptyl)benzene
To a -78° C. solution of 42.6 g. (0.134 mole) of 1-benzyloxy-3-(1,1-dimethylheptyl)benzene and 12.2 g. (0.200 mole) of t-butylamine in 300 ml. of dichloromethane is added a solution of 27.2 g. (0.151 mole), bromine in 100 ml. of dichloromethane. The reaction mixture is then allowed to warm to 25° C. and added to 500 ml. saturated sodium sulfite and 500 ml. ether. The organic extract is washed with two 500 ml. portions of saturated sodium bicarbonate, dried over magnesium sulfate and evaporated to an oil. The crude product is purified via column chromatography on 500 g. of silica gel eluted with 10% ether-hexane to give 41.9 g. (80%) of the title compound as an oil.
IR (CHCl 3 ): 1587, 1570 and 1481 cm -1 .
MS (m/e): 390, 388 (M + ), 309, 299 and 91.
PMR (CDCl 3 ): delta 0.80 (m, terminal methyl), 1.20 (s, gem dimethyl), 5.05 (s, benzylic methylene, 6.8 (m, ArH) and 7.35 (m, ArH and PhH).
PREPARATION F
Trans-4a,5,8,8a-Tetrahydronaphthalen-2(1H),6(7H)-dione 6-Ethylene Ketal
(a) 3-alpha-Phenylthio-decahydro-2,6-naphthalenedione 6-monoethylene ketal.
To a -78° C. solution of 3.08 ml. (22 mmole) of diisopropylamine in 22 ml. of tetrahydrofuran is added 8.4 ml. (21 mmole) of 2.5 M n-butyllithium in hexane. The resultant solution is stirred 30 minutes at -78° C. A solution of 2.10 g. (10 mmole) of decahydro-2,6-naphthalenedione monoethylene ketal in 5 ml. of tetrahydrofuran is slowly added and the resultant solution stirred 30 minutes at -78° C. and 30 minutes at room temperature. The reaction solution is cooled to 0° C. and a solution of 4.79 g. (22 mmole) of diphenyldisulfide is rapidly added. The reaction solution is warmed to room temperature, stirred one hour and then quenched by addition to 250 ml. ether-250 ml. saturated sodium chloride. The organic extract is dried over magnesium sulfate and evaporated to an oil. The crude oil is purified via column chromatography on 100 g. of silica gel eluted with 50% ether-hexane to yield 947 mg. (crystallized from diisopropyl ether) (30%) of the 3-alpha isomer of the title compound.
MP: 127-130° C. (from diisopropyl ether).
PMR (CDCl 3 ):delta 0.95-2.4 (m), 2.95 (m, axial methine 1,3 to axial sulfur), 3.70 (m, methine alpha to sulfur), 4.00 (s, ethylene ketal) and 7.30 (m, PhH).
MS (m/e): 318 (M + ), 209, 181, 125, 109, 99 and 86.
IR (CHCl 3 ): 1706, 1600 and 1582 cm -1 .
(b) 3-alpha-Phenylsulfenyl-decahydro-2,6-naphthalenedione6-monoethylene ketal.
To a 0° C. solution of 912 mg. (2.87 mmole) of 3-alpha-phenylthiodecahydro-2,6-naphthalenedione 6-monoethylene ketal in 50 ml. of dichloromethane is slowly added a solution of 494 mg. (2.87 mmole) of m-chloroperoxybenzoic acid in 20 ml. of dichloromethane. The resultant mixture is stirred two hours at 0° C. to 20° C. and then added to 250 ml. ether-250 ml. 10% sodium sulfite. The organic extract is washed twice with 250 ml. portions of saturated sodium bicarbonate, dried over magnesium sulfate and evaporated to an oil. The crude oil is purified via column chromatography on 50 g. of silica gel eluted with ether to yield 850 mg. (87%) of the title compound as an oily mixture of diastereomers.
PMR (CDCl 3 ): 0.9-2.8 (m), 3.46 (m, methine alpha to sulfur), 3.92 and 4.00 (s, ethylene ketal) and 7.55 (m, PhH).
To a 0° C. slurry of 21.9 g. (0.547 mole) of potassium hydride in 200 ml. of dimethoxyethane was added 43.2 g. (0.277 mole) of methyl phenylsulfinate. To the resultant mixture was added, dropwise over a 30 minute period, a solution of 49.6 g. (0.236 mole ) of decahydro-2,6-naphthalenedione monoethylene ketal in 150 ml. of dimethoxyethane. The reaction was stirred one hour at 0° C. and then quenched by the slow addition of 9 ml. (0.5 mole) of water. The quenched reaction mixture was added to 150 ml. ether-150 ml. dichloromethane-125 ml. 6N HCl-375 ml. saturated sodium chloride. The aqueous phase was extracted with another 150 ml. portion of dichloromethane. The combined organic extract was dried over magnesium sulfate and evaporated to a semisolid. It can, if desired, be purified by column chromatography as described above. It can, however, be used as is in the next step (c).
(c) Trans-4a,5,8,8a-tetrahydronaphthalene-2(1H),6(7H)-dione 6-ethylene ketal.
The crude product obtained by the alternative method under (b) was mixed with 26.8 g. (0.268 mole) of calcium carbonate in one liter of toluene and heated at 110° C. for 30 minutes. The reaction mixture was cooled, filtered through magnesium sulfate and the filtrate evaporated on a rotovapor to yield an oil which was purified via column chromatography on 500 g. of silica gel eluted with 39% ether-hexane to yield 40 g. (81%) of the title compound.
MP: 58°-59° C. (from diisopropyl ether).
IR (CHCl 3 ): 1681, 1658 (shoulder) and 1613 cm -1 .
PMR (100 MHz, CDCl 3 ): delta 1.32-2.62 (m), 4.00 (s, ethylene ketal), 5.97 (dd, J=10 and 3 Hz, olefin) and 6.71 (dd, J=10 and 2 Hz, olefin).
HRMS (m/e): 208.1099 (M + ), 180, 179, 172, 170, 153 and 99 (100%).
Analysis: Calc'd. for C 12 H 16 O 3 :C, 69.21; H, 7.74. Found: C, 69.11; H, 7.49. | Compounds having the formula ##STR1## wherein ##STR2## R 1 is hydrogen, benzyl or alkanoyl, X is C 2-4 alkylene; and
Z-W is alkyl, phenylalkyl or pyridylalkyl which can have an oxygen atom as part of the alkyl chain and their use as CNS agents, antidiarrheals and antiemetics. Processes for their preparation and intermediates therefor are described. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to staple removal devices and more particularly pertains to a staple removal device which may be employed to remove newly acquired buttons from card stock wherein a general attachment means comprises one or more staplelike members, a wire, or a string.
2. Description of the Prior Art
The use of staple removal devices is known in the prior art. More specifically, staple removal devices heretofore devised for the removal of staples and potentially utilized for removal of buttons from card stock are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
The present invention is directed to improving devices for button removal from card stock in a manner which is safe, secure, economical and aesthetically pleasing.
For example, U.S. Pat. No. 5,090,662 to Koo discloses a staple remover comprising a first end having a dual pair of staple removing jaws and a second end comprising nippers which may be employed to grasp a staple for forcible removal particularly when one end portion of a staple remains embedded within stapled materials. The Koo invention generally provides for a dual pair of staple removing jaws formed as extensions of body member flanges thereof and have the disadvantage of exhibiting excessive spacing for use in removal of buttons from card stock. The present invention employs three jaw members in adjoining disposition thereby presenting a minimal spacing thereof and furthermore providing an ability to engage the closely spaced staples, wires, or strings employed in affixing buttons to card stock having a result of cutting, straightening legs formed thereof and permitting removal of an attached button therefrom.
In U.S. Pat. No. 5,090,663 to Crutchfield et al. a staple remover is disclosed. The Crutchfield et al. invention comprises a unitary projecting head affixed to a gripping handle wherein the projecting head comprises a somewhat pointed portion for engaging, lifting, and removing a bound staple and a spring clip which retains a plurality of staples so removed. There is no provision in the Crutchfield et al. invention for pivoting jaws for cutting, removing, or otherwise straightening the legs of the small staples, wires, or strings employed in affixing buttons to card stock. The present invention employs three jaw members wherein one jaw is pivotally affixed to two opposing similar jaws for removal of buttons wherein the removal involves cutting of a fastening wire, or string and straightening of the small staplelike fastener employed or otherwise formed therein.
In U.S. Pat. No. Des. 281,662 to Augustin the ornamental design of a staple puller is described comprising a spring loaded pair of dual jaw members affixed at a common pivotal axis by a rivet member. A disadvantage of the Augustin invention is the jaw spacing which is suitable for conventional, larger staples but is incapable of unclasping the small sized staples employed in holding buttons to card stock. A further disadvantage lies in the absence of a cutting means for severing the wires or strings employed in other forms of button attachment. The present invention comprises a pair of jaw members engaging a third jaw member wherein the three laws engage a staple, wire, or string over a relatively short length thereof and thereby provides for cutting wires or strings and unclasping small staples employed in affixing buttons to card stock.
In U.S. Pat. No. Des. 309,412 to Ancona et al. the ornamental design of a staple remover is disclosed for enabling an operator to remove conventional staples from staple bound materials. A disadvantage in this prior art lies in a lack of a provision for removal of the small bodied staples employed in affixing buttons to card stock. The present invention enables removal of the small bodied staples employed for the purpose of affixing buttons to card stock. A further disadvantage in the Acona et al. invention lies in the lack of a provision for cutting wires or strings employed to affix buttons to card stock. The present invention comprises a plurality of cutting jaws which engage the wire or string member and provide severance thereof which enables the removal of buttons affixed thereby.
U.S. Pat. No. Des. 308,807 to Yu discloses the ornamental design of a staple remover. The disclosure teaches a plier style device having a pair of dual jaw members for the purpose of engaging and removing conventional staples. The disclosure makes no provision for engaging and removing small bodied staples, strings, or wires employed to affix buttons to card stock. The present invention comprises a series of three adjacently disposed jaws exhibiting relative motion therein and engaging a small bodied staple, cutting a string, or severing a wire thereby permitting removal of a button affixed thereby.
Therefore, it can be appreciated that there exists a continuing need for new and improved button removal device which can be employed to remove a button from card stock wherein the button is affixed thereon using a wirelike staple. In this regard, the present invention substantially fulfills this need.
As illustrated by the background art, efforts are continuously being made in an attempt to improve removers of staples and staplelike fasteners. No prior effort, however, provides the benefits attendant with the present invention. Additionally, the prior patents and commercial techniques do not suggest the present inventive combination of component elements arranged and configured as disclosed and claimed herein.
The present invention achieves its intended purposes, objects, and advantages through a new, useful and unobvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing only readily available materials.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of staple removal devices relevant to button removal from card stock now present in the prior art, the present invention provides an improved button removal device construction wherein the same can be utilized for the removal of buttons affixed to card stock using staples, wires, or strings. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved button removal device apparatus and method which has all the advantages of the prior art staple removal devices related to the removal of buttons from card stock and none of the disadvantages.
The invention is defined by the appended claims with the specific embodiment shown in the attached drawings. For the purpose of summarizing the invention, the invention may be incorporated into a straight torsion spring fastened to and furthermore separating a pair of flattened gripping portions wherein a first gripping portion has a pair of flattened elongated jaw members orthogonally disposed thereupon and a second gripping portion has a single elongated jaw member orthogonally disposed thereupon, and furthermore the jaw members disposed upon the first and second gripping portions are maintained in opposition and separated from each other by the action of the straight torsion spring. The force of the straight torsion spring is overcome by manual pressure in use thereby permitting the opposing jaw members to approach each other and grasp a wire, staple, or string disposed therebetween. Further manual pressure provides a shearing action which, in combination with a tensile force applied thereupon severs the wire or string and straightens the legs of a staple member.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. In as much as the foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be realized by those skilled in the art that such equivalent methods and structures do not depart from the spirit and scope of the invention as set forth in the appended claims.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
Therefore, it is an object of the present invention to provide an improved button removal device enabling the wire, string, or staple fastener affixing a button to card stock to be severed or otherwise disengaged thereby releasing the button held thereon.
It is therefore an additional object of the present invention to provide a new and improved button removal device which has all the advantages of the prior art staple remover devices employable for removing buttons from card stock and none of the disadvantages.
It is another object of the present invention to provide a new and improved button removal device which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved button removal device which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved button removal device which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such button removal devices economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved button removal device which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved button removal device capable of cutting steel and other wirelike materials employed in fastening buttons upon card stock.
Yet another object of the present invention is to provide a new and improved button removal device capable of engaging wire, string, or staple materials threadedly applied through the various hole perforating a button affixed to card stock and furthermore such engagement predisposes severance or other release of the affixing means.
Even still another object of the present invention is to provide a new and improved button removal device susceptible of singlehanded use.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. The foregoing has outlined some of the more pertinent objects of this invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the present invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is prior art.
FIG. 2 is prior art.
FIG. 3 is perspective view of the button removal device showing an operational disposition.
FIG. 4 is a perspective view of the button removal device showing a jaw member pair.
FIG. 5 is a perspective view of a button removal device showing a singular jaw member.
FIG. 6 is a perspective view the button removal device showing a gripping member.
FIG. 7 is a side sectional view of the button removal device taken substantially upon the plane indicated by the section line 7--7 of FIG. 6 showing a gripping member.
FIG. 8 is a side elevational view of a button removal device showing a straight torsion spring member.
FIG. 9 is a side elevational view of a button removal device showing a straight torsion spring member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 3 thereof, a new and improved button removal device embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
From an overview standpoint, the button removal device 10 is adapted for use with buttons 12 fastened to card stock 13 by wire, string, or staple fastening means 14 for the purpose of releasing the buttons 12 therefrom for impending use. See FIG. 3. Button removal device 10 comprises a straight torsion spring 16 affixed at one end to a first gripping member 18 and at another end to a second gripping member 20. First jaw member 22 is affixed to first gripping member 18 and second jaw member 24 is affixed to second gripping member 20 wherein the first jaw member and second jaw member may be caused to engage a button fastening means 14 by applying squeezing force to the first and second gripping members 18 and 20. Continued application of squeezing force and application of an additional pulling force directed away from the card stock will sever or otherwise release fastening means 14 thereby releasing button 12.
More specifically, it will be noted that the button removal device 10 comprises a straight torsion spring 16 permanently affixed to a first gripping member 18 and a second gripping member 20 having a first jaw member 22 and second jaw member 24 there attached. First jaw member 22 comprises an elongated metallic structure having a first end portion 30, a central portion 32, and a second end portion 34. See FIG. 4. First jaw member 22 is preferably of steel construction and generally at least a first end portion 30 may be hardened by heat treatment or other means to permit repetitive cutting of small diameter metal wires without damage.
First end portion 30 comprises a portion bifurcatingly formed into an L-shaped jaw portion 36 wherein the L-shaped jaw portion 36 is substantially orthogonally disposed with respect to central portion 32 and furthermore L-shaped jaw portion 36 is substantially orthogonally disposed with respect to gripping member 18. L-shaped jaw member 36 comprises a U-shaped portion having flattened legs 38 and a relatively small interleg spacing 40, and furthermore L-shaped jaw member 36 is smoothly enthickened from free pointed ends 44 to a transition line 45 wherein the L-shaped jaw portion 36 acquires the form of the central portion 32. Region 40 between legs 38 is necessarily uniform and may be formed therein by producing a narrow sawn slot in a solid member.
Edge 42 is preferably a hardened region and comprises a principal region for engaging to severance a button fastening means 14. First engagement of a button fastening means 14 is performed by points 44 there generally being two points 44 or otherwise sharp edges formed by grinding or shearing treatment of the free ends of legs 38. Central portion 32 comprises a substantially round wirelike elongated solid having a solid cylindrical stub 46 disposed substantially at a central position thereof and furthermore an axis of stub 46 is substantially aligned with legs 38. Stub 46 operationally performs a function of a stop which limits the engagement of the first and second jaw members 22 and 24 thereby preventing mechanical damage for excessive engagement thereof. Second end portion 34 comprises a cylindrical portion terminating in a planar end surface.
Second jaw member comprises a first end portion 50, a central portion 52, and a second end portion 54. See FIG. 5. First end portion 50 comprises a singular L-shaped jaw member 55 preferably having a hardened region 56 disposed along a substantially curving edge thereof wherein the hardened region 56 comprises a principal region for engaging to severance a button fastening means 14. L-shaped jaw member 55 is smoothly enthickened from a free pointed end 58 to a transition line 60 wherein the L-shaped jaw member 55 acquires the form of the central portion 52.
In use, first end portion 50 slidably engages legs 38 and cooperatively lifts button fastening means 14 by displacement toward thickening portions of L-shaped jaw member 55 and L-shaped jaw member 36. Central portion 52 comprises a substantially round wirelike elongated solid having a solid cylindrical stub 62 disposed substantially at a central position thereof and furthermore an axis of stub 62 is substantially aligned with L-shaped jaw member 55. Stub 62 operationally performs a function of a stop which limits the engagement of the first and second jaw members 22 and 24 thereby preventing mechanical damage for excessive engagement thereof. Second end portion 54 comprises a cylindrical portion terminating in a planar end surface.
Gripping member 18 and 22 comprises a substantially flattened paddle having a first end portion 70, a central portion 72, and a second end portion 74. See FIGS. 6 and 7. Gripping members 18 and 20 are generally of polymeric composition throughout. Gripping member 18 is substantially identical in shape and composition to gripping member 20. First end portion 70 comprises a planar portion having a widened free end 76 with curved corner treatments 78 thereof. A plane containing first end portion 70 is disposed at a slight angle to a plane common to the central portion 72 and the second end portion 74. Second end portion 74 comprises a planar portion of uniform width and terminates in a free end 80 having curved corners or a semicircular end treatment.
Central portion 72 comprises a ledge portion 82 having a protrusion 84 extending therefrom. Protrusion 84 is perforated by a stepped hole 86 having an enlarged diameter hole portion 88 disposed facing free end 80 of second end portion 74 and a reduced diameter hole portion 90 disposed facing free end 76 of first end portion 70. Enlarged diameter hole portion 88 engages an end of straight torsion spring 16 wherein the end is permanently affixed therein using a fastening means such as epoxy bonding, a press fit, or a mold in place technique. Reduced diameter hole portion 90 engages the second end portion 34 or 54 of first jaw member 22 or second jaw member 24 wherein the respective end portion is permanently affixed therein using a fastening means such as epoxy bonding, a press fit, or a mold in place technique. Pad 92 adhesively disposed upon a surface of first end portion 70 may be employed for added comfort in squeezing and enhanced frictional engagement thereof.
Straight torsion spring 16 comprises a one and one half turn spring having each free end 100 emerging from a wound section 102 in a substantially parallel disposition, and furthermore free ends 100 are caused to either lie in a common plane by forming bends therein or are freely emergent in substantially adjacent planes wherein correction for a resulting lateral misalignment is generated by altering gripping members 18 and 20 to provide for misalignment of enlarged hole portion 88 in a given gripping member 18 and 20 pair. See FIGS. 8 and 9. Straight torsion spring 16 is of polymeric, spring steel, music wire, bronze alloy, or nickel steel construction.
In an alternate embodiment, first jaw member 22 and second jaw member 24 are detachably affixed to gripping member 18 and 20.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. In as much as the present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A button removal device including a straight torsion spring separating a pair of gripping members wherein the gripping members have a cooperative set of jaws affixed thereon. A first gripping member has a split pointed jaw which engages a singular jaw located upon a second gripping member. Buttons affixed to card stock by wire or string are removed by slipping the jaws between the string or wire and the button while closing the jaws using finger pressure and pulling away thereby cutting the wire or string. Buttons affixed using staples are likewise easily removed. | 1 |
BACKGROUND TO THE INVENTION
The invention relates to centrifuging devices and to a method for controlling the acceleration thereof to a particular operating speed to prevent imbalance of the device exceeding a predetermined maximum. This is accomplished by controlling the temporal alteration of the rotational speed as the maximum permissible imbalance is approached.
In the acceleration of centrifuging devices, such as centrifuges or washing machines, imbalances frequently occur, which impose potentially unacceptable loads on the device, in particular its bearings. This is of particular significance in the case of centrifuging devices with a horizontal axis of rotation, for example the drums in washing or spinning machines, particularly those with large capacities. In such devices, on acceleration the product; e.g., the pieces of washing, is lifted by the rotating centrifuge drum, but detaches itself before the apex from the drum wall and falls in a free trajectory into the lower part of the drum. When the rotational speed is increased so much that the centrifugal force exceeds the gravitational force, the free trajectory disappears and the washing rests against the inner side of the drum. Depending on the distribution of the product; i.e., the washing, a certain imbalance results, which cannot be avoided even by careful packing of the product into the centrifuging device. In practice it is therefore necessary to limit the imbalance occurring on rotation of the centrifuging device at the final operation rotational speed to a permissible level.
According to German Patent Specification Nos: 29 15 815 or 30 39 315 in a centrifuging process the rotational speed is only increased to one at which the maximum permissible imbalance is reached. The dewatering capacity is thus limited. In German Patent Specification Nos: 22 04 325 or 29 39 340 it is proposed to measure the imbalances occurring in washing or centrifuging machines, and stop the device when the imbalance on acceleration exceeds a certain value, and subsequently to undertake one or more acceleration attempts until the design rotational speed is reached without the permissible imbalance being exceeded. However, such a method is time-consuming, and inefficient and expensive in terms of energy.
Reference is also directed to copending U.S. application Ser. No. 435,033, filed 10-18-82 in which it is proposed that, instead of switching off the centrifuging device when a particular imbalance threshold has been reached, simply to keep the rotational speed constant for a particular time. In so doing, utilization is made of the fact that the product, in particular the washing, begins to flow slowly and distributes itself more evenly over the inner wall of the drum. At the end of this pause period, in most cases the product has distributed itself so evenly that the acceleration process can be resumed without danger. Only if it is established that the imbalance has not been significantly or sufficiently reduced does the centrifuging device have to be switched off.
This technique results in a certain improvement in efficiency, but we have found that greater savings on time and energy can be achieved.
SUMMARY OF THE INVENTION
The present invention seeks to further improve on the techniques described above, and in particular to create a method in which the acceleration time of a centrifuging device up to the operating or design speed of rotation is reduced together with required energy consumption, while ensuring that a pre-set highest permissible imbalance on acceleration is safely and reliably avoided. According to the invention, the imbalance of the device is monitored and the acceleration controlled as a function of temporal changes in the measured imbalance. Control may be effected in relation to the difference between the measured imbalance and the permitted maximum value; in relation to the rate of change of the measured imbalance; or to maintain the imbalance between upper and lower threshold values at or below the maximum value. Since a temporal imbalance alteration serves as the control criterium, and not an absolute value of same, the acceleration time up to full rotational speed is shortened without the maximum permissible imbalance being exceeded, and a faster, less energy-consuming and more efficient dewatering in the centrifuging process is achieved.
In one embodiment of the invention, the control of rotational speed is carried out such that on the measured imbalance reaching an upper threshold value, the rotational speed is firstly kept at least approximately constant and a further increase in the rotational speed is made only after a time delay determined by the measured imbalance decreasing by a pre-set amount; i.e., falls to another, lower, threshold value. The cycle of interruption and further acceleration can be repeated several times until the design or operating speed is reached.
In another embodiment the difference of the measured imbalance from another imbalance value is measured and the speed of rotation regulated as a function of this differential value. For example, the differential between the measured imbalance and a fixed value, typically the maximum permissible imbalance, can be determined and the temporal alteration in the rate of rotation; i.e., the acceleration, can be made smaller, the closer the measured imbalance lies to the maximum permissible imbalance. Alternatively, the measured imbalance can be compared with the immediately preceding measurement of imbalance and consequently the rate of rise of the imbalance can be determined. The temporal alteration in rotation rate is then regulated such that the alteration is smaller; i.e., the acceleration takes place more slowly, the greater the temporal alteration in imbalance; i.e., the faster the imbalance rises per unit of time. The dependence of alteration in rotation rate and the development of imbalance can thus be selected such that an acceleration process, which is optimal in terms of expenditure of time and energy and is continuous, is made possible without idle time.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the invention will now be described by way of example and with reference to the accompanying drawing which shows in each figure a graph of the temporal course of the rotational rate and the imbalance in an accelerating centrifuging device. In the drawing:
FIG. 1 illustrates a method with interrupted acceleration;
FIG. 2 illustrates a method with continuous acceleration; and
FIG. 3 illustrates a continuous acceleration process with differential regulation.
DESCRIPTION OF PREFERRED EMBODIMENTS
Each figure is a graph which plots against time t the path of the rotation rate n of the drum of a centrifuging device, and the imbalance U occurring on the drum on acceleration. Imbalance can be understood here to be the geometric displacement of the centre of gravity in the drum, or its product with the rotating mass or the oscillating force occurring on rotation as a result of the displacement of the centre of gravity. This may be measured for example with a suitable power sensor on the bearing of the centrifuging device whereby the variation signal is indicative of the imbalance and with a horizontal drum axis the equisignal for the mass; i.e., for the residual moisture of the washing. Expediently, particularly for large and heavy centrifuging devices a hydrostatic bearing with movable support pistons and dynamic characteristic property is used, as is described for example in U.S. Pat. No: 4,113,325. Here the imbalance force can be directly determined through a measurement of the deflection of the support piston. It may also be expedient to combine the measured imbalance with the rotational rate, which is also measured, by means of a suitable circuit arrangement or with a microprocessor, and to convert to the theoretical imbalance which is to be expected in operation with the operation rotation rate provided and to use the projected imbalance as standard amount.
FIG. 1 shows an acceleration method for a centrifuging device, specifically a washing/centrifuging device with horizontal axis, in which rotation speed n first of all rises continuously. After a period of time t o a rotation speed n o and a centrifugal acceleration is reached, at which the product; i.e., the washing situated in the centrifuging drum, rests against the inner wall of the drum.
Now the regulating mechanism is switched on. The measured imbalance U or the standard level derived therefrom, lies in the example shown firstly below an upper threshold value U 1 and rises with increasing rotational speed n, until at the point of time t 1 and rotation speed n 1 it reaches the upper threshold value U 1 . At this moment the alteration in the rotation speed n is at least approximately reset to O; i.e., the rotation speed is maintained constant, at least approximately, to the value n 1 . A certain retrogression of the rotation speed or a slight increase can thereby be tolerated. If the measured imbalance already exceeds the upper threshold value U 1 at the point of time t o ; i.e., at the beginning of the regulation process, then already at this point of time the rotation speed is kept constant. During this phase, in which the rotation speed remains more or less unchanged, the product distribution in the centrifuge drum partially balances itself out through flow processes and the continuing dewatering of the centrifuged product, and the imbalance diminishes. At a point of time t 2 the imbalance has fallen by a certain amount (U 1 -U 2 ); i.e., has diminished to a lower threshold value U 2 , and at this point of time the alteration in rotation speed n is again regulated to a positive value; i.e., the acceleration process continues with an increasing rotation speed. If during this second acceleration phase the upper threshold value U 1 is again reached, for example at a point of time t 3 and at a rotation speed n 2 , then the cycle is repeated; i.e., the rotation rate is again kept constant, until the imbalance has fallen to the lower threshold value U 2 , for example at the point of time t 4 , whereupon the acceleration process is resumed up to operation rotation rate n m .
It may be expedient to limit the number of the above cycles and to interrupt the acceleration process; i.e., to reduce the rotation speed to zero, if after a certain number of cycles the upper threshold value is still exceeded; i.e., no or insufficient compensation of imbalance has taken place. Alternatively, the rotation speed reached can be kept constant, if this speed has already reached a value where a sufficient centrifugal performance is to be expected. It may also be expedient to interrupt the acceleration process and to reduce the rotation rate to zero; i.e., start again, if the imbalance is not reduced or is only reduced to an insufficient extent after the upper imbalance threshold is exceeded and, thereby initiated, after the rotation rate is kept constant. Once the maximum or design rotation speed n m is reached, it is maintained until the residual moisture, indicated by the equisignal of the imbalance sensor, has fallen to a pre-set value.
In the method illustrated in FIG. 2, the regulating mechanism is constructed and designed such that after the time t o when the rotation speed n o is reached, at which the regulating process begins, the interval ΔU o of the measured imbalance U o is formed from the maximum permissible value U m . This interval ΔU o is used as standard quantity and the rate of increase in the rotation speed n, expressed by the angle of rise α o , is regulated to a corresponding value. This regulation is continuous; i.e., as a result the rate of increase in the rotation speed n; i.e., the angle α is regulated as a function of the difference ΔU of the measured imbalance from the maximum value U m such that the rotation speed n rises all the slower, the more the imbalance U approaches the value U m . It is noted that the imbalance comparative value U m can be selected dependent on time or dependent on rotation speed.
The requisite conversion can take place by means of known electric circuit arrangements or with a microprocessor. By the continuous re-setting of the rotation rate n as a function of the respective imbalance value, an optimally short start-up time t m can be reached up to the operation rotation speed n m , whereby exceeding the maximum permissible imbalance U m can be avoided with certainty.
FIG. 3 shows another continuous acceleration method, in which after reaching the rotation rate n o after time t o the measured imbalance U o is compared with an imbalance value which is immediately adjacent in terms of time and the speed of rise of the imbalance is used as standard amount, expressed by the angle β o . Corresponding to this value the rate of increase in the rotation speed n, expressed by the angle α o , is regulated. The regulating process is again continuous, whereby in each case at an angle of rise β of the imbalance an angle of rise α of the rotation rate is regulated such that the rise in rotation speed is retarded as long as the imbalance still shows an important rise. Here too within a short period of time in an efficient manner the design rotation speed n m can be reached without the maximum permissible imbalance U m being exceeded.
It is important that the acceleration of the device is not only interrupted at a particular imbalance threshold or the rotation speed kept constant for a fixed, pre-set time, but that the interval at constant rotation rate is kept variable and is regulated as a function of the alteration in imbalance with minimal time delay. Thereby the time can be determined in which the imbalance alters by a particular amount, or the time intervals between the measuring points can be largely reduced so that the alteration speed of the imbalance is measured, which is practically equal to a differential regulation. In comparison with former methods with a single threshold value for the imbalance or fixed pauses, an optimally short acceleration time is achieved, while the imbalance remains with certainty below the permissible threshold.
The method according to the invention is particularly advantageous in the application in centrifuging devices which rotate about an horizontal axis, specifically in washing/centrifuging machines of large dimensions; i.e., with diameters in the meter- range, where great imbalance forces may occur, which cannot be avoided by a special loading of the machine, but only by a suitable acceleration process. | The invention relates to centrifuging devices, and particularly to the acceleration thereof to a design speed. In order to prevent imbalance (U) of the device exceeding a permitted maximum value (U m ) during acceleration, the imbalance (U) is monitored and acceleration (α) controlled as a function of temporal changes in the imbalance (U). Acceleration n/ t may be controlled in relation to the difference (ΔU) between the measured imbalance (U) and the maximum value (U m ), in relation to the rate of change (β) of the measured imbalance, or to maintain the imbalance (U) between upper (U 1 ) and lower (U 2 ) threshold values at or below the maximum value (U m ). Acceleration to the design speed can thus be accomplished with minimum delay and variation with reference to operating criteria of the device. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a control apparatus for an elevator. More particularly, it relates to a control apparatus for an elevator in which the cage of the elevator is safely operated even when a drastic change has arisen in a reference speed command signal, a cage speed signal or a controlled variable based on these signals.
In recent years, with the advancements of microelectronics technology and power electronics technology, there have appeared elevator control apparatuses constructed of microcomputers and semiconductor devices, such as thyristors, which make the most use of these technologies. For example, the official gazette of Japanese Patent Application Laid-open No. 223771/1985 discloses an elevator control apparatus employing two microcomputers.
FIG. 8 shows the schematic construction of the whole elevator equipped with the prior-art elevator control apparatus. Referring to the figure, numeral 1 designates a cage, numeral 2 a counterweight, and numeral 3 a rope which is wound round a sheave 4 and which has the cage 1 coupled to one end thereof and the counterweight 2 coupled to the other end thereof. Numeral 5 indicates an induction motor which drives the sheave 4, numeral 6 a pulse generator which generates pulses proportional to the movement distance of the cage 1 on the basis of the rotation of the motor 5, numeral 7 a counter circuit which counts the pulses from the pulse generator 6, numeral 8 a microcomputer system which receives a cage speed signal 7a delivered from the counter circuit 7 and controls the speed of the cage, numeral 9 a three-phase A.C. power source, and numeral 10 a power converter by which three-phase alternating currents are converted into electric power suitable for the speed control of the cage and to which a command signal 8a from the microcomputer system 8 is applied, threby to control the torque and r.p.m. of the motor 5.
FIG. 9 shows the details of the microcomputer system 8 mentioned above. This system consists of first and second microcomputers 80 and 90. The first microcomputer 80 is constructed of a CPU 81, and a ROM 83, a RAM 84, an input port 85 and an output port 86 which are connected to the CPU 81 through a bus 82. The input port 85 is supplied with the cage speed signal 7a (V T ) from the counter circuit 7. This microcomputer 80 has the functions of supervising the service of the cage 1, controlling a door, processing cage calls and hall calls, and generating a reference speed command signal V N .
The second microcomputer 90 is constructed of a CPU 91 which is connected to the CPU 81 of the first microcomputer 80 through a transmission interface 100, and a ROM 93, an input port 95 and an output port 96 which are connected to the CPU 91 through a bus 92. The input port 95 is supplied with the cage speed signal 7a (V T ) from the counter circuit 7. The second microcomputer 90 has the function of controlling the speed of the cage, and it receives the reference speed command signal V N generated by the first microcomputer 80, as a transmitted reference speed command signal V P through the transmission interface 100. Then, it determines the deviation between the transmitted signal V P and the cage speed signal 7a (V T ) and executes a phase compensation and a gain compensation so as to finally deliver a torque command T M to the power converter 10. Thus, the motor 5 is controlled, and the cage 1 is smoothly subjected to a series of operations consisting of start, acceleration, constant-speed run, deceleration and floor arrival.
By way of example, Product 8085A manufactured by Intel Inc. is utilized as the CPU, and Product 8212 similarly manufactured by Intel Inc. is utilized as the transmission interface.
In the prior-art elevator control apparatus as described above, no measure is taken against the malfunction of the transmission interface 100, and hence, problems to be stated below are involved. When an LSI constructing the transmission interface 100 causes the malfunction, any bit lacks or a specified bit becomes "1" in the transmitted reference speed command signal V P which has been transmitted from the first microcomputer 80 to the second microcomputer 90 through the transmission interface 100, and the transmitted signal V P becomes different from the original reference speed command signal V N .
This situation will be explained with reference to FIG. 10. When the transmission interface 100 is functioning normally, V N =V P holds. However, when any fault occurs in the transmission interface 100 at a time t 1 and the specified bit of the signal V P lacks, V P <V N holds as seen from FIG. 10. Then, the cage might be rapidly decelerated to endanger passengers. Besides, when the degree of deceleration is high, the rope wound round the sheave can slip to damage the equipment.
Moreover, if "1" is erected for the specified bit of the transmission interface 100, the cage is rapidly accelerated contrariwise to the above. In addition, similar problems might occur when the transmission interface 100 operates erroneously due to noise or a power source surge.
SUMMARY OF THE INVENTION
This invention has been made in order to solve the problems as mentioned above, and has for its object to provide a safe and reliable control apparatus for an elevator by which, even when a transmission speed pattern or a cage speed signal has suddenly changed due to a fault or noise, passengers are not endangered or elevator equipment is not damaged.
The control apparatus for an elevator according to this invention comprises signal setting means for setting a new value instead of a value of great variation when at least one signal at the present time among a transmission reference speed command signal transmitted to a speed controller through a transmission interface, a cage speed signal, and a controlled variable based on these signals greatly varies as compared with the time-serail value of the corresponding signal detected in the past.
In this invention, the signal setting means stores a value at the present time and also stores serially past values with respect to time as to the transmitted reference speed command signal, the cage speed signal, or the controlled variable based on these signals, and it sets the new value not greatly varying, as a present value if the value at the present time greatly varies in view of the past serial values of the corresponding signal. Accordingly, even if any of the transmission interface, cage speed signal-detection means, etc. should fail or operate erroneously, the safety of passengers can be secured, and the elevator equipment can be prevented from being damaged.
BRIEF DESCRIPTION OF THE DRAWINGS:
FIG. 1 is a principle arrangement diagram showing an example of an elevator control apparatus according to this invention;
FIG. 2 is a block diagram showing a case where constituents in FIG. 1 are configured of microcomputers;
FIG. 3 is a flow chart showing the steps of setting a signal in an embodiment of this invention;
FIG. 4 is a flow chart showing another embodiment of the steps in FIG. 3;
FIG. 5 is a flow chart showing a modification to the embodiment of FIG. 3 or FIG. 4;
FIGS. 6 and 7 are flow charts each showing an embodiment of an emergency stop command process in this invention;
FIG. 8 is an arrangement diagram showing the entirety of an elevator control system;
FIG. 9 is a block diagram of an elevator control apparatus in a prior art; and
FIG. 10 is a graph of speed characteristics for explaining the operation of the prior art.
Throughout the drawings, the same symbols indicate identical or equivalent portions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, embodiments of this invention will be described.
FIG. 1 shows a principle arrangement diagram of an elevator control apparatus according to this invention. Numeral 20 designates reference speed command signal-generation means to generate a normal reference speed command signal V N , numeral 21 designates cage speed signal-detection means to detect the speed of a cage, and numeral 22 designates a transmission interface which transmits the reference speed command signal V N to signal setting means 23. The signal setting means 23 stores, not only a value at the present time, but also past serial values with respect to time, as to a transmitted reference speed command signal V P1 obtained through the transmission interface 22, and its sets a new value not greatly varying, as a present value V P when the value at the present time suddenly changes to greatly vary in view of the past time-serial values. In addition, numeral 24 indicates a speed controller, which controls the speed of the cage on the basis of the deviation between the reference speed signal V P obtained through the signal setting means 23 and a cage speed signal V T delivered as an output from the cage speed signal-detection means 21. An output signal 24a from the speed controller 24 is applied as a torque command to the power converter 10 shown in FIG. 8.
FIG. 2 shows a circuit block diagram in the case where the arrangement illustrated in FIG. 1 is configured of microcomputers. Referring to FIG. 2, a first microcomputer 30 represents the reference speed command signal-generation means 20 shown in FIG. 1, and it has the functions of supervising the service of the cage, controlling a door, and processing cage calls and hall calls. It is constructed of a CPU 31, and a ROM 33, a RAM 34, an input port 35 and an output port 36 which are connected to the CPU 31 through a bus 32. The input port 35 is supplied with the cage speed signal 21a (V T ) from the cage speed signal-detection means 21.
In FIG. 2, a second microcomputer 40 represents the signal setting means 23 and the speed controller 24 shown in FIG. 1. It is constructed of a CPU 41 which is connected to the CPU 31 of the first microcomputer 30 through the transmission interface 22, and a ROM 43, a RAM 44, an input port 45 and an output port 46 which are connected to the CPU 41 through a bus 42. The input port 45 is supplied with the cage speed signal V T , while the output port 46 delivers the torque command 23a to the power converter 10.
Thus, the second microcomputer 40 receives the reference speed command signal V N generated by the first microcomputer 30, as the transmitted reference speed command signal V P1 through the transmission interface 22. Then, it checks whether or not the value of the transmitted signal V P1 greatly varies from the past time-serial values thereof. Besides, it sets the received signal V P1 as the reference speed signal V P when the signal V P1 does not greatly vary, and a new value as the signal V P when the signal V P1 greatly varies. Subsequently, it determines the deviation between the signal V P and the cage speed signal V T and executes a phase compensation and a gain compensation so as to finally deliver the torque command T M to the power converter 10. Consequently, the motor 5 is controlled, and the cage 1 is subjected to a series of operations consisting of start, acceleration, constant-speed run, deceleration and floor arrival in accordance with the normal reference speed command signal.
Next, the operation of the signal setting in this embodiment arranged as described above will be explained in conjunction with a flow chart shown in FIG. 3. The program illustrated in this flow chart is stored in the ROM 43 of the second microcomputer 40.
First, at a step 51, a pointer I expressive of a time is incremented by one. At the next step 52, the absolute value of the difference between the present value of the transmitted reference speed command signal V P1 and the past value thereof preceding one unit of time and stored in arrayed variables ARVP, namely, ARVP(I-1) is taken, and it is compared with a predetermined value ΔV. Here, if the absolute value is equal to or greater than ΔV, it is decided that the signal V P1 transmitted at the present time varies greatly from the past time-serial signal ARVP(I-1), and the operating flow proceeds to a step 53, at which the new value not greatly varying, here, the average of the values of the signal V P1 back to the value preceding n units of time, is set as the reference speed command signal V P and is simultaneously stored as the arrayed variable ARVP(I). On the other hand, if the aforementioned absolute value is found to be less than ΔV, it is decided that the present signal V P1 is normal, and the operating flow proceeds to a step 54, at which the signal V P1 is set as the reference signal V P and is stored as the arrayed variable ARVP(I).
The value ΔV is selected at a value which does not endanger passengers and does not damage the elevator equipment, either, even in the presence of some sudden change in the signal V P . Accordingly, the value ΔV may be selected to ΔV=5 m/min., or so. Further, the value n may be determined in consideration of the computability of the microcomputer 40 and the precision of presumption of the value of the present time, and the value at n=1, namely, preceding one unit of time may well be used as the value of the present time. Besides, as the new value, the value of the arithmetic mean indicated in this embodiment may well be replaced with a value which is presumed on the basis of a weighted mean obtained by weighting the respective time-serial values.
As described above, when the signal varies greatly, the value thereof is presumed, whereby even if the transmission interface undergoes faults ascribable to noise etc., the cage can be operated safely. Moreover, even in a case where the first microcomputer 30 generating the normal reference speed command signal V N undergoes a malfunction ascribable to noise and gives rise to a sudden change in the signal V N , the cage can be operated safely.
FIG. 4 is a flow chart showing an embodiment different from the embodiment of FIG. 3. Steps 51, 52 and 54 are the same as in FIG. 3. At a step 55, the transmitted reference speed command signal V P1 is input again by the transmission interface 22, whereupon the operating flow returns to the step 52. Thus, the same effects as in FIG. 3 can be expected concerning the malfunctions of the transmission interface etc.
FIG. 5 is a flow chart showing a modification to the embodiment of this invention illustrated in FIG. 3 or FIG. 4. The program in this flow chart consists in that the number of times which the signal has jumped or varied greatly is counted, and that if the count value (JPCNT) is not less than a predetermined number of times (OVJP), an emergency stop command EST for the elevator is turned "on," while at the same time, a non-restartable flag is set "on." It will now be explained in detail.
A step 61 in FIG. 5 decides whether or not the transmitted reference speed command signal V P1 jumps or varies greatly at the present time. For "NO," the operating flow proceeds to a step 63, and for "YES," the operating flow proceeds to a step 62, at which the stored variable JPCNT indicative of the number of times of jumps is incremented by one.
Besides, at the step 63, whether or not the number of times JPCNT reaches the predetermined number of times OVJP is decided. Here, when JPCNT≧OVJP holds, the operating flow shifts to a step 64, at which the emergency stop command EST for the elevator is turned "on," and simultaneously, the non-restartable flag NRST is turned "on." That is, the elevator is stopped suddenly and is simultaneously brought into the non-restartable state. On the other hand, when the number of times JPCNT is less than the predetermined number of times OVJP at the step 63, the operating flow proceeds to a step 65, at which both the emergency stop command EST and the non-restartable flag NRST of the elevator are turned "off" so as to keep the elevator capable of the ordinary running thereof.
Thus, the elevator can operate normally against the temporary malfunction, fault, etc. of the transmission interface attributed to noise and a power source surge, whereas the elevator is stopped suddenly and is rendered non-restartable in response to the continuous malfunction or fault of the transmission interface 22 or the first microcomputer 30, so the safety of the elevator is secured more.
The above embodiment has referred to the case where the emergency stop command is issued when a sudden change has arisen in the transmitted reference speed command signal V P1 . However, there is the possibility that a sudden change will also in the cage speed signal V T . Since the motor (5 in FIG. 8) is feedback-controlled on the basis of the deviation between the signals V P1 and V T , it holds true that the acceleration of the cage changes rapidly due to the sudden change in the signal V T .
FIG. 6 is a flow chart showing an example in the case where, when the cage speed signal V T has suddenly changed as stated above, the emergency stop command can be generated.
Referring to the figure, at a step 71, a pointer I expressive of a time is incremented by one. At the next step 72, the absolute value of the difference between the present value of the cage speed signal V T and the past value thereof preceding one unit of time and stored in arrayed variables ARVT, namely, ARVT(I-1) is taken, and it is compared with a predetermined value ΔV. Here, if the absolute value is equal to or greater than ΔV, it is decided that the signal V T transmitted at the present time greatly varies in view of the past time-serial signal ARVT(I-1), and the operating flow proceeds to a step 73, at which a new value not greatly varying is presumed, and it is set as the speed signal V T again and is simultaneously stored as the arrayed variable ARVT(I). As a method of the presumption, it is mentioned, for example, to evaluate an arithmetic mean as explained in conjunction with FIG. 3 or to evaluate a weighted mean. On the other hand, if the aforementioned absolute value is found to be less than ΔV, it is decided that the present value of the signal V T is normal, and the operating flow proceeds to a step 74, at which this value is stored as the arrayed variable ARVT(I).
As still another embodiment (not shown), the speed signal V T may well be input again as in FIG. 4 when it has varied greatly.
FIG. 7 is a flow chart showing yet another embodiment of this invention endowed with both the functions elucidated in FIG. 3 and FIG. 6.
Referring to FIG. 7, at a step 81, a pointer I expressive of a time is incremented by one, and the error or deviation ε of V P -V T is taken out. At the next step 82, the absolute value of the difference between the value of the error ε at the present time and that of the error ε before one unit of time as stored in arrayed variables ARER, namely, (ARER(I-1) is taken, and it is compared with a predetermined value ΔE. Here, if the absolute value is equal to or greater than ΔV, it is decided that the error ε transmitted at the present time varies greatly from the past time-serial signal ARER(I-1), and the operating flow proceeds to a step 83, at which a new value not greatly varying is presumed, and it is set as the present error signal ε again and is simultaneously stored as the arrayed variable ARER(I). On the other hand, if the aforementioned absolute value is found to be less than ΔE, it is decided that the signals V P and V T at the present time are normal, and the operating flow proceeds to a step 84, at which the present value of the error ε is stored as the arrayed variable ARER(I).
Accordingly, this embodiment has the effect that the cage can be safely operated in both the cases of a sudden change in the transmitted reference speed command signal V P and a sudden change in the cage speed signal V T .
As still another embodiment, the transmitted reference speed signal V P and the cage speed signal V T may well be input again when they have changed suddenly.
When the embodiment in FIG. 6 or FIG. 7 is additionally furnished with the function of counting the number of times of sudden changes as illustrated in FIG. 5, a still better effect is achieved.
In the embodiment of FIG. 7, the equation ε=V P -V T is calculated, but it is a necessary deviation variable in the feedback operation of the speed control. Therefore, when the result in the feedback operation is utilized, the actual calculation of the equation ε=V P -V T is not required.
Further, the sudden change has been found on the basis of the equation ε=V P -V T in the embodiment of FIG. 7. However, even when the sudden change of the torque command T M toward the power converter 10 as shown in FIG. 8 is found, the invention can be performed similarly.
As described above, according to this invention, the present and past time-serial values of a transmitted reference speed command signal or a cage speed signal required for the speed control calculation of an elevator or a controlled variable based on these signals are compared so as to find whether or not a sudden change exists in the present value, whereupon a new value not changing suddenly is set as a signal value at the present time. Therefore, the invention has the effect that, even when a malfunction has occurred in any of a transmission interface, cage speed signal-generation means, etc., the speed of the cage does not change rapidly, so that the elevator equipment can be prevented from being damaged, and the safety of passengers can be ensured. | A control apparatus for an elevator according to this invention comprises a signal setter for setting a new value instead of a value of great variation when at least one signal at the present time among a transmission reference speed command signal transmitted to a speed controller through a transmission interface, a cage speed signal, and a controlled variable based on these signals greatly varies as compared with the time-serial value of the corresponding signal detected in the past.
In this invention, the signal setter stores a value at the present time and also stores serially past values with respect to time as to the transmitted reference speed command signal, the cage speed signal, or the controlled variable based on these signals, and it sets the new value not greatly varying, as a present value if the value at the present time greatly varies in view of the past serial values of the corresponding signal. Accordingly, even if any of the transmission interface, cage speed signal-detector, etc. should fail or operate erroneously, the safety of passengers can be secured, and the elevator equipment can be prevented from being damaged. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Applicant claims priority under 35 U.S.C. §119 of European Application No. 14162392.6 filed Mar. 28, 2014, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a pile hammer comprising a cylinder, a piston displaceably guided in the cylinder, and a striker displaceably guided in the cylinder.
[0004] 2. Description of the Related Art
[0005] Such pile hammers, which are regularly also called diesel hammers or diesel pile drivers, are particularly used in foundation work in the construction industry. The pile hammers are used for driving posts of all kinds, such as concrete pillars, iron beams, sheet pile wall elements or the like into a construction ground.
[0006] To start such a pile hammer, the piston is pulled upward using a disengagement apparatus, and released at a specific height, thereupon dropping downward under the effect of gravity. As it drops, the piston activates a fuel pump, by way of which fuel, particularly diesel oil, is supplied to one or more injection nozzles, which inject the fuel into the combustion chamber of the cylinder. The air situated in the combustion chamber of the cylinder is compressed as the piston drops, and thereby heated so that the fuel/air mixture present in the working chamber is ignited, whereupon it combusts in the manner of an explosion. The explosion energy released during this process accelerates the piston back upward for a new work cycle, on the one hand; on the other hand, the material being pile-driven is driven into the ground.
[0007] To minimize the friction between cylinder and piston, a constant amount of lubricant is continuously introduced by way of a lubricant pump. In this connection, excess and combusted lubricant flows directly into the combustion chamber of the cylinder. As a result, the combustion process of the fuel is impaired, particularly if there is a great return flow of lubricant, and significant smoke and soot formation of the pile hammer occurs. This effect occurs above all in the partial-load range of the pile hammer.
SUMMARY OF THE INVENTION
[0008] The invention wishes to provide a remedy for this situation. The invention is based on the task of making available a pile hammer in which the amount of lubricant that flows into the combustion chamber is reduced, particularly in the partial-load range. According to the invention, this task is accomplished by means of a pile hammer including a cylinder, a piston displaceably guided in the cylinder, and a striker displaceably guided in the cylinder. The striker is disposed underneath the piston in the operating position of the pile hammer. A combustion chamber is delimited axially by a face surface of the striker that lies in the interior of the cylinder and a face surface of the piston. Using at least one fuel feed device, a predetermined amount of fuel can be introduced into the combustion chamber during each work cycle. At least one lubricant dispenser for conveying a lubricant between piston and cylinder is set up in such a manner that conveying of lubricant is brought about by means of the impact shock of the piston.
[0009] With the invention, a pile hammer is made available, in which the amount of lubricant that flows into the combustion chamber is reduced, particularly in the partial-load range. Supplying of lubricant is brought about via the impact shock of the piston. Because the lubricant dispenser is set up so that conveying of the lubricant is brought about via the impact shock of the piston, adaptation of the lubricant amount to the operating states of the pile hammer, in each instance, is achieved.
[0010] In a further development of the invention, the lubricant dispenser has a control module that is connected with a sensor for detecting the jump height of the piston and/or the impact count of the piston. As a result, metering of the lubricant in accordance with the impact shock, which is dependent on the impact count and on the jump height of the piston, is made possible.
[0011] In an alternative further development of the invention, the lubricant dispenser comprises a piston that is disposed in a housing and delimits a lubricant chamber for accommodating the lubricant, in which chamber a lubricant line ends and which chamber is biased by way of a spring element, whereby the lubricant line is closed off by way of a valve that can be activated by way of an inertia mass. As a result, simple mechanical and, at the same time, reliable regulation of the lubricant amount is achieved. At every impact of the piston of the pile hammer, the inertia mass in the lubricant dispenser is moved, thereby activating the valve, thereby pressing the lubricant, which stands under pressure by way of the biased piston, through the lubricant line.
[0012] Metering of the lubricant amount is therefore dependent on the impact energy of the piston of the pile hammer. In the case of a hard impact (high impact energy), the inertia mass of the lubricant dispenser is accelerated more strongly and therefore travels a greater distance, thereby bringing about a longer open time of the valve. As a result, a greater amount of lubricant is pressed through the lubricant line. In the case of a softer impact of the piston, the inertia mass is accelerated only slightly and therefore travels only a shorter distance, thereby bringing about a shorter open time of the valve. In this case, only a small amount of lubricant is pressed through the lubricant line.
[0013] In an embodiment of the invention, a slide bearing bushing is disposed in the cylinder, at its top, in which bushing the piston is guided. As a result, the amount of lubricant required for lubrication is reduced, thereby simultaneously minimizing the amount of non-combusted lubricant that gets into the environment.
[0014] In a further embodiment of the invention, an end piece is disposed on the cylinder, at the end side. This piece is elastically connected with the cylinder and forms a capture groove for the piston, which has a step for this purpose. The slide bearing bushing is disposed in the cylinder so as to lie against this capture groove. As a result, the piston is prevented from being accelerated out of the cylinder in the event that a mixture of fuel and lubricant/air not combusted during a work cycle causes excessive energy to act on the piston during the subsequent work cycle. If the piston is moved too far out of the cylinder due to excessive energy, the step of the piston hits against the capture groove formed by the end ring, thereby holding the piston back. Because of the elastic connection of the end ring with the cylinder, part of the movement energy of the piston is absorbed. In this connection, the piston is preferably provided with a capture piston ring, by means of which the step is formed.
[0015] In a further embodiment of the invention, the elastic connection of the end ring with the cylinder comprises an arrangement of friction springs. In this way, particularly effective absorption of movement energy of the piston is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Other objects and features of the invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
[0017] In the drawings, wherein similar reference characters denote similar elements throughout the several views:
[0018] FIG. 1 is a schematic representation of a pile hammer in the form of a diesel hammer;
[0019] FIG. 2 is a schematic representation of the piston end impact region of the pile hammer from FIG. 1 , with the flange connection of the end ring indicated;
[0020] FIG. 3 is a detail representation of Detail III from FIG. 2 ; and
[0021] FIG. 4 is a schematic representation of the lubricant dispenser of the pile hammer from FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Referring now in detail to the drawings, the pile hammer shown in FIG. 1 selected as an exemplary embodiment comprises a cylinder 1 that is open on both sides, and regularly can have a length of 3 to 8 meters and a diameter of 0.2 to 1.5 meters. A piston 2 is displaceably disposed in the cylinder 1 . A striker 3 coaxial to the piston 2 engages into the open lower end of the cylinder 1 , in displaceable manner. A ring-shaped bearing unit 9 is attached at the lower end of the cylinder 1 , in which unit a central shaft section 31 of the striker 3 is guided in tight and displaceable manner. Central shaft section 31 has an outside diameter that is reduced as compared with the inside diameter of the cylinder 1 . The pile hammer is mounted so as to be vertically displaceable along a leader, by way of guide jaws 13 disposed on the cylinder 1 .
[0023] A striker plate 32 that lies below the cylinder 1 is formed onto the lower end of the shaft section 31 , the lower convex delimitation surface 33 of which plate, directed outward, interacts with the upper end of a material to be pile-driven, for example a sheet pile wall element, during operation.
[0024] A piston section 34 having multiple circumferential sealing rings, spaced apart from one another axially, which run on the inner mantle surface 11 of the cylinder 1 , is formed onto the upper end of the shaft section 31 of the striker 3 . A combustion chamber 12 is delimited by the top of the piston section 34 of the striker 3 , together with the underside of the piston 2 as well as the inner mantle surface 11 of the cylinder 1 . The face surface of the striker 3 that faces the combustion chamber 12 of the cylinder 1 is ground to be planar with a flat fuel bowl 30 .
[0025] A damping ring 91 is disposed between the striker plate 32 of the striker 3 and the bearing unit 9 of the cylinder 1 . A further damping ring 92 is disposed adjacent to the bearing unit 9 , between the top of the bearing unit 9 and the underside of the piston section 34 of the striker 3 .
[0026] A lower working end 23 of the piston 2 , provided with circumferential sealing rings 93 spaced apart from one another axially, runs in the interior of the piston 1 , above the striker 3 . The lower free face surface 21 of the piston 2 , which is ground to be planar, is set off by a radially circumferential step.
[0027] A mass section 22 that extends into the upper section of the cylinder 1 is formed onto the lower working end 23 of the piston 2 . A capture piston ring 24 (see FIG. 2 ) is disposed on the piston 2 at the lower end of the mass section 22 , the outside diameter of which ring projects beyond the outside diameter of the piston 2 in this region.
[0028] An injection apparatus 4 is disposed on the circumference wall of the cylinder 1 , which apparatus comprises a fuel pump 41 that is connected with the injection nozzle 42 by way of a line 43 . The inlet of the fuel pump 41 is supplied with diesel oil by way of a fuel tank 5 .
[0029] The fuel pump 41 , connected with the fuel tank 5 by way of the line 43 , has a biased pump lever 44 that projects into the interior of the cylinder 1 , by way of which lever the pump is driven as the dropping piston 2 moves past it. The injection nozzle 42 is configured and oriented in such a manner that the fuel emitted is sprayed approximately onto the center of the face surface of the striker 3 in an essentially cohesive stream.
[0030] Furthermore, a lubricant dispenser 51 is disposed on the cylinder 1 , which dispenser is connected with lubricant nozzles distributed in the circumference direction of the cylinder 1 . The lubricant is dispensed between the piston 2 and the inner mantle surface 11 of the cylinder 1 by means of the lubricant nozzles.
[0031] As shown in FIG. 4 , the lubricant dispenser 51 comprises a housing 52 that is provided with attachment threads 521 at its upper end, for attaching it to the outer wall of the cylinder 1 . A piston 53 is disposed within the housing 52 , which piston is biased by way of a spring 531 and sealed off, with regard to the inner wall of the housing 52 , by means of a seal 532 . A fill level monitoring rod 533 is formed onto the piston 53 , which rod penetrates the spring as well as the cover side of the housing 52 . The piston 53 delimits a lubricant chamber 54 that can be filled with lubricant by way of a filling connector 541 . Two lubricant lines 542 are disposed in the bottom piece 522 of the housing 52 , which lines connect the lubricant chamber 54 with the lubricant exit 543 on the bottom side.
[0032] An inner housing 55 is attached within the housing 52 , on the bottom piece 522 , which housing accommodates an inertia mass 551 . The inertia mass 551 is connected with a valve 56 that is disposed in the lubricant exit 543 and biased by way of a spring 561 . When the valve 56 is activated, the connection between the lubricant lines 542 and the lubricant exit 543 is released, thereby pressing the lubricant in the lubricant space or chamber 54 , to which lubricant pressure is applied by way of the biased piston 53 , through the lubricant exit 543 . After the lubricant has exited, the piston 53 drops within the housing 2 , thereby lowering the oil level monitoring rod 533 . As a result, a reduction in filling level can be seen optically, on the basis of the part of the filling level monitoring rod 533 that projects out of the housing. Refilling of the lubricant chamber 54 with lubricant takes place by way of the filling connector 541 .
[0033] At its open end that lies opposite the striker 3 , a circumferential flange part 14 shown in FIG. 3 that extends radially outward is disposed on the cylinder 1 . The flange part 14 ends in a cylinder piece 141 that lies orthogonal to it, by means of which a flange accommodation 143 for the flange 61 of the end ring 6 is formed on one side of the spring accommodation 142 as well as on the opposite side. Furthermore, a circumferential groove 144 for accommodating the circumferential projection 62 of the end ring 6 is introduced into the inner wall of the cylinder 1 at the level of the flange part 14 . Furthermore, a bearing groove 145 is disposed below the groove 144 , in the inner wall of the cylinder 1 , which groove accommodates a slide bearing bushing 19 , which lies against the projection 62 of the end ring 6 .
[0034] The end ring 6 is configured essentially as a hollow cylinder and has a flange 61 that projects radially outward at a distance from its end facing the cylinder 1 , thereby forming a circumferential projection 62 below the flange 61 . The projection 62 makes contact in the groove 144 of the cylinder 1 , whereby the projection 62 projects inward beyond the groove 144 , thereby in turn forming a capture groove 63 against which the slide bearing bushing 19 lies. Bores 64 , 146 that correspond with one another, in each instance, are introduced into the circumferential flange 61 of the end ring 6 as well as into the circumferential flange part 14 of the cylinder 1 , through which bores the screws 18 are passed.
[0035] A ring-shaped friction spring package 7 is disposed in the flange accommodation 143 formed by the flange part 14 as well as the cylinder piece 141 , which package lies on a carriage 17 on the side opposite the flange part 14 , which carriage is disposed so as to be displaceable between the outer mantle of the cylinder 1 and the inner mantle of the cylinder piece 141 . The friction spring package 7 as well as the carriage 17 are provided with bores that correspond to the bores 146 of the flange part 14 and align with them, in which bores screws 18 are guided. A nut 181 is screwed onto each of the screws 18 , by way of which the carriage 17 is biased against the friction spring package 7 , which lies against the flange part 14 .
[0036] The pile hammer described above works as follows: In the starting state, the piston 2 is raised into an upper position by way of a disengagement apparatus—not shown. After disengagement of the piston 2 , the piston 2 falls downward under the effect of gravity, closes the working connectors 16 , and activates the pump lever 44 of the injection apparatus 4 with its face surface 21 , thereby causing the injection nozzle 42 to spray fuel onto the fuel bowl 30 of the striker 3 . Here, an ignitable mixture of fuel droplets and air is formed by means of impact atomization. When the piston 2 impacts the striker 3 , a force directed downward is exerted on the material to be pile-driven, by means of and by way of the striker 3 , which force drives the material to be pile-driven further into the ground. At the same time, the shock brought about by the impact of the piston 2 on the striker 3 moves the inertia mass 551 in the inner housing 55 against the valve 56 that is biased in the closed position by way of the spring 561 , thereby causing this valve to be opened. In this connection, the duration of opening of the valve 56 is dependent on the intensity of the impact of the piston 2 on the striker 3 . The bias of the spring 561 is set in such a manner that the required minimum amount of lubricant to be supplied is guaranteed.
[0037] During the subsequent upward movement of the piston 2 , triggered by the explosion-like combustion of the fuel, the piston releases the working connectors 16 again, thereby causing the combustion gases to relax and to flow away by way of the working connectors 16 . The piston 2 is now accelerated further upward, drawing fresh air in through the working connectors 16 , until it has reached its upper end position and the work cycle, as described, is repeated.
[0038] In the event that combustion of the fuel took place only partially during the above-mentioned work cycle, an excessive amount of fuel, possibly supplemented with excess lubricant oil, is available for the subsequent combustion process. As a result of the subsequent explosion-like combustion of the excessive fuel, the piston is accelerated upward with excessive energy, thereby moving it beyond the upper position. In this connection, the capture piston ring 24 makes contact with the slide bearing bushing 19 , and, with the bushing, with the capture groove 63 . As a result, the end ring 6 is torn along upward, with the screws 18 passed through the bores 146 of the flange part 14 . By way of the screws 18 with the nuts 181 disposed on them, the carriage 17 is drawn against the friction spring package 7 , which absorbs a large part of the kinetic energy and converts it to heat energy. By way of the reset forces of the friction spring package 7 , the screws 18 and, with them, the end ring 6 are moved back into their original position, whereupon the captured piston 2 drops downward for the next work cycle, under the effect of gravity.
[0039] In a further embodiment, not shown in the drawings, a sensor for detecting the jump height is disposed on the outside of the cylinder 1 , which sensor is connected with a control device, by way of which metered supply of lubricant takes place on the basis of the data detected by the sensor.
[0040] Although only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention. | A pile hammer includes a cylinder, a piston displaceably guided in the cylinder, and a striker displaceably guided in the cylinder. The striker is disposed underneath the piston in the operating position of the pile hammer. A combustion chamber is delimited axially by a face surface of the striker that lies in the interior of the cylinder and by a face surface of the piston. Using at least one fuel feed device a predetermined amount of fuel can be introduced into the combustion chamber during each work cycle. At least one lubricant dispenser for conveying a lubricant between piston and cylinder is set up in such a manner that conveying of lubricant is brought about via the impact shock of the piston. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Phase Application of PCT International application No. PCT/IL2008/000888, International filing date Jun. 29, 2008, entitled “A METHOD AND DEVICE FOR REMOVING CONTAMINATES FROM FLUID-MATERIAL”, published on Jan. 8, 2009 as International Publication No. WO 2009/004612, which claims priority of Israeli Patent Application No. 184441 filed on Jul. 5, 2007 both of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a method and a device for removing of contaminants from a fluid-material. More specifically, the present invention deals with a method and a device for removing suspended solid particles (SS particles) and bio-degradable dissolved organic and inorganic substances from a fluid-material.
BACKGROUND OF THE INVENTION
The American Heritage® Dictionary of the English Language, Fourth Edition, defines “fluid” as: “A continuous, amorphous substance whose molecules move freely past one another and that has the tendency to assume the shape of its container; a liquid or gas.” The term “fluid-material” in the context of the present invention refers from herein after to a material that supports or at least does not hinder the growth of microorganisms and is in either a liquid state, a gaseous state or in a mixture of liquid state and gaseous states. Examples of fluidic liquids: water and oil. Example of fluidic gasses: free environmental air and water vapor. An example of liquid and gas mixture: well-aerated-water.
“Water” in the context of the present invention refers to potable water, recreation-utilized water such as lake, pool and seawater, to seawater and brackish water used in desalination processes, and to municipal and industrial wastewater. “Water” also referrers to water used for growing sea and fresh water organisms such as algae, fish, clams and crabs in tanks, aquariums and pools.
The term “contaminates” refers from herein after to solid-state particles suspended in a fluid-material as well as to bio-degradable organic and inorganic substances dissolved in a fluid-material. Typically, but in no way limited to, organic substances are proteins, sugars and lipids. Typically, but not limited to, inorganic substances are nitrates and phosphates. In gaseous state materials the previously referred to substances are typically dissolved in water vapor; the vapor being part of the gaseous materials. The suspended solid-state particles are referred to from herein after as: “suspended solid particles” or “SS particles”.
For public health, environmental considerations and esthetic reasons contaminants are commonly separated and removed in various domestic and industrial processes and procedures. In some processes it is desired to remove both categories of contaminants: the SS-particles and the dissolved bio-degradable substances. In other cases it is desired to remove only one of the two listed contaminant categories. An example for the removal of both contaminant categories is the treatment of municipal wastewater for environmental disposal or agricultural reuse. Examples for the removal of (only) SS-particles are the pretreatment of seawater prior to desalination by reverse osmosis cartilages and the treatment of emission-gas after industrial coal burning. An example for the removing of (only) bio-degradable dissolved substances is the treatment of water discharged for dairy products production facilities.
The removal of SS-particles from fluids and gases, referred to as “filtering”, is done by passing the fluids and/or gases through a porous martial. Of the many porous media used, fabrics are especially common.
The separation ability (the filtering capability or degree) of fabrics depends on their thread density which, in turn, defines the density of pores in a give area. The number of threads per linear inch, defined by the term “mesh”, is often used to describe the filtering degree of fabric filters. Another term used to describe the nominal sieving or filtering degree is an actual linear dimension of the shortest straight-line distance (length or width) across an individual opening or pore of the filter medium. This is most often given in microns. The absolute filtration degree is the length of the longest straight-line distance across an individual opening of the filter medium.
When comparing filters the term “open area” is used. The open-area is the pore area or sum of all the areas of all the holes in the filter medium through which the fluid can pass. Filtration open area is expressed as a percentage of the effective filtration area.
In using a porous filter (fabric or other proliferated medium) the “open area” gradually decreases with the accumulation of suspended particles a layer of particles is formed, (referred to as “filtering cake”) till the filter is completely blocked. A back-flow (referred to as “backwash”) of a liquid or a gas through the filter in the opposite direction of the accumulation of the particles will remove the cake and refresh the filter. Backwashing is effective if the filtered-out particles have not been strongly attached to the filtering medium.
Porous filtering medium, when clean, have enough open area to cause insignificant pressure drops across the medium. However, as suspended SS-particles begin to plug up openings the available open area for the fixed flow rate to pass through decreases, leading to a gradual increase in the stream-through velocity through the medium. Since the pressure drop is proportional to the square of this velocity, the differential pressure across the medium will increase over time as an exponential function. Less open area also means less SS-particles required to increase pressure drop across the medium. The type of weave or knit used to construct a fabric filter can affect the open area greatly. Less open area also means less SS-particles required to increase pressure drop across the fabric element. The type of weave or knit used to construct a fabric filter can affect the open area greatly.
Focus is now turned to the aspect of removal of bio-degradable substances utilizing a porous medium:
When bio-degradable substances dissolved in a microorganisms-supporting-liquid, typically in a water solution, come into contact with a solid surface medium, microorganisms develop over the surfaces of the medium. In a gaseous material, bio-degradable substances can be dissolved in the gaseous vapor or droplets of a microorganisms-supporting-liquid that constitute part the gaseous material. As is the case for liquids, when the bio-degradable dissolved substances in a gas material, typically in water vapor or droplets, come into contact with a solid surface medium, microorganisms develop over the surfaces of the medium. The rate and type of growth depends on the length exposure time as well as on the characteristics and concentration of the dissolved substances, the dissolving material and on many environmental-growth parameters such as the composition of the medium, the temperature, the moisture and the pH. As the microorganisms develop they utilize for their multiplication and biomass-maintenance the dissolved substances—thus removing the substances from the dissolving fluid-material. Biofilm is typically formed by the utilization of dissolved organic substances. The larger the surface area available for the development of microorganisms per volume of a porous medium the more efficient is the removal of the bio-degradable dissolved substances. The growth of the microorganisms is manifested in a mucilaginous protective coating layer in which dead and living bacteria and fungi are encased. As the coating, referred from herein after as “a biofilm”, develops and thickens it gradually clogs passages and pores when it develops in a porous medium.
While SS-particles particles typically clog porous filters by forming a cake on the external surface of the receiving-side of a filtering medium, biofilm develops over all the exposed surfaces of the porous filtering medium.
The ability to remove dissolved substances from liquids and vapor by densely growing microorganisms in biofilm is favorably utilized in a wide range of devices. The devices are based on a porous medium having large and dense surface-areas exposed to the passing streams of liquid or gas containing the dissolved substances. With the increase in compaction of pours and passages, the medium becomes more readily clogged by biofilm.
In many cases the passing of either a liquid or a gas material through a porous medium causes both the accumulation of clogging SS-particles and the development of biofilm.
As the SS-particles and biofilm accumulate in the course of time (either simultaneously of separately) the narrow passages through the porous medium clog. Refreshing of the medium is typically done by flushing the medium in the opposite direction of the initial operating direction. The flushing is done with a strong liquid or gaseous stream. The tighter the SS-particles are embedded and biofilm enmeshed on and in a porous medium, more energy and efforts are required for the porous medium refreshing.
In prior art different devices and methods to make backwashing efficient have been disclosed. Examples of such devices are given in U.S. Pat. No. 6,136,202 (Foreman) and WO2005/021140 (Johnson et al. The patents describe techniques of removing the SS particles by applying water jet (Foreman) and air-bubbling (Johnson et al.) forces.
Examples of media sheets with passages between them for growing biofilm for water purification is given in U.S. Pat. No. 5,388,316, U.S. Pat. No. 5,430,925 (MacLaren) and US Patent Application 2003/0104192 (Hester et al.). The use of threads and fibers for growing biofilm is disclosed in U.S. Pat. No. 5,389,247 (Woods), U.S. Pat. No. 5,262,051 (Iwatsuka) and U.S. Pat. No. 6,190,555 (Kondo). Once biofilm has developed and the organic substances removal becomes ineffective the medium has to be refreshed by energetic backwashing or/and physical scraping (accompanied at times by chemical treatments).
Another aspect of purifying liquids, typically wastewater, is the use of loose floating particles with large surface area for biofilm development. In the explanation that follows the use of floating particles is given in reference to wastewater but the use of particles can be made in other microbiological supporting liquids. The floating particles, referred from herein after as “free-drifting particles”, are small particles with a density slightly lower than water that are kept suspended in the water by air diffusers or mechanical mixers are described in U.S. Pat. No. 5,458,779 (Odegaard) and are known as the Kaldnes Moving Bed Reactor (KMB) or the NATRIX Technology. A refinement in the use of the KMB technology is described by Shechter et al. in U.S. Pat. No. 6,616,845 in which suspended inert free-drifting particles are used in conjunction with vertical partition elements to control the free movement of the particles. The particles used in both patents are made plastic material having irregular shape with large porosity.
Water purification effectiveness of carrier particles diminishes as biofilm develops and clogs the water passages within the particles. To remedy the clogging the suspended particles have to be periodically treated. Treatment is typically done by gathering the particles and mechanically or chemically removing the biofilm prior to re-use or replacing clogged particles with new ones. Both options are time consuming and expensive.
Typically the structures of both SS-particles removing media (fabric filters and plate-surface filters made of inert materials) and the structure of media for intentionally growing biofilm (such as stacked sheets made of inert materials with spaces between them such as packed threads and fibers) are kept in a fixed state throughout the cycle of accumulation and backwash procedure for the refreshing of the media. The “open-area” and distance between the threads and fibers in the medium maintain the initial ratio throughout the operational life of the media.
Amongst commonly used filtering media, knit fabrics are widely used. An example of such use is given in DE102005023150 (Sabine) which describes a filter sock for removing dirt particles from a fluid comprises a wire-reinforced tube of knitted fabric. An independent claim in the patent includes a filter sock with a filter fabric layer formed by circular knitting and incorporating a reinforcing wire into the filter layer. Another example is DE102004020848 (Hans-Joaachim and Diether) which discloses a filter sock for removing dirt particles from a liquid, having a tubular filter layer of knitted fabric and includes wire reinforcement attached to the filter layer. An independent claim in the patent includes a filter device includes a filter sock located in a hollow profile (specifically a tube) with several radial openings. In both quoted patents the configuration of the knit fabric (the structural configuration between the filaments of the fabric) does not change in the course of using and cleaning of the filtering medium.
It is the aim of the present invention to disclose a method and a device for the removing of contaminants from fluid-materials by a substrate that can be easily and efficiently refreshed by stretching and backwashing when it becomes clogged.
SUMMARY OF THE INVENTION
In accordance with an embodiment of the present invention a method for removing contaminants from a fluid-material is disclosed comprising: providing at least one substrate comprising a three-dimensional knit in an initial configuration made of knitted polymeric fiber which substantially resumes the initial configuration after it is released from stretching or compressing force.
The said at least one substrate is submerged in a fluid-material for treatment of the fluid-material.
Furthermore, the removing of contaminants in accordance with an embodiment of the preset invention comprises retaining contaminants by the substrate while the fluid-material flows through the substrate.
Furthermore, the removing of contaminants in accordance with an embodiment of the preset invention comprises using the substrate as support for biofilm growth for bio-degradation of dissolved substances in the fluid-material.
Furthermore, in accordance with an embodiment of the present invention, the substrate has a dimension which changes substantially more than other orthogonal dimensions of the substrate, when subjected to stretching or compressing forces.
Furthermore, in accordance with an embodiment of the present invention, the method comprises stretching the substrate to release formed biofilm from the substrate.
Furthermore, in accordance with an embodiment of the present invention, the method comprises stretching the substrate to release the retained suspended solid particles from the substrate.
Furthermore, in accordance with an embodiment of the present invention, the substrate comprises polymeric fibers made from material selected from a group of polymer compounds consisting Polyamide, Polyester, Polyurethane, Polyvinyl, Acryl, Polyethylene, Polypropylene, Polycarbonate, PEEK and Polystyrene.
Furthermore, in accordance with an embodiment of the present invention, the substrate comprises mono-filament polymeric fibers.
Furthermore, in accordance with an embodiment of the present invention, the substrate comprises mono-filament fibers and multi-filament fibers.
Furthermore, in accordance with an embodiment of the present invention, the plurality of substrates comprises a plurality of substrates in a stacked formation.
Furthermore, in accordance with an embodiment of the present invention, at least one substrate is placed between two substantially opposite perforated limiters.
Furthermore, in accordance with an embodiment of the present invention, the substrate is made from a bio-degradable material.
Furthermore, in accordance with an embodiment of the present invention, the substrate comprises a plurality of free drifting particles drifting in the treated fluid-material.
In accordance with an embodiment of the present invention a device for treatment of a fluid-material is disclosed comprising at least one substrate comprising a three-dimensional knit in an initial configuration made of knitted polymeric fiber which substantially resumes the initial configuration after it is released from stretching or compressing forces.
Furthermore, the device in accordance with an embodiment of the present invention comprises at least one substrate is placed between two substantially opposite perforated limiters.
Furthermore, the device, in accordance with an embodiment of the present invention, wherein the polymeric fiber is made from material selected from a group of polymer compounds consisting Polyamide, Polyester, Polyurethane, Polyvinyl, Acryl, Polyethylene, Polypropylene, Polycarbonate, PEEK, and Polystyrene.
Furthermore, the device in accordance with an embodiment of the present invention, wherein the plurality of substrates comprises a plurality of substrates in a stacked formation.
Furthermore, the device in accordance with an embodiment of the present invention, wherein the stacked formation is placed in a support frame.
Furthermore, the device in accordance with an embodiment of the present invention wherein the substrate is provided with handles so as to facilitate the stretching of the substrate.
Furthermore, the device in accordance with an embodiment of the present invention, wherein the substrate comprises a plurality of free drifting particles drifting in the treated fluid-material.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better understand the present invention, and appreciate its practical applications, the following Figures are provided and referenced hereafter. It should be noted that the Figures are given as examples only and in no way limit the scope of the invention. Like components are denoted by like reference numerals.
FIG. 1 is a side view isometric illustration of a three-dimensional (3D) knit segment made of mono-filament or multi-filament polymers in accordance with an embodiment of the present invention, in a cramped state.
FIG. 2 is a side view illustration of the 3D knit segment shown in FIG. 1 in a stretched state.
FIG. 3 is a side view isometric illustration of the 3D knit segment shown in FIG. 1 in a cramped state with suspended solid (SS) particles and biofilm patches imbedded on and in the knit matrix.
FIG. 4 is a side view isometric illustration of the 3D knit segment in a stretched state with SS-particles and biofilm patch segments released from a clogged 3D knit matrix (shown in FIG. 3 ), in the process of being refreshed.
FIG. 5 is an isometric illustration of a fluid-material treatment device in accordance with an embodiment of the present invention, constructed of a plurality of face-to face positioned 3D knit sheets having water passing through the 3D knit sheets.
FIG. 6 is an illustration of a fluid-material treatment device comprising 3D knit sheet in accordance with a preferred embodiment of the present invention with handles-for-stretching at two opposite edges of the sheet.
FIG. 7 is an isometric illustration of a fluid-material treatment device constructed of a support-frame (SF) containing a 3D knit sheet, in accordance with an embodiment of the present invention.
FIG. 8 a is an illustration of a fluid-material treatment device constructed of an assembly of tilted support-frame units (a unit of which is shown in FIG. 7 ), in accordance with an embodiment of the present invention.
FIG. 8 b is a side-view illustration of the fluid-material treatment device shown in FIG. 8 a.
FIG. 9 is an isometric illustration of a fluid-material treatment device in accordance with an embodiment of the present invention, constructed of an assembly of parallel and horizontally positioned support-frame unites (a unit of which is shown in FIG. 7 ).
FIG. 10 is a cross-section illustration of a water treatment device in accordance with an embodiment of the present invention, to be typically utilized in home and garden aquariums and ponds.
FIG. 11 is an illustration of an air-lift fluids treatment device, typically utilized for water, with free-floating 3D knit sheet-particles or pads, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
The present invention deals with a method and a device for the removal of contaminants from fluid-materials. In accordance with embodiments of the present invention the removal of the two contaminant components: SS-particles and dissolved bio-degradable substances, is done by utilizing a “stretchable”, three dimensional knit fabric (referred to as “3D knit”). The removal can either be done simultaneously or done separately for each of the components. The biodegradation utilizing 3D knits can be done both in aerobic and anaerobic conditions. The terms “Purification” and “treatment” refer from herein after to the process of the removing of the containments from a fluid-material.
Embodiments of the present invention are 3D knits composed of mono-filament polymers. In other embodiments of the present invention 3D knits are composed of both mono-filament and multi-filament polymers.
The 3D knits are structured with two faces of knitted loops having connecting filaments between the two faces and filaments intertwined in the space between the two faces. The close proximity of the looped fibers in the 3D knit in the two faces allows for the streaming of fluid-materials through the knit fabric while filtering and retaining SS-particles. The large surface area of the fibers in 3D knit fabric, composed of the connecting fibers and the fibers of faces, readily enable the development of biofilm supported by dissolved substances in the streaming-through fluid-material.
The 3D knit is constructed with interlock knitted on alternate knitting needles, where the sequence of the knitting needles defines the distance between the faces of the knit (the width of the structure). The 3D knit is elastic, flexible and resilient, so that when it is subjected to crushing forces it may yield and when relieved from these forces it regains its original configuration.
In the context of the present invention, of the three dimensions of the knit the X and Y dimensions indicate the width and length dimensions respectively, “two faces of knitted loops” refers to the two opposite flat-sides of the knit. The Z dimension indicates the thickness of the knit (see 50 in FIG. 1 ).
The present invention refers to the core of the device disclosed in WO2006/033101 (Hascalovich P. and Tokarsky B.), which described the use of fibers produced from threads of high stiffness for textile cores and sandwich structures. The 3D textile in the mentioned patent application is preferably produced from anisotropic synthetic materials, which have a long range ordering in one preferred direction over other orthogonal directions. Non-limitative examples of fibers made from such materials include crystalline or semi-crystalline nylon 6,6, isotactic polypropylene, and HDPE (High Density Polyethylene), Polyester.
Despite the above, it is not to be construed that the present invention is limited in any way only to the use of anisotropically oriented materials for the fabrication of the 3D knit. Preferable construction materials may also be selected from the following list: Polyamide (e.g., PA 6), Polyester (e.g., PCT, PET, PTT), Polyurethane (e.g., PUR, EL, ED), Polyvinyl (e.g., CLF, PUDF, PVDC, PVAC), Acryl (PAN), Polyethylene, Polypropylene, Polycarbonate, Polystyrene. PEEK Carbon, Basalt and similar materials may also be of use.
In embodiments of the present invention the choice of the mono-filament or multi filament polymers used and the knitting technology of the filaments are such that the produced 3D knit comprises knitted loops that form substantially parallel rows or columns. The “X-dimension” of the knit refers to the orthogonal dimension in which pulling the edges of the knit in opposite directions would result in substantial separation of the rows of loops with respect to one another. The orthogonal direction in which no gaps or only relatively minor gaps are found between the rows of loops upon pulling of the edges is referred to as the “Y-dimension”. On stretching the knit in either the X-dimension or Y-dimension the thickness of the knit, referred to as the orthogonal “Z-dimension” diminishes somewhat due to the stretching of the fibers, but the knit remains resilient and regains its original configuration when the pulling forces are stopped. The construction of the knit is demonstrated in FIG. 1 and FIG. 2 .
The choice of the type or mode of knitting, typically done by automatic industrial knitting machines, together with the choice of the composition of the filaments, predetermines the compaction of the fibers in the knit, thus the porosity, surface area and the specific weight of the knit can be engineered. The 3D knit comprises a single fiber or a plurality of fibers, depending on the engineering of the 3D knit.
The terms “submerged” from herein after refers to a 3D knit being fully surrounded and covered, partially covered, floating, wetted, and moistened in or by a fluid-material.
When submerged by a fluid-material the high surface area of the filaments per unit volume of the 3D knit serves as an attachment and growing platform for extensive development of biofilm. After its development, upon stretching the 3D knit in the X-dimension, the biofilm looses its grip on and between the filaments and can be removed with ease by backwashing.
The external layer of 3D knits in the X and Y dimensions in a cramped state, comprise proliferated surfaces (both sides of the knit) with an abundance of small pores and narrow passages between the loops and filaments. The small size of the pores and passages bestows physical SS filtering characteristics that depend on the type or mode of knitting and on the choice of filaments used in producing the knit. A fluid-material with SS particles that passes through several layers of a 3D knit, not necessarily all having the same filtering characteristics, undergoes a thorough SS sieve-filtering and removal process. After filtering, upon stretching the 3D fiber layers in the X-dimension, the geometric structure of the pores and passages changes and widens, the SS particles are released from the retaining grip of the knit and can be washed and removed with ease.
The choice of the knitting technique and the chemical composition and width of the filament chosen broadly determines the physical characteristics of the 3D knit: resilience, “stretchability” and “compaction” (the size of the “open-spaces” in the fabric). To substantially broaden the physical limitations of 3D knits made of mono-filament fibers, multi-fiber filaments are knitted amongst and or between the mono-filament fibers. While the mono-filaments bestow the desired flexible and resilient 3 dimensional configuration to the 3D knit fabric, the multi-filament fibers “stretch-out” of the orderly configuration of the mono-filaments and narrow the pores, passages and gaps that run through the 3D fabric.
To illustrate the ability to engineer the characteristics of a 3D knit the following example is given: 40-60 microns size silicate SS particles in a water solution are not retained by a 3D knit fabric made of a 0.4 mm mono-fiber polyamide filament (“Nylon-6”) produced by the SiderArc Company, Italy, having 4 knit loops per cm and a width of 1 cm. As the diameter of the filaments in the same knit-construction is reduced below 0.2 mm the “stretchability” characteristics of the fabric diminishes. It becomes negligible in a width below 0.1 mm. The SS-particles retention ability of the 3D fabric does not improve with the reduction in the diameter of the mono-filaments. By intertwining yarn of small diameter 78/68/2 denier polyamide multi-filaments between 0.4 mm mono-fiber knit-loops in a 3D knit with a construction as previously detailed, the SS-particles retaining capacity of the knit of 40-60 micron size particles improves substantially with some or most of the particles retained, depending on the ration between the mono- and multi-filaments used. When the a ratio of 4 to 1 multi- to mono-fibers is constructed about 60% of the SS particles are retained while the 3D knit fabric does not lose its resilience and “stretchability” characteristics. By varying the knitting design, the characteristics of the mono-filaments, the characteristics of the multi-filaments and the ratio multi-/mono-filaments used (if multi-filaments are used at all) a 3D fabric can be tailored-made for SS-particles retention, biofilm development (as a function of the surface area in a given volume of a 3D knit).
Reference is now made to the Figures.
FIG. 1 and FIG. 3 are illustrations of cramped 3D knits. FIG. 2 and FIG. 4 are illustrations of stretched 3D knits.
FIG. 1 is an isometric side view illustration of a 3D knit segment 10 made of mono-filament or alternatively, from mono-fiber filament polymers intertwined with multi-filament fibers viewed in a relaxed, cramped configuration. The 3D knit remains and returns to a cramped state when no stretching forces are applied and after stretching forces are applied and relaxed. The knit comprises knitted loops arranged in dense parallel rows or columns 12 forming two flat surfaces or faces 14 with connecting filaments 15 between the faces. Mono-filament fibers are designated 15 and multi-filament fibers are designated 13 . A high density of perpendicularly aligned passages and pores run through the faces of the knit allowing for the passage of fluid-material and for the building patches of biofilm on and between the surfaces of the filaments. Suspended solids (SS) particles in the water are caught amongst the fibers (shown in FIG. 3 ). FIG. 1 can be viewed as a small fragment of a large sheet or pad of 3D knit or can be viewed as a segment of a loose, free floating biofilm supporting particles (as explained in FIG. 11 ). Coordinate system 50 in the Figure is a directional-diagram indicating the spatial configuration of 3D knit 10 , indicating the X, Y and Z dimensions.
FIG. 2 is an isometric side view illustration of a 3D knit segment 10 in a stretched state. The parallel rows or columns 12 forming two faces 14 are shown distanced and separated in the X-dimension with connecting filaments 15 and 13 between the faces 14 stretched and flattened. Element 50 in the Figure is directional-diagram indicating the spatial configuration of 3D knit segment 10 .
FIG. 3 is a side view isometric illustration of a 3D knit segment 10 in a cramped state, with SS particles 16 and biofilm patches 19 shown retained on and in the fabric matrix of the knit. Fluid-material 18 is shown approaching and streaming through the breadth dimension of the 3D knit.
FIG. 4 is a schematic an isometric view of a biofilm and SS-particles loaded and clogged 3D knit segment 10 (illustrated in FIG. 3 ) at the moment of being stretched. On stretching 3D knit 10 , SS-particles 16 and biofilm patches 18 disintegrate and are released from the knit. Backwash fluid-material stream 20 removes the SS particles and biofilm patch-particles from the fabric matrix of the knit and refreshes the knit for re-use. On subsiding the forces that stretch 3D knit 10 , the knit returns to its cramped (and clean) state (as illustrated in FIG. 1 ).
Reference is now made to FIG. 5 through FIG. 10 .
The Figures illustrate various mechanical-devices utilizing 3D knits fibers as a device for the removal of contaminants from a fluid-material. In the illustrated mechanical-devices 3D knit fabric sheets are used either as sheets with no support frame, referred to as “bare” sheets ( FIG. 5 , FIG. 6 and FIG. 10 ) or as sheets encased and supported by a stabilizing supportive frame ( FIG. 7 , FIG. 8A , FIG. 8B , and FIG. 9 ).
FIG. 5 is an isometric illustration of a fluid-material treatment device 22 , in accordance with an embodiment of the present invention. Treatment device 22 is constructed of an assembly of (“bare”) 3D knit sheets 24 positioned in a face-to-face parallel configuration. 3D knit sheets 24 are confined by a frame 23 comprising bars 28 , 30 , 32 and are either loosely stacked one on top of the other or are individually inserted into tracks or slits 34 that run along on opposite side-walls of frame 23 and secure the sheets in place. A stream of fluid-material, 26 to be treated is shown in the Figure entering the 3D knit sheets 24 from the top of treatment device 22 in a perpendicular or close to a perpendicular angle to the face-surface of upper 3D sheet 24 and exits device 22 from the bottom 3D sheet, having passed through the all the parallel positioned 3D knit sheets.
In yet another embodiment of the present invention, a stream of fluid-material to be treated (designated 26 in FIG. 5 ) enters the stacked 3D knit sheets from the bottom of treatment device 22 and flows towards the upper surface of the device, in a reverse direction of the stream-path described above.
In another embodiment of the present invention, a stream of fluid-material to-be treated (designated 29 in FIG. 5 ) enters treatment device 22 in alignment with the parallel layering of the stacked 3D sheets 24 and exits treatment device 22 after having passed in between and through stacked 3D knit sheets 24 .
When 3D knit sheets 24 become clogged and the fluid-material (stream 26 or 29 ) no longer streams freely through, the sheets are removed from device 22 and cleaned for re-use by stretching and simultaneously backwashing, as clarified in FIG. 4 .
FIG. 6 is a schematic illustration of a fluid-material treatment device 25 constructed of a 3D knit sheet 27 with handles-for-stretching 37 at two opposite edges of the sheet. In accordance with an embodiment of the present invention, in order to simplify and optimize the refreshing for re-use of clogged 3D knit sheets. handles-for-stretching 37 are connected to bars 36 that connected to 3D knit 27 and run all along opposite edges of the 3D knit sheet. Pulling in opposite directions of handles-for-stretching 37 pull bars 36 apart and facilitate the easy and uniform stretching at will of 3D knit 27 .
FIG. 7 is an isometric illustration of a fluid-material treatment device with a support frame (SF) 51 in accordance with another embodiment of the present invention. Treatment device 51 is constructed of a support-frame (SF) 38 made of two substantially parallel and perforated limiters 33 and 35 with a 3D knit sheet device 25 (shown in FIG. 6 ) inserted between the two limiters. The perforation of the limiters is made so as not to substantially hinder the passage of the fluid-material into and from the 3D knit sheet 25 inside the SF. The SF can be engineered to support a single and a plurality of 3D knit sheets 25 . The limiters, which are substantially rigid, are connected and fixed in position by bars 39 that are place along the two opposite longitudinal edges of the limiters. Shown in the Figure are four bars (two on each side). When large SF are used or other engineering considerations so require, additional bars are included in the structure.
FIG. 8A and FIG. 9 illustrate fluid-material treatment devices, utilizing a plurality of parallel positioned SF devices 51 (illustrated in FIG. 7 ) in accordance with embodiments of the present invention. Depending on engineering calculations and requirements the treatment devices are constructed in various sizes and have a varying number of SF devices. In addition, the devices are constructed so as to be portable or stationary. When a to-be-treated fluid-material passes trough or in a close proximity to the surface of the SFs, biofilm and SS-particles gradually build in and on the 3D knit. When the 3D knit sheets clog, backwash fluid-material is passed through the SFs while the 3D knit sheets are simultaneously stretched. Depending on the construction and usage, the devices are either removed from the fluid-material to be backwash-treated, or backwashing is done by reversing the direction of the current in the fluid-material treatment facility. Electrical motors pulling cables connected to the handles-for-stretching 37 typically do the stretching of the 3D knit sheets in the assemblies.
FIG. 8A is an isometric illustration of a fluid-material treatment device 40 , in accordance with a preferred embodiment of the present invention, comprising an assembly of fluid-material treatment SF devices 51 (as shown in FIG. 7 ) submerged in the fluid-material to-be-treated. Treatment device 40 comprises two horizontal rectangle frame-structures 44 and 45 , composed of bars connected in parallel by vertical bars 46 at the four corners of the rectangles. The SF devices 51 are fixed in parallel to each other between the rectangle frame structures in a predetermined slanted angle relative to the surface on which treatment device 40 rests on and perpendicular to the flow direction of the stream of fluid-material 42 that passes through the SF devices 51 . Depending on the extent of blockage (clogging) in the SF devices, the intensity of the fluid-material stream and the density of the 3D knit sheets in the SFs some of the fluid-material streams upwards on the surface of the SFs instead of passing through them (designated stream 42 a ). The two upper corners of the SF devices 51 connect to rectangle frame-structure 44 , the lower corners of SF devices 51 connect in a slanted configuration to rectangle frame-structure 45 . Depending on engineering considerations the slant-angle of SF devices 51 can determined. FIG. 8A illustrates SF devices 51 positioned at a 45 degree slant. Handles-for-stretching 37 of the SFs 51 protrude from both vertical sides of fluid-material treatment device 40 enabling the stretching of the 3D knit sheets 25 in SFs 51 for cleaning of clogged knits.
Illustrated in FIG. 8B is a side view of fluid-material treatment device 40 shown in an isometric view in FIG. 8A . Broken-line 48 indicates positions where additional SF devices 51 can be placed in fluid-material treatment device 40 .
FIG. 9 is an isometric illustration of a fluid-material treatment device 41 in accordance with another preferred embodiment of the present invention, constructed of an assembly of SF devices 51 fluid-material treatment devices in a horizontal positioned formation fixed in place by a support frame. Fluid-material treatment device 41 is constructed of a horizontal bottom frame structure 49 with four bars 47 extending vertically from the four corners of the structure. SF devices 51 are stacked and fixed in place between the upper SF device, designated 54 , and structure 49 at the four corners to vertical bars 47 in parallel and in a horizontal formation relative to frame structure 49 . A stream of to-be-treated fluid-material 56 is shown in the Figure entering treatment device 41 from the top of the stack in a substantially perpendicular angle with respect to the upper face-surface and exits treatment device 41 from the bottom of the device, having passed through all of the 3D knit sheets in the SFs.
In yet another embodiment of the present invention, a stream of fluid-material-to-be treated (designated 56 in FIG. 9 ) enters the SFs 51 from the bottom of fluid-material treatment device 41 and flows towards the upper surface of the device, in a reverse direction of the stream-path previously described.
In another preferred embodiment of the present invention, a stream of to-be-treated fluid-material (designated 55 in FIG. 9 ) enters fluid-material treatment device 41 in alignment to the parallel positioned SFs 51 and exits device 41 after having passed in between the 3D knit sheets in SF devices 51 .
The horizontal orientation of the SF devices 51 minimizes the resistance of treatment device 41 to strong currents 55 that stream through the device. The horizontal orientation diminishes the contact of the matrix of the 3D knit fibers with the passing fluid-material, thus limiting the development of biofilm on the filaments of the 3D knit 25 yet the diminished resistance to the passing fluid-material current insures longer endurance of the submerged structure.
The positioning of SF devices 51 , in parallel and in alignment with the incoming fluid-material stream (as shown in 55 in FIG. 9 ), reduces the resistance of fluid-material treatment device 41 to the current flow of the fluid-material and enables only a diminished SS-particles filtering effect by the SFs. The term “parallel” meaning that the two substantially opposite surfaces of the knit in the SF devices 51 are substantially parallel to the incoming liquid flow.
Positioning SF devices 51 parallel and in a perpendicular configuration to an incoming fluid-material stream (shown in FIG. 9 as stream 56 ) maximizes the resistance of fluid-material treatment device 41 to the current flow of the fluid-material and enables a thorough SS-particles filtering effect.
Slant-positioning of SF devices in the perpendicular direction of incoming liquid (shown in SF devices 51 in treatment device 40 in FIGS. 8A and 8B ) sets a compromise between direct perpendicular and aligned streaming of liquid (as streams 56 and 55 in FIG. 9 through fluid-material treatment device 41 )
An example of utilizing fluid-material treatment device 41 illustrated in FIG. 9 is the removal of SS particles from water, typically seawater, in desalination processes. Seawater is pumped from the depth of the sea and flushed onto the upper SF surface 54 , through a large number of SF devices 51 (having different 3D knits) and exits the device 41 from the bottom surface (stream designated 56 ). After the SF devices 51 filtration the seawater enters reverse osmosis cartages (RO) in a desalination plant. In passing through the SF devices 51 the 3D knit retains the particles, preventing their harmful effects on the delicate RO filtration cartages. Periodically, at set time intervals or in accordance to accumulated clogging, the 3D knit sheets in the SF are stretched and a simultaneously a dose seawater that has previously been passed through the stacked bed is briefly injected to backwash and clear the bed. After a brief interruption the 3D knit sheets are relaxed and water treatment device 41 is ready for re-use. The backwashing seawater is returned to the sea with the removed SS particles. SF devices 51 can be stacked in device 41 with or without gaps between the SFs.
Fluid-material treatment device 22 ( FIG. 5 ) illustrates the use of 3D knit sheets 24 , without the deployment of support frames. Fluid-material treatment devices 40 and 41 ( FIGS. 8A and 9 , respectively) utilize SF devices 51 ( FIG. 7 ) for stabilizing 3D knit sheets. The trade-off and choice between the various possible configurations in planning a fluid-material treatment device is a matter of engineering calculations and considerations.
FIG. 10 is cross-sectional illustration of a water treatment device 60 in accordance with an embodiment the present invention. Water treatment device 60 is typically used for water treatments in domestic and small scale aquariums and ponds. Water treatment device 60 is constructed two box elements made of a rigid material: an upper box element 62 and a lower box element 70 . Box element 62 is constructed of an outer shell 64 that encompasses a propeller 66 and an electric motor 68 that drives propeller 66 . Lower box element 70 is constructed of an outer shell 72 with two perforated partitioning walls 74 and 76 and a removable solid lid 75 that bridges between the edges of the partitioning wall and reaches all the way to outer wall 78 of box 70 . Electrical motor 68 in element 62 is sealed in a water tight box 69 . Elements 62 and 70 are joint (along designated line 71 in the Figure) in a manner that makes it possible to disconnect the joint with ease. Pads of 3D knit 86 are stacked together (with no SFs) so as to fill the entire volume of the space defined by wall 74 and 76 and lid 75 . Several wide slits run the breadth of wall 78 and enable water to enter from the surrounding to the volume in element 70 defined by encasing 72 lid 75 and perforated wall 76 . In element 62 , above the rotational plane of propeller 66 , on wall 82 (opposite side of wall 78 in element 70 ) is a slit-opening, designated 84 . In turning, propeller 62 drives water towards the bottom of motor box 69 and out through slit 84 (the stream designated 90 in the Figure). The water driven out from slit 84 is replaced by water entering filtering device 60 through slits 80 (the stream designated 92 ). The water is driven through perforated wall 76 , through pads 86 , through perforated wall 74 and towards slit 84 . The water stream inside filtering device 60 is designated 92 . In passing through pads 86 SS-particles 94 are blocked and accumulated in the 3D knit of the pads. If left to operate for considerable length of time (typically, within a week in a warm water aquarium) distinct biofilm agglomerations 96 develop within the matrix of pads 86 . When pads 86 are clogged propeller 66 is stopped and filtering device 60 is easily disassembled into two elements, 62 and 70 . Pads 86 are removed from element 70 and manually stretched under a current of water to remove the SS-particles and biofilm agglomerates and prepare the pads for re-use. After cleaning, the pads are stacked and returned to element 70 . Element 70 is joint to element 62 and filtering device 60 is ready for re-use.
Reference is now made to the use of small 3D knit fabric elements as free floating biofilm supporting particles:
FIG. 11 is an illustration of an air-lift liquid treatment device 100 using free-drifting 3D knit pads, referred to from herein after as “platelets” 120 , in accordance with an embodiment of the present invention. Liquid treatment device 100 is typically used for the treatment of wastewater—thus reference will be made to wastewater in explaining the structure of device 100 . Free-drifting platelets 120 have typical length and berth dimensions of, but not limited to, 4 to 10 millimeters and specific weight close to specific gravity weight of water, being between 0.65 and 0.95. FIG. 11 illustrates a cylinder container 101 having a conical bottom 112 with an air-baffle outlet 114 at the center of the cone. An intense raising air-bubbles column 116 , released from air-baffle 114 at the center of container 101 , causes an air-lift effect and the circulation of to-be-treated wastewater, designated by arrows 118 . Together with the circulating wastewater 3D knit platelets 120 are circulated. In the course of circulation wastewater passes through and over the surfaces of the platelets, enabling the development of biofilm on and in the platelets in the process of biodegradation of organic substances dissolved in the treated wastewater. The platelets have a very high ratio of available biofilm growing surfaces to packing-volume, thus increasing the cost-effect efficiency of operating free-drifting particles water treatment devices. In addition, as the wastewater passes through the platelets SS particles are “caught” and retained by the platelets.
In another preferable embodiment of the 3D knits for fluid-material treatment in accordance with the present invention the 3D knits are produced from bio-degradable fibers such as poly-vinyl alcohol (PVAC) and additives. The bio-degradable fiber filaments are so composed that the bio-degradation takes place at a relatively slow rate (depending on the organic load of the fluid-material and the ambient temperature), enabling intensive surface development of biofilm that leads to efficient fluid-material dissolved compounds degradation. When the 3D knit fiber bio-degrades and crumble the supported biofilm of the filaments is released and dispersed to the surrounding and becomes available organic matter to be degraded by biofilm organisms found on surviving filaments in the fluid-material treatment device. To function efficiently a balance has to be kept between the biodegradation of the biofilm support filaments and the degrading of the fluid-material dissolved compounds.
In another embodiment of the 3D knits for fluid-material treatment in accordance with the present invention bio-degradable 3D knit platelets are used in air-lift liquid treatment devices. The bio-degradation of the platelets is designed to be slow in order to assure that the addition of the bio-degradable matter of the platelets to the concentration of the total organic substances in the to-be-treated liquid is insignificant. The bio-degradation of the platelets eliminates the necessity to “fish” and remove the particles from the liquid and clean them for re-use. New platelets are added to the liquid to compensate for the decay of the “used” and clogged platelets.
It should be clear that the description of the embodiments and attached Figures set forth in this specification serves only for a better understanding of the invention, without limiting its scope.
It should also be clear that a person skilled in the art, after reading the present specification could make adjustments or amendments to the attached Figures and above described embodiments that would still be covered by the present invention. | A method for removing contaminants from a fluid-material comprising: providing at least one substrate comprising a three-dimensional knit in an initial configuration made of knitted polymeric fiber which substantially resumes the initial configuration after it is released from stretching or compressing force; and submerging said at least one substrate in a fluidic material for treatment of the fluidic material. | 1 |
COMPUTER PROGRAM LISTING APPENDIX
[0001] A computer program listing appendix containing the source codes of two computer programs that may be used in conjunction with the present invention is incorporated herein by reference and appended hereto as one (1) original compact disk, and an identical copy thereof, containing a total of fifteen (15) files as follows:
[0002] Directory of D:\Laptop
Filename Size/Type Modified Anamolil.txt 2KB Feb. 20, 2002 9:32 AM Text Document Chart3D.txt 37KB Feb. 20, 2002 9:32 AM Text Document FormChart2D.txt 8KB Feb. 20, 2002 9:32 AM Text Document FormChartHistory.txt 16KB Feb. 20, 2002 9:32 AM Text Document FormDiffFrame.txt 1KB Feb. 20, 2002 9:32 AM Text Document FormGenericPass.txt 1KB Feb. 20, 2002 9:32 AM Text Document FormMainMap.txt 43KB Feb. 20, 2002 9:32 AM Text Document FormManual.txt 15KB Feb. 20, 2002 9:32 AM Text Document FormPerReadPerLane.txt 22KB Feb. 20, 2002 9:32 AM Text Document FormStart.txt 4KB Feb. 20, 2002 9:32 AM Text Document FormWholeLane.txt 4KB Feb. 20, 2002 9:32 AM Text Document ModuelUtilities.txt 4KB Feb. 20, 2002 9:32 AM Text Document ReportAnamoli.txt 2KB Feb. 20, 2002 9:32 AM Text Document WaveClass.txt 12KB Feb. 20, 2002 9:32 AM Text Document
[0003] Directory of D:\PLC
Size/ Filename Type Modified KegMapManualHX44_13_08_31_2001.opt 4KB Feb. 20, 2002 OPT 9:33 AM File
TECHNICAL FIELD
[0004] The present invention relates to the field of bowling lane maintenance machines. More particularly, the invention relates to a computer driven apparatus to measure topographical parameters of a bowling lane surface for later use in bowling lane maintenance applications.
BACKGROUND
[0005] In the prior art, automated machines for measuring relatively precise topographical parameters of a bowling lane surface are unknown. There are automated machines for measuring the profile of lane conditioning oil which has been laid down on top of the surface of a bowling lane. One such prior art reference is U.S. Pat. No. 5,717,220, which discloses a machine for automatically measuring the profile of lane dressing on a bowling lane. In the '220 patent, a sample of lane dressing taken from the lane is optically analyzed to determine the thickness of the application of the lane dressing from end board to end board. However, this analysis provides no information regarding the actual surface of the bowling lane itself, which sits beneath the dressing fluid.
[0006] While machines such as those disclosed in the '220 patent can provide information regarding the profile and pattern of dressing fluid that has been deposited on a lane, they provide no information regarding the bowling lane surface and hence the oil pattern that should be applied to the lane to ensure a fair application of lane dressing for a single lane or for an entire facility. Moreover, the apparatus disclosed in the '220 patent does not provide information that may be later used while repairing or resurfacing a lane.
[0007] In the prior art lane topographical measurements have been taken using a manual apparatus that employs a feeler gauge to display lane height. This machine was not automated. It is desirable then to provide a machine that will automatically measure one or more parameters of lane topography to provide information for lane maintenance procedures and applications.
SUMMARY OF THE INVENTION
[0008] The bowling lane measuring apparatus of the present invention solves the prior art problems discussed above and provides a distinct advance in the state of the art. More particularly, the invention allows the automated measurement of topographical features of a bowling lane surface that may be used in bowling lane maintenance for applications such as applying conditioning oil to a bowling lane, resurfacing a bowling lane, and others. The invention measures one or more of a plurality of parameters describing bowling lane surface topography including lane surface elevation, cross-wise tilt, and lengthwise tilt of the lane.
[0009] The preferred embodiment of the present invention includes a controller for operating a drive mechanism that propels the measuring apparatus, and one or more sensors operated by the controller to measure topographical parameters of the bowling lane surface. In one preferred aspect, the apparatus measures bowling lane surface elevation by measuring bowling lane height with respect to the measuring apparatus in selectable increments along the surface of the bowling lane. In another preferred aspect of the invention, the measuring apparatus measures crosswise tilt along the width of a bowling lane in selectable increments. In another preferred aspect of the invention, the measuring apparatus measures lengthwise tilt of the length of the lane surface in selectable increments. These and other aspects of the invention are described more fully in the detailed description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A preferred embodiment of the invention is described in detail below with reference to the attached drawing figures, wherein like reference numerals designate the same or similar parts throughout the several views:
[0011] [0011]FIG. 1 is a top front perspective view of one embodiment of the lane mapper of the present invention;
[0012] [0012]FIG. 2 is a side elevational view of one embodiment of the lane mapper of the present invention sitting on a bowling lane with the near side wall of the machine removed to reveal internal details;
[0013] [0013]FIG. 3 is a front elevational view of one embodiment of the lane mapper of the present invention sitting on a bowling lane with the wall removed;
[0014] [0014]FIG. 4 is a bottom perspective view of a portion of one embodiment of the lane mapper of the present invention including the lane height detection sensor and crosswise tilt sensor;
[0015] [0015]FIG. 5 is an enlarged, fragmentary cross sectional side view of the lane height detection sensor assembly;
[0016] [0016]FIG. 6 is a fragmentary, front elevational view of the lane height sensor assembly;
[0017] [0017]FIG. 7 is a fragmentary, top plan view of the lane height sensor assembly;
[0018] [0018]FIG. 8 is a fragmentary, top plan view of a portion of one embodiment of the lane mapper of the present invention;
[0019] [0019]FIG. 9 is a flow diagram showing one embodiment of a computer program for driving the preferred embodiment of the lane mapper of the present invention.
[0020] [0020]FIG. 10 is an example graphical display capable of being produced by one embodiment of the present invention; and
[0021] [0021]FIG. 11 is an example three-dimensional graphical display capable of being produced by one embodiment of the present invention.
DETAILED DESCRIPTION
[0022] A preferred embodiment of the bowling lane measurement apparatus of the present invention, referred to as a lane mapper, is indicated to by the numeral 10 in FIG. 1. Apparatus 10 broadly includes housing 12 , drive assembly 14 , lane height measurement assembly 16 , crosswise tilt measurement assembly 18 , lengthwise tilt measurement assembly 20 , and controller assembly 22 .
[0023] Referring to FIG. 1, housing 12 includes rear wall 24 , front wall 26 , side wall 28 , side wall 30 , and a top door that is not shown. Rear wall 24 has four caster wheels 32 mounted at the four corners thereof for rollably supporting apparatus 10 in the storage position with apparatus 10 tipped on its rear end. Rear wall 24 also has a centrally disposed, rearwardly projecting mounting bracket 34 (FIG. 2) for receiving a rearwardly projecting lengthwise tilt assembly mounting arm 68 . Also attached to rear wall 24 internally of housing 12 is power distribution assembly 36 including a power switch 38 mounted thereon. Between rear wall 24 and front wall 26 and mounted to side walls 28 and 30 is a transverse dividing wall 40 . Mounted between dividing wall 40 and rear wall 24 is a single speed drive motor 44 , and, a controller assembly 22 .
[0024] Drive assembly 14 includes drive motor 44 with drive sprocket 46 mounted on the output shaft 48 of motor 44 . (FIG. 2) Drive assembly 14 further includes a long drive shaft 50 extending transversely between and journalled by left and right walls 28 , 30 with two drive wheels 52 mounted adjacent the opposite ends thereof. A driven sprocket 54 fixed to drive shaft 50 in alignment with drive sprocket 46 receives driving power from drive sprocket 46 via an endless chain 56 . A notched counter wheel 58 (FIG. 2) is operably coupled with the left end of drive shaft 50 by means of a chain 57 that is turned by a sprocket 59 fixed to shaft 50 . A photoelectric sensor 60 (FIG. 2) senses the rotation of notched wheel 58 and is used for indicating the distance of travel of apparatus 10 . Sensor 60 is in electrical communication with controller assembly 22 .
[0025] Referring to FIG. 2, lengthwise tilt measurement assembly 20 includes a fore-and-aft mounting beam 62 with two skid pads 64 affixed to the bottom thereof. Mounted to the top of beam 62 is a sensor in the form of digital level 66 , which is in electrical communication with controller assembly 22 . Mounting beam 62 is attached to bracket 34 by arm 68 . A transverse pivot 67 secures arm 68 to bracket 34 and allows for vertical displacement of lengthwise tilt measurement assembly 20 . Likewise, a transverse pivot 70 secures the opposite end of arm 68 to mounting beam 62 and allows for vertical displacement of the assembly.
[0026] Lane height measurement assembly 16 , as best seen in FIG. 4, includes a wheel housing 72 and a wheel housing 74 . Rotatably mounted within housing 70 are two fore-and-aft aligned wheels 76 and 78 . Rotatably mounted in wheel housing 74 is a single wheel 80 . Horizontal supports 82 and 84 rigidly fix wheel housings ( 72 , 74 ) 41 inches apart so that the rollers will be engaged with the bowling lane surface 86 just inboard of the lane edges on opposite sides of the lane as shown in FIG. 3.
[0027] As is best seen in FIGS. 4 and 5, mounted to the back wall of wheel housings 72 and 74 is an I-shaped track beam 88 . Slidably carried on track beam 88 for reciprocal travel therealong is a laser support guide 90 . Support guide 90 has an I-shaped cavity formed therein to receive track beam 88 and maintain the guide in a constant horizontal plane while allowing the guide to move freely in the horizontal direction. Mounted to laser support guide 90 is a laser mounting bracket 92 . Mounted to the top of laser mounting bracket 92 is a sensor in the form of a laser mounted within a laser housing 94 , and mounted to the bottom of laser support bracket 92 is a plunger assembly 96 . Also mounted on the top of laser support bracket 92 is a belt clasp 106 .
[0028] As illustrated best in FIGS. 4, 5 and 6 , plunger assembly 96 includes an upright plunger 98 , a coil spring 100 encircling plunger 98 , a plunger block and receiving tube 102 , and a transverse plunger arresting pin 104 passing through the upper end of plunger 98 . Plunger 98 is slidably received withing plunger block and receiving tube 102 . Plunger arresting pin 104 prevents plunger 98 from dropping out of plunger block and receiving tube 102 . At its upper end spring 100 bears against block and receiving tube 102 to yieldably bias plunger 98 in the downward direction so that when the apparatus is positioned for operation the plunger head will be in contact with the top surface of bowling lane 86 . The laser (not shown) within laser housing 94 shines its beam 105 down onto the top face of plunger 98 and is capable of measuring any relative change in plunger height with respect to the laser to an accuracy of 3 microns or 0.0000118 inches. Laser sensor assembly 18 preferably includes an Omron Z4M-W40RA laser displacement sensor.
[0029] Mounted to wheel housing 72 adjacent its upper end is an H-shaped in plan mounting member 108 . Mounted to and extending leftwardly from member 108 are two vertically spaced, threaded bolts 110 upon which are mounted a sheave support block 112 . Rotatably mounted to block 112 is a freely rotating driven cog sheave 114 . Mounted to right wheel housing 74 adjacent its upper end is an H-shaped in plan support member 116 . Mounted to member 116 is a laser sensor drive motor assembly 118 including a motor 120 , a drive shaft 122 , and a drive cog sheavel 24 (FIG. 4). Laser motor drive assembly 118 is in electrical communication with controller assembly 22 .
[0030] Wall 28 and wall 30 each have two slots 126 formed therein. The rearward slots 126 receive H-shaped mounting members 108 and 116 within them respectively. Forward slots 126 each allow the passage of an endless cog belt 128 therethrough. Cog belt 128 is entrained around wheel 114 and drive wheel 124 and is connected to belt clasp 106 on guide 90 associated with plunger assembly 96 . When laser motor drive 120 turns drive wheel 124 , belt 128 is driven linearly, causing laser support guide 90 to move the laser assembly and plunger assembly 96 horizontally across the bowling lane. Displacement of the laser assembly and plunger assembly horizontally across the bowling lane is measured by a photoelectric sensor of the same type as photoelectric sensor 60 described above detecting the rotation of a notched wheel similar to notched wheel 58 described above. Front wall 26 has a pair of wheel supports 130 and 132 attached thereto with lane-engaging wheels 134 and 136 rotatably mounted therein respectively. Also attached to front wall 26 is a handle 138 .
[0031] Crosswise tilt measurement assembly 18 is disposed between divider wall 40 and front wall 26 . Assembly 18 includes a transverse mounting beam 140 , which is attached to the top at its opposite ends of wheel housings 72 and 74 . Mounted to the top of beam 140 is a sensor in the form of digital level 142 , which is in electrical communication with controller assembly 22 . Digital levels 66 and 142 are preferably Wyler model Clino 2000 digital levels which are accurate to 0.0001 inches.
[0032] As best seen in FIG. 3, an outboard, inwardly extending and spring-biased, conically shaped, guide wheel 144 is provided. Similarly, wheel housing 74 includes an outboard, inwardly extending and spring-biased, conically shaped, guide wheel 146 . Guide wheels 144 and 146 are positioned to engage the respective lane edge surfaces of a bowling lane in order to keep apparatus 10 centered on the lane.
[0033] Controller assembly 22 includes a programmable logic controller (PLC) that controls the operation of the lane mapper. The PLC controls the motors and receives signals from each of the sensors. The sensory information received by the PLC includes the distance the lane mapper has traveled down the bowling lane and the bowling lane surface information sensed by the lane mapper, including the lengthwise and crosswise tilt and the lane surface height with respect to the laser. The distance traveled information is used both in controlling the motion of the lane mapper and as a reference when recording lane surface characteristic information. In addition to the PLC, the controller assembly includes an on-board memory for temporarily storing the measurements made by the lane mapper. The controller assembly is connected by an interface to a laptop computer (not shown) that may be placed on top of the lane mapper. In a preferred embodiment the laptop computer has a software program based on the Windows Operating System that provides an interface between a user and the lane mapper. The PLC receives instructions from the laptop over the interface and controls the uploading of the result information from the lane mapper to the laptop computer. The software running on the laptop can then present the results in various formats as described further below.
[0034] Operation of the lane mapper will now be described in conjunction with FIG. 9, a flow diagram of one embodiment of the control logic employed in the present invention. Although the preferred embodiment employs a programmed PLC, this flow logic maybe embodied in a computer program, in a programable logic chip, in custom designed hardware, or in some combination of the above.
[0035] The flow diagram starts at step 200 where default values and user selected values are loaded into the controller, and the sensors on the machine are calibrated and checked for proper operation. The user selected values are entered into a software program in the laptop that is in communication with the PLC. The user can set the number of steps or locations where the lane mapper will take readings. The user can also set the distance between lane-surface height measurements within each step, the distance between steps, the distance between crosswise tilt measurements, and the distance between lengthwise tilt measurements. At step 202 the jam detection algorithm is activated. The jam detection algorithm will run continuously in the background throughout operation of the lane mapper to check that the laser sensor and machine are operating correctly. At step 204 the machine checks for a sensor carriage jam which will have occurred if the laser support guide 90 is not moving properly. At step 206 the controller checks for lane travel jam by checking for certain patterns in the motor sensor data or photoelectric sensor 60 data which indicate a jam has occurred.
[0036] Once the sensors have been calibrated and the jam detection algorithm has been activated, measurements may begin at step 208 . This process starts with the controller aligning the laser sensor at the first position on the left at step 210 . Once the laser sensor is aligned, a reading of the lane height is taken and stored at step 212 . At step 214 the laser sensor is incremented to the right by the programed increment amount. The default value in the preferred embodiment is ½″ increments, but this may be changed. When the measurement process begins the lane height measurements are made by incrementing the laser and plunger from left to right. After the laser sensor has been incremented, the controller will check at step 216 to determine if the laser sensor has reached the end of its run. If the laser sensor has not yet traversed the width of the lane, control returns to step 212 where another laser reading is taken and the process repeats. If the laser sensor has reached the end of its run, control proceeds to step 218 where the crosswise tilt of the lane is measured by reading the crosswise tilt digital level. “Control then proceeds” to step 220 where lengthwise tilt is read by reading the lengthwise tilt digital level.
[0037] Once a step measurement has been completed and the crosswise and lengthwise tilt have also been recorded, the controller moves the recorded data from the memory into a transfer buffer at step 222 . At step 224 , the data is transferred to an attached computer, which in the preferred embodiment is a laptop computer. The controller then determines whether the data transfer is complete at step 226 before proceeding to step 228 where the lane mapper is incremented lengthwise down the lane to the next step for the next set of measurements. At step 229 the program checks to determine if the lane mapper has reached the end of its measurement run down the lane. If yes, the program proceeds to step 231 where the controller causes the lane mapper to return to the foul line. If the lane mapper has not reached the end of its run, the controller proceeds to step 230 . Because the laser sensor is all the way to the right, the second step lane height measurements will be made from right to left. As the lane mapper increments down the lane from step to step, the laser sensor runs alternate so that runs on odd increments are from left to right and runs on even increments are from right to left. After the lane mapper has been incremented one step down the lane, the laser sensor is aligned at the first position on the right at step 230 . This process is identical to that described for step 210 , except that it is performed on the right. Program flow then returns to step 212 , the beginning of the laser reading loop where the laser measurements are taken until the entire lane width has been measured as previously described.
[0038] Resident in the laptop computer is a user interface program that provides a graphical user interface that allows the user to programmably select measurement settings including the distance between steps down the bowling lane, the distance between lane height measurements within each step, and the distance between and frequency of lengthwise and crosswise tilt measurements. The program also stores measurement data transferred by the PLC to the laptop in a database. The database records the lane measurements and also records the facility and lane number to which the measurements refer. The software allows the user to view the lane measurements either as numerical outputs or in a graphical format. The graphical format can take the form of a two-dimensional graph showing the cross section of lane height measurements for a particular step and also may be displayed as a three-dimensional graph showing lane height measurements for an entire bowling lane.
[0039] [0039]FIG. 10 shows an example graphical display of the data recorded by the lane mapper generated by the user interface program. In FIG. 10 the user can select the bowling lane center he wishes to view data from by using the drop down menu 240 . Menu 246 allows the user to select from each step of data taken for a particular lane on a given date. The user may select the step to be displayed by highlighting the entry desired. Once the center and lane have been selected, the user interface program populates the chart with the relevant data. This data includes a numeric presentation 242 and 244 of the crosswise and lengthwise tilt respectively. Graph 248 displays the data for a cross section of the lane surface height at one step in graphical format. Sliding scale control 249 allows the user to select the particular reading within a step to be displayed on the screen. Graph 250 shows the crosswise tilt for the selected step and graph 252 shows the overall lengthwise tilt for the entire lane from front to back. Button 254 causes the user interface program to create a three dimensional graph of the entire selected bowling lane such as is shown in FIG. 11. Over box 251 and under box 253 allow the user to enter the values that filter the report to exclude measured values between the limits set by the over value and under value. Thus any single read that is over or under the user entered values will be displayed on the report. These values are typically the American Bowling Congress maximum tolerance specifications for crowns and depressions. Thus, this report shows any reads that are not within the tolerance range. The report is displayed by setting the over and under values and then clicking on the over under report button 255 . Difference button 243 activates the generation of a report that will identify holes or hills on the lane for an area of 10 reads within a single step, which is approximately equivalent to the width of 5 boards in the lane. The user can input values into Val 1 Box 247 and Val 2 Box 245 . The difference report will show any values within the 5 board area outside of the ranges entered in the Val 1 and Val 2 boxes.
[0040] In FIG. 11 the three dimensional display 256 gives a view of the lane surface for the entire lane based on the data that was stored from a lane mapper run. The graph may be displayed in color and key 258 shows the elevation associated with each region on the three dimensional graph 256 . The bottom of FIG. 11 includes a region 260 in which the user may make selections regarding the display, printing, and saving of the three dimensional map.
[0041] Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
[0042] Having thus described the preferred embodiment of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: | An automated lane surface measuring device comprising a controller for operating a drive mechanism for propelling the measuring apparatus and one or more sensors operated by the controller to measure topographical parameters of the bowling lane surface. In one embodiment the apparatus measures bowling lane surface elevation by measuring bowling lane height with respect to the measuring apparatus in selectable increments along the surface of the bowling lane. The measuring apparatus may also measure crosswise tilt along the width of a bowling lane in selectable increments. The measuring apparatus may also measure lengthwise tilt of the length of the lane surface in selectable increments. | 0 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to the art of lighting and more particularly to an arrangement for lighting the cabin of an aircraft.
Prior fluorescent lamps have been introduced into their holders through the insertion of their lateral or end contact pins into a guiding slot, and are then placed into their operative position through the application of pressure with a concurrent rotation of the lamp. This "turning-in" sequence cannot be implemented in a particularly comfortable manner, and especially in the utilization of such fluorescent lamps in the passenger cabins of airplanes subject to extremely narrow or restrictive space conditions, the insertion of such fluorescent lamps necessitates the expenditure of considerable amounts of effort.
Additionally, it is also known to secure the fluorescent lamps in their holders through the employment of a latching lever, particularly during their use in airplanes. However, these mechanisms have required large volumes of space in which to operate; space which comes at a premium on an airplane.
One aspect of the present invention is directed to alleviating this problem by providing a compact self-locking mechanism to mount lamps within their respective holders while maintaining positive electrical contact. The present invention employs a unique lampholder. The lampholder of the present invention may utilize a pair of retaining springs, a pair of biasing springs and a plunger. The retaining springs of the present invention serve to lock the lamp pins in position. The biasing springs serve to oppose the retaining springs and also serve to position the lamp pins. Preferably, the springs serve as conductors in addition to their structural purpose. The plunger serves to separate the retaining springs to release the lamp pins from contact with the springs. The lampholder may also have a separate set of flexible tabs to prevent the lamp pins from exiting the lampholder prematurely or unintentionally. By utilizing the lampholder of the present invention, a positive electrical contact is maintained with the lamp even though it may be subjected to substantial vibration. The present invention accomplishes this purpose while providing an easy means of installing and removing lamps within the lampholder.
Another aspect of the present invention is directed to solving the problems associated with fixture maintenance and weight considerations. Previous light systems have utilized a dedicated power supply for each light fixture. Additionally, removal and installation of light fixtures has required the use of tools. This slows maintenance and therefore increases the costs associated with maintenance of such a lighting system. The present invention provides an easy, tool free method for removing and replacing light fixtures. The present invention may utilize a unique fixture that may be in previously known mounts but may also utilize a unique combination of fixture mounts and fixtures. The present invention allows a lighting system to benefit from a division or sharing of circuit elements across more than one fixture to minimize the weight associated with such lighting systems.
The lighting system includes a power source, two pairs of lampholders, and an electrical circuit. The electrical circuit is in electrical communication with the first pair of lampholders and the power source. The second pair of lampholders is in electrical communication with the first pair of lampholders. The power source provides power to both pairs of lampholders. The electric circuit has some elements which control both pairs of lampholders, and other elements which control only the first pair of lampholders. There may also be a second electric circuit electrical communication with the second pair of lampholders which has elements which control only the second pair of lampholders.
Other principal features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 is a top plan view of a preferred embodiment of the present invention;
FIG. 2 is a front elevation view of the embodiment of FIG. 1;
FIG. 3 is a left side view of the embodiment of FIG. 1;
FIG. 4 is a right side view of the embodiment of FIG. 1;
FIG. 5 is a top plan view of a housing of the present invention;
FIG. 6 is a front elevation view of the housing of FIG. 5;
FIG. 7 is a side view of the housing of FIG. 5;
FIG. 8 is an elevation view of an output end of the present invention;
FIG. 9 is a right side view of the output end of FIG. 8;
FIG. 10 is an elevation view of an input end of the present invention;
FIG. 11 is a right side view of the input end of FIG. 8;
FIG. 12 is a plan view of a mounting of the present invention;
FIG. 13 is a right side view of the mounting of FIG. 12;
FIG. 14 is an elevation view of a plunger of the present invention;
FIG. 15 is a right side view of the plunger of FIG. 14;
FIG. 16 is an elevation view of a housing of the present invention;
FIG. 17 is a right side view of the housing of FIG. 16;
FIG. 18 is an elevation view of retaining contacts of the present invention;
FIG. 19 is a right side view of the contacts of FIG. 18;
FIG. 20 is an elevation view of biasing contacts of the present invention;
FIG. 21 is a right side view of the contacts of FIG. 20;
FIG. 22 is an elevation view of a base of the present invention;
FIG. 23 is a right side view of the base of FIG. 22;
FIG. 24 is a front elevation view of a lampholder assembly of the present invention;
FIG. 25 is a right side view of the lampholder assembly of FIG. 24;
FIG. 26 is a rear elevation view of the lampholder assembly of FIG. 24;
FIG. 27 is a top plan view of the lampholder assembly of FIG. 24;
FIGS. 28A,28B, and 28C is a plan view of an example layout of mountings of the present invention;
FIGS. 29A and 29B is a plan view of the connections between two mountings of the present invention;
FIG. 30 is a perspective view of a power supply circuit card assembly of the present invention;
FIG. 31 is a plan view of a circuit card of the power supply of FIG. 30;
FIG. 32 is an elevation view of the circuit card assembly of FIG. 30 without the EMI housing;
FIG. 33 is a plan view of another circuit card of the power supply of FIG. 30;
FIG. 34 is a perspective view of another power supply circuit card assembly of the present invention;
FIG. 35 is a plan view of a circuit card of the power supply of FIG. 33;
FIG. 36 is an elevation view of the circuit card of FIG. 34; and
FIG. 37 is a schematic of a circuit of the present invention.
FIG. 38 is a cross-section of the lampholder assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1-4, a preferred embodiment of the cabin lighting system of the present invention is shown at 10. Lampholder assembly 12 is attached to a housing 14 that may extend for any desired length. Housing 14 is attached to both an output end 16 and an input end 18 which in turn are each attached to a mounting 20. FIG. 4 is shown without mounting 20. Each mounting 20 is attached to a location within the structure that the lighting system is intended to illuminate. A lamp (not shown) may be fitted between lampholders 12.
Referring now to FIGS. 5-7 the housing 14 may be seen in more detail. Housing 14 may have openings 22 at each end that are configured to receive lampholders 12. Additionally, housing 14 may be configured to receive an output end 16 at 24 and an input end 18 at 26.
FIGS. 8 and 9 show an output end 16 of the present invention. Output end 16 may be configured to connect to a mounting 20 at 28. Output end 16 may also be configured to allow wiring to pass through at 30 to an associated input end 18. Lastly, output end 16 may also be configured to attach to housing 14 at 32.
FIGS. 10 and 11 show an input end 18 of the present invention. Input end 18 may be configured to connect to a mounting 20 at 34. Input end 18 may be configured to receive electrical power via electrical wiring or connections at 36 from an associated output end 16 or an external power supply. Lastly, input end 16 may be configured to attach to housing 14 at 38.
FIGS. 12 and 13 show a mounting 20 of the present invention. Mounting 20 may be configured to receive wire connectors generally at 40 to establish connections between either a power supply external to the lighting system and a primary fixture or a primary fixture and a secondary fixture. Mounting 20 may also have a channel to allow wiring to pass at 42. Mounting 20 may also have a lower chamber 44 to receive a tab from either an input end 18 or an output end 16. Lastly, mounting 20 may be configured to attach to a structure with a fastener plate 46.
Referring now to FIGS. 14-27 components of a lampholder assembly 12 are shown in FIGS. 14-23 and the lampholder assembly is shown in FIGS. 24-27. The operation of the lampholder assembly will be explained below. A plunger 48 is shown in FIGS. 14 and 15. A housing 50 is shown in FIGS. 16 and 17. Housing 50 is configured to receive lamp pins at 52. Retaining springs 54 are shown in FIGS. 18 and 19. Biasing springs 56 are shown in FIGS. 20 and 21. A base 58 is shown in FIGS. 22 and 23. Base 58 may be configured to attach to housing 14 at 60. Base 58 may also be configured at 62 to receive and guide plunger 48.
The assembled lampholder 12 is shown in FIGS. 24-27 and 38. Lampholder assembly 12 preferably is designed to accommodate a two pin lamp (shown in outline in FIG. 38). The operation of the lampholder assembly 12 may perhaps best be understood in reference to FIG. 24,27, and 38. Plunger 48 may be depressed to force retaining springs 54 apart. A lamp's pins may then pass into the opening of the housing 50 past flexible tabs 57 and retaining springs 54 until the pins reside on the biasing springs 56. The plunger 48 may then be released to allow the retaining springs 54 to maintain the lamp pins position within the housing 50 and to allow the biasing springs 56 to bias the lamp pins against the retaining springs 54. The biasing springs 56 serve to maintain electrical contact between the springs 54 and 56 and the lamp pins. The retaining springs 54 serve to retain the lamp within the housing and to provide electrical contact with the lamp pins. To release the lamp from the lamp holder assembly 12 one may depress the plunger 48 to again allow the retaining springs 54 to separate and to force the biasing springs 56 down. The lamp pins are then released from contact with the springs 54 and 56 and may then pass out of the housing 50 after passing flexible tabs 57. Biasing springs 56 extend out of the housing and may be connected to a power supply at 59.
FIG. 28 shows a preferred layout of mountings 20 of the present invention. An important aspect of the present invention is the reduction in weight over prior lighting systems. The present invention may utilize a first circuit that is connected to a power source that in turn provides conditioned power to a second circuit. The first circuit may be located in a primary fixture and the second circuit may be located in a secondary fixture. Prior systems utilized duplicative electric circuit elements. The present invention removes duplicative circuit elements and thereby saves weight. This is especially important in aircraft where fuel savings may be realized.
The present invention utilizes a system of mountings 20 that each have a set of integral contacts. Referring to FIG. 28, a first mounting 64 may receive power from a source external to the lighting system (not shown). First mounting 64 may then be connected to a primary fixture that receives the power passing through the first mounting 64. The primary fixture may then provide light and condition the power for transmission to a secondary fixture. Primary fixture may be connected to a second mounting 66. Second mounting 66 may then be in electrical communication with a third mounting 68 through wiring 70. A secondary fixture may then be connected to the contacts of the third mounting 68. A fourth mounting 72 may be provided to mount the secondary fixture to the structure external to the lighting system.
FIG. 29 shows a more detailed view of the electrical communication that may be established between a second mounting 66 and a third mounting 68 by wiring 70. Electrical connections may be established at 74 between a primary fixture and the second mounting 66. These connections may pass through second mounting 66 via a contact system 40. Wiring 70 may extend from the contact system 40 and pass through a channel 42 to connect with third mounting 68 at another contact system. A secondary fixture may be electrically connected to the third mounting 68 at 76 to receive conditioned electrical power.
FIG. 30 shows a first circuit assembly for a primary fixture at 78. A set of three leads 80 extend from the first circuit assembly 78 that may connect to a first mounting 64 to receive power from a source external to the lighting system. Two leads 82 may extend from the first circuit assembly 78 to attach to biasing springs 56 to provide power at one end of a lamp through a lampholder assembly 12. Two leads 84 may extend from the first circuit assembly 78 to attach to biasing springs 56 to provide power at another end of a lamp through another lampholder assembly 12. Three leads 86 may extend from the first circuit assembly 78 to attach to a second mounting 66 to provide conditioned power to a secondary fixture. First circuit assembly may be located within a housing 14 of a primary fixture.
Referring to FIGS. 31-33, the circuit carets internal to the first circuit assembly 78 may be seen. A first circuit card 88 may provide an EMI filter, a rectifier, a power control circuit, a dim control circuit, a soft start circuit, and a pulse width modulator which may be utilized to control both primary and secondary fixtures. First circuit card 88 may also provide a resident capacitor, a set of filament voltage dividers, and a thermistor to further condition the power for the primary fixture only.
Referring now to FIGS. 34-36, a second circuit 92 which may reside within a secondary fixture may be seen. Second circuit 92 may be configured to receive conditioned power from a first circuit card 88 and to further condition that power to apply it to a secondary fixture lamp. Second circuit 92 may provide a resident capacitor, a set of filament voltage dividers, and a thermistor.
Referring now to FIG. 37, a complete schematic of the electrical configuration of the present invention may be seen at 94. A primary fixture lamp 96 and a secondary fixture lamp 98 is shown connected to the remaining portions of the circuit. The first circuit 88 of the present invention encompasses all circuit elements within areas 100 and 102 as defined by clashed lines. Secondary circuit 92 encompasses all circuit elements within area 104 as defined by dashed line.
A preferred embodiment of the present invention is described in great detail below. | The present invention is a unique lighting system. The lighting system includes a unique mount and mounting system, a unique lampholder and a unique power conditioning circuit arrangement. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to air conditioning units in general, and particularly to an improved base pan for a packaged air conditioning unit.
2. Background of the Prior Art
Large, ground-mounted or roof-mounted air conditioning units for residential or light industrial use, commonly referred to as "packaged" air conditioning units, are subjected to significant structural stress during the course of their operation.
Rain and snow commonly enter the cabinet of such units through an inlet grill or through vent holes. In addition, condensation continuously forms on the indoor coil of such units and then drips downward. This precipitation and condensate, of course, can cause corrosion of corrosive components of the air conditioning unit. It is desirable in many instances to employ corrosive metal components in an air conditioning unit, because such materials, in general, are structurally strong, and at the same time non-flammable. Air conditioning units must meet stringent standards of the National Fire Safety Code before receiving approval of the Underwriter Laboratories.
The component of an air conditioning unit most susceptible to corrosion problems is the unit's base pan, which is mounted on the ground and which supports the unit's chassis and internal equipment components. Base pans of packaged air conditioning units have long been observed to rust out over time, and eventually fail to support internal components and walls of the unit.
In order to address the problem of base pan corrosion, some manufacturers have provided a two piece base pan having a base section and a drip pan. However, in many instance, both pieces of a base pan of this configuration have been observed to corrode.
There exists a need for an air conditioning unit base pan which is inexpensive, structurally strong, resistant to corrosion, and at the same time, essentially non-flammable and within fire code standards.
SUMMARY OF THE INVENTION
According to its major aspects and broadly stated, the present invention is an improved base pan for a packaged air conditioning unit.
An important feature of the present invention is the selection of material for the base pan. Preferably the base pan is made of a non-corrosive polymer despite the fact that metal base pans of the prior art offer the advantages of being inexpensive, structurally strong, and non-flammable despite being corrosive. Preferably, a base pan according to the invention is made of a polypropylene material. A most preferred material for the base pan is AZDEL of the type manufactured by General Electric Corporation.
While non-corrosive, inexpensive, and structurally strong, the above materials are also flammable. To the end that a base pan according to the invention is fire-resistant despite the selection of a flammable material, regions of the base pan that will be exposed to significant heat during the course of operation are coated with a non-flammable material. A typical air conditioner base pan includes an airflow section above which are supported compartment partitions, a unit's indoor coil, and a unit's blower. Return air from the building, which is cooled, flows into the area above the base pan airflow region, and is forced back into the building after being cooled. In the present invention, the airflow region of the base pan is coated with a non-corrosive, non-flammable material in order to make this area of base pan flame resistant. The airflow section of a base pan, according to the invention, can be covered by any conventional method with a metal coating. Most preferably, the airflow region of the base pan is coated with zinc spray which is sprayed on to the base pan's airflow section. Provided by this design is an inexpensive, non-corrosive, and flame-resistant base pan.
The base pan is preferably a unitary article of manufacture formed by a process of compression molding.
In addition to its material selection, structural features of the improved base pan contribute to improved structural integrity of the base pan and of other components of the air conditioning unit. The base pan is generally flat but is characterized by a gentle crown so that moisture dropping to the center of the pan tends to drain toward the pan's periphery. Unit wrappers which comprise the unit chassis include drainage slits through which liquid falling toward the periphery of the pan exits the unit.
The airflow region of the base pan, is formed on a raised platform which is raised from the remainder of the base pan. The raised airflow region is formed at one corner of the pan so that the airflow region partially borders on a corner of the base pan, and partially borders toward the base pan center. Ramp members are formed between the border of the raised platform and the base pan.
The combination of a raised platform and the ramp members serve an important function. Specifically the combination of the raised airflow region and the ramp members serve to direct precipitation and condensate away from the airflow compartment, wherein the unit components subjected to the most severe stress are contained.
The base pan further comprises a number of integrated positioning formations which are formed as contiguous elements with the remainder of the base pan. In a conventional design, mounting brackets are mounted to the base pan for supporting air conditioning unit components. The present design which features integrated positioning formations, reduces the number of parts required to make an air conditioning unit and reduces assembly time. Furthermore, the integrated positioning formations improve the structural integrity of the base pan by reducing the number of bolt holes required to be formed on the base pan, and by reducing the load requirements of the base pan.
These and other features of the present invention will become clear to a skilled artisan from a reading of the ensuring detailed description in conjunction with the referred drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein like numerals are used to indicate the same elements throughout the views,
FIG. 1 is a perspective view of an air conditioning unit having a containment system according to the invention integrated therein;
FIG. 2 is a perspective view illustrating the base pan, the first unit wrapper, a compressor compartment partition, and a condenser compartment partition;
FIG. 3 is a perspective installation showing the base pan, and the unit wrappers of the invention;
FIG. 4 is a first perspective view of a base pan according to the invention;
FIG. 5 is a second perspective view of a base pan according to the invention.
FIG. 6 is a top view of a base pan bottom according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description of an air conditioning unit of the type which the present invention is integrated is made with reference to FIG. 1. Air conditioning unit 10 includes an indoor evaporator section 12 and an outdoor section 14. On installation, indoor section 12 connects to air ducts that supply conditioned air to the interior space of a building, while outdoor section 14 extends to the outside of a building.
Indoor section 12 of unit 10 includes a compressor 16 for increasing the pressure of refrigerant flowing in an outdoor coil or condenser (not shown), and a blower 18 for blowing air across an indoor coil, otherwise known as an evaporator (not shown), through which cool liquid refrigerant flows.
Unit 10 may also have heating coils 20 or other heating elements which when activated work to supply heat to a building. When unit 10 is in a heating mode of operation, air that is blown by blower 18 is warmed by heating elements 20. When unit 10 is in a cooling mode of operation, air blown by blower 18 is cooled by the evaporator. Whether unit 10 is in a cooling mode or a heating mode, air that is blown by the blower enters a building through supply air duct 22. Air that has circulated in a building returns to unit 10 through return air duct 24.
In addition to having an outdoor coil or condenser, outside section of unit 10 includes an outdoor fan. The outdoor fan draws outside air into unit 10 through grating 25 (see FIG. 3) and blows such air across a unit condenser which is filled with hot refrigerant. Outside air is directed out of unit 10 through vent 26. In this way, the condenser and fan operate to remove heat from a building.
During the course of operation of unit 10, the aforementioned components will be subjected to considerable structural stress. Rain and snow can enter into unit 10 directly through vent 26 or grating 25 to cause corrosion of or otherwise interfere with the operation of, a system fan, a condenser, or another component of unit 10. In addition, condensate will form on the indoor coil when unit 10 is in cooling mode of operation. This condensate will drip off of the inner coil and may cause corrosion of or otherwise interfere with operation of indoor components of unit 10.
As a result of the stress they encounter, components of packaged, ground-mounted air conditioning units normally require regular maintenance and servicing, and often require replacement. Accordingly, one object of the present invention is to provide a containment system which allows easy access to components of the unit.
Components of the containment system of unit 10, including the unit's exterior cabinet and its internal partitions are also subjected to significant structural stress. Accordingly, another object of the present invention is to provide a containment system which is designed to withstand significant structural stress.
Now referring to FIGS. 2 and 3, a containment system for a ground-mounted packaged air conditioning unit will be described in detail.
Containment system 30 includes a horizontally-oriented base pan 32 a first vertically-oriented unit wrapper 34 supported by base pan 32, a second vertically-oriented unit wrapper 36 supported by base pan 32, a condenser compartment partition 38, a compressor compartment partition 40, a top cover indoor section 42, and a top cover outdoor section 43. Unit wrappers 34 and 36, condenser partition 38 and the compressor partition 40 are formed preferably of sheet metal. First and second unit wrappers 34 and 36 form a unit chassis.
Base pan 32 of the containment system includes a plurality of positioning cleats 44 spaced apart from one another formed about the periphery of base pan 32. For each positioning cleat formed about the periphery of the base pan 32, there is a corresponding notch 46 formed on one of the unit wrappers 34 and 36. Each unit wrapper has an L-shaped cross-section and extends the length of one side 50 plus one end 52 of the base pan. The unit wrappers are joined at seams formed at opposite corners, such as 58 and 60 of the base pan.
Compressor compartment partition 40 partially defines a compressor compartment for the containment system. Meanwhile, condenser compartment partition 38 defines a condenser compartment along with second unit wrapper 36. Like the unit wrappers, the compressor and condenser compartment partitions 40,38 include spaced apart notches 46 formed along their bottom edge which engage complementary positioning cleats formed on base pan 32.
A first group of positioning cleats formed about the base pan's periphery receives the unit chassis. A second group of positioning cleats formed at the base pans' interior receives compressor compartment partition 40, where a third group of positioning cleats also formed at the base pan's interior receives condenser compartment partition 38.
A top cover 64 comprising an indoor section 42 and an outdoor section 43 is then secured to the unit wrappers 34 and 36, and to bracket 68 which extends from first wrapper 34 to second wrapper 36 perpendicularly between the wrappers. The two-part cover configuration allows easy access to components located in either the indoor section 12 or the outdoor section 14 of the unit. The two-part cover design allows components located in one compartment to be accessed with removal of only one small component of the containment system.
Assembly of the containment system is as follows. First, base pan 32 is provided, and situated in a stable position or else situated on a conveyor belt for transport along an assembly line. Then, internal components of air conditioning unit 10 including compressor 16 the condenser blower 18, the outdoor fan and heating elements 20 can be mounted to or positioned on base pan 32 or else are mounted to internal mounting brackets which are secured to base pan 32.
Once internal components of the packaged air conditioning unit are mounted directly or indirectly to or positioned on the base pan 32, the remainder of the containment system components are installed. First unit wrapper 34 is abutted against base pan 32 so that notches 46 of wrapper 34 interlock with positioning cleats 44 formed on base pan 32. In this way, unit wrapper 34 is easily moved into a proper position on the base pan. Once unit wrapper 34 is positioned in a proper position, screws are driven through holes 37 of wrapper 34 and bored through base pan 32 to firmly secure wrapper 34 to base pan 32. The notch and cleat arrangement greatly simplifies and speeds up the task of installing containment system components.
After first unit wrapper 34 is installed, the containment system's compartment partitions are installed. Compressor compartment partition 40 is first moved into an appropriate position on base pan 32 by interlocking notches 46 of partition 40 with positioning cleats 44 of base pan 32. To firmly secure compressor partition 40 in a secure position, screws or bolts are driven through axially aligned holes of unit wrapper 34 and of an elongated tab (not shown) extending perpendicularly from an edge of partition 40. Condenser compartment partition 38 is then moved into position by interlocking notches 46 of partition 38 with at least one cleat formed on base pan 32. Condenser compartment partition 38 is secured to compressor compartment partition by driving bolts or screws through aligned holes formed on an elongated tab 70 of compressor partition 40 and on condenser compartment partition 38. Screws or bolts are also driven through aligned holes of rear elongated tab 72 and of unit wrapper 34. In addition, screws are driven through holes 49 of compressor and condenser partition 38, 40 and bored into base pan 32.
Second unit wrapper 36 is moved into an appropriate position again by engaging notches of wrapper 46 with positioning cleats 44 of base pan 32. Second unit wrapper 36 is secured by driving bolts or screws through aligned holes of pan 32 and wrapper 36 as best seen in FIG. 3. In addition, second wrapper 36 is secured to first wrapper 34. At each seam 54 and 56 (located at diagonally above opposing corners of pan) bolts or screws are driven through holes formed on an elongated tab e.g. 76 formed on one of the wrappers and through corresponding holes 78 formed on the other unit wrapper. For example, holes 78 formed at the edge 80 of first wrapper 34 will align with holes formed on an elongated tab (not shown) of second wrapper 36. Skilled artisans will recognize that the ordering of the above installation steps can be altered.
Because the unit wrappers 34,36 and the compartment partitions 38 and 40 all firmly abut base pan 32 all of these containment system components contribute to the lateral stiffening of base pan 32. Such lateral stiffening is especially important considering that the base pan will be subjected to significant environmental stress over time, and may become brittle if, for example, it is made of a corrosive material. The lateral stiffening provided by containment system components 34, 36, 38 and 40 will reinforce base pan 32 so that it is strong enough to support unit components eg. 16, 18, 20 despite being corroded or otherwise weakened. For eliminating or mitigating corrosion of base pan 32, base pan 32 may be made of a non-corrosive or corrosion-resistant material. A preferred material for base pan is AZDEL, a composite available from General Electric Corporation as will be described in further detail herein.
Even if the base pan is made of a non-corrosive or corrosion resistant material, then the lateral stiffening provided by vertical containment components 34, 36, 38 and 40 is beneficial because such stiffening allows a relatively weak and inexpensive material to be used as a base pan.
After the vertically oriented containment components 34, 36, 38, and 40 are installed, the containment system's cover is installed. Cover 64 includes indoor section 42 and outdoor section 43. Before installing indoor cover 42 and outdoor cover 43, bracket 68 is mounted between first wrapper 34 and second wrapper 36. Specifically, bracket 68 is positioned perpendicularly between first and second wrappers 34 and 36 on guide cavities 84, 86 as shown in FIGS. 2 and 3 and secured to the wrappers by way of screws or bolts driven through aligned holes of bracket 68 and of the unit chassis. Bracket 68 includes a first elongated tab 88 for receiving indoor cover section 42 and a second elongated tab 90 for receiving outdoor cover section 43. Cover sections 42,43 are secured to the remainder of the containment system by way of screws or bolts. Specifically, indoor section 42 is secured by screws or bolts driven through aligned holes eg. 94,96 of indoor section 42 and of bracket 68 and through aligned holes of cover section 42 and unit wrappers 34 and 36. Outdoor cover 43 is secured by driving screws or bolts through aligned holes of outdoor section and of bracket 68, and through aligned holes of outdoor section 43 and first and second wrappers 34 and 36.
Most of the sensitive components of the air conditioning unit 10, including compressor 16, the indoor coil, blower 18, and heating elements 20 will be located inside the indoor compartment 12. Because cover 64 is divided into two parts: An indoor section and an outdoor section, servicing, maintaining and replacing of internal components of unit is simplified by the fact that only one relatively small component of the containment system needs to be removed to allow access to these internal components.
With reference now to FIGS. 4-6 features of a preferred base pan according to the invention will be described in detail.
An important feature of the present invention is selection of material for base pan 32. Preferably base pan 32 is made of a non-corrosive polymer material. This in contrast to base pans of the prior art which are typically made of inexpensive metal which offers the advantages of being inexpensive, structurally strong, and non-flammable despite being corrosive. A base pan according to the present invention can be made of virtually any polypropylene material. A most preferred material for the base pan is AZDEL of the type manufactured by General Electric Corporation of Stamford Conn.
While non-corrosive, inexpensive, and structurally strong, the above preferred materials are also flammable. To the end base pan 32 is fire-resistant despite comprising a flammable material, regions of the base pan that will be exposed to significant heat during the course of operation are coated with a non-flammable material. A typical air conditioner base pan includes an airflow section, shown generally by 102 above which are supported compartment partitions 38 and 40, a unit's indoor coil and a unit's blower 18 as shown in FIGS. 1 and 2. Return air from the building which is cooled flows into an airflow compartment, the area above the airflow section 102 of base pan 32, and is forced back into the building after being cooled. In the present invention, the airflow section of the base pan is coated with a non-corrosive, non-flammable material in order to make this area of the base pan flame resistant. A base pan according to the invention can be coated for example, by any metal applied by any conventional coating method. In one preferred embodiment, the airflow section of the base pan is coated with zinc. The zinc material applied to the base pan may be ARC SPRAY 02ZZINCWIRE of the type manufactured by Hobart-Tafa Technologies of Concord, N.H. Applied by spraying onto the airflow section of the base pan, this metal coating features the advantage of adhering especially strongly to a polypropylene substrate. The design described above provides an inexpensive, non-corrosive, and flame resistant base pan.
The base pan is preferably a unitary article of manufacture formed by a process of compression molding.
In addition to its material selection, structural features of improved base pan 32 contribute to improved structural integrity of the base pan and of other components of air conditioning unit 10. The top surface of base pan 32 is generally flat but is characterized by a gentle crown so that moisture dropping to a point in proximity with the center of the pan tends to drain toward the pan's periphery. As best seen in FIG. 3, unit wrappers 34 and 36 include drain slits 106 formed at a level approximately flush with the surface of base pan 32, for allowing precipitation and condensate to drain from base pan 32. A preferred containment system which can be used in combination with the base pan described herein is described in commonly assigned application Ser. No. 08/631,359 entitled Containment System for Packaged Air Conditioning Unit incorporated by reference herewith.
Airflow section 102 of base pan 32 is formed on a raised platform which is raised from the remainder of the base pan's top surface. The raised airflow section 102 is formed at one corner of the pan so that the airflow region partially borders on a corner of base pan 32, and partially borders toward the base pan interior. Ramp members 108 are formed between the border of the raised platform and base pan 32.
The combination of raised platform 102 and ramp members 108 serve an important function. Specifically, the combination of raised airflow section 102 and ramp members 108 serves to direct precipitation and condensate away from the airflow compartment, wherein the unit components subjected to the most significant degree of stress are housed. The ramp members, in general, are sloped more severely than other areas of the top surface. While the values are not critical the slope over ramp members typically about 4.5° while the remainder of the pan top surface is sloped to a slope of about 1.5° toward channel 110 or toward the periphery of the top surface.
Condensate or other moisture droplets that drop onto the airflow section 102 of base pan 32 are directed to channel 110 which is formed within the airflow section. In the embodiment shown in FIGS. 3 and 4, channel 110 includes three sides 112, 114, and 116 formed along the periphery of airflow section 102 and a fourth side 118 which divides airflow section 102 into a drain pan section 120 and a return air section 122. As shown in FIG. 2, the indoor coil of unit 10 is positioned above fourth channel side 118 so that most of the condensate formed on the indoor coil drops into channel 110 at the fourth side thereof.
Channel 110 is sloped throughout its length so that condensate and other liquid collecting therein drains through drain hole 126 in fluid communication with the exterior of air conditioning unit. Drain hole 126 may be interfaced, for example, to a drainage system of a building or with a garden irrigation system. While a minimal amount of liquid is expected to drop thereon, return air surface 122 of air flow section 102 slopes toward fourth side 118 of channel 110. Drain pan surface 120 of airflow section 102, meanwhile, is sloped or crowned so that liquid dropping thereon drains toward channel 110.
As seen in FIGS. 4 and 5, the top surface of base pan 32 is elevated from the ground by neck 130 which extends the entire periphery of base pan 32. Neck 130 is supported by rim 132 which extend perpendicularly from neck 130 throughout its length. The periphery of rim 132 is offset typically about 0.75 inches from the periphery of the top surface of base ban 32. This design allows packaging of unit 10 such that direct contact with the unit chassis or with cover 64 minimized during shipment of unit 10. Shown in FIG. 6., stiffening ribs 134 formed throughout the underside of base pan 32 laterally stiffen base pan to further increase the base pan's structural integrity.
In addition the features thusfar described, base pan 32 further comprises a number of positioning formations 140 which are formed as integral elements with the remainder of base pan 32. In a conventional design, mounting brackets are mounted directly to the base pan, and air conditioning equipment components, e.g. 16, 18, are then secured to the mounting brackets. The present design having integrated positioning formations 140 reduces the number of parts required for assembly of an air conditioning unit and reduces assembly time. Furthermore, positioning formations 140 improve the structural integrity of the base pan by reducing the number of bolt holes required to be formed on the base pan, and by reducing the overall load supported by base pan 32. In the present invention, positioning formations 140 merely non-fixedly position air conditioner components in a proper orientation and do not fully support the load of the components. In general, air conditioner components, e.g. 16, 18 are secured to unit 10 in a fixed position by bolts or screws driven through aligned holes of the components and of the unit chassis 34, 36.
Positioning formations 140 formed on base pan 32 can take a variety of different forms which will depend on the specific features of the mounting apparatus of the particular component being positioned. In the embodiment of FIGS. 1-6, the indoor coil of unit 10 is positioned by a positioning formation which comprises first set of ridges 142, a second set of ridges 144 and a pair of elongated bar mounts 146, 148. The positioning formations which position blower 18 and compressor 16 comprise a set of two holes 152 and a set of four holes 156, respectively. The condenser of unit 10, meanwhile, is positioned by a positioning formation comprising a set of tabs 160, three positioning pedestals 162, a first set of ridges 164, and a second set of ridges 166.
It will be recognized that while the containment system and base pan of the invention have been described with reference specifically to a packed air conditioning unit, that the teachings herein can be applied to any containment structure for containing internal equipment component, which will be subjected to significant structural stress over time.
While the present invention has been explained with reference to a number of specific embodiments, it will be understood that the spirit and scope of the present invention should be determined with reference to the appended claims. | An improved base pan is disclosed for a large ground or roof mounted "packaged" air conditioning unit. The base pan comprises a non-corrosive polymeric material but includes a section which is coated with a non-flammable substance. An airflow section of the base pan is defined by a raised platform, which, in combination with a set of ramp members, directs precipitation and condensation from the sensitive airlow section. Moisture droplets which do fall on the sensitive airflow section are directed toward a channel which uniformly slopes toward a drain hole. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic sewing apparatus for hemming and closing a sleeve used in automatically making a tubular sleeve from a sleeve blank by sewing machines.
The apparatus for making a sleeve, such as making the short sleeve of a T-shirt, requires a device for making a folded line by folding an edge of the sleeve blank in an S-form, a sewing machine for hemming the blank along the folded line, a device for folding the hemmed piece in two along a line orthogonal to the hemming line, that is, folding in halves, and another sewing machine for sewing the edges of the folded piece together into a tubular form.
2. Description of the Prior Art
In the sleeve making apparatus including the noted devices, generally hitherto, each device was mutually separated and some steps of the process of making the sleeve with the apparatus is separated according to the devices. That is, one operator hems with a sewing machine, and the hemmed piece is taken out of the sewing machine and manually folded in half by another operator, and the folded piece is fed into another sewing machine by another operator, then the edges of the folded blank are sewn together.
In such a sleeve making process with such separated steps many operators are required and an assembly line is generally formed in order to improve productivity. Even in the assembly line, a waiting time between consecutive steps is likely to occur, and overall job efficiency is, consequently not high. Therefore, product cost is forced to increase, and working space for folding the blank is needed, aside from the space for installing two sewing machines, and a large working space is required on the whole.
Contrary to the manual work, U.S. Pat. No. 4,428,315 discloses a fully automated assembly for a sleeve making apparatus. In this assembly, by raising the pickup head engaged with the center line of the back side of the sleeve blank, the sleeve blank is folded in, two in the vertical plane, and free edges of the folded blank are put on a conveyor to convey the blank along a folding line direction, then the blank is drawn out of the pickup head and folded in halves.
The assembly disclosed in the noted patent is a fully automatic sleeve making apparatus, which saves labor and installation space, improves efficiency, and lowers product cost. In such an automatic sewing apparatus, however, the blank fold apparatus is very complicated, and it is necessary to pick up the entire blank to and fold it in two, and draw out the folded blank while sliding on the pickup head, so that if the blank is, for example, slippery, it is hard to form the fold neatly. And even when it is folded neatly, it is often somewhat when unfolded the blank is drawn out from the pickup head, so that actually a neatly folded blank is not obtained. As a result, it is very difficult to make a tubular sleeve as intended.
Furthermore, the blank for forming a sleeve is roughly divided into two types by the cutting shape. One is a linear edge type which forms an acute angle between the hemming line and the edges to be sewn together next in order to make the blank folded in two after hemming tubular, and the other is a bent edge on an intermediate part of the edges of the blank. In these two types of blanks, it is necessary to turn the edge direction at the beginning of sewing or in the midst of sewing, but such an operation was not taken into consideration in the conventional fully automatic apparatus disclosed in the above noted patent.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the invention to provide an automatic sewing apparatus for hemming and closing a sleeve capable of making a tubular sleeve as specified at high productivity by exhibiting an accurate blank deflecting function and adequate edge direction turning function, in a simple structure, while reducing cost by saving labor and enhancing efficiency by totally automating.
It is another object of the invention to fabricate two types of sleeves, by using only one apparatus, including the adequate direction turning function on two blanks differing in the cutting shape.
To achieve the above objects, the invention presents an automatic sewing apparatus for hemming and closing a blank comprising:
a sewing table having an L-shaped blank mounting surface and inner corner sides:
a first sewing machine for hemming the blank to form a hemmed piece, the first sewing machine being installed on the sewing table at one inner corner side;
a feed device having a conveying surface in the same plane as the sewing table;
a folding device for folding back the edge of an opening side of the blank along the running direction, the folding device being installed on the conveying surface of the feed device before the first sewing machine;
at least one sensor for detecting the hemmed piece on the conveying surface;
a deflecting device for folding the hemmed piece into halves along a line orthogonal to the hemming line, so that a front end of the hemmed piece is piled on its rear end to form a deflected piece, said deflecting device being installed at the delivery side of the first sewing machine;
a second sewing machine being installed at another inner corner side on the sewing table for closing the deflected piece;
a transfer device for transferring the deflected piece in a direction orthogonal to a feed direction of the feed device along the upper surface of the sewing table toward the second sewing machine; and
a turning device for turning the deflected piece so that said front and rear ends coincide to a feed direction of the second sewing machines
wherein, after turning the deflected piece by the turning device, said front and rear ends are sewn together by the second sewing machine.
According to this construction of the invention, the hemming step of the opening side of the sleeve, the two-fold deflecting step of the hemmed piece, and the tubular sleeve making step by sewing together edges of the deflected piece may be done continuously only by placing the sleeve blank on the feed device conveying surface. Besides, by the turning device, the deflected piece :s turned in a direction so that the edges may run along the feed direction of the second sewing machine.
The turning device of the invention is suited to the deflected piece, the edges of which to be sewn are straight when operating at the upstream side of the transfer device, and is ,suited to the deflected piece the edges of which are bent when operating just before the second sewing machine at the downstream side of the transfer device. For controlling the turning device, a detection sensor, or a counter for measuring the number of stitches of the sewing machine may be used.
Meanwhile, the turning device can convert the deflected piece direction by turning itself with the deflected piece held on the table, and by using the device, by pressing one point of the piece, it is possible to rotate about the pressed point by moving the other portion of the piece by means of the feed device or the transfer device.
It is another feature of the invention to deflect the front end of the hemmed piece dropped on the rear end of the hemmed piece in halves along the line orthogonal to the sewing line of the first sewing machine, by the deflecting device, after stopping the running of the front end portion of the hemmed piece being conveyed above the conveying surface. In the apparatus, a clamp is used for stopping the front end, but the hemmed piece can be folded back in two on the conveying surface without turning the clamp itself.
The mechanism of the deflecting device may be simplified by elevatably installing the clamp among the plurality of conveyor belts arranged at intervals so as to open toward the upstream side, or means for lifting the front end of the hemmed piece higher than the conveying surface may be separated from the clamp, with the clamp installed above the conveying surface. The deflecting device is preferably controlled by a sensor for detecting the hemmed piece on the conveying surface.
In the invention, when folding the blank in an S-form so that the edge of the opening side of the sleeve of the blank may be at the upper side and hemming the blank, developing means for developing the S-bent portion flat so that the edge may come to the lower side of the blank.
The other features and effects of the invention will be better appreciated and understood from the following detailed description of the embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a general view of an automatic sewing apparatus for hemming and closing a sleeve according to one embodiment of the invention.
FIG. 2 is a partially cut-away magnified perspective view showing the structure of a deflecting device.
FIG. 3 is a perspective view showing the structure and operation from a first sewing machine to the deflecting device through a hemmed piece developing tool.
FIG. 4 is a perspective view of essential parts showing the holding state and lifting the front end portion of the hemmed piece by the plaiting device.
FIG. 5 is a perspective view of essential parts showing the state right after deflecting the hemmed piece in halves by the deflecting device.
FIG. 6 is a perspective view of essential parts showing the structure and operation of a transfer device.
FIG. 7A to FIG. 7D are longitudinal front views of essential parts sequentially showing the operation for flattening and extending the hemmed piece.
FIG. 8 is a perspective view of essential parts showing the structure and operation of a second sewing machine including a turning member.
FIG. 9 is a perspective view of essential parts showing the state of contacting with the deflected piece as the turning member moves down.
FIG. 10 is a perspective view of essential parts showing the state of the deflected piece turned in direction by the turning member.
FIG. 11A to FIG. 11D are explanatory plan views sequentially showing the changes accompanying the sewing action of the blank having bent edges.
FIG. 12A to FIG. 12C are explanatory plan views sequentially showing the blank direction turning action having a straight edge part.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a plan view showing schematically a general structure of an automatic sewing apparatus for hemming and closing a sleeve, in which numeral 1 is a sewing machine table having an L-shaped blank mounting plane 1a, and a first sewing machine 2 and a second sewing machine 3 installed at the inner corner sides of the sewing machine table 1. On the blank mounting plane 1a of the table part 1A of the first sewing machine 2 side of the sewing machine table 1, several narrow first conveyor belts 4A are disposed in parallel at proper intervals in the direction orthogonal to the blank feeding direction before and after the first sewing machine 2 as shown in FIG. 2 through FIG. 6. Contiguously to the conveying end portion of each first conveyor belt 4A, several narrow second conveyor belts 4B having a conveying surface flush with the first conveyor belts 4A and in the same conveying direction are disposed, in parallel. The blank feed device 4 which nearly extends the overall length of the table part 1A is composed of these first conveyor belts 4A and second conveyor belts 4B.
On the conveying surface of the first conveyor belts 4A, a folding device 5 is disposed before the first sewing machine 2. The folding device 5 is intended to fold an edge of a sleeve blank W in the shape as shown in FIG. 1 mounted along a fitting guide 9 on the conveying surface of the first conveyor belts 4A along the edge, in an S-form by means of three laminated plate members 5a, 5b, 5c, and by feeding the blank W passing through the folding device 5 to the first sewing machine 2, the S-formed folded edge is hemmed along the folding line to form a hemmed piece W1. Besides, on the conveying surface of the first conveyor belts 4A, at the delivery side of the first sewing machine 2, a bar-shaped developing tool 6 is installed. The developing tool 6 has one end fixed on a holding plate 7 for pressing down the hemmed piece W1 delivered from the first sewing machine 2, on the first conveyor belts 4A as shown in FIG. 3, and the other end of the tool 6 is projected obliquely across the hemming line H in the feed direction X of the blank W, and as shown in FIG. 7A to FIG. 7D, the S-formed folded part Wa of the hemmed piece W1 is sequentially developed flatly along with the conveyance of the hemmed piece W1 so that the edge of the blank W may be at the lower side of the hemmed piece W1 itself.
Along one edge in the widthwise direction of the holding plate 7, an air blow pipe 8 is fixed and another air blow pipe 11 is supported on a bracket 10 fixed at one end in the widthwise direction of the table part 1A corresponding to the front end part of the air blow pipe 8. On the peripheral walls of these air blow pipes 8 and 11, as indicated by arrows in FIG. 7B to FIG. 7D, nozzle holes 8A and 11A for blowing air toward the S-formed folded part Wa of the hemmed piece W1 are formed, and flattening of the piece W1 is assisted by the air blown from these nozzle holes 8A, and 11A, when flattening and developing the S-formed folded part Wa of the hemmed piece W1 by the developing tool 6.
Numeral 12 is a deflecting device for folding the hemmed piece W1 in halves after passing under the developing tool 6 along the line orthogonal to the hemming line H. The deflecting device 12 comprises an air cylinder 17 and a plurality of clamps 16 each having a fixed tongue 13, a movable tongue 14 and an air cylinder 15, as shown in FIG. 2 to FIG. 5. The fixed tongues 13 are disposed between adjacent conveyor belts 4A, 4A and the movable tongues 14 are disposed opposite to these fixed tongues 13. Each of the movable tongues 14 is constructed to be free to be driven by the cylinder 15 to open and close vertically toward the upstream side of the conveyor belts 4A. Each clamp 16 is free to hold and release the front end portion of the hemmed piece W1 conveyed on the conveyor belts 4A. The air cylinder 17 is installed as a driving mechanism for elevating the clamp for elevating and lowering all the blank clamps 16 between the holding position of the hemmed piece W1 shown in FIG. 3 and the upper position shown in FIG. 4 and FIG. 5. First and second sensors 19, 20 are mounted on a bracket 18 at an interval in the feeding direction X so as to detect the presence or absence of the hemmed piece W1 conveyed on the conveyor belts 4A.
The air cylinder 17 is fixed in the middle part of the portal frame 21 set up on the sewing machine table 1, and at the lower end of the piston rod 17a of the air cylinder 17 a support frame 22 for the blank clamp 16 is fixed and linked. The first blank sensor 19 and the second sensor 20 are designed to detect whether the hemmed piece W1 conveyed on the conveyor belts 4A is present at the specified position or not, and issue a detection signal. By the operation of the cylinder 15, based on the detection signal detecting the presence of the hemmed piece W1 by both sensors 19, 20, the both tongues 13, 14 of the clamp 16 are closed to hold the front end part of the hemmed piece W1, and by the actuation of the air cylinder 17, the clamp 16 and the front end part of the hemmed piece W1 are lifted above the conveying surface of the conveyor belts 4A to be stopped in the state shown in FIG. 4. Besides, in the holding and lifting state of the front end part as shown in FIG. 4, the rear end part of the hemmed piece W1 is conveyed continuously by the conveyor belts 4A, and when the second blank sensor 20 detects the absence of the hemmed piece W1, it indicates that the rear end part has passed. As a result, the signal is issued, and on the basis of the detection output signal, both tongues 13, 14 of the clamp 16 are opened by operation of the cylinders 15, and holding of the front end part of the hemmed piece W1 is canceled, so that the front end part is spontaneously lowered onto the rear end of the hemmed piece W1 so that the hemmed piece W1 is folded in half along the line orthogonal to the hemming line H. In FIG. 3 to FIG. 5, numeral 23 is an air blow pipe for blowing air toward the hemmed piece W1 lifted with the front end held by the clamp 16, and assisting the folding of the hemmed piece W1.
The deflected piece W2 thus folded in two is sent out, as shown in FIG. 6, onto the second conveyor belts 4B from the first conveyor belts 4A. The second conveyor belts 4B are arranged so as to be driven independently of the first conveyor belts 4A in order to match the sewing timing of the second sewing machine 3.
Numeral 24 denotes a transfer device for transferring the deflected piece W2 (FIG. 6) conveyed by the second conveyor belts 4B in a direction orthogonal to the feeding direction of the second conveyor belts 4B along the top surface of the table part 1B of the second sewing machine 3 side, and feeding the front and rear ends of the deflected piece W2 to the second sewing machine 3. The pressing transfer device 24 comprises a movable frame 27 freely supported by a guide rail 26 mounted on an L-arm 25 above the table part 1B to move vertically in a direction orthogonal to the feed direction of the second conveyor belts 4B, and a plate-shaped transfer member 29 having a pressing surface 29a for pressing the projected edge portion W1a to the mounting surface 1a of the table 1 long the hemming line H, which extends outside of the conveying surface of the second conveyor belts 4B, in the lowered state the member 29 is supported free to move up and down through a cylinder 28 attached to the movable frame 27 in the vertical position. Near the transfer device 24 there is provided a spot pressing member 30 for turning a direction of the deflected piece W2. The member 30 is free to move vertically through a pen cylinder 31, for pressing the local part near the conveying final end of the projected edge portion W1a to the upper surface of the table 1, along the hemming line H of the deflected piece W2, when the sewing line W1b to be sewn by the second sewing machine 3 of the deflected piece W2 is almost linear. A third sensor 32 is disposed in the gap between the adjacent surface of the second conveyor belts 4B so as to detect whether the edge portion W1 a of the blank W1 has come up to the sewing line of the second sewing machine 3 or not, so that the piece W2 is fed by adjusting the position and direction with respect to the sewing line of the second sewing machine 3.
The pressing member 30 operates when the sewing line W1b to be sewn by the second sewing machine 3 of the piece W2 is nearly linear, as mentioned above and as shown in FIG. 12A. When the piece W2 conveyed in the X direction by the second conveyor belt 4B passes over the third sensor 32a at the front side, the pressing member 30 is moved down, and as shown in FIG. 12B, the portion near the end part of the projected edge portion 1a is pushed against the upper surface of the table 1, and as a result the deflected piece W2 is turned in the direction of arrow R about the pressing point through, the conveying force of the second conveyor belts 4B. When the third sensor 32b at the rear end detects the sewing line W1b, the operation of the second conveyor belts 4B is stopped, thereby turning the direction of the piece W2 so that the linear sewing line W1b of the piece W2 to be sewn may come on the sewing line of the second sewing machine 3 as shown in FIG. 12C.
When the deflected piece W2 is turned in the specified position and direction by the pressing member 30 and the second conveyor belts 4B, the plate-shaped transfer member 29 at the lower end of the movable frame 27 presses the edge part W1a along the hemming line H of the deflected piece W2 against the blank mounting surface 1a of the table 1 through the cylinder 28. In succession, the movable frame 27 moves linearly in a direction orthogonal to the feed direction of the second conveyor belts 4B along the guide rail 26, and by this movement the deflected piece W2 is transferred along the upper surface of the table part 1B of the second sewing machine 3 side, and its edges are supplied beneath the presser foot 36 of the second sewing machine 3.
If the sleeve blank W is in the shape shown in FIG. 11A above the table part 1B of the second sewing machine 3, and the sewing line W1b of the deflected piece W2 to be sewn by the second sewing machine 3 is folded on the way as shown in FIG. 11C, the turning member 35 is disposed to change the direction of the deflected piece W2. The turning member 35 comprises two elastic rollers 35a, 35b freely rotating about horizontal axes 40a, 40b as shown in FIGS. 8 to 10, and a frame body 41 for bearing these rollers 35a, 35b is movable vertically by an air cylinder 37. The frame body 41 is designed to be rotatable about a vertical axis 39 by an air cylinder 38 in the lowered state. Furthermore, in the upper part of the presser foot 36 of the second sewing machine 3, there is a sensor 42 for detecting the deflected piece W2 transferred by the pressing transfer device 24 supplied above the presser foot 36, and a counter is disposed for measuring the number of stitches of the sewing machine 3 actuating by receiving a detection signal of the sensor 42. The second sewing machine 3 comprises the devices for sewing the chaining thread continuous to the sewing machine needle into the stitch at the beginning of sewing and includes, a chaining thread cutter 44, a chaining thread suction/discharge tube 45, chaining thread direction changing tubes 46, 47, and a chaining thread holder 48. These elements are disclosed in Japanese Laid-open Patent No. 1-171597 (corresponding to U.S. Pat. No. 4,934,293), and are known, and specific structural explanation thereof is omitted herein.
The turning member 35 is designed to operate in case the sleeve blank W is in a shape as shown in FIG. 11A, and the sewing line W1b of the deflected piece W2 to be sewn by the second sewing machine 3 is folded on the way as shown in FIG. 11A to FIG. 11C. The turning member 35 is usually placed in the upward position by the air cylinder 37 a as shown in FIG. 8. When the deflected piece W2 is supplied beneath the presser foot 36 of the second, sewing machine 3, the second sewing machine 3 is placed in action by receiving the detection signal from the sensor 42. The first linear portion W1 of the folded sewing line W1b is sewn by a specified number of stitches. When the linear sewing by the specified number of stitches is over, the air cylinder 37 receiving a signal, from the stitch counter is extended, and the turning member 35 moves down as shown in FIG. 9. The peripheral surfaces of the two rollers 35a, 35b are pressed against the deflected piece W2 on the table part 1B in front of the second sewing machine 3, while the turning member 35 is rotated about the vertical axis 39 as shown in FIG. 10 through the operation of the air cylinder 38. This rotation is designed to turn the direction of the deflected piece W2 into a position so that the second linear portion W2 of the bent sewing line W1b may come on the sewing line of the second sewing machine 3.
The turning pressing member 30 and the turning member 35 are designed so that one of the operating states may be selected by the operator as desired through a changeover switch, depending on the cutting shape of the sleeve blank W1. In FIG. 6, numeral 33 designates an air blow pipe for flattening the deflected piece W2, and in FIG. 1, numeral 34 is a stacker device for stacking up a plurality of sleeves fabricated in tubular form and discharging them outside as one lot, and a belt conveyor 43 is disposed at the second sewing machine 3 side for discharging products by conveying toward the stacker unit 34 after sewing the sleeves.
The thus arranged automatic sewing apparatus for hemming and closing a sleeve, operates as described below. The operation of the individual devices have been explained so far in relation to their structure, and the general operation is mainly explained below while referring to the drawings.
When the sleeve blank W is placed on the first conveyor belt 4A of the blank feed device 4 on the same plane as the table part 1A of the sewing machine table 1, with the edge running along the fitting guide 9 on the conveying surface, the sleeve blank W is conveyed in the direction indicated by the arrow X by the conveyor belts 4A. In the process of this conveyance, in the first place, the edge of the blank W is folded in an S-form by the folding device 5, is supplied from its front end into the first sewing machine 2, and is hemmed along the folding line. In succession, the S-formed folding part Wa of the hemmed piece W1 sent out from the first sewing machine 2 is conveyed, and is simultaneously flattened and developed by the blank developing tool 6 and the air blown out of the nozzle holes 8A, 11A, and is supplied into the deflecting device 12.
When the first blank sensor 19 detects that the front end of the hemmed piece W1 conveyed by the conveyor belts 4A toward the deflecting device 12 has reached the specified position, the blank clamp 16 holds the front end part of the hemmed piece W1 by the action of the cylinder 15 on the basis of the detection signal from the sensor 19, and by the action of the air cylinder 17, the blank clamp 16 and the front end part of the hemmed piece W1 are lifted upward from the conveying surface of the conveyor belts 4A to be stopped in the state as shown in FIG. 4. In this state, when the rear end of the hemmed piece W1 conveyed by the conveyor belt 4A reaches the specified position, the second blank sensor 20 issues an absence signal of the hemmed piece W1, and according to this signal the action of the cylinder 15 cause the blank clamp 16 to clear the holding of the front end part of the hemmed piece W1. As a result, the front end portion of the hemmed piece W1 drops spontaneously on the rear end portion of the hemmed piece, and the hemmed piece W1 is deflected in half as shown in FIG. 5, i.e., is folded along the line orthogonal to the hemming line H, the deflected piece W2 is sent out by the conveyor belt 4A, and the clamp 16 of the deflecting device 12 is lowered, thereby returning to the waiting state for the next hemmed piece W1.
The operation described so far refers to the sleeve blank W as shown in FIG. 11A, and it is the same if the sewing line W1b of the deflected piece W2 by the second sewing machine 3 is folded on the way as shown in FIG. 11C, or the sewing line W1b of the deflected piece W2 by the second sewing machine 3 is nearly straight as shown in FIG. 12, but after this step the operation is different, and each case is described separately hereinafter.
First of all, when the sewing line W1b of the deflected piece W2 formed by the second sewing machine 3 a is folded on the way as shown in FIG. 11C, the deflected piece W2 extending from the deflecting device 12 is flattened by the air blown out from the air blow pipe 33, and when the flattened deflected piece W2 reaches the specified position, it is stopped in the specified position and specified direction by receiving the detection signal of the front side third sensor 32a, and the lower end pressing surface 29a of the pressing transfer device 24 presses the edge part W1a along the hemming line H of the deflected piece W2 to the mounting surface 1a of the table 1.
In succession, the movable frame 27 moves linearly in the direction orthogonal to the feed direction of the second conveyor belts 4B as indicated by the arrow Y in FIG. 6 along the guide rail 26, and as a result of the movement the deflected piece W2 is transferred along the upper surface of the table part 1B of the second sewing machine 3 side, and its edge is positioned beneath the presser foot 36 of the second sewing machine, 3. The second sewing machine 3 is placed in action by receiving the detection signal from the blank sensor 42, and the linear portion E1 of the folded line W1b is sewn with the specified number of stitches. When linear sewing with the specified number of stitches is complete a signal is received from the stitch counter, the turning member 35 moves down as shown in FIG. 9, and the peripheral surfaces of the two rollers 35a, 35b press the portion near the sewing line E1 of the deflected piece W2 to the table part 1B. The turning member 35 is rotated about the vertical axis 39 as shown in FIG. 10 through the operation of the air cylinder 38. By this rotation, the second linear portion E2 of the folded sewing line W1b of the deflected piece W2 is turned in its direction to such a position as to come onto the sewing line of the second sewing machine 3, and the second linear portion E2 of the folded sewing line W1b is sewn by the second sewing machine 3, thereby fabricating a tubular sleeve as shown in FIG. 11D. Meanwhile, sewing of the first and second linear portions E1, E2 is done continuously without stopping the second sewing machine 3. Thus a fabricated sleeve is sent into the stacker device 34, and is formed in to a plurality of laminates. The plurality of laminated sleeves are discharged outside as one lot.
On the other hand, when the sewing line W1b to be sewn by the second sewing machine 3 is almost linear, as shown in FIG. 12A to FIG. 12C, the deflected piece W2 is flattened by the air blown from the air blow pipe 33, and when the flattened deflected piece W2 passes through a specified position, the pressing member 30 moves down through the pen cylinder 31, which operates by receiving a detection signal from the front side third sensor 32a, and as shown in FIG. 12A, the portion near the rear end of the projected edge part W1a of the deflected piece W2 conveyed in the direction X by the second conveyor belts 4B is pressed on the top surface of the table 1, as shown in FIG. 12B, in the conveying state. As a result, the blank W1 is rotated in the direction of arrow R about the pressing point through the conveying force of the second conveyor belts 4B, and when the sewing line W1b formed by the second sewing machine 3 is detected by the rear side third sensor 32b, the second conveyor belts 4B are stopped. The direction of the deflected piece W2 is accordingly changed to such a position that the sewing line W1b may come onto the sewing line by the second sewing machine 3 as shown in FIG. 12C.
In succession, the plate-shaped transfer member 29 of the transfer device 24 is lowered and its lower end pressing surface 29a presses the edge part W1a along the hemming line H of the deflected piece W2 against the mounting surface 1a of the table 1, and then the movable frame 27 moves linearly in a direction orthogonal to the feed direction of the second conveyor belts 4B as indicated by arrow Y in FIG. 6 along the guide rail 26. As a result of this movement the deflected piece W2 is moved along the upper surface of the table part 1B to the second sewing machine 3, and its front and rear edges are supplied beneath the presser foot 36 of the second sewing machine 3. Then the second sewing machine 3 is placed in action by receiving the detection signal of the blank sensor 42, and a tubular sleeve is made by being sewn together along the linear sewing lines W1b of both edges. Thus a fabricated sleeve is, as in the case above, sent into the stacker device 34. As a plurality of laminates, and the plurality of laminated sleeves are discharged outside as one lot.
Thus, by only putting the sleeve blank W successively on the conveying surface of the feed device 4 at a specified position at one end of the sewing machine table 1, the procedure of making a tubular sleeve making procedure of by S-folding, hemming by the first sewing machine 2, developing and flattening of the S-fold, folding into two halves, changing the direction of the plaited blank W1, and sewing of the edge portions of the deflected piece W2 may be done full-automatically and continuously. Thereby, labor is saved, productivity is enhanced, and the space of the entire apparatus may be small.
In either case two types of sleeve blanks W differing in shape, may be manufactured by using only one automatic sewing apparatus, only by selecting the changeover switch by the operator, for the direction turning action suited to each case.
In particular, by holding the front end part of the hemmed piece W1 when being conveyed through the conveyor belts 4A by the clamp 16 a which is operated by receiving a detection signal of the first sensor 19, and lifting and holding the holding point, the hemmed piece W1 is conveyed continuously with its rear end placed on the conveyor belts 4B. Only by releasing the hold by the blank clamp 16, which receives a signal from the second sensor when the rear end part reaches a specified position, the hemmed piece W2 is folded into halves on the horizontal plane, and therefore as compared with the case of picking up the entire blank or pushing up the center of it to fold it in two on the vertical plane, the deflecting function may be realized more securely and accurately regardless of the material and characteristic of the blank W.
As the blank developing tool 6 in the embodiment, a plate-shaped one may be also used. In the foregoing embodiment, two direction turning members 35, 30 are disposed so as to be applicable whether sewing line W1b of the deflected piece W2 by the second sewing machine 3 is curved or straight, and the operating states of the two members 35, 30 are selected by the changeover switch, but either one of the direction turning members may be provided.
In the embodiment, first the blank edge is folded in an S-form by the folding member 5, and the folded line is hemmed by the overlock sewing machine, and then the S-folded portion is flattened by the developing tool 6, so that the edge is sewn to the lower side of the blank. But it may also be possible to use the folding member in a horizontal J-form, fold the edge to the lower side of the blank, and sew by using a lock stitch sewing machine or an interlock stitch sewing machine. | An automatic sewing apparatus for hemming and closing a sleeve is used for making a tubular sleeve a short-sleeved T-shirt. After placing the sleeve blanks on a conveyor only, subsequent operations are done fully automatically and continuously to make tubular sleeves, resulting in labor savings, productivity enhancement, and a reduction in savings production cost. In particular two types of shapes cut for sleeves can be sewn by using the apparatus by turning them in the appropriate direction. The apparatus comprises a first sewing machine for hemming and a second sewing machine for edge sewing disposed at both inner corner sides of an L-shaped sewing table, a blank feed device installed at a table part of the first sewing machine side, a folding member for the blank edge, a hemmed piece deflecting device, and direction turning members for turning the deflected piece. | 3 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a hydraulic system for an agricultural implement, e.g. a disk harrow and more particularly to such a system which will automatically control the elevation of the farm implement.
The operation of an agricultural implement, in a specific embodiment a large trail behind type, in the field requires the constant attention of the operator of the host tractor pulling the implement. The direction and speed of the tractor must be controlled carefully for maximum efficiency. For instance, when the tractor operator is tilling a field using a disk harrow the elevation and penetration of the cultivator disks has to be set within an operative range to give adequate tillage performance and to minimize the draft load on the host tractor. Oftentimes as the implement is dragged across the field varying soil conditions are encountered requiring adjustment of the cultivator disks to assure optimum performance. Adjustment, for instance, of the elevation of a disk harrow is best accomplished from inside the operator's cab on the tractor vehicle. Furthermore, when the tractor and its attendant implement get to the headland of the field the reversing of the direction of the tractor places a large burden on the operator, as the operator must turn the vehicle while raising and lowering the trail behind implement. This operation must be performed quickly and with a high degree of precision. After the tractor vehicle and the implement have been turned around and are heading back down the field the operator must now set the optimum working height of the trail behind implement. This is most easily accomplished from inside the cab as it would prevent the need for the operator to stop the tractor, dismount from the tractor and adjust the implement.
It is known in the prior art to provide automatic depth control for a trail behind implement. It is also taught in U.S. patent application Ser. No. 156,896, now U.S. Pat. No. 4,337,959, entitled "Self Leveling and Height Control Hydraulic System", assigned to the same assignee as this invention, to utilize a rotary flow divider in maintaining disk harrow position control. The contribution that the instant invention makes to the prior art is that a trail behind implement, in this case a disk harrow, utilizes a rotary flow divider for self-leveling and height control and also incorporates an electrical sensing circuit for sensing the position of the implement and communicating this information to the tractor vehicle operator in the operator's work station. Furthermore, the operator's work station incorporates a manual control element for adjusting the height of the trail behind implement relative to the ground plane.
It is, therefore, an object of this invention to provide an electrical control system for cooperation with a hydraulic system of an implement which will be self-leveling and will provide automatic height control.
It is another object to provide a hydraulic system which is capable of performing certain operations on the trail behind implement automatically without the attention of, or only minimum attention of, the vehicle operator in the control of the implement.
Another object of the invention is to use a rotary flow divider to meter fluid flow to each of a plurality of hydraulic cylinders used in coordinating the elevation of a trail behind working implement. Another object of the invention is to provide an interface between the rotary flow divider and the operator's work station to enable the operator to control the height and self-leveling feature of the trail behind implement controlled by the rotary flow divider.
These and other objects of the instant invention, and many of the attendant advantages thereof, will become more readily apparent upon a careful perusal of the following description when considered in light of the accompanying drawings wherein:
FIG. 1 is a representative embodiment of the environment of the invention; and
FIG. 2 is a combined electrical schematic and hydraulic flow diagram of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 presents a tractor vehicle generally 10 to which a trail behind implement such as the disk harrow generally 12 is hitched to be trailed behind the tractor vehicle. The operator's work station 14 of the tractor includes a steering wheel 16, the seat 20, and a housing 22 containing the adjustable count selector. Electrical conduit 24 is connected between the adjustable count selector 22 and a revolution count generator 26 incorporated into a rotary flow divider generally 30.
The disk harrow gangs such as 32 are supported on frame members such as 34 which are carried on ground engaging wheels such as 36, 40, 42 and 44. Wheels 40 and 42 are representative of two wheel sets on a common axle carried on respective left inboard bell crank 46 and right inboard bell crank 50 to raise and be lowered simultaneously. Outboard wheels 36 and 44 are mounted for rotatable movement on left 52 and right 54 outboard bell cranks respectively.
Left and right outboard cylinders 56 and 60 are connected to respective bell crank levers 52 and 54 such that when the rams of these hydraulic cylinders are extended the wheels attached to the bell crank will be pivoted downwardly causing the frame sections 32 to be raised. Left and right inboard cylinders 62 and 64 are connected to respective bell cranks 46 and 50 to raise, when the piston rods thereof are extended, the center section of the trail behind implement. In the embodiment shown a master/slave hydraulic fluid delivery arrangement is utilized as more clearly shown in FIG. 2.
The hydraulic connection to the tractor as generally shown in FIG. 2 is through a conventional hydraulic coupler indicated generally 66 with which conduits 70 and 72 communicate. The tractor has a conventional hydraulic system which includes at least a reservoir 74, a pump 76 and a directional control valve 80 movable by an operator in the tractor. Movement of the control valve from its central neutral position will selectively connect one of the conduits 70 or 72 with the pump to receive hydraulic fluid under pressure while simultaneously connecting the other conduit to the reservoir 74. To raise the implement pressure is directed to the conduit 70 and conduit 72 is connected to the reservoir. The conduit 70 extends to and communicates with the rotary flow divider generally 30 and more specifically 82. The rotary flow divider 82 shown in this embodiment is a two rotor device having a first rotor 84 connected to a second rotor 86 by means of a shaft 90. Fluid is supplied to each rotor through the manifold 92 directly connected to the conduit 70. The rotary flow divider will equalize the flow to the left and right side sets of hydraulic cylinders in a well known manner characteristic of the operation of a rotary flow divider. The rotary flow divider 82 divides the flow from the source of hydraulic fluid 76 when the directional control valve is in a first position 94 to the conduits 96 and 100 supplying the respective right 64 and left 62 side hydraulic cylinders. The conduits 96 and 100 connect with the head ends of the right 64 inboard cylinder and the left 62 inboard cylinder. Pressure in the head end of these cylinders will cause the pistons and affixed rods to extend, rotating bell cranks 46 and 50 counterclockwise. As these two cylinders are the master cylinders they will provide hydraulic fluid from the rod ends of the hydraulic cylinders to the head ends of the outboard cylinders 60 and 56 respectively. These outboard cylinders will also rotate their bell cranks 54 and 52 in unison with the inboard bell cranks 46 and 50. Since the wheels 36, 40, 42 and 44 are journalled on the bell cranks 52, 46, 50 and 54 they will engage the ground. The frame sections to which the hydraulic cylinders and bell cranks are pivotally secured will be raised relative to the ground. As the outboard cylinders 60 and 56 are extended fluid expelled from the rod ends thereof will pass through conduits 102 and 104 to conduit 106 which is separated from hydraulic conduit 72 by a solenoid operated valve 110. Hydraulic flow through hydraulic conduit 72 will pass to the reservoir 74 when the directional control valve 80 is in the first position 94. The directional control valve 80 could alternatively be a four position valve with a float position.
In its de-energized position as shown the solenoid valve 110 incorporating position and check valve 112, permits flow only toward conduit 72.
Each master and accompanying slave cylinder, i.e., right outboard cylinder 60 and right inboard cylinder 64 on one end and left inboard cylinder 62 and left outboard cylinder 56 on the other end supplied by conduits 96 and 100 respectively incorporate a counter balance valve such as 114 in conduit 96 hydraulically in parallel with a one-way check valve 116, allowing fluid flow from the rotary flow divider 82 to the right inboard cylinder 64. The counter balance valves 114 and generally 134 provide for smooth and controlled lowering and a rapid raising of the implement. The rapid raise is achieved by the first 116 and second 148 one-way check valves. The controlled lowering is achieved by the counter balance valves such as 114 which are piloted from respective conduits 96 and 100. In order for the counter balance valves to open there must be a positive pressure in conduits 96 and 100 thus there is no cavitation on lowering the implement which will then lower smoothly.
The second counter balance valve generally 134 will operate identically to the first pilot operated relief valve 114.
It should be pointed out that a second one-way check valve 148 is arranged in a hydraulically parallel relationship in line 100 with the second counter balance valve generally 134.
The hydraulic flow diagram shown in FIG. 2 is interfaced with an electrical counter and control system that is contained in the same housing generally speaking as the rotary flow divider generally 30 in FIGS. 1 and 2. The adjustable count selector is an operator controlled element that typically would be located within the operator's work station to enable the operator to change the setting of the element as the machine progresses through the field or is set up prior to its operation. This element is connected to a counter unit 150 that counts the revolutions of the shaft 90 of the rotary flow divider as communicated by electrical lines 152 and 154. The counter unit incorporates a counter logic circuit for producing an electrical signal at a preset count as set in on the adjustable count selector 22. The counter is also connected to a normally open switch 156 interposed in electrical conduit 160 leading to the solenoid operated valve 110. Electrical conduit 162 completes this circuit from the solenoid operated valve back to the counter 150. The normally open switch 156 is actuated through a hydraulic pressure responsive operator 164 that senses hydraulic pressure fluid levels in conduit 100.
In its de-energized position as shown, the solenoid valve 110 positions the check valve 112 in conduit 106/72 which permits flow only toward conduit 72. The pilot operated check valves 132 and 142 permit flow only toward conduits 130 and 104. However, the presence of pressure in conduits 100 or 96 is communicated through pilot lines 126 and 128 to open the check valves either 132 or 142 respectively. When this happens there is a free path for the exhaust of fluid from the rod ends of the cylinders 60 and 56 to the tractor reservoir 74. When the hydraulic cylinders are fully extended the pressure on the head end side will be relieved a certain degree by the orifices 164, 166, 170 and 172, which will serve to allow phasing of the cylinders, but the pressure on the head end side may raise above the normal working pressure. That pressure peak will be communicated through line 164 to the pressure actuated electrical switch 156, which is normally biased open but will close when the pressure exceeds the normal working pressure. When the switch 156 closes the solenoid valve 110 energizes so that fluid may freely flow in either direction through lines 106/72. The conduits 160 and 162 connect with a normally closed switch in counter element 150. The counter unit 150 may be a mechanical counter which counts the number of revolutions made by the shaft 90 of the rotary flow divider 82.
With the implement now in its raised position and the solenoid valve 110 actuated the operator can return the implement to its proper working height by shifting the directional control valve 80 to pressurize conduit 72 and simultaneously connecting conduits 70 to the reservoir 74. Fluid will be directed to the rod ends of the cylinders 60 and 56 and subsequently to the rod ends of cylinders 64 and 62 causing them to contract and thereby lower the implement. As the hydraulic cylinders contract fluid expelled from the head ends of cylinders 64 and 62 will be directed through conduits 96 and 100 eventually to the rotary flow divider 82. As the flow passes through the flow divider 82 the shaft 90 will be rotated. The counter unit 150 will count the revolutions of the shaft 90 and open the normally closed switch in counter element 74 when a predetermined total related to the distance the implement is to be lowered as set by the operator's adjustment of the adjustable count selector 22 in the vehicle operator's work station is attained. When the switch in the counter element opens the solenoid valve 110 is de-energized and shifted to the position in which the check valve 112 blocks flow to the rod end of hydraulic cylinders 60 and 56 while check valves 116 and 144 block return of fluid expelled from the head end of cylinder 64 and 62 to the reservoir. Thus even if conduit 72 continues to be pressurized the implement will be positioned and maintained at a proper height subject only to the operator affecting the setting of the adjustable count selector 22 on the tractor.
The rotary flown divider 82 also performs a function of assuring level lift of the implement by metering the flow to and from the conduits 96 and 100. The function and operation of both the rotary flow divider 82 and the re-phasing valves or differential relief valves 144 and 146 are explained in patent application Ser. No. 156,890, now U.S. Pat. No. 4,335,894 by W. C. Swanson for "Implement Level Lift System With Re-phasing Valves" which application has an assignee common herewith.
Pilot lines 124 and 136 function as a thermorelief by opening the counter balance valves 114 and 134 whenever expansion of fluid, for instance from the heat of the sun, causes a pressure rise in the cylinders 56, 60, 62 and 64. With these valves open the expanded fluid from the rams may be dispensed to the rubber conduit hoses.
While a single embodiment of the present invention has been shown and described herein it will be appreciated that various changes and modifications may be made without departing from the spirit of the invention as defined by the scope of the appended claims. Substitutions of equipment in the embodiment not critical to the invention are contemplated by the inventor. For instance it is expected that the disk harrow implement shown could be replaced by other types of tillage equipment or trail behind implements while benefiting from the advantages of this invention. | An implement having a rotary flow divider controlling fluid to and from at least two independent hydraulic rams for raising and lowering the implement in a level manner. A counter monitors the revolutions of the flow divider and actuates an electric circuit which controls solenoid valves to stop the implement at the proper height. A cab mounted adjustable count selector is provided to adjust the desired height of the implement. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This application relates to lubricating oil compositions containing hydrocarbyl methylol poly(oxyalkylene) amino ethanes which contribute despersancy and detergency to the compositions.
Lubricating oil compositions, particularly for use in internal combustion engines, have long performed many functions other than simply lubricating moving parts. Modern-day, highly compounded lubricating oil compositions provide anti-wear, anti-oxidant, extreme-pressure and anti-rust protection in addition to maintaining the cleanliness of the engine by detergency and dispersancy. Many lubricating oil additives are well known for accomplishing these functions. For maintaining engine cleanliness, a well-known class of ashless detergents which have been found to be particularly useful are polyoxyalkylene carbamates. U.S. Pat. Nos. 4,160,648 and 4,247,301 disclose and claim fuel compositions containing certain poly(oxyalkylene) aminocarbamates and polyoxyalkylene polyamines as deposit control additives. While, in general, deposit control additives are not believed to be useful dispersants for lubricating oil compositions generally, certain aminocarbamates and certain polyether amines are useful in this regard. U.S. application Ser. No. 403,606, now U.S. Pat. No. 4,438,022 filed July 30, 1982 discloses polyether polyamine ethanes as lubricating oil dispersants.
SUMMARY OF THE INVENTION
It has been found that improved lubricating oil compositions comprise a major amount of an oil of lubricating viscosity and an amount sufficient to provide dispersancy of hydrocarbyl methylol poly(oxyalkylene) amino ethanes of molecular weight from about 300 to about 2,500, and preferably from about 800 to about 1,500 and having at least one basic nitrogen atom; wherein poly(oxyalkylene) moiety is composed of oxyalkylene units selected from 2 to 4 carbon epoxide units and containing at least sufficient branched chain oxyalkylene units to render said additive soluble in said lubricating oil composition. The polyoxyalkylene chain is bonded through a terminal oxygen to an ethane or substituted ethane chain or connecting group which is in turn bonded to the nitrogen atom of an amine or polyamine having from 1 to about 12 amine nitrogens and about 2 to about 40 carbon atoms with a carbon-nitrogen ratio of between 1:1 and 10:1. The hydrocarbyl-terminating group contains from 1 to 30 carbon atoms and is bonded to the polyoxyalkylene units through an ether oxygen atom.
DETAILED DESCRIPTION OF THE INVENTION
The present invention herein consists of a hydrocarbyl methylol polyoxyalkylene amino ethane, and a lubricating oil composition containing a major amount of oil of lubricating viscosity and from about 0.01 to about 10 weight percent of said additive. The methylol polyoxyalkylene amino ethane has a molecular weight of from about 300 to about 2500 and preferably from about 800 to about 1500. The composition consists of three parts or moieties. One is the amino moiety, the second the methylol poly(oxyalkylene) moiety comprising at least one hydrocarbyl-terminated methylol polyoxyalkylene polymer, bonded through the third moiety, an ethane connecting group or linkage, connected in turn to the nitrogen atom of the amine or polyamine.
As a dispersant, the polyoxyalkylene moiety, the amino moiety, and the ethane moiety are selected to provide solubility in the oil composition and dispersant activity without contributing to deposit formation. The additives may be termed hydrocarbyl methylol poly(oxyalkylene) amino ethanes or for convenience, "methylol polyether amino ethanes". The additives may be prepared from the reaction of a suitable halogenating agent containing the desired ethane moiety, such as ethylene chlorohydrine, with the appropriate substituted epoxide, polymerizing to the polyoxyalkylene chain. This is in turn reacted with a longer chain epoxide containing the appropriate hydrocarbyl cap, which is followed by reaction of the capped polyether chloride with the appropriate polyamine to form the active composition. The initial epoxide reaction is carried out at relatively low temperatures, i.e., 0° C. and under; while the second epoxide reaction is carried out at higher temperatures relative to the first, e.g., 20° C. to 80° C.
Poly(oxyalkylene) Component
The polyoxyalkylene moiety is ordinarily prepared by the reaction of an appropriate epoxide with an appropriate chlorohydrin containing the desired ethane connecting group. In the preferred embodiment ethylene chlorohydrin is used, which is reacted under polymerization conditions with the lower alkylene oxides or oxiranes containing from 2 to 4 carbon atoms, such as ethylene oxide, propylene oxide or butylene oxide. The resulting poly(oxyalkylene) polymer contains at least one oxyalkylene unit, preferably 1 to 30 units, more preferably 5 to 30 units and most preferably 10 to about 25 oxyalkylene units.
In the polymerization reaction, a single type of alkylene oxide may be employed. Copolymers, however, are equally satisfactory and random copolymers are readily prepared by contacting the ethylene chlorohydrin compound with a mixture of alkylene oxides. Blocked copolymers of oxyalkylene units also provide satisfactory polyoxyalkylene polymers for the practice of the present invention. Blocked copolymers are prepared byreacting the chlorohydrin with first one alkylene oxide and then the other in any order, or repetitively, under polymerization conditions.
The reaction is promoted or "catalyzed" by the use of an appropriate Lewis acid or protic acid catalyst, examples of which include boron trifluoride:diethyletherate (BF 3 OEt 2 ), aluminum trichloride (AlCl 3 ); para-toluene sulfonic acid, and trifluoromethane sulfonic acid. This initial reaction is carried out at relatively low temperatures, i.e., from about -60° C. to about 0° C. and allowed to warm slowly to room temperature after 80% to 99% of the epoxide has reacted, approximately two hours to eight days.
1-Methylol Hydrocarbyl Cap
The polyoxyalkylene moiety is capped with a 1-methylol hydrocarbyl group. This is accomplished by warming the polyoxyalkylene moiety in the presence of the catalyst to between 20° C. to 80° C. and adding an epoxide containing the desired hydrocarbyl group. The hydrocarbyl group includes branched or straight chain 5 to 30 carbon alkyl groups optionally substituted with hetero atoms, including hydroxyl, amino, or halo groups. These epoxides may have the epoxide ring at one end of the molecule or at some intermediate point in the alkyl group.
The 1-methylol hydrocarbyl cap may include a short polyoxyalkylene group having from 0 to 4, more preferably 0 to 1 oxyalkylene unit terminating with the 1-methylol hydrocarbyl group. The oxyalkylene units contain from 5 to about 30 carbon atoms.
The terminal oxygen atom in the polyoxyalkylene chain is bound to the ethane or substituted ethane connecting group, which is in turn bound to a nitrogen atom of the amine or polyamine.
In general, the poly(oxyalkylene) compounds are mixtures of compounds that differ in polymer chain length. However, their properties closely approximate those of a polymer represented by the average composition and molecular weight.
Ethane Moiety
The ethane connecting group ordinarily consists of a 2-carbon chain, or a 2-carbon chain with branched units extending from these carbons atoms. The branches of the connecting group consist of low molecular weight alkyl groups of up to 5 carbon atoms. Additionally, in the present invention, when the ethane connecting group contains branched alkyl groups, the branched groups will not contain the same number of carbon atoms as those extending from the oxyalkylene units of the polyoxyalkylene moiety.
Amine Component or Moiety
The amine moiety of the polyether amino ethane is preferably derived from ammonia or, more preferably, from a polyamine having from about 2 to about 12 amine nitrogen atoms and from about 2 to about 10 carbon atoms. The polyamine preferably has a carbon to nitrogen ratio of from about 1:1 to about 10:1. The polyamine will contain at least 1 primary or secondary amine nitrogen atom. The polyamine may be substituted with a substituent group selected from (A) hydrogen; (B) hydrocarbyl groups from about 1 to about 10 carbon atoms; (C) acyl groups from about 2 to about 10 carbon atoms; and (D) monoketo, monohydroxy, monocyano, lower alkyl and lower alkoxy derivatives of (B), (C). "Lower", as used in lower alkyl and lower alkoxy, means a group containing about 1 to 6 carbon atoms. "Hydrocarbyl" denotes an organic radical composed of carbon and hydrogen which may be aliphatic, alicyclic, aromatic or combinations thereof, e.g. aralkyl. Preferably, the hydrocarbyl group will be free of aliphatic unsaturation, i.e., ethylenic and acetylenic, particularly acetylenic unsaturation. The substituted polyamines of the present invention are generally, but not necessarily, N-substituted polyamines. The acyl groups falling within the definition of the aforementioned (C) substituents are such as propionyl, acetyl, etc. The more preferred substituents are hydrogen, C 1 to C 6 alkyls, and C 1 -C 6 hydroxyalkyls.
The more preferred polyamines finding use within the scope of the present invention are polyalkylene polyamines, including alkylene diamine and including substituted polyamines, e.g. alkyl and hydroxyalkyl substituted polyalkylene polyamines. Preferably the alkylene groups contain from 2 to 6 carbon atoms, there being preferably from 2 to 3 carbon atoms between the nitrogen atoms. Such groups are exemplified by ethyleneamines and include ethylene diamine, diethylene triamine, di(trimethylene) triamine, dipropylenetriamine, triethylenetetramine, etc. Such amines encompass isomers which are the branched-chain polyamines and the previously mentioned substituted polyamines, including hydroxy and hydrocarbyl-substituted polyamines. Among the polyalkylene polyamines, those containing 2 to 12 amine nitrogen atoms and 2 to 24 carbon atoms, are especially preferred and the C 2 to C 3 alkylene polyamines are most preferred, in particular, the lower polyalkylene polyamines, e.g. ethylene diamine, tetraethylenepentamine, etc.
In many instances a single compound will not be used as reactant in the preparation of the compositions of this invention, in particular the polyamine component. That is, mixtures will be used in which one or two compounds will predominate with the average composition indicated.
Compositions
The final compositions comprising the present invention are prepared by the reaction of the hydrocarbyl terminated methylol polyoxyalkylene halo ethane moiety, with ammonia or with the appropriately selected polyamine. The basic substitution reaction yields the attachment of the amine or polyamine to the polyoxyalkylene and the elimination of hydrogen halide.
The class of preferred methylol polyether amino ethanes may be described by the following formula: ##STR1## where R=a 5 to 30 carbon aliphatic, olefinic or alkylaryl group, which may be branched or straight chain and which may be substituted with hetero substituents selected from hydroxyl, amine, or halo groups;
where R'=hydrogen, CH 3 --C 2 H 5 --;
where R" and R'" independently=hydrogen or ##STR2## wherein x=0 to 5;
where x and x' independently=H, or alkyl groups of up to 5 carbons, and are different from R'.
where m=1 to 30 oxyalkylene units; and
where n=0 to 4 oxyalkylene units.
The oils which find use in this invention are oils of lubricating viscosity derived from petroleum or synthetic sources. Oils of lubricating viscosity normally have viscosities in the range of 35 to 50,000 Saybolt Universal Seconds (SUS) at 100° F. and more usually from about 50 to 10,000 SUS at 100° F. Examples of such base oils are naphthenic bases, paraffin base and mixed base mineral oils, synthetic oils, for example, alkylene polymers, such as the polymers or propylene, butylene, etc. and mixtures thereof.
Usually included in the oils besides the subject additives are such additives as dispersants/detergents, rust inhibitors, antioxidants, oiliness agents, foam inhibitors, viscosity index improvers, pour point depressants, etc. Usually, these other additives will be present in amounts of from about 0.5 to 15 weight percent of the total composition. Generally, each of the additives will be present in the range from about 0.01 to 5 weight percent of the total composition.
It is also contemplated that the methylol polyether amino ethanes may be used as concentrates, and could be used as additive to fuels or lubricating oils subsequent to their preparation. In concentrates, the weight percent of these additives will usually range from about 0.3 to 50 weight percent. The concentrate would ordinarily comprise an inert stable oleophilic organic solvent and the carrier of said solvent boiling in the range of from about 150° to 400° F. and the concentrate would preferably contain from about 10 to 50 weight percent of the methylol polyether amino ethane compound.
The following examples are presented to illustrate a specific embodiment of the practice of this invention and should not be interpreted as a limitation upon the scope of that invention.
EXAMPLE 1
Twelve grams (0.15 mole) chloroethanol was added to 200 ml CH 2 Cl 2 in a 2-liter, round-bottom flask, equipped with a magnetic stirrer, a thermometer, an addition funnel, and a N 2 atmosphere. The mixture was cooled in an ice/salt bath to approximately 0° C. After about 10 minutes, 4.0 grams (0.03 mole) boron trifluoride: diethyletherate (BF 3 OEt 2 ) was quickly added with stirring. 184 grams (2.55 mole) butylene oxide was then added slowly, over approximately two and one-half hours, while keeping the temperature below 10° C. The reaction was continuously stirred and the amount of butylene oxide remaining was monitored by gas chromatograph until less than 1% remained--approximately two and one-half hours.
The temperature was then increased to approximately 30° C., and 45 grams (0.19 mole) of C 16 alpha olefin epoxide (hexadecenyl epoxide) was added rapidly to the above product. The mixture was stirred for one and one-half hours at reflux temperature, cooled to room temperature, quenched with 50 ml of methanol and the reaction placed in a separation funnel. The mixture was then extracted first with 50 ml water and then 50 ml saturated NaHCO 3 solution. The mixture was then washed three times with H 2 O. The product was dried over Mg SO 4 , filtered, and stripped, yielding 188 grams of a clear oil: Hydroxyl Number=40; Cl=2.15%.
170.08 grams (0.19 mole) of the above product was placed in a 2-liter, round-bottom flask, equipped with a magnetic stirrer, a thermometer, and a N 2 atmosphere. 881 grams (14.7 mole) of ethylene diamine was added to the flask. The temperature was increased to 80° C. The progress of the reaction was monitored by thin layer chromatography and permitted to react for approximately seven days, then diluted with ether and washed with water. The product was dried over K 2 CO 3 , filtered and stripped, yielding 155 grams of product. Total Nitrogen=1.50%; Basic Nitrogen=1.49%.
EXAMPLE 2
The same procedure as detailed in Example 1 was followed except that 95 grams (0.4 mole) of C 16 alpha olefin epoxide (hexadecenyl epoxide) was added following the reaction of all of the butylene oxide. 242 grams of the final product was yielded: Basic Nitrogen=1.23%.
EXAMPLE 3
Thirty-six grams (0.45 mole) chloroethanol was added to 600 ml CH 2 Cl 2 in a 2-liter, round-bottom flask, equipped with a mechanical stirrer, a thermometer, an addition funnel and a N 2 atmosphere. The mixture was cooled in a dry ice/acetone bath to approximately -30° C. and 10.9 grams (0.08 mole) boron trifluoride:diethyletherate was quickly added with stirring. 536 grams (7.4 mole) of butylene oxide was then added over an 11-hour period.
The reaction was continuously stirred and the amount of butylene oxide remaining was monitored by gas chromatography until less than 1% remained--approximately five days. the temperature was increased to room temperature and stirred for two days. The mixture was extracted first with water and then with saturated NaHCO 3 solution. The mixture was then washed three times with water. The product was dried over anhydrous Mg SO 4 , filtered and stripped to yield 571 grams of a clear oil: Hydroxyl Number=47; Cl=2.35%.
Twenty-five grams of the above product was added to 30 ml CH 2 Cl 2 in a 250 ml round-bottom flask, equipped with a magnetic stirrer, a thermometer and a N 2 atmosphere. The reaction was cooled to 2° C. in an ice/salt bath and 0.5 grams (0.03 mole) of boron trifluoride:diethyletherate was quickly added. After about five minutes, the mixture was heated to 35° C. and 6.6 grams (0.03 mole) of C 16 alpha olefin epoxide (hexadecenyl epoxide) was added in two minutes. The reaction temperature was increased to 45° C. and stirred two hours. The mixture was then cooled to room temperature and quenched with methanol. The mixture was then washed with 50 ml water, then 50 ml saturated NaHCO 3 solution and finally three times with water. The product was dried over anhydrous K 2 CO 3 , filtered and stripped to give 28 grams of a clear oil: Hydroxyl Number=39; Cl=2.22%.
All specific embodiments of the invention have been described in detail. It should be understood that the invention is to be given the broadest possible interpretation within the terms of the following claims. | Additives for lubricating oils for internal combustion engines which contribute dispersancy and detergency to the lubricating oils are disclosed. The additives are hydrocarbyl methylol poly(oxyalkylene) amino ethanes comprising a hydrocarbyl-terminated methylol poly(oxyalkylene) chain of 2 to 4 carbon oxyalkylene units bonded to an ethane or substituted ethane chain in turn bonded to a nitrogen atom of an amine or polyamine having from 1 to 12 amine nitrogens and from 2 to 40 carbon atoms. | 2 |
This is a continuation, of application Ser. No. 08/067,523, filed May 25, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to the use of defined linear peptides in the treatment of diabetic and other non-HIV neuropathic pain syndromes.
Several pain syndromes associated with disorders of the peripheral and central nervous system ("neuropathic pain") exist and few if any effective treatments for such pain are known.
Patients with such conditions make up a large proportion of those whose pain remains resistant to current therapies. Among the most common causes are the neuropathies associated with diabetes, cancer chemotherapy, herpes zoster, cervical or lumbar root compression owing to degenerative spine disease, malignant lesions of nerve plexus or root, nerve trauma, including amputation, HIV infection, and lesions of central pain pathways, including spinothalamic tract, thalamus, or thalamic radiations [Max, M. B., "Neuropathic Pain Syndromes", in Advances in Pain Research and Therapy, V18 (ed. M. Max et al) Raven Press, New York, 1991]. Drug-induced, or toxic, neuropathies have also been described. Thus the antivirals ddI and ddC commonly cause peripheral neuropathies, as do Vincristine (a cancer chemotherapeutic agent), Dilantin (a seizure medication), high dose vitamins, Isoniazid (a tuberculosis medication), and folic acid antagonists.
Patients' symptoms may include the unusual sensations of burning, tingling, electricity, pins and needles, stiffness, numbness in the extremities, feelings of bodily distortion, allodynia (pain evoked by innocuous stimulation of the skin), and hyperpathia (an exaggerated pain response persisting longs after pain stimuli cease).
The neuropathic pain syndromes result, apparently, from a variety of lesions and appear to encompass a mixed group of underlying physiological abnormalities. However, recent findings and treatment modalities have begun to suggest the existence of a common, unifying defect for a number of pain syndromes. As this may now be envisioned to occur, novel treatments which reverse or restore the normal functioning of the seemingly diverse lesions may be envisioned with efficacy against many diverse neuropathies.
The underlying basis for this new conception relates to evidence that a specific growth factor or neurotrophin, secreted by neurons, glia, neighboring parenchymal cells, or in endocrine fashion, is needed to support and maintain the normal functioning and viability of sensory neuronal pathways, either in the periphery or the brain. Pathologies caused by different mechanisms or etiologic agents, as detailed above, may have as a common convergence the loss or diminution of the needed neurotrophin. This then results in Wallerian type degeneration, nerve dystrophy or other dysfunctional or neurophysiological abnormality, the end result being hyperalgesia and enhanced pain nociception.
The synthesis of peptide T and its use in the treatment of mental disorders and memory deficits not caused by HIV infection has been disclosed in U.S. Pat. No. 5,063,206, the disclosure of which is incorporated herein by reference.
Recently it has been reported (Brenneman et al, Peptide T prevents gp120 induced neuronal cell death in vitro:relevance to AIDS dementia, Drug Dev. Res. 15:361-369, 1988.) that peptide T, which has structural relatedness to the neurotrophin vasoactive intestinal peptide (VIP), also will act to maintain the growth and viability of neurons in culture dishes. Structure-activity studies indicate that this activity of peptide T is due to a specific homology with VIP.
Additionally, peptide T has been reported to have benefit in the neurological pain (MacFadden et al, (abstr) Role of peptide T in palliation of HIV-1 related painful peripheral neuropathy, VII Intnat Conf AIDS (Firenze) 1991 #W.B.217) caused by HIV infection. However, unlike the treatment of diabetic and other non-HIV neuropathic pain syndromes, in the treatment of HIV-related painful peripheral neuropathy, the function of peptide T is to block the toxic actions of virally derived proteins on the nervous system.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for alleviating the symptoms of neuropathic pain, in whatever non-HIV clinical setting it may occur, by administering to a patient suffering from such symptoms an effective amount of a peptide capable of blocking the loss, destruction, or dysfunction of those cellular constituents which lead to non-HIV neuropathic pain.
It is another object of the present invention to treat patients suffering from neuropathic pain syndrome, other than HIV-related neuropathy, with an amount of defined linear peptides, including peptide T, sufficient to ameliorate the symptoms associated with the syndrome.
An additional object of the present invention is the use of intranasal therapy using defined linear peptides, including peptide T, which reduces the symptoms of diabetic and other non-HIV related neuropathic pain.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph illustrating the neuronal cell count of neuronal cell cultures treated for five days with an active peptide (DAPTA), an inactive peptide (TTN(dY)T), or a control (no peptide).
FIG. 2 is a graph comparing the duration of survival of hippocampal neuronal cell cultures maintained in the presence of an active peptide (DAPTA) or in the presence of a control (vehicle containing no peptide).
DETAILED DESCRIPTION OF THE INVENTION
The class of compounds for use in the practice of the invention contain peptides of the formula (I):
R.sup.a -Ser-Thr-Thr-Thr-Asn-Tyr-R.sup.b (I)
wherein
R a represents an amino terminal residue which is Ala-, D-Ala, or Cys-Ala; and
R b represents a carboxy terminal Thr-, Thr-amide, and derivatives thereof, such as esters and amides;
or a linear peptide of the formula (II):
R.sup.1 -R.sup.2 -R.sup.3 -R.sup.4 -R.sup.5 (II)
wherein
R 1 is an amino terminal residue which is X-R' or R' wherein R' is Thr-, Ser-, Asn-, Leu-, Ile-, Arg- or Glu- and X is Cys;
R 2 is Thr, Ser, or Asp;
R 3 is Thr, Ser, Ash, Arg, Gln, Lys or Trp;
R 4 is Tyr; and
R 5 is preferably a carboxy terminal residue which is R"X or R" wherein R" may be any amino acid (Thr, Arg or Gly being preferred); or an ester or amide derivative thereof;
or a linear peptide of the formula (III):
R.sup.1' -R.sup.2 -R.sup.3 -R.sup.4 -R.sup.5' (III)
wherein
R 1' is an amino terminal residue Ala-R 1 , d-Ala-R' or X-Ala-R'; and
R 5' is a carboxy terminal residue or, preferably, an amide or ester derivative thereof;
or the physiologically acceptable salts of the peptides of formulas (I), (II) or (III).
While the preferred amino acids at R 5 and R 5' have been designated, it is known that the amino acid at this position may vary widely. In fact, it is possible to terminate the peptide with R 4 (tyrosine) as the carboxy terminal amino acid wherein R 5 or R 5' is absent. Such peptides retain the binding properties of the group taught herein. Serine and threonine appear to be interchangeable for purposes of biological properties taught herein. The active compounds of the invention may exist as physiologically acceptable salts of the peptides.
Most preferred peptides, as well as peptide T above, are the following octapeptides of formula (I):
D-Ala-Ser-Thr-Thr-Thr-Asn-Tyr-Thr, and D-Ala-Ser-Thr-Thr-Thr-Asn-Tyr-Thr-amide;
and the following pentapeptides of formula (II):
Thr-Asp-Asn-Tyr-Thr, Thr-Thr-Ser-Tyr-Thr, and Thr-Thr-Asn-Tyr-Thr
and their analogues with D-Thr as the amino terminal residue and/or an amide derivative at the carboxy terminal.
The compounds of the invention may be beneficially modified by methods known to enhance passage of molecules across the blood-brain barrier. Acetylation has proven to be especially useful for enhancing binding activity of the peptide. The terminal amino and carboxy sites are particularly preferred sites for modification.
The peptides of this invention may also be modified in a constraining conformation to provide improved stability and oral availability. Unless otherwise indicated the amino acids are, of course, the natural form of L-stereoisomers.
The hereindescribed peptides were custom synthesized by Peninsula Laboratories under a confidentiality agreement between the inventors and the manufacturer. The Merrifield method of solid phase peptide synthesis was used. (See U.S. Pat. No. 3,531,258 which is incorporated herein by reference.) The synthesized peptides are especially preferred. While peptide T and the pentapeptide which is a portion thereof could be isolated, the peptides prepared in accordance with Merrifield are free of viral and cellular debris. Hence, untoward reactions due to contaminants does not occur when the synthesized peptides are used.
The peptides that are preferably to be administered intranasally or sublingually in accordance with the invention may be produced by conventional methods of peptide synthesis. Both solid phase and liquid phase methods, as well as other methods e.g., enzymatic methods, may be used. We have found the solid phase method of Merrifield to be particularly convenient. In this process the peptide is synthesized in a stepwise manner while the carboxy end of the chain is covalently attached to an insoluble support. During the intermediate synthetic stages the peptide remains in the solid phase and therefore can be conveniently manipulated. The solid support is a chloromethylated styrene-divinylbenzene copolymer.
An N-protected form of the carboxy terminal amino acid, e.g. a t-butoxycarbonyl protected (Boc-) amino acid, is reacted with the chloromethyl residue of the chloromethylated styrene divinylbenzene copolymer resin to produce a protected amino acyl derivative of the resin, where the amino acid is coupled to the resin as a benzyl ester. This is deprotected and reacted with the next required amino acid thus producing a protected dipeptide attached to the resin. The amino acid will generally be used in activated form, e.g. by use of a carbodiimide or active ester. This sequence is repeated and the peptide chain grows one residue at a time by condensation at the amino end with the required N-protected amino acids until the required peptide has been assembled on the resin. The peptide-resin is then treated with anhydrous hydrofluoric acid to cleave the ester linking the assembled peptide to the resin, in order to liberate the required peptide. Side chain functional groups of amino acids which must be blocked during the synthetic procedure, using conventional methods, may also be simultaneously removed. Synthesis of a peptide with an amide group on its carbons terminal can be carried out in a conventional manner, using a 4-methylbenzylhydroxylamine resin.
As an aspect of the invention, we provide a pharmaceutical composition comprising a peptide compound of the invention in association with pharmaceutically acceptable carrier or excipient, adapted for use in human or veterinary medicine. Such compositions may be presented for use in a conventional manner in admixture with one or more physiologically acceptable carriers or excipients. The compositions may optionally further contain one or more other therapeutic agents.
Thus, the peptides according to the invention may be formulated for oral, sub-lingual, intranasal, buccal, parenteral, topical or rectal administration.
In particular, the peptides according to the invention may be formulated for injection or for infusion and may be presented in unit dose form in ampoules or in multidose containers with an added preservative. The compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain formulatory agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient may be in powder form for constitution with a suitable vehicle, e.g., sterile, pyrogen-free water, before use. In particularly preferred embodiments, the active ingredient may be administered sub-lingually or intranasally, preferably in more than one daily application.
The pharmaceutical compositions according to the invention may also contain other active ingredients such as antimicrobial agents, or preservatives.
The compositions may contain from 0.001-99% of the active material.
The invention further provides a process for preparing a pharmaceutical composition which comprises bringing a peptide of the invention into association with a pharmaceutically acceptable excipient or carrier.
For administration by injection, nasal spray or infusion, the total daily dosage as employed for treatment of an adult human of approximately 70 kg body weight will range from about 0.02 to about 50 mg, typically from about 0.02 to about 30 mg, for example, from 0.02 mg to 10 mg. The total daily dosage may be administered in a single dosage application or in several dosage applications (e.g., 1 to 4 partial dosage applications), which combined, equal the total daily dosage, depending on the route of administration and the condition of the patient.
It was found that the affinity constants are similar to more potent than those of morphine. On the basis of this affinity, dosage of 0.33-0.0003 mg/kg per day was suggested. This has proven to be effective. A blood concentration 10 -6 to 10 -11 molar blood concentration is suggested. In monkeys 3 mg/kg per day achieves a serum concentration of 150×10 -9 M. This concentration is 15 times greater than necessary to achieve a concentration of 10 -8 M. Primates generally require 10 times the dose used on humans.
Antigenic sequences from crab as well as proteins from other invertebrates can also be added to the peptides of the invention to promote antigenicity.
A preferred embodiment of the present invention comprises delivery of the short peptide sequence by sublingual or intranasal administration. The dosage levels of the peptides may vary, but generally are from about 0.2 to 50 mg/day, for example, about 0.2, 1.2, 6 or 30 mg/day, given sublingually or intranasally by metered spray, in three generally equally divided doses every eight hours.
In one embodiment, the peptides would be administered intermittently. In other words, a pharmaceutical composition containing the active peptide would be administered continually over a period of time, e.g. 2-3 months, whereafter the administration would be discontinued for a period of time, e.g. 2-3 months. In another embodiment, the dose of the active peptide would be varied over the course of administration. For example, a relatively higher dose, e.g. 6 mg/day, would be administered for a predetermined period of time, followed by administration of a relatively lower dose, e.g. 0.2 mg/day. The use of a peptide of the present invention, including peptide T, has no toxic effect on blood cell counts, EKG, blood chemistries or urinalysis. Intranasal or sublingual administration of a peptide according to the present invention is a preferred and safe therapeutic means for ameliorating the symptoms of diabetic and other non-HIV related neuropathic pain syndromes.
EXPERIMENTAL METHODS AND DATA
A) In vitro use of peptide T to promote neuronal survival
The neuroprotective and neurotropic actions of the herein defined peptides were determined by their effects upon fetal rodent neuronal cultures. More specifically, dissociated hippocampal and/or cortical cultures were prepared from 2-day-old rat neonates (Sprague-Dawley rats) by previously described methods (Brenneman et al, Peptide T prevents gp120 induced neuronal cell death in vitro:relevance to AIDS dementia, Drug Dev, Res. 15:361-369, 1988), with the modification that rat neonates rather than mouse embryo's were the source of the brain tissue for the cultures. The dissociated cells were be plated at low density (50,000 cells/35-mm dish) upon confluent layers of astrocytes. The astrocyte feeder layers were prepared from the hippocampi and/or cortices of 2-day-old rat pups. Following treatment with 0,125% trypsin for 15 min, the tissue was triturated and plated at 2.5×10 5 cells into 35-mm tissue culture dishes coated with Vintrogen (Collagen, Palo Alto) and poly-L-lysine (M 1 30-70K 10 -5 M borate, pH 8.4, Sigma). The resulting feeder layers were grown in Eagle's minimal essential medium (MEM, formula 82-0234, Gibco) with 10% fetal bovine serum until confluent (12-14 days); feeder layers prepared in this way were devoid of neurons and consisted predominantly of flat cells that were stained by antibodies to glia fibrillary acidic protein. When hippocampal and/or cortical neurons were added to the confluent feeder cultures, the medium was changed to 94% MEM, 5% horse serum (Gibco) and an added nutrient supplement containing insulin, transferrin, putrescine, selenium, corticosterone, progesterone and triiodothyronine. The resulting mixed neuron/glia cultures are treated one day after plating with 5'-fluoro-2'-deoxyuridine (15 μg/ml plus uridine, 35Mg/ml) to suppress the overgrowth of background cells. The neuronal cultures were allowed to grow for one week prior to the beginning of the experimental period and the medium was changed prior to adding peptides or controls.
B) Neuronal survival assay in vitro
Dilutions of peptide T or analogs were added to 7-day-old neuronal cultures. The test period of exposure to peptides was five days long, a period in which cell survivability can be accurately quantitated. At the end of the test period, neurons were identified immunocytochemically with antisera to neuron-specific enolase. Neurons were counted in 100 fields at predetermined stage coordinates. Cultures were coded and counted in a blinded fashion without knowledge of sample treatment. The total area counted was 50 mm 2 . (% survival=#cells experimental/control x100), equivalent to 100 fields. Each value reported is the mean of six separate dishes. Error bars represent the standard error of the mean and analysis of variance was by Student-Keuls multiple comparison of means. The Control culture has neuron counts that ranged from 750-1000 cells per 50 mm 2 . The results of the 5-day neuronal cell survival tests are presented in FIG. 1, wherein the neuronal cell counts (as a percentage of Control) are shown graphically as a function of the concentration of the various peptides or Control being tested. It can be seen that over the concentration range of 10.0 to 0.01 nM an active peptide as contemplated by the present invention (D-ala 1-peptide T-amide, DAPTA) caused an increase in neuronal survival. The maximum effect was detected at 0.1 nM, with approximately a 25% increase in cell survival compared to vehicle (Control) treated cultures. An inactive peptide T analog with a D-tyrosine substitute [TTN(dY)T] did not cause this increase, nor did the vehicle control. By these results the active peptide (DAPTA) was shown to be, by itself, a neurotrophin for rat cortical neurons as their survival in culture after five days was significantly greater than vehicle treated cultures.
The beneficial effect was shown to be receptor mediated and specific as it occurred for an active peptide T analog but not and inactive one, and the effect was shown to be potent as it occurs at low concentrations. The bi-phasic nature of the response showed that the dose response curve for neuronal cell death in dissociated hippocampal and/or cortical neurons was generally V-shaped. The reasons for the biphasic nature of this response are unclear, but they may include one or more of the following: particle agonist-antagonist properties, activation of another receptor, down-regulation of receptors at high doses, or ligand self-association at high concentration.
A comparison of neuronal survival, based on the percentage of the five-day survival count illustrated in FIG. 1, was made for cultures of hippocampal neuronal cells maintained for twenty one days either in the presence of active peptide (DAPTA) or in the presence of vehicle alone (Control). The results of this comparison are illustrated in FIG. 2, wherein the percentage of neuronal survival (based on the cell count at 5 days) is plotted as the ordinate and the time of treatment, in days, is plotted as the abscissa. Reference to FIG. 2 clearly indicates that treatment of hippocampal neurons in culture with D-Ala-peptide T amide (DAPTA) at 0.1 nM resulted in a 4-fold increase in cell survival after twenty one days compared to vehicle treated cultures and that at all times during the twenty one day test period cell survival rate was enhanced for DAPTA-treated cells. Thus it can be concluded that the normal apoptosis and cell death which occurs in the cultures can be substantially inhibited by addition of the hereindescribed peptides which promote neuron survival, a hallmark of a neurotrophic agent.
The above in vitro assay of neuropathic activity is well correlated with in vivo effect. Thus several recent publications indicate that peptide T and related structures, whose activity was first described based upon in vitro methods such as that described in herein, are able to support the growth and arborization of rodent cortical neurons as determined by Gogli and other histochemical staining methods (see Hill et al, HIV Envelope Protein-Induced Neuronal Damage and Retardation of Behavioral Development in Rat Neonates, Brain Research, Vol. 603, pages 222-233 (1993)). Additional evidence shows that peptide T and related peptides support growth of cortical and other neurons when injected into animals (see Socci et al, Chronic Peptide T Administration Prevents Neurocortical Atrophy Resulting From Nucleus Basalis Lesions in Age Rats, Society For Neuroscience Abstracts, Vol 18, Abstract No. 489.13 (1992)), which describes the use of peptide T to block the attrition of neurons as a part of normal aging, an in vivo neurotrophic effect, first described by in vitro observations such as those illustrated in FIGS. 1 and 2 herein.
C) Alleviation of neuropathic pain in a person with diabetes
A 62 year old male patient suffering from severe type II adult onset diabetes for over 10 years and having symptoms of severe diabetic peripheral neuropathy for over three years was treated by administering intranasal peptide T at a rate of 6 mgs per day in three evenly divided doses. After only one day, the patient could feel the sheets around his feet which had been completely numb and without feeling previously. In addition, of four extremely tender and highly infected sores on the soles of his feet, two had completely healed up after twelve weeks of peptide T treatment, and the two remaining sores were completely uninfected, much less tender, and were progressing to healing. Also, the patient, who had not walked for several years because of the extreme pain of the neuropathy in his legs and feet, was able to walk to work some 10 blocks each way every day after only a few weeks of treatment with peptide T. The patient also indicated that his extreme itchiness, the "pruritus" characteristic of diabetes, that used to bother him around the waistband of his pants vanished after 2 weeks of using peptide T, even though he had tried many different remedies over the years without noticing any significant relief.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 6(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 10 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: peptide(ix) FEATURE: (A) NAME/KEY: Peptide(B) LOCATION: 1(D) OTHER INFORMATION: /product="OTHER"/label=Ra/note="may be nothing"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 1..2(D) OTHER INFORMATION: /product="OTHER"/label=Ra /note="may be Cys-Ala"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 2(D) OTHER INFORMATION: /product="OTHER"/label=Ra/note="may be Ala or D-Ala"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 9(D) OTHER INFORMATION: /product="OTHER"/label=Rb/note="may be carboxy terminal Thr"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 9..10(D) OTHER INFORMATION: /product="OTHER"/label=Rb/note="may be Thr-amide, an ester or amide derivative thereof"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 10(D) OTHER INFORMATION: /product="OTHER"/label=Rb/note="may be nothing"(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:XaaXaaSerThrThrThrAsnTyrXaaXaa1 510(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 7 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: peptide(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 1..2 (D) OTHER INFORMATION: /product="OTHER"/label=R1/note="an amino terminal residue which is Cys-R',wherein R'is Thr, Ser, Asn, Leu, Ile, Arg,or Glu"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 3(D) OTHER INFORMATION: /product=" OTHER"/label=R2/note="is Thr, Ser, or Asp"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 4(D) OTHER INFORMATION: /product="OTHER"/label=R3/note="is Thr, Ser, Asn, Arg, Gln, Lys or Trp"(ix) FEATURE:( A) NAME/KEY: Peptide(B) LOCATION: 5(D) OTHER INFORMATION: /product="OTHER"/label=R4/note="is Tyr"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 6..7(D) OTHER INFORMATION: /product="OTHER"/label=R5/ note="is a carboxy terminal residue which is R''Xor R'', wherein R''may be any amino acid oran ester or amide derivative thereof"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 1(D) OTHER INFORMATION: /product="OTHER"/label=R1/note="may be nothing"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 2(D) OTHER INFORMATION: /product="OTHER"/label=R1/note="may be Thr, Ser, Asn, Leu, Ile, Arg, or Glu"(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:XaaXaaXaaXaaXaaXaaXaa1 5(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 7 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: peptide(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 1..3(D) OTHER INFORMATION: /product="OTHER" /label=R1'/note="is an amino terminal residue X-Ala-R'whereinX is Cys and R'is Thr, Ser, Asn, Leu, Ile, Arg,or Glu"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 4(D) OTHER INFORMATION: /product="OTHER"/label=R2/note="is Thr, Ser, or Asp"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 5(D) OTHER INFORMATION: /product="OTHER"/label=R3/note="is Thr, Ser, Asn, Arg, Gln, Lys, or Trp"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 7(D) OTHER INFORMATION: /product="OTHER"/label=R5'/note="is a carboxy terminal residue or an amideor ester derivative thereof"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 1(D) OTHER INFORMATION: /product="OTHER"/label=R1' /note="is nothing"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 2..3(D) OTHER INFORMATION: /product="OTHER"/label=R1'/note="is Ala-R'or d-Ala-R', wherein R'is Thr,Ser, Asn, Leu, Ile, Arg, or Glu"(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3: XaaXaaXaaXaaXaaTyrXaa15(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 5 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: Not Relevant(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4: ThrAspAsnTyrThr15(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 5 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: Not Relevant(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:ThrThrSer TyrThr15(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 5 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: Not Relevant(D) TOPOLOGY: Not Relevant(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:ThrThrAsnTyrThr 15__________________________________________________________________________ | The present invention relates to methods of treating diabetic and other non-HIV related neuropathic pain. The methods involve administration of an effective amount of defined linear peptides to patients. The peptides can be administered for example, as a powder or a solution obtained by dissolving a powder in a pharmaceutically acceptable solvent. Intranasal or sublingual administration of the defined peptides is the most preferred treatment. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is entitled to the benefit of and incorporates by reference subject matter disclosed in the International Patent Application No. PCT/IB2014/061645 filed on May 23, 2014 and Danish Patent Application No. 201300384 filed on Jun. 21, 2013.
TECHNICAL FIELD
The present invention relates to inverters, in particular to inverters having AC and DC input power modes.
BACKGROUND
FIG. 1 shows a simple motor system, indicated generally by the reference numeral 1 . The motor system 1 comprises a three-phase motor 2 , an AC power source 4 , a rectifier 6 , an inverter 8 and a control module 10 .
The output of the AC power source 4 is connected to the input of the rectifier 6 . The output of the rectifier 6 provides DC power to the inverter 8 . In a manner well known in the art, the inverter module includes a switching module, typically comprising insulated gate bipolar transistors (IGBTs) that are driven by gate control signals in order to convert the DC voltage into an AC voltage having a frequency and phase dependent on the gate control signals. The gate control signals are provided by the control module 10 . In this way, the frequency and phase of each input to the motor 2 can be readily controlled.
The inverter 8 is in two-way communication with the control module 10 . The inverter typically monitors currents and voltages in each of the three connections to the motor 2 and provides that current and voltage data to the control module 10 (although the use of both current and voltage sensors is by no means essential). The control module 10 may make use of the current and/or voltage data (where available) when generating the gate control signals required to operate the motor as desired; another arrangement is to estimate the currents from the drawn voltages and the switching pattern—other control arrangement also exist.
The motor 2 may be used in a wide variety of applications. In some applications, it may be important that the motor 2 functions, even if the AC power supply 4 fails. For example, the motor 2 may be used to operate a cooling fan. If the motor 2 fails, then the cooling fan does not operate and, unless other control arrangements are provided, the device being cooled may overheat.
In such circumstances, it is known to provide a backup power supply, in the event that the AC power supply 4 fails. For example, a bank of batteries providing a DC power source may be provided in the event that the AC power source 4 fails.
Although the use of AC and DC power supplies for a motor drive system is known, there remains a need for improved algorithms for controlling such systems. In particular there remains a need for novel algorithms for controlling the entry into an emergency mode of operation in the event that the AC power supply fails and the exiting of the emergency mode of operation in the event that the AC power supply is restored.
The present invention seeks to address at least some of the problems outlined above.
SUMMARY
The present invention provides a method of controlling a motor drive, the method comprising a normal operation mode wherein a DC link voltage is charged using an AC supply (typically a mains power supply) and an emergency mode wherein the DC link voltage is charged using a DC supply (for example provided by a battery), wherein: in the normal mode of operation, determining whether the DC link voltage falls below a first threshold (indicative of the AC power supply being lost) and, if so, entering the emergency mode of operation; and in the emergency mode of operation, determining whether the DC link voltage rises above a second threshold (indicative of the AC power supply being restored) and, if so, entering the normal mode of operation. The method further comprises entering a first coast mode before entering the emergency mode of operation from the normal mode of operation and/or entering a second coast mode before entering the normal mode of operation from the emergency mode of operation.
The present invention also provides a control module configured to determine a DC link voltage of a motor drive, wherein: in a normal mode of operation, the control module determines whether the DC link voltage falls below a first threshold and, if so, enters an emergency mode of operation, wherein in the emergency mode, the DC link voltage is charged using a DC supply; and in the emergency mode of operation, the control module determines whether the DC link voltage rises above a second threshold and, if so, enters the normal mode of operation, wherein in the normal mode the DC link voltage is charged using an AC power supply, wherein the control module is further configured to enter a first coast mode before entering the emergency mode of operation from the normal mode of operation and/or to enter a second coast mode before entering the normal mode of operation from the emergency mode of operation.
Thus, in the normal mode of operation, if the DC link voltage falls below a threshold indicative of the AC power supply being lost, the emergency mode is entered (often following an intervening coast mode). Similarly, in the emergency mode, if the DC link voltage rises above a threshold indicative of the AC power supply being restored, the normal mode is entered (often following an intervening coast mode). In the coast mode(s), the motor is not driven and so power is not drained from the DC link capacitor 28 .
In some forms of the invention, the first coast mode is entered for a first period of time (such as 10 ms). Thus, the emergency mode may be entered after a coast period of, for example, 10 ms. Other time periods for the first coast mode are possible, such as 1 ms, 1 second or 10 seconds. The coast period that is appropriate might be dependent on the power level of the motor being used; for example, higher power motors might require longer coast periods. In some embodiments (e.g. when low power motors are being used), the period of the first coast mode may be reduced to zero. The first coast mode may be a user configurable parameter.
Alternatively, or in addition, the first coast mode may be exited when the DC link voltage falls below a third threshold voltage. Thus, in some forms of the invention, the first coast period is a minimum of the first period of time, but may be longer if the DC link voltage has not fallen below the third threshold voltage after that period of time. Alternatively, there may be no minimum first coast period, such that the first coast mode lasts only until the DC link voltage falls below the third threshold voltage.
In some forms of the invention, the second coast mode is entered for a second period of time (such as 10 ms). Thus, the normal mode may be entered after a coast period of, for example, 10 ms. Other time periods for the second coast mode are possible, such as 1 ms, 1 second or 10 seconds. The coast period that is appropriate might be dependent on the power level of the motor being used; for example, higher power motors might require longer coast periods. In some embodiments (e.g. when low power motors are being used), the period of the second coast mode may be reduced to zero. The second coast mode may be a user configurable parameter.
Alternatively, or in addition, the second coast mode may be exited when the DC link voltage rises above a fourth threshold voltage. Thus, in some forms of the invention, the second coast period is a minimum of the second period of time, but may be longer if the DC link voltage has not risen above the fourth threshold voltage after that period of time. Alternatively, there may be no minimum second coast period, such that the second coast mode lasts only until the DC link voltage rises above the fourth threshold voltage.
The emergency mode may include limiting the output power and/or the motor speed and/or motor current. This may be achieved, for example, by limiting one or more of motor speed, motor torque and output current in the emergency mode (for example, under the control of a control module). By way of example, the output current may be limited to 55% of the normal output current and/or the motor speed may be limited to 45 Hz. Further, the amount by which said one or more of motor speed, motor torque and output current is/are limited in the emergency mode may be variable (for example, under the control of a control module).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in further detail with reference to the following schematic drawings, in which:
FIG. 1 shows a known inverter drive system;
FIG. 2 shows an inverter drive system in accordance with an embodiment of the present invention;
FIG. 3 is a flow chart showing an algorithm in accordance with an aspect of the present invention;
FIG. 4 shows the DC link voltage and the input current to the drive in an exemplary use of a circuit in accordance with an aspect of the present invention;
FIG. 5 shows the DC link voltage and the input current to the drive in another exemplary use of a circuit in accordance with an aspect of the present invention;
FIG. 6 shows speed and torque curves on entry into an emergency mode in an embodiment of the present invention; and
FIG. 7 shows speed and torque curves on exiting an emergency mode in an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 2 shows an inverter drive system, indicated generally by the reference numeral 20 , in accordance with an embodiment of the present invention. The system 20 comprises an AC mains supply 21 , a DC voltage supply 22 , a filter 24 , a rectifier 26 , a DC link capacitor 28 , an inverter 30 and a motor 32 . The AC mains supply 21 may, for example, provide a voltage of 400V (as suggested in FIG. 2 ), but the principles of the present invention apply regardless of the absolute values being used.
In the normal use of the system, the DC link capacitor is charged by the AC mains supply 21 that is rectified by the rectifier 26 . In the event that the AC mains supply 21 fails, the DC link capacitor 28 is charged by the DC voltage supply 22 .
As described in detail below, a controller (not shown in FIG. 2 ) is used to control the inverter 30 appropriately, depending on whether the DC link capacitor 28 is being charged by the AC mains supply 21 or the DC voltage supply 22 . When the AC mains supply 21 is available, the inverter (and hence the motor 32 ) is operated in a normal mode. When the AC mains supply 21 is not available (such that the DC voltage supply is used), the inverter (and motor) are operated in an emergency mode. In the emergency mode, the motor frequency (and hence the motor speed) is limited. For example, the motor speed may be limited to 45 Hz. The output power is also limited (for example by limiting the output current to 55% of the normal output current). Of course, 45 Hz and 55% of normal output current are provided by way of example only. These values may also be variable; for example, the values may be calculated by a controller depending on the available DC power.
FIG. 3 is a flow chart showing an algorithm, indicated generally by the reference numeral 40 , in accordance with an aspect of the present invention.
The algorithm 40 starts at step 42 , where the system 20 is in the normal mode of operation. At step 44 , it is determined whether the DC link voltage (i.e. the voltage across the capacitor 28 ) has fallen below a voltage threshold (300V is suggested by way of example). If not, the algorithm 40 returns to step 42 such that the system remains in the normal mode.
If, in step 42 , it is determined that the DC link voltage has dropped below the voltage threshold, this indicates that the AC power supply 21 has been lost, and the algorithm 40 moves to step 46 , where the motor is allowed to coast (step 46 ) for a short period of time (10 ms in one embodiment of the invention, but other durations could be used).
After the coasting period, the algorithm moves to step 48 where it is determined whether the DC link voltage has dropped below another voltage threshold (250V is suggested by way of example in FIG. 3 ). If so, the algorithm 40 moves to step 50 : if not, the algorithm returns to step 46 such that the motor coasts until the DC link voltage drops below the relevant voltage threshold.
At step 50 , the system 20 enters the emergency mode. In the emergency mode, the DC link capacitor 28 is charged by the DC supply 22 . As described in detail below, the DC link voltage is lower in the emergency mode than in the normal mode and this has implications for the motor speed and torque that are available.
At step 52 , it is determined whether the DC link voltage has risen above a voltage threshold (350V is suggested by way of example in FIG. 3 ). If not, the algorithm returns to step 50 (such that the system 20 remains in the emergency mode). If so, this indicates that the AC power supply is operational and is charging the DC link voltage. In response, the algorithm 40 moves to step 54 where the motor is allowed to coast for a short period (such as 10 ms) before it is determined (at step 56 ) whether the DC link voltage has risen above another voltage threshold (480V is suggested by way of example in FIG. 3 ). If not, the algorithm 40 returns to the coasting step 54 . If so, the algorithm returns to step 42 where the normal mode is entered once again.
Thus, the determination of whether the system 20 should operate in the normal mode or the emergency mode depends on the DC link voltage. The DC link voltage is readily detected by a standard motor drive controller (such as the controller 10 shown in the prior art system 1 described above).
Although the algorithm 40 suggests that the modes are changed whenever the DC link voltage rises above or falls below the relevant voltage threshold, the algorithm may be adapted to ensure that short-duration voltage sags and dips are disregarded, thereby preventing the mode from changing as a result of normal fluctuations in the relevant power supplies.
As described above, when transitioning between normal and emergency modes of operation, a coast period is inserted. In the coast period, the motor is not driven and so power is not drained from the DC link capacitor 28 . When entering the emergency mode of operation, a coasting period allows the DC link voltage to drop from the level generated when the AC power supply 21 is available to a level generated from the DC power supply 22 . Without this coast period, current spikes are likely to occur during the transition to the emergency mode. On exiting the emergency mode without using a coast period, over-voltage conditions can occur, since in-rush protection may not be activated. Over-current conditions can also occur. By reducing the occurrence of over-current and over-voltage conditions, the provision of coast periods can improve the lifetime of the relevant drive components.
FIG. 4 shows the DC link voltage 61 and the input current 62 to the drive in the system 20 during a period when the system 20 is entering the emergency mode of operation.
Initially (at the time generally indicated by the reference numeral 63 ), the system 20 is operating in the normal mode (and so the algorithm is at step 42 ). In the normal mode, the AC power supply 21 is charging the DC link capacitor 28 .
At time 64 , the AC power supply 21 is lost. The motor 32 continues to be operated in the normal mode such that the inverter 30 draws power from the DC link capacitor 28 . As a result, the DC link voltage drops. When the DC link voltage drops below the relevant threshold (e.g. 300V in the algorithm 40 described above), the system 20 enters a coast mode (step 46 ) such that the motor 32 is no longer being drive by the inverter 30 . At this stage, the DC link voltage is no longer drained by the inverter 30 and the speed of the motor 32 drops.
After the coasting delay (of perhaps 10 ms), the emergency mode is entered. The DC link voltage is now charged by the DC voltage supply 22 and the DC link voltage rises to a new operating level (indicated generally by the reference numeral 65 ), which, as shown in FIG. 4 , is lower than the normal mode DC link voltage.
FIG. 5 shows DC link voltage 71 and the input current 72 to the drive in the system 20 during a period when the system 20 is exiting the emergency mode of operation.
Initially (at the time generally indicated by the reference numeral 73 ), the system 20 is operating in the emergency mode (and so the algorithm is at step 50 ). In the emergency mode, the DC power supply 22 is charging the DC link capacitor 28 .
During a period indicated generally by the reference numeral 74 , the AC power supply 21 is reactivated. This results in the DC link voltage starting to rise (and also results in spikes being seen in the DC link voltage and current).
When the DC link voltage rises above the relevant threshold (e.g. 350V in the algorithm 40 described above), the coasting step 54 is activated. During the coasting step, the DC link capacitor 28 is charged but the motor 32 is not being driven. As indicated generally by the reference numeral 75 , this results in the DC link voltage 75 rising to the required voltage during the normal mode. When the coasting period is complete, the motor is activated once more and the system operates in the normal mode.
In the algorithm 20 described above, on exiting the normal mode, the motor 32 coasts during step 46 and then the DC link voltage is measured in step 48 . It is not necessary to have both of these steps in all embodiments of the invention. For example, once the coasting step 46 has been carried out, the algorithm may move directly to the emergency mode (step 50 ), thereby omitting step 48 . In an alternative embodiment, the coasting mode may simply operate until the DC link voltage drops below the relevant threshold (e.g. 250V) (so that there is no minimum coasting period as defined by the step 46 above).
Similarly, on exiting the emergency mode, it is not necessary in all embodiments of the invention for the motor 32 to coast during step 54 and then for the DC link voltage to be measured in step 56 . For example, once the coasting step 54 has been carried out, the algorithm may move directly to the normal mode (step 42 ), thereby omitting step 56 . In an alternative embodiment, the coasting mode may simply operate until the DC link voltage rises above the relevant threshold (e.g. 480V) (so that there is no minimum coasting period as defined by the step 54 above).
A number of other variants to the algorithm 40 described above could be provided. For example, some or all of the decision points 44 , 48 , 52 and 56 could be implemented using interrupts in a manner well known in the art. Furthermore, at least one of the coasting steps 48 and 54 could be omitted; this might be appropriate, for example, when the algorithm 40 is being used with low power motors.
FIG. 6 shows torque and speed curves (indicated generally by the reference numerals 80 and 81 respectively) on entry into an emergency mode in an embodiment of the present invention.
Initially, the system is in the normal mode (step 42 of the algorithm 40 ). In the normal mode, both the motor speed 82 and the motor torque 86 are high. If a drop in the DC link voltage is detected, the motor enters the coasting state 46 . In the coasting state, the motor 32 is not being driven, so the torque drops to zero (as indicated by the reference numeral 87 ). Due to inertia, the motor continues to spin, but the speed drops (as indicated by the reference numeral 83 ).
Once the emergency mode is entered, the motor 32 is once again driven. At this stage, the motor speed rises (as indicated by the reference numeral 84 ) and a motor torque is applied (as indicated by the reference numeral 88 ). The motor speed continues to rise until it reaches the normal operation speed of the motor 32 in the emergency mode (as indicated by the reference numeral 85 ).
As is clearly shown in FIG. 6 , the motor speed 85 in the emergency mode is lower than the motor speed 82 in the normal mode. This is achieved by limiting the output power of the inverter 30 (for example by limiting the output current or the motor speed) and is provided in order to reduce the load on the DC power supply 22 (which is typically a battery). The torque available from the motor 32 is linked to the motor speed and so the torque 89 in the emergency mode is also lower than the torque 86 in the normal mode.
FIG. 7 shows torque and speed curves (indicated generally by the reference numerals 90 and 91 respectively) on exiting an emergency mode in an embodiment of the present invention.
Initially, the system is in the emergency mode (step 50 of the algorithm 40 ). As explained above, in the emergency mode, both the motor speed 92 and the motor torque 96 are relatively low. If a rise in the DC link voltage is detected, the motor enters the coasting state 52 . In the coasting state, the motor 32 is not being driven, so the torque drops to zero (as indicated by the reference numeral 97 ). Due to inertia, the motor continues to spin, but the speed drops (as indicated by the reference numeral 93 ).
Once the normal mode is entered, the motor 32 is once again driven. At this stage, the motor speed rises (as indicated by the reference numeral 94 ) and a motor torque is applied (as indicated by the reference numeral 98 ). The motor speed continues to rise until it reaches the normal operation speed of the motor in the normal mode (as indicated by the reference numeral 95 ).
As is clearly shown in FIG. 7 , the motor speed 92 in the emergency mode is lower than the motor speed 95 in the normal mode and the torque 96 in the emergency mode is lower than the torque 99 in the normal mode.
The embodiments of the invention described above are provided by way of example only. The skilled person will be aware of many modifications, changes and substitutions that could be made without departing from the scope of the present invention. For example, the particular voltages and times mentioned in the algorithm 40 described above are provided by way of example only. The claims of the present invention are intended to cover all such modifications, changes and substitutions as fall within the spirit and scope of the invention. | A method of controlling a motor drive having a normal mode wherein a DC link voltage is charged using an AC (e.g. mains) power supply and an emergency mode wherein the DC link voltage is charged using a DC supply (e.g. from a battery) is described. In the normal mode of operation, if the DC link voltage falls below a threshold indicative of the AC power supply being lost, the emergency mode is entered, typically following an intervening coast mode (during which the motor is not driven). Similarly, in the emergency mode, if the DC link voltage rises above a threshold indicative of the AC power supply being restored, the normal mode is entered, typically following an intervening coast mode. | 7 |
CLAIM OF PRIORITY
[0001] This application claims priority to an application entitled “Gain-flattened wideband erbium-doped optical fiber amplifier,” filed in the Korean Intellectual Property Office on May 17, 2003 and assigned Serial No. 2003-31402, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an optical fiber amplifier, and more particularly to a wideband erbium-doped optical fiber amplifier for amplifying C-band and L-band optical signals.
[0004] 2. Description of the Related Art
[0005] An optical fiber amplifier is an apparatus used in an optical transmission system to amplify optical signals without optoelectric conversion. Accordingly, the optical fiber amplifier has a simple and economic construction. Such an optical fiber amplifier includes (1) a gain medium optical fiber, (2) a pumping light source necessary in optical pumping, (3) a wavelength division multiplexing (WDM) optical coupler for coupling an optical signal and pumping light to the gain medium optical fiber, and (4) an optical isolator for passing forward light and intercepting backward light.
[0006] The optical signal is amplified through an induced discharge of rare-earth elements, such as erbium, added to the gain medium optical fiber. Specifically, the pumping light excites the rare-earth element ions added to the gain medium optical fiber. Thereafter, the optical signal incident to the gain medium optical fiber is amplified through the induced discharge of the excited ions. In current ultrahigh speed WDM optical transmission systems, a wavelength band of 1.55 μm is widely used along with erbium-doped optical fiber amplifiers suitable for amplifying such a wavelength band. WDM optical technology is capable of simultaneously transmitting a plurality of channels with different wavelengths using a single-core optical fiber. WDM optical technology, researches are actively seeking wider transmission bands, for example by using optical signals not only the C-band, having a wavelength band of 1525 to 1565 nm, but also the L-band, having a wavelength band of 1570 to 1610 nm. In particular, researchers are seeking a wideband erbium-doped optical fiber amplifier (which is one of core elements of a WDM optical communication system) that can amplify not only C-band optical signals but also L-band optical signals.
[0007] A typical C-band erbium-doped optical fiber amplifier utilizes a population inversion of 70 to 100%. This produces non-uniform gain characteristics (according to wavelengths) for the C-band erbium-doped optical fiber amplifier. Usually, the C-band erbium-doped optical fiber amplifier has the highest gain at a wavelength of 1530 nm and has the lowest gain at a wavelength of 1560 nm. Various gain-flattening methods are used, since the C-band erbium-doped optical fiber amplifier has non-uniform gain characteristics. Conventional gain-flattening methods include a method employing an optical filter, a method employing a Fabry-Perot filter, a method employing a Mach-Zender interferometer, a method employing a dielectric thin film, and a method employing an optical Fiber Bragg Grating (FBG), etc. In such gain flattening methods, a filter designed to have a loss spectrum that is opposite to the gain spectrum of the C-band erbium-doped optical fiber amplifier is used, thereby obtaining a uniform gain regardless of wavelengths. Among the various gain flattening methods described above, the method employing an optical Fiber Bragg Grating is generally utilized.
[0008] An optical fiber grating is an optical fiber element having optical fiber cores each of which has a periodically changing refractivity. They either reflect or eliminate optical signals (channels) of specific wavelengths from multi-wavelength optical signals incidented to the optical fiber grating. Optical fiber gratings may be classified into long period (reflection type) and short period (elimination type) optical fiber gratings. In the short period optical fiber grating, optical fiber cores have a refractivity changing in a period of several hundreds nanometers (which is generally called “grating period”). Optical fiber mode coupling occurs between a forward mode and a backward mode, thereby reflecting only a channel of a specific wavelength from an incidented multi-wavelength optical signal. In contrast, in the long period optical fiber grating, a grating period is several hundreds micrometers. Optical fiber mode coupling occurs between two forward modes, thereby eliminating only a channel of a specific wavelength from an incidented multi-wavelength optical signal. A transmission (reflection) spectrum of an optical fiber grating can be properly adjusted according to the grating period, grating intensity, grating length, and refractivity distribution.
[0009] In one method of employing a long period optical fiber grating for flattening the gain of the C-band erbium-doped optical fiber amplifier, the long period optical fiber grating is first designed to have a transmission spectrum opposite to the gain spectrum of the C-band erbium-doped optical fiber amplifier. Then it is inserted into the C-band erbium-doped optical fiber amplifier, thereby enabling the gain to be uniform regardless of the wavelengths. This method does not require a separate additional optical element since there is no reflected optical signal. However, this method has a number of shortcomings including having a spectrum characteristic that is very sensitive to temperature. In order to overcome such temperature sensitivity, another method employing a chirped optical fiber grating (or Chirped Fiber Bragg Grating; CFBG) has been proposed. This method has a short period optical fiber gratings. The CFBG has a grating with a grating period that changes linearly or non-linearly in a longitudinal direction of the grating. In this method, the CFBG is designed with a reflection spectrum opposite to the gain spectrum of the C-band erbium-doped optical fiber amplifier. Then, it is inserted into the erbium-doped optical fiber amplifier, thereby enabling the gain to be uniform. However, this method requires an additional optical element such as an optical isolator in order to prevent an optical signal reflected by the CFBG from coupling and interfering with a forward optical.
[0010] When compared to a C-band erbium-doped optical fiber amplifier, an L-band erbium-doped optical fiber amplifier shows no difference in the pumping light source.
[0011] However, it is about five to ten times longer, since the L-band erbium-doped optical fiber amplifier utilizes population inversion of about 40%. Further, an article entitled “Flat gain erbium-doped fiber amplifier in 1570 nm-1600 nm region for dense WDM transmission systems”, OFC '97, vol. PD3, 1997, by M. Fukushima, Y Tashiro, and H. Ogoshi, has shown that the gain flattening characteristic of an L-band erbium-doped optical fiber amplifier is improved through co-pumping by auxiliary pumping light source of the C-band (1530, 1550, or 1570 nm) wavelength together with an existing high power LD light source of 980 or 1480 nm However, such a method requires a separate exterior light source as an auxiliary pumping light source.
[0012] [0012]FIG. 1 illustrates a conventional wide band erbium-doped optical fiber amplifier. The conventional erbium-doped optical fiber amplifier 100 is disposed on an external optical fiber 110 and includes a first and a second amplifying section 170 and 180 and a first and a fifth WDM coupler 121 and 125 for connecting the first and second amplifying section 170 and 180 in parallel to each other.
[0013] The first WDM coupler 121 divides an optical signal of 1550 and 1580 nm wavelength bands received through the external optical fiber 110 into optical signals of a 1550 nm wavelength band (C-band) and a 1580 nm wavelength band (L-band). Then it outputs the C-band optical signal to a first optical path and the L-band optical signal to a second optical path.
[0014] The first amplifying section 170 includes a first and a second isolator 131 and 132 , a first pump LD 141 , a second WDM coupler 122 , a first erbium-doped optical fiber 151 , and a chirped optical fiber grating 160 . Each of the first isolator 131 and the second isolator 132 intercepts backward light such as Amplified Spontaneous Emission (ASE) noise outputted from the first erbium-doped optical fiber 151 . The first pump LD 141 outputs a first pumping light having a wavelength of 980 nm or 1480 nm. The second WDM coupler 122 is interposed between the first isolator 131 and the second isolator 132 . It couples the C-band optical signal having passed the first isolator 131 with the first pumping light inputted from the first pump LD 141 . Then, it outputs the coupled light. The first erbium-doped optical fiber 151 experiences a population inversion (is pumped) by the first pumping light that has passed the second isolator 132 . It also amplifies the C-band optical signal that has passed the second isolator 132 . The chirped optical fiber grating 160 gain-flattens the C-band optical signal received from the first erbium-doped optical fiber 151 .
[0015] The second amplifying section 180 includes a third isolator 133 , a second and a third pump LD 142 and 143 , a third and a fourth WDM coupler 123 and 124 , and a second erbium-doped optical fiber 152 . The second pump LD 142 intercepts backward light such as ASE noise outputted from the second erbium-doped optical fiber 152 . The second pump LD 142 outputs a second pumping light having a wavelength of 980 nm or 1480 nm. The third WDM coupler 123 couples the L -band optical signal that has passed the third isolator 133 with the second pumping light received from the second pump LD 142 . Then it outputs the coupled light. The third pump LD 143 outputs a third pumping light having a wavelength of 1550, 1530 or 1570 nm. The fourth WDM coupler 124 couples the L-band optical signal inputted from the third WDM coupler 123 with the second and third pumping lights. Then it outputs the coupled light. The second erbium-doped optical fiber 152 experiences a population inversion by the second and third pumping lights received from the fourth WDM coupler 124 . It also amplifies the L-band optical signal received from the fourth WDM coupler 124 .
[0016] The fifth WDM coupler 125 couples the C-band and L-band optical signals received through the first and second optical paths. Then it outputs them through the external optical fiber 110 .
[0017] The first erbium-doped optical fiber 151 and the second erbium-doped optical fiber 152 have similar construction. The second erbium-doped optical fiber 152 has a length larger than that of the first erbium-doped optical fiber 151 . Further, each of the first and second erbium-doped optical fibers 151 and 152 has a forward pumping construction in which the received optical signal and the pumping light progress in the same direction. However, each of them may have a backward pumping construction in which the inputted optical signal and the pumping light progress in opposite directions, if necessary.
[0018] As described above, the conventional wideband erbium-doped optical fiber amplifier 100 has gain flattening characteristics of not only the C-band but also the L-band optical signal. However, the conventional wideband erbium-doped optical fiber amplifier 100 has a number of limitations, including (1) that the first amplifying section 170 must include the second isolator 132 which is an additional element for preventing generation of backward ASE noise and (2) the second amplifying section 180 requires the second pump LD 142 as a separate and auxiliary pumping light source.
SUMMARY OF THE INVENTION
[0019] Accordingly, the present invention has been made to reduce or overcome the above-mentioned problems occurring in the prior art. One object of the present invention is to provide a gain-flattened wideband erbium-doped optical fiber amplifier which does not require a separate pumping light source. Consequently, enabling a simpler and lower-cost optical fiber amplifier.
[0020] In accordance with the principles of the present invention, a wideband erbium-doped optical fiber amplifier is disposed among an optical fiber through which a first and second wavelength-band optical signals (for example, the C-band and L-band) are transmitted and forms a first optical path and a second optical path parallel to each other is provided, the amplifier including a first amplifying section disposed on the first optical path, including a first erbium-doped optical fiber to amplify the first-band optical signals, a filter to gain-flatten the amplified first-band optical signals, wherein a reflected portion of the first band optical signal by the filter is directed to the second optical path; and a second amplifying section disposed on the second optical path, having a second erbium-doped optical fiber to amplify received second-band optical signals, wherein the reflected first-band optical signal is used to pump the second erbium-doped optical fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0022] [0022]FIG. 1 illustrates a conventional wideband erbium-doped optical fiber amplifier;
[0023] [0023]FIG. 2 illustrates a gain-flattened wideband erbium-doped optical fiber amplifier according to a first embodiment of the present invention;
[0024] FIGS. 3 to 7 are graphs for describing the output characteristics of the erbium-doped optical fiber amplifier shown in FIG. 2; and
[0025] [0025]FIG. 8 illustrates a gain-flattened wideband erbium-doped optical fiber amplifier according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. For the purposes of clarity and simplicity, well-known functions or constructions are not described in detail as they would obscure the invention in unnecessary detail.
[0027] [0027]FIG. 2 illustrates a gain-flattened wideband erbium-doped optical fiber amplifier according to a first embodiment of the present invention. The wideband erbium-doped optical fiber amplifier 200 is disposed on an external optical fiber 210 . It includes a first and a second amplifying section 280 and 290 , and a first and a fifth WDM coupler 221 and 225 for connecting the first and the second amplifying section 280 and 290 in parallel to each other.
[0028] The first WDM coupler 221 divides an optical signal of 1550 and 1580 nm wavelength bands received through the external optical fiber 210 into optical signals of a first wavelength band (for example 1550 nm, the C-band) and a second wavelength band (for example 1580 nm, the L-band). It then outputs the first or C-band optical signal to a first optical path and the second or L-band optical signal to a second optical path.
[0029] The first amplifying section 280 includes a first isolator 231 , a first pump LD 241 , a second WDM coupler 222 , a first erbium-doped optical fiber 251 , a circulator 260 , and a filter 270 .
[0030] The first isolator 231 intercepts backward light such as ASE noise outputted from the first erbium-doped optical fiber 251 .
[0031] The first pump LD 241 outputs a first pumping light having a wavelength of 980 nm or 1480 nm. A laser diode (LD) or a light emitting diode (LED) may be employed as the first pump LD 241 .
[0032] The second WDM coupler 222 couples the C-band optical signal that has passed the first isolator 231 with the first pumping light received from the first pump LD 241 . It then outputs the coupled light.
[0033] The first erbium-doped optical fiber 251 experiences a population inversion (is pumped) by the first pumping light received from the second WDM coupler 222 . It also amplifies the C-band optical signal received from the second WDM coupler 222 .
[0034] The circulator 260 has three ports, a first port through a third port. The circulator 260 receives light through an upper port and outputs the received light through adjacent lower ports. Specifically, the first port of the circulator 260 is connected with the first erbium-doped optical fiber 251 . The second port of the circulator 260 is connected with the filter 270 . The third port of the circulator 260 is connected with the second amplifying section 290 . In the circulator 260 , the C-band optical signal received through the first port is outputted through the second port. The filtered C-band optical signal received through the second port is outputted through the third port.
[0035] The filter 270 is designed to have a transmission spectrum characteristic opposite to the gain spectrum characteristic of the first erbium-doped optical fiber 251 . In the gain spectrum, a non-uniform portion (i.e. the filtered C-band optical signal) is reflected by the filter 270 . The reflected C-band optical signal is inputted to the second port of the circulator 260 as a second pumping light.
[0036] The second amplifying section 290 includes a second isolator 232 , a second pump LD 242 , a third and a fourth WDM coupler 223 and 224 , and a second erbium-doped optical fiber 252 .
[0037] The second isolator 232 intercepts backward light such as ASE noise outputted from the second erbium-doped optical fiber 252 .
[0038] The third WDM coupler 223 couples the L-band optical signal that has passed the second isolator 232 with the second pumping light received from the circulator 260 . It then outputs the coupled light.
[0039] The second pump LD 242 outputs a third pumping light having a wavelength of 1550, 1530 or 1570 nm. An LD or LED may be employed as the second pump LD 242 .
[0040] The fourth WDM coupler 224 couples the L-band optical signal received from the third WDM coupler 223 with the second and third pumping lights. It then outputs the coupled light. The second erbium-doped optical fiber 252 experiences a population inversion (is pumped) by the second and third pumping lights received from the fourth WDM coupler 224 . It also amplifies the L-band optical signal received from the fourth WDM coupler 224 .
[0041] The fifth WDM coupler 225 couples the C-band and L-band optical signals received from the first and second optical paths with each other. It then outputs them through the external optical fiber 210 .
[0042] Although each of the first and second erbium-doped optical fibers 251 and 252 has a forward pumping construction in the present embodiment, they may have either a forward pumping construction or a backward pumping construction. In the erbium-doped optical fiber amplifier 200 , the gain of the first amplifying section 280 is first flattened using the filter 270 . Thereafter, the C-band optical signal reflected by the filter is supplied to the second erbium-doped optical fiber 252 as an auxiliary second pumping light. Consequently, the erbium-doped optical fiber amplifier 200 of the present invention has a simpler construction, as well as enabling a competitive price.
[0043] FIGS. 3 to 7 are graphs for describing output characteristics of the erbium-doped optical fiber amplifier 200 shown in FIG. 2. FIG. 3 shows a gain spectrum of the first erbium-doped optical fiber 251 which has a maximum gain value in a short wavelength region of the spectrum. FIG. 4 shows a transmission spectrum of the filter 270 which has a minimum gain value in a short wavelength region of the spectrum. FIG. 5 shows a gain spectrum of the first amplifying section 280 that is gain-flattened by the filter 270 . FIG. 6 shows a gain spectrum of the second amplifying section 290 that is gain-flattened by employing the C-band optical signal reflected by the filter 270 as the auxiliary second pumping light. FIG. 7 shows a gain spectrum of the erbium-doped optical fiber amplifier 200 in which both the C-band optical signal and the L-band optical signal are gain-flattened by the filter 270 .
[0044] [0044]FIG. 8 illustrates a gain-flattened wideband erbium-doped optical fiber amplifier according to a second embodiment of the present invention. The wideband erbium-doped optical fiber amplifier 300 is disposed on an external optical fiber 310 . It includes a first and a second amplifying section 380 and 390 and a first and a fifth WDM coupler 321 and 325 for connecting the first and the second amplifying section 380 and 390 in parallel to each other. The erbium-doped optical fiber amplifier 300 has a construction similar to that of the erbium-doped optical fiber amplifier 200 shown in FIG. 2, except for the pumping structure of the second amplifying section 390 .
[0045] The first WDM coupler 321 divides an optical signal of 1550 and 1580 nm wavelength bands received from the external optical fiber 310 into optical signals of a 1550 nm wavelength band (C-band) and a 1580 nm wavelength band (L-band). Then it outputs the C-band optical signal to a first optical path and the L-band optical signal to a second optical path.
[0046] The first amplifying section 380 includes a first isolator 331 , a first pump LD 341 , a second WDM coupler 322 , a first erbium-doped optical fiber 351 , a circulator 360 , and a filter 370 .
[0047] The first isolator 331 intercepts backward light such as ASE noise outputted from the first erbium-doped optical fiber 351 .
[0048] The first pump LD 341 outputs a first pumping light having a wavelength of 980 nm or 1480 nm. An LD or LED may be employed as the first pump LD 341 . The second WDM coupler 322 couples the C-band optical signal that has passed the first isolator 331 with the first pumping light received from the first pump LD 341 . It then outputs the coupled light.
[0049] The first erbium-doped optical fiber 351 experiences a population inversion by the first pumping light received from the second WDM coupler 322 . It also amplifies the C-band optical signal received from the second WDM coupler 322 .
[0050] The circulator 360 has three ports, a first port through a third port. The circulator 360 receives light through an upper port and outputs the received light through adjacent lower ports. Specifically, the first port of the circulator 360 is connected with the first erbium-doped optical fiber 351 . The second port of the circulator 360 is connected with the filter 370 . The third port of the circulator 360 is connected with the second amplifying section 390 . In the circulator 360 , the C-band optical signal received from the first port is outputted through the second port. The filtered C-band optical signal received from the second port is outputted through the third port.
[0051] The filter 370 is designed to have a transmission spectrum characteristic opposite to the gain spectrum characteristic of the first erbium-doped optical fiber 351 . In the gain spectrum, a non-uniform portion (i.e. the filtered C-band optical signal) is reflected by the filter 370 . The reflected C-band optical signal is inputted to the second port of the circulator 360 as a second pumping light.
[0052] The second amplifying section 390 includes a second isolator 332 , a second pump LD 342 , a third and a fourth WDM coupler 323 and 324 , and a second erbium-doped optical fiber 352 .
[0053] The second isolator 332 intercepts backward light such as ASE noise outputted from the second erbium-doped optical fiber 352 .
[0054] The second pump LD 342 outputs a third pumping light having a wavelength of 1550, 1530 or 1570 nm. An LD or LED may be employed as the second pump LD 342 .
[0055] The fourth WDM coupler 324 couples the L-band optical signal that has passed the second isolator 332 with the third pumping light. It then outputs the coupled light.
[0056] The third WDM coupler 323 outputs the second pumping light received from the circulator 360 to the second erbium-doped optical fiber 352 . It also allows the L-band optical signal received from the second erbium-doped optical fiber 352 to pass intact through the third WDM coupler 323 .
[0057] The second erbium-doped optical fiber 352 experiences a population inversion by the third pumping light received from the fourth WDM coupler 324 and the second pumping light received from the third WDM coupler 323 . It also amplifies the L-band optical signal received from the fourth WDM coupler 324 . In this manner, the second erbium-doped optical fiber 352 is pumped forward by the third pumping light and backward by second pumping light.
[0058] The fifth WDM coupler 325 couples the C-band and L-band optical signals received from the first and second optical paths. It then outputs them through the external optical fiber 310 .
[0059] While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | A wideband erbium-doped optical fiber amplifier is disposed among an optical fiber through which a first and second band-band optical signals (for example, the C-band and L-band) are transmitted and forms a first optical path and a second optical path parallel to each other. The wideband erbium-doped optical fiber amplifier comprising a first amplifying section disposed on the first optical path, including a first erbium-doped optical fiber to amplify the first-band optical signals, a filter to gain-flatten the amplified first-band optical signals, wherein a reflected portion of the first band optical signal by the filter is directed to the second optical path; and a second amplifying section disposed on the second optical path, having a second erbium-doped optical fiber to amplify received second-band optical signals, wherein the reflected first-band optical signal is used to pump the second erbium-doped optical fiber. | 7 |
RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 11/385,984, filed Mar. 20, 2006, entitled “METHOD AND APPARATUS FOR AUTOMATIC POWER-UP AND POWER-DOWN OF A COMPUTER SYSTEM BASED ON THE POSITIONS OF AN ASSOCIATED STYLUS AND/OR HINGE,” naming Regis Nicolas and Neal Osborn as inventors, assigned to the assignee of the present invention, which is a continuation of U.S. patent application Ser. No. 11/125,543, filed May 9, 2005, now U.S. Pat. No. 7,046,237, entitled “METHOD AND APPARATUS FOR AUTOMATIC POWER-UP AND POWER-DOWN OF A COMPUTER SYSTEM BASED ON THE POSITIONS OF AN ASSOCIATED STYLUS AND/OR HINGE,” naming Regis Nicolas and Neal Osborn as inventors, assigned to the assignee of the present invention, which is a continuation of U.S. patent application Ser. No. 09/522,274, filed Mar. 9, 2000, now U.S. Pat. No. 6,924,791, entitled “METHOD AND APPARATUS FOR AUTOMATIC POWER-UP AND POWER-DOWN OF A COMPUTER SYSTEM BASED ON THE POSITIONS OF AN ASSOCIATED STYLUS AND/OR HINGE,” naming Regis Nicolas and Neal Osborn as inventors, assigned to the assignee of the present invention. These applications are incorporated herein by reference in their entirety and for all purposes.
BACKGROUND OF THE INVENTION
As the components required to build a computer system have reduced in size, new categories of computer systems have emerged. One of the new categories of computer systems is the “palmtop” computer system. A palmtop computer system is a computer that is small enough to be held in the hand of a user and can therefore be “palm-sized.” Most palmtop computer systems are used to implement various Personal Information Management (PIM) applications such as an address book, a daily organizer and electronic notepads, to name a few. Palmtop computers with PIM software have been know as Personal Digital Assistants (PDAs).
Data entry on a palmtop computer has been a challenge. Since palmtop computer systems are very small, full-sized keyboards are generally not efficient input devices. Palmtop computers using keyboards have keyboard devices that are so small that a user cannot touch-type. Furthermore, to use a keyboard device, a user must either place the palmtop computer system down onto a flat surface, so the user can type with both hands, or the user holds the palmtop computer system with two hands and types with thumbs only.
Instead of a mechanical keyboard device, some palmtop computers utilize a touch screen and display an image of a small keyboard thereon. When a particular button is pressed or tapped, a small keyboard image is displayed on the display screen. The user then interacts with the on-screen small keyboard image to enter characters, usually one character at a time. To interact with the displayed keyboard image (e.g., “virtual keyboard”), the user taps the screen location of a character with a pen or stylus. That corresponding character is then recognized and added to a data entry field, also displayed on the screen. However, for experienced users, the virtual keyboard input system can be a tedious input process.
Instead of using a mechanical keyboard device or a displayed keyboard, many palmtop computers employ a pen and a digitizer pad as an input system. The pen and digitizer pad combination works well for palmtop computers because the arrangement allows a user to hold the palmtop computer system in one hand while writing with the pen onto the digitizer pad with the other hand.
A number of palmtop computer systems that rely on the pen and digitizer pad combination as the primary means of input have been introduced to the market. Most of these pen-based palmtop computer systems provide some type of handwriting recognition system whereby the user can write words and letters on the digitizer pad with a stylus. The palmtop computer system then converts the user's handwriting into a machine readable format such as ASCII code characters. Examples of pen-based palmtop computer systems that provide handwriting recognition include the Apple Newton (trademark) device and the Tandy Zoomer (trademark) device.
Digitizers have eliminated the need for a mechanical keyboard device. Therefore, palmtop computer systems are readily portable and can easily be carried on or near the user, e.g., in a pocket, purse or briefcase. Since they can be carried by a user, the user has many opportunities to use the palmtop computer during the day. Since the palmtop computer is typically battery operated, it is recommended to turn off the computer at the completion of each separate use. As such, each time the palmtop is used, an on/off button is typically pressed to turn on power to the computer system, including the display device. Therefore, each time the palmtop computer is to be used, the on/off button is pressed and after use the on/off button is pressed again to turn off the palmtop computer. The more times the computer is used, the more times the on/off button needs to be pressed to gain access to the palmtop computer. If the palmtop computer is being used merely to access (or amend or transmit) a small bit of information and then turned off, the process of pressing the on/off button twice can be a substantial amount of the user's task just to obtain or amend the desired information thereby rendering tedious the use of the computer.
Users always want easier ways and mechanisms to access information on the palmtop computer. Any improvement that reduces the user's repetitive tasks in obtaining information and making use of a palmtop computer system is open to wide consumer acceptance. Therefore, it would be advantageous to make easier and less tedious the user's tasks in accessing information from a palmtop computer system.
SUMMARY OF THE INVENTION
Accordingly, what is needed is an improvement that reduces the number of repetitive tasks required of a user in order to obtain information and make use of a palmtop computer system. What is needed is a method and system that reduces the repetitive tasks required in turning on and turning off the palmtop computer system. The present invention provides these advantages and others not specifically mentioned above but described in the sections to follow.
A method and system are described for automatic power-up and automatic power-down of a computer system based on the position and/or rotation of an associated stylus and/or hinge. In one embodiment, the computer system is a portable computer having a logic board, a display screen, a digitizer and a receiving slot for an associated stylus. The stylus is used with the digitizer in well known character recognition modes. When the stylus is removed from the receiving slot, a switch automatically turns full power onto the computer system thereby allowing a user full use of the computer without requiring an on/off button to be pressed. When the stylus is inserted back into the receiving slot, the switch automatically returns the computer to a power reduction mode where one or all of the components of the computer are powered down. Again, the power reduction mode is entered without requiring the user to press the on/off button. The switch can be made of a single detector or a dual detector combination and can be of a mechanical, electro-magnetic, optical, inductive, capacitive or electrical nature. The switch and detector can also be implemented using a microswitch device. By using the position of the stylus to automatically perform power on and off functions, the repetitive tasks required to access information from the palmtop are reduced.
In another embodiment, the stylus-based automatic power-up and power-down features work in concert with other power-up and power-down mechanisms of the computer, such power-on interrupts, the on/off button, and time-out power off modes. In another embodiment, the stylus is a hinge attached to a cover that can be rotated to protect the palmtop computer (like a book cover) or rotated away to use the palmtop computer (like opening a book). When rotated to cover, the switch automatically powers down the computer. When rotated out for computer use, the switch automatically powers up the computer. By using the position of the hinge to automatically perform power up and down functions, the repetitive tasks required to access information from the palmtop are reduced.
More specifically, an embodiment of the present invention includes a computer system comprising: a processor coupled to bus; a memory unit coupled to the bus; a display screen coupled to the bus; a digitizer coupled to the bus; a case for supporting the processor, the memory unit, the display screen and the digitizer, the case having a slot located therein for receiving a stylus; a detector for detecting a stylus within said slot; and a switch coupled to the detector and for generating a signal to power up the processor, the display screen and the digitizer when the stylus is removed from the slot and wherein the switch is also for generating a signal to place the processor, the display screen and the digitizer into a power conservation mode when the stylus is inserted into the slot. Embodiments include a power on and power off method implemented in accordance with the above.
Embodiments also include a computer system comprising: a processor coupled to bus; a memory unit coupled to the bus; a display screen coupled to the bus; a digitizer coupled to the bus; a case for supporting the processor, the memory unit, the display screen and the digitizer, the case having a slot located therein for receiving a hinge attached to a protective cover; a detector for detecting the rotational positions of the hinge within the slot; a switch coupled to said detector and for generating a signal to automatically power up the processor, the display screen and the digitizer when the hinge is rotated such that the cover is not laid over the display screen and wherein the switch is also for generating a signal to automatically place the processor, the display screen and the digitizer into a power conservation mode when the hinge is rotated such that the cover is laid over the display screen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is system illustration of a palmtop or “palm sized” computer system connected to other computer systems and the Internet via a cradle device.
FIG. 2A is a top side perspective view of a palmtop computer system that can be used as a platform for the automatic power-up and power-down embodiments of the present invention.
FIG. 2B is a bottom side perspective view of the palmtop computer system of FIG. 2A .
FIG. 3 is an exploded view of the components of the palmtop computer system of FIG. 2A .
FIG. 4 is a perspective view of the cradle device for connecting the palmtop computer system to other systems via a communication interface.
FIG. 5 is a logical block diagram of the palmtop computer system in accordance with an embodiment of the present invention.
FIG. 6 is a front view of a palm top computer system illustrating the display screen, digitizer regions and an exemplary menu of a text display application.
FIG. 7 is a cross section of a stylus receiving slot incorporated within the casing of the portable computer system of an embodiment of the present invention and having a single proximity detector element.
FIG. 8 is a cross section of a stylus receiving slot incorporated within the casing of the portable computer system of an embodiment of the present invention and having a pair of proximity detector elements.
FIG. 9A and FIG. 9B are steps performed by an embodiment of the present invention for automatically powering-up and automatically powering-down a computer system based on the position of a stylus.
FIG. 10 illustrates a three dimensional view of a stylus receiving slot and a stylus for use in the hinge embodiment of the present invention.
FIG. 11 illustrates a perspective view of the portable computer system with the hinge embodiment of the present invention.
FIG. 12A and FIG. 12B are steps performed by an embodiment of the present invention for automatically powering-up and automatically powering-down a computer system based on the rotation of a hinge.
FIG. 13 illustrates a casing used in one embodiment of the present invention having a slot (or rail) for receiving a stylus or a cover hinge.
FIG. 14 illustrates the slot (or rail) for receiving a stylus or a cover hinge and also illustrates a detector element in the slot.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, a method and system for automatically powering-up and automatically powering-down a computer system based on the position and/or rotation of an associated stylus, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one skilled in the art that the present invention may be practiced without these specific details or with equivalents thereof. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
Some portions of the detailed descriptions which follow are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, computer executed step, logic block, process, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing terms such as “accessing” “processing” or “computing” or “translating” or “calculating” or “determining” or “scrolling” or “displaying” or “recognizing” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Exemplary Palmtop Computer System Platform
FIG. 1 illustrates a system 50 that can be used in conjunction with the automatic power on and power off features of the present invention. System 50 comprises a host computer system 56 which can either be a desktop unit as shown, or, alternatively, can be a laptop system 58 . Optionally, one or more host computer systems can be used within system 50 . Host computer systems 58 and 56 are shown connected to a communication bus 54 , which in one embodiment can be a serial communication bus, but could be of any of a number of well known designs, e.g., a parallel bus, Ethernet Local Area Network (LAN), etc. Optionally, bus 54 can provide communication with the Internet 52 using a number of well known protocols.
Importantly, bus 54 is also coupled to a cradle 60 for receiving and initiating communication with a palm top (“palm-sized”) portable computer system 100 of the present invention. Cradle 60 provides an electrical and mechanical communication interface between bus 54 (and anything coupled to bus 54 ) and the computer system 100 for two way communications. Computer system 100 also contains a wireless infrared communication mechanism 64 for sending and receiving information from other devices.
FIG. 2A is a perspective illustration of the top face 100 a of one embodiment of the palmtop computer system of the present invention. The top face 110 a contains a display screen 105 surrounded by a bezel or cover. A removable stylus 80 is also shown. The display screen 105 is a touch screen able to register contact between the screen and the tip of the stylus 80 . The stylus 80 can be of any material to make contact with the screen 105 . As shown in FIG. 2A , the stylus 80 is inserted into a receiving slot or rail 350 . Slot or rail 350 acts to hold the stylus when the computer system 100 a is not in use. As described more fully below, slot or rail 350 also contains switching devices for automatically powering down and automatically power up computer system 100 a based on the position of the stylus 80 . The top face 100 a also contains one or more dedicated and/or programmable buttons 75 for selecting information and causing the computer system to implement functions. The on/off button 95 is also shown.
FIG. 2A also illustrates a handwriting recognition pad or “digitizer” containing two regions 106 a and 106 b . Region 106 a is for the drawing of alpha characters therein for automatic recognition (and generally not used for recognizing numeric characters) and region 106 b is for the drawing of numeric characters therein for automatic recognition (and generally not used for recognizing numeric characters). The stylus 80 is used for stroking a character within one of the regions 106 a and 106 b . The stroke information is then fed to an internal processor for automatic character recognition. Once characters are recognized, they are typically displayed on the screen 105 for verification and/or modification.
The digitizer 160 records both the (x, y) coordinate value of the current location of the stylus and also simultaneously records the pressure that the stylus exerts on the face of the digitizer pad. The coordinate values (spatial information) and pressure data are then output on separate channels for sampling by the processor 101 ( FIG. 5 ). In one implementation, there are roughly 256 different discrete levels of pressure that can be detected by the digitizer 106 . Since the digitizer's channels are sampled serially by the processor, the stroke spatial data are sampled “pseudo” simultaneously with the associated pressure data. The sampled data is then stored in a memory by the processor 101 ( FIG. 5 ) for later analysis.
FIG. 2B illustrates the bottom side 100 b of one embodiment of the palmtop computer system of the present invention. An optional extendible antenna 85 is shown and also a battery storage compartment door 90 is shown. A communication interface 108 is also shown. In one embodiment of the present invention, the serial communication interface 108 is a serial communication port, but could also alternatively be of any of a number of well known communication standards and protocols, e.g., parallel, SCSI, Firewire (IEEE 1394), Ethernet, etc. In FIG. 2B is also shown the stylus receiving slot or rail 350 .
FIG. 3 is an exploded view of the palmtop computer system 100 in accordance with one implementation. System 100 contains a front cover 210 having an outline of region 106 and holes 75 a for receiving buttons 75 b . A flat panel display 105 (both liquid crystal display and touch screen) fits into front cover 210 . Any of a number of display technologies can be used, e.g., LCD, FED, plasma, etc., for the flat panel display 105 . The touch screen can be a digitizer. A battery 215 provides electrical power. The digitizer can be implemented using well known devices, for instance, using the ADS-7846 device by Burr-Brown that provides separate channels for spatial stroke information and pressure information. A contrast adjustment (potentiometer) 220 is also shown. On/off button 95 is shown along with an infrared emitter and detector device 64 . A flex circuit 230 is shown along with a PC board 225 containing electronics and logic (e.g., memory, communication bus, processor, etc.) for implementing computer system functionality. The digitizer pad is also included in PC board 225 . A midframe 235 is shown along with stylus 80 . Position adjustable antenna 85 is shown. The midframe 235 contains the stylus receiving slot or rail 350 and also anchors the automatic power on and automatic power off switch devices. The automatic power on and automatic power off switch devices of the present invention are located in region 510 , in one embodiment.
A radio receiver/transmitter device 240 is also shown between the midframe and the rear cover 245 of FIG. 3 . The receiver/transmitter device 240 is coupled to the antenna 85 and also coupled to communicate with the PC board 225 . In one implementation, the Mobitex wireless communication system is used to provide two way communication between system 100 and other networked computers and/or the Internet via a proxy server. In other embodiments, TCP protocol can be used.
FIG. 4 is a perspective illustration of one embodiment of the cradle 60 for receiving the palmtop computer system 100 . Cradle 60 contains a mechanical and electrical interface 260 for interfacing with serial connection 108 ( FIG. 2B ) of computer system 100 when system 100 is slid into the cradle 60 in an upright position. Once inserted, button 270 can be pressed to initiate two way communication between system 100 and other computer systems coupled to serial communication 265 .
FIG. 5 illustrates circuitry of computer system 100 , some of which can be implemented on PC board 225 . The computer system 100 can be used to perform character recognition processes and authentication of the present invention, e.g., processes 600 and 640 ( FIG. 13A and FIG. 13B ) and process 650 ( FIG. 14 ). Computer system 100 includes an address/data bus 99 for communicating information, a central processor 101 coupled with the bus 99 for processing information and instructions, a volatile memory 102 (e.g., random access memory RAM) coupled with the bus 99 for storing information and instructions for the central processor 101 and a non-volatile memory 103 (e.g., read only memory ROM) coupled with the bus 99 for storing static information and instructions for the processor 101 . Computer system 110 also includes an optional data storage device 104 (e.g., memory stick) coupled with the bus 99 for storing information and instructions. Device 104 can be removable. As described above, system 100 also contains a display device 105 coupled to the bus 99 for displaying information to the computer user. PC board 225 can contain the processor 101 , the bus 99 , the ROM 103 and the RAM 102 .
Also included in computer system 110 of FIG. 5 is an alphanumeric input device 106 which in one implementation is a handwriting recognition pad (“digitizer”) having regions 106 a and 106 b ( FIG. 2A ), for instance. Device 106 can communicate information (spatial data and pressure data) and command selections to the central processor 101 . System 110 also includes an optional cursor control or directing device 107 coupled to the bus for communicating user input information and command selections to the central processor 101 . In one implementation, device 107 is a touch screen device incorporated with screen 105 . Device 107 is capable of registering a position on the screen 105 where the stylus makes contact and the pressure of the contact. The display device 105 utilized with the computer system 110 may be a liquid crystal device, cathode ray tube (CRT), field emission device (FED, also called flat panel CRT) or other display device suitable for creating graphic images and alphanumeric characters recognizable to the user. In the preferred embodiment, display 105 is a flat panel display.
Signal communication device 108 , also coupled to bus 99 , can be a serial port for communicating with the cradle 60 . Device 108 can also include an infrared communication port.
Each of the devices shown in FIG. 5 receives power from a battery device or other voltage source. This power can be interrupted via a switch device. In one embodiment, the switch is controlled by power on/off button 95 ( FIG. 3 ). When the switch is in power off mode, the devices of FIG. 5 are disabled except for the RAM 102 which continues to receive power to maintain the volatile data. When the switch is on, power is restored to all of the devices of FIG. 5 . As described in more detail below, in the present invention, the switch can be controlled by the position of stylus 80 with respect to a receiving slot and/or by the rotation of a cover hinge within the receiving slot.
FIG. 6 is a front view of the palmtop computer system 100 with a menu bar 305 open displaying a pull down window having several selections that can be made by the user. Buttons on screen 105 can be selected by the user directly tapping on the screen location of the button with stylus 80 . Also shown are two regions of digitizer 106 a and 106 b . Region 106 a is for receiving user stroke data (and pressure data) for alphabet characters, and typically not numeric characters, and region 106 b is for receiving user stroke data (and pressure data) for numeric data, and typically not for alphabetic characters. Physical buttons 75 are also shown. Although different regions are shown for alphabetic and numeric characters, the present invention is also operable within a single region that recognizes both alphabetic and numeric characters. Also shown in FIG. 6 is the position of the stylus receiving slot or rail 350 . It is appreciated that while the stylus receiving slot or rail 350 is depicted on the left of the computer 100 , it can also be deployed on the right or along the top edge or along the bottom edge.
It is appreciated that, in one embodiment, the digitizer region 106 a and 106 b is separate from the display screen 105 and therefore does not consume any display area.
Automatic Power on and Automatic Power Off Using the Position of a Stylus and/or Cover Hinge
In accordance with embodiments of the present invention the electronics of FIG. 5 are selectively placed into various power modes in response to a switch circuit. However, in one embodiment, the RAM 102 is dynamic RAM and is constantly refreshed to maintain the volatile data regardless of the power mode of the remainder of computer 100 . For instance, in the full power or “power-up” mode, each of the electronic devices receives (consumes) nominal power from a voltage source (e.g., a battery). In a power conservation mode, also called “power down” mode, certain electronic devices receive less than their nominal power in order to conserve power. The power conservation mode also includes the scenario where the electronics devices are fully powered off, except for RAM 102 . The devices are commanded to be in either the power-up mode or the power-down mode by a mode signal generated by a switch circuit in accordance with the present invention.
FIG. 7 illustrates a cut away cross sectional view of the stylus receiving slot or rail 350 of one embodiment of the present invention 510 a . FIG. 7 also illustrates a switch device 410 that generates a mode signal over line 390 . The mode of the switch 410 is controlled by a detector device 420 and the modes are: stylus-in; and stylus out. Stylus in corresponds to power-down and stylus out corresponds to power-up. The detector device 420 is placed inside the stylus receiving slot or rail 350 that holds the stylus 80 when it is not in use. The detector device 420 is coupled to the switch circuit 410 and can be implemented, in one embodiment, as a microswitch. The devices of system 100 are commanded to be in either the power-up mode or the power-down mode by a mode signal generated by the switch circuit 410 .
The stylus receiving slot or rail 350 is a part of the case 235 of the portable computer 100 ( FIG. 3 and FIG. 6 ). According to this embodiment of the present invention, when the stylus 80 is inserted into slot 350 all the way, its presence becomes detected by detector 420 which generates a signal to switch 410 . The switch 410 via control signal 390 controls the components of FIG. 5 (except the RAM) such that they are placed into a power conservation mode thereby causing computer system 100 to power down.
FIG. 14 illustrates a three dimensional perspective view of the detector 420 located within the slot 350 of the casing 235 in one embodiment of the present invention. In the example of FIG. 14 , the slot is cut open on one side (the facing side) to expose part of the stylus (or cover hinge) but could alternatively be completely cylindrical in shape.
Alternatively, when the stylus 80 of FIG. 7 is removed from slot 350 , its absence is detected by detector 420 which generates a signal to switch 410 . The switch 410 via control signal 390 controls the voltage source such that power to the components of FIG. 5 is established thereby causing computer system 100 to power up for use. The user typically inserts the stylus 80 into slot 350 when he/she is done using computer 100 and the user typically removes the stylus 80 from slot 350 when he/she is ready to use computer 100 . By using the location of stylus 80 as a tool for automatically powering up and powering down computer 100 , the user does not have to press any on/off button 95 . This embodiment of the present invention therefore reduces the number of repetitive tasks the user has to perform in order to use computer 100 . It is appreciated that the detector device 420 can be implemented using a number of well known technologies for detecting the presence of an object, e.g., the detector device can be implemented as a mechanical detector device, an inductive device, a capacitive device, an optical detector device, an electrical device or an electro-magnetic device.
FIG. 8 illustrates a cut away cross sectional view of the stylus receiving slot or rail 350 in accordance with another embodiment of the present invention 510 b . In this embodiment, the detector device is implemented using two different detector elements 380 a and 380 b . In this embodiment, the detectors not only report that the stylus 80 has been inserted into slot 350 but also that the stylus 80 is in the process of being slid into or slid out of the slot 350 . Both detector elements 380 a and 380 b are coupled to the switch circuit 375 . The mode of the switch 375 is controlled by detector device 380 a - 380 b and the basic modes are: stylus-in; and stylus out. Stylus in corresponds to power-down and stylus out corresponds to power-up. In one embodiment, the stylus 80 has a metal surface and when placed into slot 350 , a circuit or connection is made through the stylus 80 between metal detectors 380 a and 380 b . This generates a signal to switch 375 which enters the power-down mode as represented by a mode signal over line 390 .
It is appreciated that detectors 380 a and 380 b can also be implemented using optical detector elements, mechanical detector elements, inductive detector elements, magnetic (e.g., reed relay), capacitive detector elements or electro-magnetic detector elements. It is further appreciated that the stylus detectors located with slot 350 can be implemented using the input/output (I/O) rail technology described in co-pending U.S. patent application Ser. No. 09/484,086, filed on Jan. 18, 2000, by Neal Osborn, Francis Canova, Jr. and Nicholas Twyman, entitled, “Connector for Handheld Computer,” which is assigned to the assignee of the present invention and also hereby incorporated by reference.
FIG. 9A and FIG. 9B illustrate the logical states of a power state machine 610 implemented in accordance with an embodiment of the present invention. It is appreciated that the mode signal generated at line 390 is only one piece of information that is used to either power-up or power-down the computer 100 . At state 620 , the computer 100 is in the power-down state, e.g., the devices of FIG. 5 are placed into a power conservation mode, except for the RAM 102 which continuously receives power. At step 625 , if an interrupt is received by the computer 100 , then state 640 is entered, otherwise state 630 is entered. At step 630 , if the on/off key 95 is pressed, then state 640 is entered because the computer is currently in the power-down state, otherwise step 635 is entered. At step 635 , if the switch (either 410 or 375 ) generates a mode signal over line 390 indicating that the stylus 80 has been removed from slot 350 then state 640 is entered, otherwise state 620 is entered.
At state 640 , the computer 100 automatically is placed into the power-up state where nominal power is supplied to (consumed by) the devices of FIG. 5 . At step 645 of FIG. 9B the computer remains in the power-up state. At step 650 of FIG. 9B , if a time-out occurs within computer 100 , then state 665 is entered, otherwise state 655 is entered. A time-out occurs whenever no user activity is detected by computer 100 for a predetermined period of time. At step 655 , if the on/off key 95 is pressed, then state 665 is entered because the computer is currently in the power-up state, otherwise step 660 is entered. At step 660 , if the switch (either 410 or 375 ) generates a mode signal over line 390 indicating that the stylus 80 has been re-inserted into slot 350 then state 665 is entered, otherwise state 645 is entered.
At state 665 of FIG. 9B , the computer 100 automatically is placed into the power-down or power conservation state where all devices of FIG. 5 except for the RAM 102 device are placed into a power conservation mode. State 620 ( FIG. 9A ) is then entered again.
FIG. 10-FIG . 12 B illustrate the cover hinge embodiment of the present invention. In this embodiment, slot 350 can receive a stylus shaped device 80 that is also connected to a cover and thereby acts as a hinge for the cover. FIG. 11 illustrates a perspective view of the system 100 d . The slot 350 is open in this embodiment (see also FIG. 13 and FIG. 14 ) and more closely resembles a rail thereby allowing the cover 550 to extend outside the rail 350 and rotate about the axis of the rail 350 . When the cover rotates clockwise 570 , the hinge 80 also rotates and the cover 550 is rotated away from display 105 so that the user can use the computer. Alternatively, when the cover 550 rotates counter-clockwise 560 , the hinge 80 also rotates and the cover 550 is rotated such that it is laid over display 105 to protect the facing surface of computer 100 when the user is done working on the computer. The cover 550 can be made of leather or any soft protective surface material. It is appreciated that a stylus can be inserted into a slot (similar to rail 350 ) that runs along the left hand edge of system 100 d.
In this embodiment, the hinge 80 is not generally removed from the rail 350 very often but it is rather rotated. Therefore, in accordance with this embodiment of the present invention, when the cover 550 is rotated counter-clockwise such that it is laid over screen 105 , computer 100 d automatically enters a power-down state. Alternatively, when cover 550 is rotated clockwise such that it does not lay over screen 105 , computer 100 d automatically enters a power-up state. It is appreciated that the hinge 80 can be located on the left or right side of computer 100 d or it can be located on the top or bottom edge of computer 100 d.
FIG. 10 illustrates a detector pair 450 a and 450 b that can be used to detect the rotational position of the hinge 80 . On the surface of the hinge 80 is laid a circular “L” shaped metal tracing 440 a and 440 b . Region 440 b is a ring shaped metal piece. Region 440 a on the other hand does not extend all the way around hinge 80 . Detector 450 b is a metal detector that is ring shaped. Detector 450 a is only semi-ring shaped, e.g., “C shaped,” and does not extend all the away around rail 350 . Although not shown in FIG. 10 for clarity, the left edge of cover 550 ( FIG. 11 ) is connected to the right edge of hinge 80 . When hinge 80 of FIG. 10 is in the position shown, but located inside rail 350 , metal area 440 b contacts metal detector 450 b but metal area 440 a does not contact metal detector 450 a . Therefore, there is no electrical connection between detectors 450 a and 450 b . In this configuration, switch 375 then generates a power-up mode signal because the cover is in the open position, e.g., not laid over display 105 . The devices of system 100 are commanded to be in either the power-up mode or the power-down mode by a mode signal generated by the switch circuit 375 .
When hinge 80 is rotated clockwise 445 about ⅓ turn (e.g., the cover is closed and laid over display 105 ), metal area 440 b contacts metal detector 450 b and metal area 440 a contacts metal detector 450 a . Therefore, there is an electrical connection between detectors 450 a and 450 b . In this configuration, switch 375 then generates a power-down mode signal because the cover is in the closed position, e.g., laid over display 105 . In this manner, switch 375 is able to detect the rotational position of hinge 80 , and therefore of cover 550 .
FIG. 12A and FIG. 12B illustrate the logical states of a power state machine 710 implemented in accordance with the cover and hinge embodiment of the present invention. It is appreciated that the mode signal generated at line 390 is only one piece of information that is used to either power-up or power-down the computer 100 d . At state 745 , the computer 100 d is in the power-down state, e.g., the devices of FIG. 5 , except for the RAM 102 which continuously receives power, are placed into a power conservation mode. At step 625 , if an interrupt is received by the computer 100 , then state 765 is entered, otherwise state 755 is entered. At step 755 , if the on/off key 95 is pressed, then state 765 is entered because the computer is currently in the power-down state, otherwise step 760 is entered. At step 760 , if the switch (either 410 or 375 ) generates a mode signal over line 390 indicating that the hinge 80 has been rotated, e.g., clockwise, such that cover 550 is removed from the display 105 , then state 765 is entered, otherwise state 745 is entered.
At state 765 , the computer 100 d automatically is placed into the power-up state where nominal power is supplied to (consumed by) the devices of FIG. 5 . At step 720 of FIG. 12B the computer remains in the power-up state. At step 725 of FIG. 12B , if a time-out occurs within computer 100 d , then state 740 is entered, otherwise state 730 is entered. A time-out occurs whenever no user activity is detected by computer 100 d for a predetermined period of time. At step 730 , if the on/off key 95 is pressed, then state 740 is entered because the computer is currently in the power-up state, otherwise step 735 is entered. At step 735 , if the switch (either 410 or 375 ) generates a mode signal over line 390 indicating that the hinge 80 has been rotated counter-clockwise such that cover 550 is laid over display 105 then state 740 is entered, otherwise state 720 is entered.
At state 740 of FIG. 12B , the computer 100 d automatically is placed into the power-down state where the devices of FIG. 5 , except for the RAM 102 device, are placed into a power conservation mode. State 745 ( FIG. 9A ) is then entered again.
The user typically inserts the closes the cover 550 (over display 105 ) when he/she is done using computer 100 d and the user typically opens the cover 550 , exposing display 105 , when he/she is ready to use computer 100 d . By using the rotational position of hinge 80 as a tool for automatically powering up and powering down computer 100 d , the user does not have to press any on/off button. This embodiment of the present invention therefore reduces the number of repetitive tasks the user has to perform in order to use computer 100 d.
It is appreciated that in an alternative to the cover hinge embodiment, the hinge is located between two parts of the system 100 where the system 100 actually folds in half. In this case, the cover is actually the other half of the system 100 and not merely a protective layer or surface. In this case, when the device is opened and fully extended, the hinge automatically powers up the system 100 . On the other hand, when the hinge is rotated such that the device is fully retracted and folded, the hinge automatically causes the system 100 to enter the power conservation mode.
The preferred embodiment of the present invention, a method and system for automatically powering-up and automatically powering-down a computer system based on the position and/or rotation of an associated stylus, is thus described. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as limited by such embodiments, but rather construed according to the below claims. | A method and system for changing the power state of a portable electronic device is disclosed. A portable electronic device may be powered up or powered down responsive to a user interaction with the portable electronic device. The user interaction may be an insertion of a stylus or other user interface object into a housing of the portable electronic device. Alternatively, the user interaction may be a removal of a stylus or other user interface object from the housing of the portable electronic device. The user interaction may be a rotation of a cover of the portable electronic device. | 6 |
CROSS-REFERENCE TO PRIORITY/PCT/PROVISIONAL APPLICATIONS
This application claims priority under 35 U.S.C. §119 of French Application No. 04 05176, filed May 13, 2004, and French Application No. 04 07210, filed Jun. 30, 2004, and of U.S. provisional application No. 60/599,021, filed Aug. 6, 2004, each expressly incorporated by reference and each assigned to the assignee hereof.
BACKGROUND
1. Field of the Invention
The field of the invention is that of dental compositions. More specifically the dental compositions developed in the context of the present invention can be used for producing dental prostheses and for dental restoration.
2. Related Art
These dental compositions are conventionally epoxy resins, or photocurable silicones or free-radically polymerizable acrylate resins. These compositions further include particulate reinforcing fillers (of hydrophobicized silica, for example), photoinitiators, and, optionally, photosensitizers, and even other functional additives such as pigments or stabilizers.
After they have been mixed, these compositions are shaped and then photocrosslinked to a structural mass similar to that of the teeth.
For example, patent application FR-A-2 784 025 describes dental compositions based on silicone resins which are polymerizable/crosslinkable cationically and under irradiation, with or without subsequent thermal postcrosslinking. These silicone resins contain oxirane (epoxide, oxetane, etc.) or vinyl ether functionalities. Such compositions comprise:
one or more cationically polymerizable and/or crosslinkable polydimethylsiloxanes which carry at one at least of their ends reactive functions of formula:
an effective amount of at least one onium borate initiator:
at least one photosensitizer, and
at least one inert dental or reinforcing filler based on dental glasses, polymethyl methacrylate or pyrogenic silica, optionally treated with hexamethyldisilazane or polydimethylsiloxane, with a specific surface area of 200 m 2 /g.
These dental compositions are intended for the manufacture of dental prostheses or dentures and for dental restoration.
These silicones have the advantage over cationically crosslinking organic resins of being highly transparent to UV-visible light and therefore of enabling the production of very thick materials (several millimeters thick) which are photocrosslinked within a very short time (less than a minute) with a UV lamp emitting in the visible range >400 nm.
These silicones, however, are formulated with iodonium salts and photosensitizers, especially thioxanthones, which give rise to great color variation when exposed to radiation with a wavelength greater than 390 nm during photocrosslinking. This is manifested in a pinkish coloration in the end product (after exposure), which is undesirable from an esthetic standpoint. Moreover, another problem resulting from the use of photosensitizers concerns inadequate crosslinking kinetics when very thick materials (several millimeters thick) are prepared.
It is therefore apparent that the prior art does not provide a satisfactory solution to the twin problem of the low color stability of finished dental products (after crosslinking) and of the inadequate crosslinking kinetics when very thick materials (several millimeters thick) are prepared.
SUMMARY OF THE INVENTION
One of the essential objectives of the present invention is therefore to remedy this by providing new photocurable dental compositions, based in particular on units which are cationically polymerizable under UV (oxiranes, for example), which do not exhibit the drawbacks of the prior art.
These objectives, among others, are attained by the present invention, which first provides a dental composition photocurable by radiation with a wavelength greater than 390 nm, comprising:
(1) at least one cationically reactive compound (A); (2) at least one dental filler (B); (3) optionally at least one dispersant (C) comprising at least one organic polymer or copolymer; (3) at least one cationic photoinitiator (D); and (4) at least one photosensitizer (E) which is a thioxanthone salt substituted by at least one group G containing an ammonium function, the said photosensitizer (E), optionally in combination with at least one camphorquinone, phenanthrenequinone and/or substituted anthracene, has the formula:
in which:
R 22 and R 23 are identical or different and represent a hydrogen or an optionally substituted C1-C10 alkyl radical; preferably R 22 ═R 23 ═methyl, (Y − ) being an anionic entity selected from the group consisting of: BF 4 − , PF6 − ; SbF 6 − ; the anion (I) of formula [BX a R b ] − defined below, R f SO 3 − ; (R f SO 2 ) 3 C − or (R f SO 2 ) 2 N − , where R f is a linear or branched alkyl radical substituted by at least one halogen atom, preferably a fluorine atom, and even more preferably (Y − ) is selected from the borates of the following formulae: [B(C 6 H 3 (CF 3 ) 2 ) 4 ] − and [B(C 6 F 5 ) 4 ] − ;
the said anion (I) of formula [BX a R b ] − being defined in the following manner:
a and b are integers ranging from 0 to 3 for a and from 1 to 4 for b, with a+b=4, the symbols X represent:
a halogen (chlorine, fluorine) atom, with a=0 to 3, or an OH function, with a=0 to 2,
the symbols R are identical or different and represent:
a phenyl radical substituted by at least one electron-withdrawing group such as, for example, OCF 3 , CF 3 , NO 2 or CN and/or by at least two halogen atoms (especially fluorine), when the cationic entity is an onium of an element from groups 15 to 17, a phenyl radical substituted by at least one electron-withdrawing element or group, in particular a halogen atom (especially fluorine), CF 3 , OCF 3 , NO 2 or CN, when the cationic entity is an organometallic complex of an element from groups 4 to 10, or an aryl radical containing at least two aromatic nuclei, such as, for example, biphenyl, naphthyl, optionally substituted by at least one electron-withdrawing element or group, in particular a halogen atom, especially fluorine, OCF 3 , CF 3 , NO 2 or CN, irrespective of the cationic entity.
It is to the inventors' merit to have shown, surprisingly and unexpectedly, that a certain class of thioxanthone makes it possible to remedy the problems associated with the use of photosensitizers, namely the low color stability of the finished dental products (after crosslinking) and the inadequate crosslinking kinetics when very thick dental materials (several millimeters thick) are prepared.
DESCRIPTION OF PREFERRED EMBODIMENTS
According to one very advantageous embodiment, the photosensitizer (E) and the cationic photoinitiator (D) are selected such that they are composed of the same anion; the anion preferably is selected from the borates of the following formulae: [B(C 6 H 3 (CF 3 ) 2 ) 4 ] − and [B (C 6 F 5 ) 4 ] − .
As a particularly preferred embodiment the photosensitizer (E), optionally in combination with at least one camphorquinone, phenanthrenequinone and/or substituted anthracene, is selected from the compounds of the formula:
The cationically reactive compounds (A) useful according to the invention may include the monomers and/or (co)polymers comprising:
epoxides, vinyl ethers, oxetanes, spiro-ortho-carbonates, spiro-ortho-esters and combinations thereof.
According to one preferred embodiment the cationically reactive compound (A) is composed of at least one silicone oligomer or polymer (A-1) which is crosslinkable and/or polymerizable, is liquid at ambient temperature or thermofusible at a temperature lower than 100° C., and comprises:
a) at least one unit of the following formula:
in which:
a=0, 1 or 2, R 0 , identical or different at each occurrence, represents an alkyl, cycloalkyl, aryl, vinyl, hydrogeno or alkoxy radical, preferably a C1-C6 lower alkyl, Z, identical or different at each occurrence, is an organic substituent containing at least one reactive oxirane, alkenyl ether, oxetane, dioxolane and/or carbonate function, and b) at least two silicon atoms.
The unit (M-1) preferably comprises substituents Z selected from the group consisting of the following radicals:
with R″ representing a C 1 -C 6 linear or branched alkyl radical.
According to a second advantageous version of the present invention, the silicone oligomer or polymer (A-1) is composed of at least one silicone whose average formula corresponds to one of the formulae selected from the group consisting of the formulae (S-1) to (S-92) described below:
where L=H; OH; Me; phenyl; C1-C12 alkyl; C1-C6 cycloalkyl; or the groups:
in which formulae R o or R 0 , which are identical or different, represent an alkyl, cycloalkyl or aryl radical, preferably a C1-C6 lower alkyl.
in which formulae the group D is a linear or branched C1-C12 alkyl and n is an integer between 1 and 20 (inclusive), with Ar=aryl group.
According to one preferred embodiment the cationically reactive compound (A) is a silane (G-3) of formula:
in which:
R, identical or different at each occurrence, represents an alkyl, cycloalkyl, aryl, vinyl, hydrogeno or alkoxy radical, preferably a C1-C6 lower alkyl,
Z, identical or different at each occurrence, is an organic substituent containing at least one oxirane, alkenyl ether, oxetane and/or carbonate function, and
a+b=3.
According to one preferred embodiment the silane (G-3) is selected from the group consisting of the molecules (S-93) to (S-95):
According to another preferential embodiment the cationically reactive compound (A) (G) is an organic compound (G-4) selected from the group consisting of the molecules (S-96) to (S-104):
in which formulae n is an integer between 1 and 10 (inclusive):
with n<100 and D=linear or branched C 1 -C 12 alkyl.
Selectable molecules of type (S-103) include the resin UVR6150® sold by the company Dow Chemical; and
with n<100 and the group D=linear or branched C1-C12 alkyl.
For the resins of type (S-104), that where n=0 is particularly suitable for the invention.
According to another advantageous version of the present invention, the cationically reactive compound (A) is combined with an organic epoxy or oxetane resin representing less than 80% by mass of the fraction of the silicone oligomer or polymer (A-1). Among the functional organic resins selected, preference would be given to those for which the percentage by mass of reactive function is less than 20% and preferably less than 15%. There will be a corresponding decrease in the volume contraction on polymerization.
Preference will be given to selecting the resins of formula (R-1) and (R-2)
with n<100 and D=linear or branched C1-C12 alkyl.
Among the resins of type (R-1) it is possible to select the resin UVR6150 sold by the company Dow Chemical.
with n<100 and D=linear or branched C1-C12 alkyl.
Among the resins of type (R-2) it is possible to select the resin where n=0.
Different types of dental filler (B) can be used for preparing the compositions according to the invention. The fillers are selected as a function of the end use of the dental composition: they affect important properties such as appearance, penetration of UV radiation, and also mechanical and physical properties of the material obtained after crosslinking and/or polymerization of the dental composition.
As a reinforcing filler use may be made of untreated or treated pyrogenic silica fillers, amorphous silica fillers, quartz, glasses or nonvitreous fillers based on oxides of silicon, of the type for example of those described in patent U.S. Pat. No. 6,297,181 (without barium), of zirconium, of barium, of calcium, of fluorine, of aluminum, of titanium or of zinc, borosilicates, aluminosilicates, talc, Spherosil, ytterbium trifluoride, fillers based on polymers in the form of ground powder, such as inert or functionalized polymethyl methacrylates, or polyepoxides or polycarbonates, whiskers of ceramics (Si—C, Si—O—C, Si—N, Si—N—C, Si—N—C—O), and glass fibers.
The following are cited by way of example:
inert fillers based on polymethyl methacrylate LUXASELF®, sold by the company UGL, which can be used in the dental field and are pigmented pink, polydimethylsiloxane—or hexamethyldisilazane—treated fumed silica fillers with a specific surface area of 200 m 2 /g, untreated fumed silica fillers (Aerosil AE200 or OX50®, sold by the company Degussa), and glasses based on silicon oxides, barium oxide and/or strontium oxide.
According to one preferred embodiment the dental filler (B) is an inorganic glass or a fumed silica.
In accordance with one advantageous feature of the invention the dental filler (B) represents up to 85% by weight, preferably between 50 and 85% by weight, and more preferably between 60 and 85% by weight, relative to the total weight of the dental composition.
In accordance with the invention the dispersant (C) is selected from the group consisting of the following: polyurethane/acrylate copolymers optionally converted to an alkylammonium salt form, acrylic copolymers optionally converted to an alkylammonium salt form, monodiesters of carboxylic acids, polyesters, polyethers, polyurethanes, modified polyurethanes, polyol polyacrylates, copolymers thereof or mixtures thereof. The dispersants sold under the brand name Disperbyk® (from the company Byk) or Solsperse® (from the company Avecia) are particularly suitable for the invention. Mention may be made, in particular and by way of example, of the following commercial products: Disperbyk® 164, Disperbyk® 161, Disperbyk® 166, Disperbyk® 2070, Disperbyk® 9075, and Disperbyk® 9076. Mention may also be made of the dispersants cited in the following patents:
patent U.S. Pat. No. 5,882,393, describing dispersants based on polyurethane/imidazole acrylates or epoxides; patent U.S. Pat. No. 5,425,900, describing dispersants based on polyurethanes; patent U.S. Pat. No. 4,795,796, describing dispersants based on polyurethane/polyoxyalkylene glycol monoalkyl ethers; patent application WO-A-99/56864, describing dispersants based on polyurethane/poly(oxy-alkylene-carbonyl)s: derived from ε-caprolactone and from δ-valerolactone; and patent EP-0 403 197, describing grafted polyol polyacrylate dispersants comprising a random polyurethane/polyvinyl/polyacrylate copolymer and a polyoxyalkylene polyether.
Quantitatively speaking, the dispersant (C) is present in a proportion of 50 ppm to 1%, preferably 100 ppm to 5000 ppm.
The amine index of the dispersant (C) is preferably less than or equal to 60 and more preferably between 0.1 and 50 mg of potassium hydroxide per gram of dispersant (C).
The acid index of the dispersant is advantageously less than or equal to 200, preferably less than or equal to 100, and more preferably between 1 and 60 mg of potassium hydroxide per gram of dispersant.
The cationic photoinitiators (D) are selected from the onium borates (individually or in a mixture) of an element from groups 15 to 17 of the Periodic Table [Chem. & Eng. News, Vol. 63, No. 5, 26, dated Feb. 4, 1985] or of an organometallic complex of an element from groups 4 to 10 of the Periodic Table [same reference].
According to one preferential embodiment the cationic photoinitiator (D) is of borate type and is selected from those for which:
a) the cationic entity of the borate is selected from:
(1) onium salts of the formula:
[(R 1 ) n -A-(R 2 ) m ] + (VII)
in which: A represents an element from groups 15 to 17 such as, for example: I, S, Se, P or N, R 1 represents a C6-C20 heterocyclic or carbocyclic aryl radical, it being possible for said heterocyclic radical to contain nitrogen or sulfur as heteroelements, R 2 represents R 1 or a C1-C30 linear or branched alkyl or alkenyl radical, said radicals R 1 and R 2 being optionally substituted by a C1-C25 alkoxy, C1-C25 alkyl, nitro, chloro, bromo, cyano, carboxyl, ester or mercapto group, m and n are integers, with n+m=v+1, v being the valence of the element A, (2) oxoisothiochromanium salts, specifically those described in patent application WO 90/11303, particularly the sulfonium salt of 2-ethyl-4-oxoisothiochromanium or of 2-dodecyl-4-oxoisothiochromanium, and the oxoisothiochromanium salts of structural formula V:
in which:
A represents
n1=an integer between 1 and 3;
z1=an integer between 0 and 3;
x represents a group of formula M 1 Y 1 r1 (1) or of formula Q 1 (2), where in M 1 Y 1 r1 (1): M 1 =Sb, As, P, B or Cl, Y 1 represents a halogen (preferably F or Cl) or O, and r1 is an integer between 4 and 6; the formula Q 1 (2) represents a sulfonic acid;
R 81 -SO 3 where R 81 is an alkyl or aryl group, or an alkyl or aryl group substituted by a halogen, preferably F or Cl,
R 101 represents an alkyl or a cycloalkyl group, preferably C 1 -C 20 , or an aryl group,
R 21 represents a hydrogen, an alkyl, alkenyl, cycloalkenyl or cycloalkyl group, preferably C 1 -C 20 , or an aryl group, all of the R 21 s being independent of one another,
R 31 represents a hydrogen, an alkyl, alkenyl, cycloalkenyl or cycloalkyl group, preferably C 1 -C 20 , or an aryl group, all of the R 31 s being independent of one another,
R 41 represents a hydrogen, halogen, an alkenyl group, vinyl for example, or a cycloalkenyl, alkyl, or cycloalkyl group, preferably C 1 -C 20 , an alkoxy or thioalkoxy group, preferably C 1 -C 20 , a poly(alkylene oxide) group having up to 10 alkylene oxide units and terminated by a hydroxyl or an alkyl (C 1 -C 12 ), or an aryl group, or an aryloxy or thioaryloxy group,
R 51 represents a halogen, an alkenyl group, vinyl for example, or a cycloalkenyl, alkyl, or cycloalkyl group, preferably C 1 -C 20 , an alkoxy or thioalkoxy group, preferably C 1 -C 20 , a poly(alkylene oxide) group having up to 10 alkylene oxide units and terminated by a hydroxyl or an alkyl (C 1 -C 22 ), or an aryl group, or an aryloxy or thioaryloxy group,
R 61 represents a hydrogen, an alkyl, alkenyl, cycloalkenyl or cycloalkyl group, preferably C 1 -C 20 , or an aryl group,
R 71 represents a hydrogen, an alkyl, alkenyl, cycloalkenyl or cycloalkyl group, preferably C 1 -C 20 , or an aryl group; and
(3) organometallic salts of the following formula:
(L 1 L 2 L 3 M) +q (VIII)
in which:
M represents a metal from group 4 to 10, especially iron, manganese, chromium or cobalt,
L1 represents 1 ligand bonded to the metal M by π electrons, the ligand being selected from η 3 -alkyl, η 5 -cyclopentadienyl and η 7 -cycloheptatrienyl ligands and the η 6 -aromatic compounds selected from optionally substituted η 6 -benzene ligands and compounds having 2 to 4 fused rings, each ring being capable of contributing to the valence layer of the metal M via 3 to 8 π electrons,
L2 represents a ligand bonded to the metal M by π electrons, the ligand being selected from η 7 -cycloheptatrienyl ligands and the η 6 -aromatic compounds selected from optionally substituted η 6 -benzene ligands and compounds having 2 to 4 fused rings, each ring being capable of contributing to the valence layer of the metal M via 6 or 7 π electrons,
L3 represents 0 to 3 identical or different ligands bonded to the metal M by σ electrons, the ligand(s) being selected from CO and NO2+; the total electronic charge q of the complex to which L1, L2 and L3 contribute, and the ionic charge of the metal M, being positive and being 1 or 2; and
b) the anionic borate entity has the formula:
[BX a R b ] − (I)
in which formula:
a and b are integers ranging from 0 to 3 for a and from 1 to 4 for b, with a+b=4,
the symbols X represent:
a halogen (chlorine, fluorine) atom, with a=0 to 3, or an OH function, with a=0 to 2,
the symbols R are identical or different and represent:
a phenyl radical substituted by at least one electron-withdrawing group such as, for example, OCF 3 , CF 3 , NO 2 or CN and/or by at least two halogen atoms (especially fluorine), when the cationic entity is an onium of an element from groups 15 to 17, a phenyl radical substituted by at least one electron-withdrawing element or group, in particular a halogen atom (especially fluorine), CF 3 , OCF 3 , NO 2 or CN, when the cationic entity is an organometallic complex of an element from groups 4 to 10, or an aryl radical containing at least two aromatic nuclei, such as, for example, biphenyl, naphthyl, optionally substituted by at least one electron-withdrawing element or group, in particular a halogen atom, especially fluorine, OCF 3 , CF 3 , NO 2 or CN, irrespective of the cationic entity.
According to one preferred embodiment the cationic photoinitiator (D) is an iodonium salt.
Without any limitative effect, there now follow further details regarding the subclasses of onium borate and of organometallic-salt borate that are more particularly preferred in the context of the use in accordance with the invention.
According to a first preferred version of the invention the especially suitable species of the anionic borate entity are the following:
1′: [B(C 6 F 5 ) 4 ] − 5′: [B(C 6 H 3 (CF 3 ) 2 ) 4 ] − 2′: [(C 6 F 5 ) 2 BF 2 ] − 6′: [B(C 6 H 3 F 2 ) 4 ] − 3′: [B(C 6 H 4 CF 3 ) 4 ] − 7′: [C 6 F 5 BF 3 ] − 4′: [B(C 6 F 4 OCF 3 ) 4 ] −
According to a second preferred version of the invention the onium salts of formula (VII) that can be used are described in numerous documents, and particularly in patents U.S. Pat. Nos. 4,026,705, 4,032,673, 4,069,056, 4,136,102, and 4,173,476.
Among these salts, particular privilege will be given to the following cations:
[(C 8 H 17 )-O-(C 6 H 4 )-I-C 6 H 5 )] + ; [C 12 H 25 -(C 6 H 4 )-I-C 6 H 5 ] + ; [(C 8 H 17 -O-(C 6 H 4 )) 2 I] + [(C 8 H 17 )-O- (C 6 H 4 )-I-C 6 H 5 )] + ; [(C 6 H 5 ) 2 S-(C 6 H 4 )-O-C 8 H 17 ] + ; [CH 3 -C 6 H 4 -I-C 6 H 4 -CH 2 CH (CH 3 ) 2 ] + ; [(C 12 H 25 -(C 6 H 4 )-I-(C 6 H 4 )-CH-(CH 3 ) 2 ] + ; [(C 12 H 25 -C 6 H 4 ) 2 I] + ; [(C 6 H 5 ) 3 S] + ; [CH 3 -(C 6 H 4 )-I-(C 6 H 4 )-CH(CH 3 ) 2 ] + (η5-cyclopentadienyl) (η6-toluene)Fe + ; (η5-cyclopentadienyl) (η6-cumene)Fe + , (η5-cyclopentadienyl) (η6-1-methylnaphthalene)Fe + ; [(C 6 H 5 )-S-C 6 H 4 -S-(C 6 H 5 ) 2 ] + ; [(CH 3 -(C 6 H 4 )-I-(C 6 H 4 )-OC 2 H 5 ] + ; [(C n H 2n+1 -C 6 H 4 ) 2 I] + with n=1 to 18.
According to a third preferred version, the organometallic salts (3) of formula (VIII) that can be used are described in documents U.S. Pat. No. 4,973,722, U.S. Pat. No. 4,992,572, EP-A-203 829, EP-A-323 584, and EP-A-354 181. The organometallic salts more readily employed according to the invention are in particular:
(η 5 -cyclopentadienyl) (η 6 -toluene)Fe + , (η 5 -cyclopentadienyl) (η 6 -1-methylnaphthalene)Fe + , (η 5 -cyclopentadienyl) (η 6 -cumene)Fe + , bis(η 6 -mesitylene)Fe + , bis(η 6 -benzene)Cr + .
In accord with these three preferred versions mention may be made, as examples of onium borate photoinitiators, of the following products:
(P-16): [(C 8 H 17 )-O-C 6 H 4 -I-C 6 H 5 )] + , [B(C 6 F 5 ) 4 ] − ; (P-17): [C 12 H 25 -C 6 H 4 -I-C 6 H 5 ] + , [B(C 6 F 5 ) 4 ] − ; (P-18): [(C 8 H 17 -O-C 6 H 4 ) 2 I] + , [B(C 6 F 5 ) 4 ] − ; (P-19): [(C 8 H 17 )-O-C 6 H 4 -I-C 6 H 5 )] + , [B(C 6 F 5 ) 4 ] − ; (P-20): [(C 6 H 5 ) 2 S-C 6 H 4 -O-C 8 H 17 ] + , [B(C 6 H 4 CF 3 ) 4 ] − ; (P-21): [(C 12 H 25 -C 6 H 4 ) 2 I] + , [B(C 6 F 5 ) 4 ] − ; (P-22): [CH 3 -C 6 H 4 -I-C 6 H 4 -CH(CH 3 ) 2 ] + , [B(C 6 F 5 ) 4 ] − ; (P-23): (η5-cyclopentadienyl)(η6-toluene)Fe + , [B(C 6 F 5 ) 4 ] − ; (P-24): (η5-cyclopentadienyl)(η6-1-methylnaphthalene)Fe + , [B(C 6 F 5 ) 4 ] − ; (P-25): (η5-cyclopentadienyl)(η6-cumene)Fe + , [B(C 6 F 5 ) 4 ] − ; (P-26): [C 12 H 25 -C 6 H 4 ) 2 I] + , [B(C 6 H 3 (CF 3 ) 2 ] − ; (P-27): [CH 3 -C 6 H 4 -I-C 6 H 4 -CH 2 CH(CH 3 ) 2 ] + , [B(C 6 F 5 ) 4 ] − ; (P-28): [CH 3 -C 6 H 4 -I-C 6 H 4 -CH 2 CH(CH 3 ) 2 ] + , [B(C 6 H 3 (CF 3 ) 2 ) 4 ] − ; and (P-29): [CH 3 -C 6 H 4 -I-C 6 H 4 -CH(CH 3 ) 2 ] + , [B(C 6 H 3 (CF 3 ) 2 ) 4 ] − .
As other reference for defining the onium borates (1) and (2) and the organometallic-salt borates (3), mention may be made of the entirety of the content of patent applications EP 0 562 897 and 0 562 922.
As further example of onium salt which can be used as photoinitiator, mention may be made of those disclosed in US patents U.S. Pat. No. 4,138,255 and U.S. Pat. No. 4,310,469.
Use may also be made of other cationic photoinitiators, for example:
hexafluorophosphate or hexafluoroantimonate iodonium salts, such as:
[CH 3 -[(C 6 H 4 )-I-[(C 6 H 4 )-CH(CH 3 ) 2 ] + , [PF 6 ] − ; [CH 3 -(C 6 H 4 )-I-(C 6 H 4 )-CH 2 CH(CH 3 ) 2 ] + , [PF 6 ] − ; [(C 12 H 25 -C 6 H 4 ) 2 I] + , [PF 6 ] − ; or
the ferrocenium salts of these various anions.
In the context of the invention, the material obtained after crosslinking exhibits color stability, good mechanical properties, good elasticity, and good compressive strength.
Besides the reinforcing fillers, pigments may be used to color the dental composition in accordance with the intended use and ethnic groups.
For example, red pigments are used in the presence of microfibers for the dental compositions used for preparing dental prostheses, in order to simulate blood vessels.
Use is also made of pigments based on metal oxides (iron oxides and/or titanium oxide and/or aluminum oxide and/or zirconium oxide, etc.) for the dental compositions used for preparing restoration material, so as to give an ivory-colored crosslinked material.
Other additives may be incorporated into dental compositions according to the invention. Examples include biocides, stabilizers, flavors, plasticizers, and adhesion promoters.
Among the additives that may be considered, use will be made advantageously of organic coreactants which are crosslinkable and/or polymerizable. These coreactants are liquid at ambient temperature or thermofusible at a temperature lower than 100° C., and each coreactant comprises at least two reactive functions such as oxetane-alkoxy, oxetane-hydroxyl, oxetane-alkoxysilyl, carboxyl-oxetane, oxetane-oxetane, alkenyl ether-hydroxyl, alkenyl ether-alkoxysilyl, epoxy-alkoxy, epoxy-alkoxysilyl, dioxolane-dioxolane-alcohol, etc.
The dental compositions according to the invention may be used for numerous dental applications, and especially in the field of dental prostheses, in the field of dental restoration, and in the field of temporary teeth.
The dental composition according to the invention is preferably in the form of a single product comprising the various components (“monocomponent”), thereby facilitating its employment, particularly in the field of dental prostheses. If appropriate the stability of this product may be ensured by means of amine-functional organic derivatives in accordance with the teaching of document WO 98/07798.
In the field of dental prostheses, the product in the “monocomponent” form may be deposited with the aid of a syringe directly on the plaster model or in a core. It is then polymerized (polymerization by possible successive layers) with the aid of a UV lamp (visible light spectrum 200-500 nm).
In general it is possible to produce an esthetic and durable dental prosthesis in 10 to 15 minutes.
It should be noted that the products obtained from the dental composition according to the invention are nonporous. Hence, after optional polishing with the aid of a felt brush, for example, the surface of the dental prostheses obtained is smooth and bright and therefore does not require the use of varnish.
The applications in the field of dental prostheses are essentially those of the attached prosthesis, and can be divided into two types:
total prosthesis in the case of a patient with no teeth at all; partial prosthesis owing to the absence of several teeth, resulting either in a temporary prosthesis or in a skeleton brace.
In the field of dental restoration, the dental composition according to the invention may be used as material for filling the anterior and posterior teeth in different colors (for example, “VITA” colors), and is rapid and easy to use.
Since the dental composition is nontoxic and can be polymerized in thick layers, it is not essential to polymerize the material in successive layers. In general a single injection of the dental composition is sufficient.
The preparations for dental prostheses and for restoration materials are carried out according to the usual techniques of the art.
In the case of application of the dental composition to a tooth, either the tooth may be pretreated with a mordant and then with a bonding primer, which may itself be photocrosslinkable, or else the dental composition may be prepared as a mixture with a bonding primer prior to its use.
The examples and tests below are given by way of illustration. They make it possible in particular to understand the invention more clearly and to highlight some of its advantages and to illustrate a number of its embodiment versions.
EXAMPLES AND TEST
a) Structures
Definition:
The total color difference ΔE represents the change which is due not to the lightness but to the color changes that are expressed as rectangular coordinates a* and b* with the aid of a spectrocolorimeter (CIELAB model).
Δa is termed the red-green chromatic shift. Δb is termed the yellow-blue chromatic shift. If Δa is positive, the shade is more red. If Δa is negative, the shade is more green. If Δb is positive, the shade is more yellow. If Δb is negative, the shade is more blue.
The chromatic shift or chromaticity difference Δc is expressed by the relationship
Δ c =[(Δ a ) 2 +(Δ b ) 2 ] 1/2 .
The values of a* measured for 144 composites were reported by Inokoshi in 1996 (Bologna International Symposium) and range between −5 and +4 and more specifically between −1 and +1. Arbitrarily, a low chromatic shift is defined when Δc is <3 between an initial measurement made ¼ hour after crosslinking and 5 days after crosslinking and storage in the dark. The composite is photocrosslinked over a thickness of 2 mm.
b) The glasses used are glasses sold by the company Schott under the reference G018-163 or G018-066, containing or not containing a radiopacifier based on strontium oxide with particle sizes of 0.7 μm, 1.5 μm or 3.5 μm and untreated or treated with glycidyloxy-trimethoxysilane or with γ-methacryloyloxypropyl-trimethoxysilane.
The examples presented below describe the benefit obtained by switching from a conventional thioxanthone as described in our patent application WO00/19967 to a thioxanthone substituted by at least one ammonium function, according to the invention.
Preparation of a thioxanthone containing ammonium borate functionality, compound (V):
An opaque flask is charged in the absence of light with 1.02 g of 3-(3,4-dimethyl-9-oxo-9H-thioxanthen-2-yloxy)-2-hydroxypropyl) trimethylammonium chloride (sold by the company Aldrich), 2.688 g of “Kisbore” salt KB(C 6 F 5 ) 4 (sold by the company Rhodia) and 50 ml of isopropanol and this initial charge is left with magnetic stirring at ambient temperature for 48 hours. The mixture is subsequently run into demineralized water (200 ml). A yellow precipitate is formed. The suspension is filtered on a commercial Büchner funnel and the solid is dried in an oven at 100° C. for 24 h. This gives the salt termed (V) (melting point 235° C.; absorption maximum λmax=397.3 nm).
Preparation of a thioxanthone containing ammonium borate functionality (VI)
An opaque flask is charged in the absence of light with 1.05 g of 3-(3,4-dimethyl-9-oxo-9H-thioxanthen-2-yloxy)-2hydroxypropyl)trimethylammonium chloride (Aldrich), 2.25 g of potassium tetrakis(3,5 trifluoro-methylphenyl)borate salt (Aldrich) and 50 ml of isopropanol and this initial charge is left with magnetic stirring at ambient temperature for 48 hours. The mixture is subsequently run into demineralized water (200 ml). A yellow precipitate is formed. The suspension is filtered on a commercial Buchner funnel and the solid is dried in an oven at 100° C. for 24 h. This gives the salt termed (VI) (melting point 230° C.; absorption maximum λmax=395 nm).
Example 1
Preparation Of A Control Formulation 1
A Hauschild centrifugal mixer is charged with 5 g of siloxane resin having a monomer (S-1) content >90% and obtained by hydrosilylation of vinylcyclohexene oxide and with 0.6 g of a 4% solution of Disperbyk164® dispersant in this resin (S-1); 0.625 g of photoinitiator system in (S-1), containing 30% of photoinitiator (P-27) and 0.23% of photosensitizer based on chloropropoxythioxanthone (CPTX), sold by the company Lambson, is added, all in solution in the resin (S-1) without solvent.
This initial charge is stirred with the centrifugal mixer at 3000 rpm at ambient temperature for 16 s and then 13.25 g of quartz (particle size 1.5 μm, sold by the company Schott under the reference G018-163 UF1.5 and treated with 2% of glycidyltrimethoxysilane) are added. The mixture is stirred with the centrifugal mixer at 3000 rpm for 16 s and 1.5 g of ytterbium trifluoride are added.
Stirring is repeated with the centrifugal mixer at 3000 rpm for 16 s and then 1.5 g of fumed silica (SiO 2 >99%) sold by the company Degussa under the reference OX50®, are added, followed by stirring for 16 s. Finally, 2.5 g of fumed silica sold by the company Degussa under the reference R202® are added. Stirring with the centrifugal mixer is carried out for 16 s.
The formulations crosslink over a thickness of 2 to 2.5 mm with an irradiation time which is dependent on the thioxanthone used, using an Optilux Demetron lamp, this time being generally between 30 s and 1 minute.
With the aid of a Minolta CR200 colorimeter or chromameter, the L*, a* and b* values are measured after ¼ hours after crosslinking against a white background and after 5 days after crosslinking. The resulting chromatic shift Δc is deduced from these measurements: Δc=[(Δa) 2 +(Δb) 2 ] 1/2
Example 2
Preparation of a Formulation According to the Invention:
The experiment of example 1 is repeated, replacing the control thioxanthone by thioxanthones (IX) and (V), alone or in combination with the following derivatives:
9,10-dibutoxyanthracene (PS-39), phenanthrenequinone (PS-33), and camphorquinone (PS-34).
A control formulation based on compounds (PS-34) and (PS-39) is also formulated.
In examples 2e to 2h, the 3.5-micron G018-066 filler is replaced by a G018-163 glass treated with GLYMO (2.5%) and then by the resin (S-1) at 5%.
The results are set out in table I.
TABLE I
Photo-
Concentration (s)
T = 1/4 hour; L a, b
T = 5 d; L, a, b
Example
sensitizer (s)
ppm
L*
a*
b*
L*
a*
b*
Δc
1a (comparative)
CPTX
60
72.3
4.7
3.9
76.6
1.97
6.36
3.65
2a (inventive)
(IX)
80
76.5
0.96
10.6
79.3
−0.13
10.4
1.1
2b (inventive)
(IX)
220
74.5
4.14
14.3
76.7
3.2
15.3
1.37
2c (inventive)
(V)
220
77.7
0.98
12.4
80.4
−0.31
11.9
1.38
2d (inventive)
(V)
170
78.8
0.50
9.3
80.3
−0.8
8.73
1.42
2e (inventive)
(V);
170;
73.4
0.46
14.16
76.47
−1.0
13.04
1.84
(PS-39)
130
2f (inventive)
(V);
170;
70.1
−0.21
15.68
73.69
−1.33
13.94
2.07
(PS-34);
100;
(PS-39)
120
2g (inventive)
(V);
170;
69.08
1.41
15.58
73.42
−0.79
15.07
2.26
(PS-33);
50;
(PS-39)
110
2h (comparative)
(PS-34);
100;
Kinetics insufficient for crosslinking over 3 mm
(PS-39)
160
in 1 minute
It is observed that the crosslinking with a Demetron Optilux 500 dentist's lamp of dental compositions formulated with the photosensitizers (V) or (IX), alone or in combination with other photosensitizers, for example (PS-39), (PS-34) or (PS-33), does not give rise to any coloration defect (no phenomenon of pinking during irradiation, with a low chromatic value a immediately after irradiation). A similar improvement is observed when a thioxanthone of formula (VI) is used.
The use of a thioxanthone (V), (VI) or (IX) according to the invention makes it possible to avoid the coloration problems but also the kinetic problems which are encountered using solely camphorquinone (S-34) in combination with the anthracene derivative (PS-39) (comparative exemple 2).
It is thereby shown that thioxanthones containing ammonium functionality give rise to an increased coloring stability. An initial pink color change is observed with the comparative composition of example 1 (CPTX), even at a low level of 60 ppm, which attenuates over time but which is still measurable after 5 days (a*=1.97), in contrast to the use of thioxanthones containing ammonium functionality, which do not give rise to this coloration defect at a low level and which, surprisingly, make it possible to preserve a greater color stability. | Dental compositions are described which are photocurable by radiation with a wavelength greater than 390 nm. The compositions include a cationically active compound, a dental filler, optionally a dispersant, a cationic photoinitiator and a photosensitizer which is a thioxanthone salt substituted by at least one group containing an ammonium function. The composition has the advantage of remedying the color stability problems of finished dental products after crosslinking. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is the U.S. national phase, under 35 USC 371, of PCT/DE2003/004038, filed Dec. 9, 2003; published as WO 2004/054804 A1 on Jul. 1, 2004, and claiming priority to DE 102 58 326.9 filed Dec. 13, 2002, the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to methods for controlling a first roller, which takes up a dampening agent from a dampening agent source, and a second roller and to dampening units. The rollers are part of a roller train which is used for conveying the dampening fluid to the forme cylinder.
BACKGROUND OF THE INVENTION
[0003] A dampening unit is known from U.S. Pat. No. 3,168,037. Either a fountain roller, which takes up the dampening agent from a dampening agent reservoir, or a transfer roller which is rolling off on the fountain roller, are driven by a controllable drive mechanism in such a way that a rotating speed of these two rollers can be changed. However, the magnitude of the rotating speed of these two rollers is always identical.
[0004] A dampening unit is known from U.S. Pat. No. 3,986,452. A fountain roller, taking up a dampening agent from a dampening agent reservoir, and at least one further roller, which is in roller-to-roller contact with the fountain roller, have controllable drive mechanisms, each of which drive mechanisms is independent of the other. This further roller is in a roller-to-roller contact with a dampening agent application roller that is placed against a forme cylinder. A traversing bridge roller is placed against the dampening agent application roller.
[0005] A dampening unit, with a fountain roller taking up a dampening agent from a dampening agent reservoir and with a slip roller rolling off on the fountain roller, is known from EP 0 893 251 A2. Both rollers can be driven by separate drive mechanisms, if required. Both rollers always have the same surface speed.
[0006] A film-type dampening unit for rotary printing presses is known from EP 0 462 490 A1. In a roller train extending from a dampening agent tank as far as the forme cylinder and consisting of three or four rollers, a fountain roller and a metering roller are driven together by a first electric motor. A dampening agent distribution roller following the metering roller in the roller train is additionally moved axially back and forth by a mechanism. A bridge roller is placed against a dampening agent application roller which is placed against the dampening agent distribution roller and the forme cylinder.
[0007] A dampening unit of an offset rotary printing press is known from DE 29 32 105 C2. The dampening unit has a roller train, consisting of three rollers, extending from the dampening agent pick-up up to the forme cylinder. Each one of the three rollers is driven independently of each other by a controllable electric motor, each of which controllable electric motor preferably can be set in an infinitely variable manner.
[0008] A drive mechanism for the dampening unit of an offset printing press is known from DE 38 32 527 C2. A traversing bridge roller is provided, which is simultaneously placed against a dampening agent application roller and an ink application roller. The bridge roller is pneumatically driven. Its number of revolutions is controlled by changing the pneumatic pressure.
[0009] A dampening unit for a printing press is known from DE 299 00 216 U1. A first roller, which takes up a dampening agent, and a second roller, which is connected with the first roller for transferring dampening agent, are provided. Both of these rollers are rotatably driven. A slippage between the two rollers exists, which slippage can be set by a control device when the dampening unit is operated.
[0010] Drive mechanisms for a printing group are known from WO 03/039873 A1. The rotatory driving device and the traversing driving device of a roller are arranged on opposite ends of the roller.
[0011] A dampening unit of an offset rotary printing press is known from JP-A-01 232 045. The dampening unit has a roller train consisting of three rollers that are positioned extending from the dampening agent pick-up up to the forme cylinder. The fountain roller, which is the first roller, as well as the transfer roller which is the second roller are driven independently of each other, each by a controllable motor.
SUMMARY OF THE INVENTION
[0012] The object of the present invention is directed to providing a method for controlling a first roller, which takes up a dampening agent from a dampening agent source, and a second roller.
[0013] In accordance with the present invention, the object is attained by the provision of a roller train that conveys dampening fluid from a source of dampening fluid to a forme cylinder in a printing press. The roller train includes at least first and second rollers, the first of which contacts the dampening fluid and the second of which is in contact with the first. Each of these at least two rollers has its own separate drive motor. The first and second rollers are a roller train that may include other rollers which may also have their own drive sources. Surface speeds of the at least first and second rollers may be different from each other.
[0014] The advantages to be gained by the present invention lie, in particular, in that the first or fountain roller and an adjacent second dampening agent transfer roller can be controlled completely independently of each other. The slippage that is formed between them, because of an intentional difference in their surface speeds, is adjustable as may be needed, for accomplishing a correct metering of a dampening agent which is to be applied to the rollers. The adjustment of the slippage takes place, in particular, as a function of a change of the surface speed of the forme cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Preferred embodiments of the present invention are represented in the drawings and will be described in greater detail in what follows.
[0016] Shown are in:
[0017] FIG. 1 , a dampening unit with four rollers in a roller train extending to the forme cylinder in accordance, with the present invention, and in
[0018] FIG. 2 , a dampening unit with three rollers in a roller train extending to the forme cylinder also in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In somewhat schematic representations, FIGS. 1 and 2 each show a dampening unit 01 , preferably a film-type dampening unit 01 in accordance with the present invention and, with a first roller 04 and a second roller 06 . The first roller 04 takes up a dampening agent 02 , such as, for example, water 02 or an alcohol-water mixture 02 from a dampening agent source 03 , such as, for example, a dampening agent reservoir 03 , and, in particular, a dampening agent tank 03 , or from a dampening agent trough 03 . The first roller 04 transfers at least a portion of the dampening agent 02 directly to the second roller 06 , which is arranged adjacent to the first roller 04 . Therefore, the first roller 04 is preferably embodied as a fountain roller 04 or as a duct roller 04 . Alternatively, the dampening agent source 03 can be embodied as, for example, a spray crosspiece 03 with a least one spray nozzle 03 , which sprays the dampening agent 02 onto the first roller 04 , and wherein the dampening agent 02 is now applied to the first roller 04 in the form of finely distributed droplets. Further possible configurations provide for embodying the dampening unit 01 as a brush dampening unit or as a centrifugal dampening unit, with which the dampening agent 02 is also applied to the first roller 04 in a contactless manner. The second roller 06 can be a metering roller 06 , a dampening agent transfer roller 06 or a distribution roller 06 , each one of which is preferably provided with a chrome-plated surface, or with a ceramic-coated surface. The first roller 04 is the first of several rollers in a roller train, over which the dampening agent 02 is conveyed from the dampening agent reservoir 03 to the forme cylinder 09 of a printing press operated by the offset printing process, to which the dampening unit 01 has been assigned. The two embodiments of the present invention, as depicted in FIGS. 1 and 2 , differ, in particular, in the number of rollers which are arranged in the roller train.
[0020] The printing press is configured as, for example, a jobbing printing press. Its printing group has at least one forme cylinder 09 and one transfer cylinder, which is not specifically represented, and wherein these two cylinders roll off on each other. A jobbing printing press, and preferably a jobbing printing press which is operating using the offset printing method, is understood to be a printing press with a forme cylinder 09 , wherein only a single printing forme is arranged on its forme cylinder 09 in the axial direction of the forme cylinder, wherein the printing forme preferably has several print image locations in a direction extending axially in respect to the forme cylinder 09 , and wherein the print image locations are not in a predetermined format,so that these print image locations can have any arbitrary width within defined limits, in particular in a direction extending axially with respect to the forme cylinder 09 .
[0021] To attain a good printing result, dampening units 01 , which use a dampening agent 02 to which dampening agent 02 , for example for reducing environmental stress or for the reduction of its cost, preferably no alcohol at all, or only very little alcohol and, in particular isopropyl alcohol (IPA) of clearly less than 5% of the volume of all the matter added to the dampening agent 02 as a whole has been added, require a very precise setting of the amounts of dampening agent 02 . This precise setting of the amount of dampening agent 02 is matched to the respective production speed of the printing press and to the amount of dampening agent 02 that is to be conveyed to the forme cylinder 09 during the production of the printing press, i.e. while it is printing. To make matters worse, it is necessary to accomplish an increasingly higher production speed of the printing presses. Today's printing presses easily attain a production speed of their printing group cylinders in the range of 70,000 to 80,000 revolutions per hour. If the diameters of the transfer cylinders and of the forme cylinders 09 , which are in operative contact with each other, are identical, the production speed of the printing press corresponds to the surface speed v 09 of the forme cylinder 09 . The dampening unit 01 , with the characteristics which will be described in what follows, assures the transport of a sufficient amount of dampening agent 02 , which amount can be exactly metered, even at such high production speeds.
[0022] Furthermore, the amount of the dampening agent 02 which is required at the forme cylinder 09 for attaining good printing results is a function of the emulsification properties of the ink used and of the amount of ink required for producing the printed product. The ink and the dampening agent 02 form a mixture in which depending on the condition of the ink, a volumetric portion of the amount of the dampening agent 02 , which can be varied within defined limits, can be mixed together with the ink. The ink switched back into the dampening unit 01 can absorb the dampening agent 02 in amounts between 15% and 25%, for example. The amounts absorbed increase with an increase in the surface speed v 09 of the forme cylinder 09 . However, a threshold value for the amount of dampening agent 02 emulsified by the ink is set because, for example, the ink which is imprinted on a material to be imprinted, such as, for example, a paper web, must dependably dry in the course of the passage of the material to be imprinted through a drying unit, such as, for example, a headset dryer, which is arranged downstream of the printing group. Because of the desired high production speed of the printing press, of 12 m/s or more, the retention time of the material to be imprinted in the drying unit is very short.
[0023] The more colored print image locations a printed product has, the more ink is needed at the forme cylinder 09 . Accordingly, to set a required balance between ink and dampening agent 02 , it is also necessary, in such a case, to make available a greater amount of dampening agent 02 at the forme cylinder 09 if a more color-intensive printed product is produced by the printing press. Therefore, to obtain a satisfactory printing result, the dampening unit 01 , with the characteristics to be described in what follows, matches the amount of dampening agent 02 made available at the forme cylinder 09 also as a function of the condition of the ink and as a function of the amounts of the ink required for the printed product to be formed.
[0024] In order to make possible an adaptation of the requirements of the amounts of dampening agent 02 made available at the forme cylinder 09 , as a function of the production speed of the printing press and as a function of the balance between ink and dampening agent 02 to be set, the first roller 04 and the second roller 06 have separate drive mechanisms 07 , 08 , which can be controlled independently of each other. Drive mechanisms 07 , 08 for the first roller 04 and for the second roller 06 respectively, which drive mechanisms 07 , 08 can be controlled independently of each other, have the advantage that a surface speed v 04 of the first roller 04 , as generated by the drive mechanism 07 , and a surface speed v 06 of the second roller 06 , as generated by the drive mechanism 08 , do not rigidly follow a parameter affecting the amount of dampening agent 02 . Instead, for accomplishing a matching of the amounts of dampening agent 02 to be conveyed, the ratio of the surface speeds v 04 , v 06 with respect to each other, can also be variably set according to the requirements, by which variation the metering of the dampening agent 02 to be conveyed by the dampening unit 01 is considerably affected. As a function of the actually existing printing process, and for the same value of the surface speed v 09 of the forme cylinder 09 , different settings of the surface speed v 04 of the first roller 04 and of the surface speed v 06 of the second roller can result, as well as differences regarding their ratio with respect to each other.
[0025] As a rule, the surface speed v 04 of the first roller 04 , as generated by the first drive mechanism 07 , and the surface speed v 06 of the second roller 06 , as generated by the second drive mechanism 08 are different from each other. Preferably, the surface speed v 04 of the first roller 04 is less than the surface speed v 06 of the second roller 06 . The surface speeds v 04 , v 06 can be set independently of each other and can both be set variably. In a preferred embodiment of the present invention, the surface speed v 06 of the second roller 06 lies, for example, between twice and four-and-a half times, and in particular is three times that of the surface speed v 04 of the first roller 04 . The magnitude of the surface speed v 04 of the first roller 04 is limited by the requirement that the first roller 04 must dependably pick up the dampening agent 02 out of the dampening agent reservoir 03 on its surface. Experience has shown that, at a surface speed v 04 of the first roller 04 , starting at more than 2 m/s, the dependable pickup of dampening agent 02 is no longer assured. At surface speeds above that value, considerable amounts of the dampening agent 02 are flung off the surface of the first roller 04 . Therefore, the surface speed v 04 of the first roller 04 is preferably set to values which are lower than its upper limit speed, such as, for example, to a value of at most 1.5 m/s. In contrast to this, the surface speed v 09 of the forme cylinder 09 lies in a range of 12 m/s to 15 m/s, for example.
[0026] If the surface speed v 06 of the second roller 06 is greater than the surface speed v 04 of the first roller 04 , which as a rule, is the case, a slippage exists between the first roller 04 and the second roller 06 , because the surface speed v 04 of the first roller 04 lags behind the surface speed v 06 of the second roller 06 . This slippage, which is formed by a ratio of the two surface speeds v 04 , v 06 of the two rollers 04 , 06 , can be variably set by the use of the drive mechanisms 07 , 08 of the first roller 04 and of the second roller 06 , which drive mechanisms 07 , 08 are independent of each other.
[0027] The amount of dampening agent 02 which is to be conveyed by the roller train of the dampening unit 01 must be adjusted as a function of a change of the surface speed v 09 of the forme cylinder 09 which is driven by a further, separate drive mechanism 18 , such as, for example, when increasing the surface speed v 09 of the forme cylinder 09 , for example when increasing the surface speed v 09 from a set-up speed of the printing press to its production speed. For example, the set-up speed of the printing press lies between 1.7 m/s and 3.4 m/s, and preferably lies between 2 m/s and 2.6 m/s, and therefore amounts to between 11% and at most to 25% of the production speed of the printing press, or the surface speed v 09 of the forme cylinder 09 . Thus, to reach the production speed, the surface speed v 09 of the forme cylinder 09 is increased by a magnitude of between four times to nine times, starting from the set-up speed. A rapidly reacting dampening system unit 01 , which can be matched to the requirements of the dampening agent 02 to be conveyed, is therefore required for such a large increase in speed. In the same way, the conveyed amount of dampening agent 02 must also be adjusted during a period of start-up of the printing press from its stopped state, or when the production speed is being reduced. Moreover, as previously mentioned, the actual requirement for dampening agent 02 is a function of the amount of ink needed for the production of the printed product. In many cases of application, and in particular in connection with printing presses with a large increase in speed, a sufficient reaction to this matching requirement is not always possible with a rigid coupling, such as, for example, with a gear coupling between the first roller 04 and the second roller 06 .
[0028] To provide the required matching, the number of revolutions of the drive mechanisms 07 , 08 of the first and second rollers 04 , 06 , respectively of the dampening unit 01 are controllable, and preferably are infinitely variably controllable, and in particular are electronically controllable. Control of the numbers of revolution can be performed remotely, such as, for example, from a control console that is assigned to the printing press. The drive mechanisms 07 , 08 for the first roller 04 and for the second roller 06 , respectively are preferably embodied as electric motors 07 , 08 , such as, for example, a.c. or d.c. motors 07 , 08 , or as frequency-controlled, multiphase a.c. motors 07 , 08 . The drive mechanism 18 of the forme cylinder 09 can also be embodied as an electric motor 18 , such as, for example, an a.c. or a d.c. motor 18 or as a frequency-controlled multiphase a.c. motor 18 . In a manner that is the same as the drive mechanisms 07 , 08 of the rollers 04 , 06 of the dampening unit 01 , this motor 18 can also be controllable. The drive mechanism 18 of the forme cylinder 09 is independent of the drive mechanisms 07 , 08 of the rollers 04 , 06 of the dampening unit 01 . There is no positive connection between the drive mechanisms 07 , 08 of the rollers 04 , 06 and the drive mechanism 18 of the forme cylinder 09 . It is not a requirement that the drive mechanism 18 of the forme cylinder 09 only drives the forme cylinder 09 . The drive mechanism 18 can transfer the torque it has generated at least to the forme cylinder 09 , and possibly also to the transfer cylinder, which is not specifically represented, and which works together with the forme cylinder 09 .
[0029] If required, the control device for the drive mechanisms 07 , 08 , 18 can be expanded into a regulating device by adding a positive feedback device, that is picking up an actual value, and an evaluation device for evaluating a feed-back signal. The actual value of a number of revolutions of the rollers 04 , 06 or of the forme cylinder 09 is detected, for example, by the use of a sensor which is providing an electrical output signal. The control or the regulation of the drive mechanisms 07 , 08 is preferably performed with the aid of a suitable computing unit which is not specifically represented, and which, for example, predetermines a corridor for advantageous setting values.
[0030] The first roller 04 and the second roller 06 of the dampening unit 01 constitute the first and second rollers in the roller train that is conveying the dampening agent 02 to the forme cylinder 09 . The surface speed v 04 of the first roller 04 and the surface speed v 06 of the second roller 06 can be set independently of each other and each without a rigid dependence on the surface speed v 09 of the forme cylinder 09 . As a rule, the surface speed v 04 of the first roller 04 , or the surface speed v 06 of the second roller 06 are both less than the surface speed v 09 of the forme cylinder 09 .
[0031] In a first operating state of the dampening unit 01 , it is possible to provide an operating mode so that the surface speed v 09 of the forme cylinder 09 and the surface speed v 06 of the second roller 06 are at a first ratio with respect to each other, while in a second operating state of the dampening unit 01 , the surface speeds v 09 , v 06 are at a second ratio with respect to each other. The surface speed v 09 of the forme cylinder 09 can have the same value during both of the operating states of the dampening unit 01 , or alternatively can assume values which differ from each other.
[0032] The roller train to the forme cylinder 09 can be expanded by the addition of a third roller 11 , or also by the addition of a fourth roller 13 , wherein the third roller 11 is placed downstream of the second roller 06 and the fourth roller 13 is placed downstream of the third roller 11 . The third roller 11 is coupled, for example by the use of a set of gears 12 , such as, for example, a gear wheel drive 12 or a belt drive 12 , with the second roller 06 . Alternatively, driving of the third roller 11 can take place by friction, for example at the second roller 06 , or by friction with the forme cylinder 09 . The surface speeds of the several rollers provided in the roller train extending from the dampening agent reservoir 03 to the forme cylinder 09 has been respectively set in such a way that there is slippage between the second roller 06 and the third roller 11 , or between the third roller 11 and the fourth roller 13 . The slippage between the first roller 04 and the second roller 06 can be, for example, 1:3, wherein the first roller 04 rotates slower than the second roller 06 . The slippage between the second roller 06 and the third roller 11 can be selected to be considerably greater, wherein, for example, the third roller 11 rotates very much faster than the second roller 06 .
[0033] For accomplishing an improved distribution of the dampening agent 02 on the surfaces of the rollers 06 , 11 , 13 which are arranged in the roller train, and for preventing patterning, at least one of these rollers 06 , 11 , 13 , which follow the first roller 04 in the roller train, can be embodied to also perform traversing movements. It is advantageous to decouple or to separate the traversing drive mechanism 19 provided for this purpose from the rotatory drive mechanisms 07 , 08 of the rollers 06 , 11 , 13 and to configure it to be controllable independently of the latter. The frequency of the traversing movement, in particular, can be freely selected. The length of the traversing movement is for example ±8 mm. However, it is also possible to provide a variably adjustable length for the traversing movement of, for example, between 0 mm and 16 mm. The traversing drive mechanism 19 is embodied, for example, as an electrical motor 19 , such as, for example, a linear motor 19 . The roller 11 or 13 , which is transferring the dampening agent 02 to the forme cylinder 09 , is, in particular, driven by friction by the forme cylinder 09 .
[0034] An inking unit 16 , with at least one ink application roller 17 which can be placed against the forme cylinder 09 , is assigned to the forme cylinder 09 . The inking unit 16 inks a printing forme, which is not specifically represented and which is mounted on the surface of the forme cylinder 09 by use of the ink application roller 17 . The roller 06 or 11 or 13 which is primarily applying the dampening agent 02 to the forme cylinder 09 , and,depending on the embodiment of the roller train, which is the second roller 06 , the third roller 11 or the fourth roller 13 , can then advantageously be placed simultaneously against the forme cylinder 09 and also against the ink application roller 17 , or against an ink distribution roller of the inking unit 16 which is working together with the forme cylinder 09 . The placement of the roller 06 , 11 or 13 , which applies the dampening agent 02 to the forme cylinder 09 , against the ink application roller 17 can therefore occur either directly or can occur indirectly, for example via a bridge roller 14 which is embodied as an ink distribution roller 14 . In connection with a dampening unit 01 that is configured with four rollers 04 , 06 , 11 , 13 in the roller train in particular, it is also possible to provide a further second bridge roller 23 , that is represented in dashed lines in FIG. 1 and which is placed upstream of the first bridge roller 14 , wherein the upstream located bridge roller 23 is arranged between the first bridge roller 14 and the third roller 11 , i.e. the roller 11 which, in the roller train, is arranged upstream of the fourth roller 13 , which fourth roller 13 applies the dampening agent 02 to the forme cylinder 09 . Preferably, the first bridge roller 14 is seated in a frame, which is not specifically represented, and is movable by at least one actuating device, such as, for example, by a remote-controlled working cylinder, and in particular by a pneumatic cylinder which is not specifically represented, in such a way that it can selectively assume, for example while being controlled from a control console, one of four operating positions as described in what follows. In one operating position the first bridge roller 14 is placed against the ink application roller 17 and not against the roller 06 , 11 or 13 which is applying the dampening agent 02 to the forme cylinder 09 . In another, second operating position, the bridge roller 14 is placed against the roller 06 , 11 or 13 which is applying the dampening agent 02 to the forme cylinder 09 and not against the ink application roller 17 . In a further or third operating position, the bridge roller 14 is placed simultaneously against the roller 06 , 11 or 13 that is applying the dampening agent 02 to the forme cylinder 09 and also against the ink application roller 17 , which is its normal operating position, and wherein the bridge roller 14 can be additionally moved into the other operating positions. The bridge roller 14 furthermore can be simultaneously removed from contact with the roller 06 , 11 or 13 which is applying the dampening agent 02 to the forme cylinder 09 and from contact with the ink application roller 17 . The bridge roller 14 is placed into contact if it is touching one of the rollers 06 , 11 or 13 which is applying the dampening agent 02 to the forme cylinder 09 , and/or if it is touching the ink application roller 17 , or is at least in an operative contact with them, for conveying the ink or the dampening agent 02 . It is removed out of contact if its surface does not touch the surface of one of the rollers 06 , 11 or 13 , or if the surfaces of the rollers 06 , 11 or 13 are at least not in operative contact for conveying the ink or the dampening agent 02 . The upstream positioned bridge roller 23 can also have several operating positions by being either in contact with the first bridge roller 14 or with the third roller 11 of the roller chain, or by being removed from contact with at least one of these rollers 11 , 14 , wherein at least one actuating device, which is not specifically represented, such as, for example, a working cylinder, and in particular a pneumatic cylinder, is provided. The actuating device moves the upstream located bridge roller 23 from one operating position into the other operating position. The operation of this actuation device can preferably also take place by remote control, and in particular can be accomplished from the control console.
[0035] Upon contact between the rollers, a flattened contact strip of a width of between 3 mm and 8 mm, and preferably of between 5 mm and 6 mm, is formed extending in the axial direction of, and between the rollers 04 , 06 , 11 , 13 on their surfaces. The flattened contact strip between the roller 06 , 11 , or 13 which is applying the dampening agent 02 to the forme cylinder 09 , or between the ink application roller 17 and the forme cylinder 09 , can have a width of from 8 mm up to 10 mm. The contact force between the rollers 04 , 06 , 11 , 13 , 17 and the forme cylinder 09 is set, for example manually, by the use of an adjusting spindle, preferably through a path change, wherein the set width of the contact strip remains unchanged during the printing process. If the width of the contact strip is to be changeable during the printing process, it is advantageous to perform the setting of the rollers 04 , 06 , 11 , 13 , 17 by the use of a roller lock, which roller lock performs, while, for example, being remotely controlled preferably by actuation from the control console, a radial lift. As a rule, the setting of the width of the contact strip takes place independently of the surface speed v 09 of the forme cylinder 09 .
[0036] The bridge roller 14 is preferably structured so that it is able to perform traversing movements and is driven, for example, by a traversing drive mechanism 21 , which is preferably embodied as a controllable motor 21 , such as, for example, a linear motor 21 , and which is preferably independently of its rotatory movement. A further drive mechanism 22 for the bridge roller 14 , which is independent of the other drive mechanisms 07 , 08 , 18 , can be provided as, for example, a motor 22 , preferably an a.c. or d.c. motor 22 or a frequency-controlled multiphase a.c. motor 22 , and in particular as an electrical motor 22 which can be remote-controlled.
[0037] If the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , is driven by friction, this roller 11 or 13 can be seated in the frame in such a way that an axial or transverse lift or displacement of, for example, 3 mm to 4 mm, is possible. This lift or axial displacement is performed in that roller 11 or 13 is taken along by the traversing movement of the bridge roller 14 . Preferably no, or only a minimal slippage of less than 2%, and preferably of less than 1%, exists between the roller 11 or 13 , which is applying the dampening agent 02 , and the forme cylinder 09 . As an alternative to frictional driving, and in connection with special applications, it is, however, also possible to provide the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , with its own drive mechanism, which is not specifically represented, for the rotatory movement, which dampening agent application roller drive mechanism is independent of the other drive mechanisms 07 , 08 , 18 , 22 , and which may be, for example a motor, and preferably may be an a.c. or a d.c. motor or a frequency-controlled multiphase a.c. current motor.
[0038] To change the dampening unit 01 between a first operating mode, for “direct dampening,” and a second operating mode, for “indirect dampening,” the roller 11 or 13 , that is used for applying the dampening agent 02 to the forme cylinder 09 , can be placed against the bridge roller 14 or can be moved away from it. For this purpose, the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , which, in this case, is the roller 13 , is represented in two operating positions, as is shown in FIG. 2 . In the dot-dash line representation, the roller 13 has been moved away from the bridge roller 14 . To move the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , into its desired operating position, at least one actuating device, which is not specifically represented, and which preferably is remote-controlled, for example from the printing press control console, is provided, for example as a working cylinder, and preferably as a pneumatic cylinder. This actuating device brings the roller 11 or 13 , that is applying the dampening agent 02 to the forme cylinder 09 , into one of the two operating positions with respect to the bridge roller 14 , or moves it away from the forme cylinder 09 . The roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , can be seated in eccentric bushings, for example, and in which eccentric bushings the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , can be moved into its desired operating position by the actuating device. The operating mode characterized as “direct dampening” is selected if the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , is placed against the forme cylinder 09 and is moved away from the bridge roller 14 . In this mode of operation the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , only applies the dampening agent 02 to the forme cylinder 09 . The mode of operation characterized as “indirect dampening” is selected if the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , is simultaneously placed against both the forme cylinder 09 and the bridge roller 14 . During this “indirect dampening,” the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , also conveys a not inconsiderable amount of ink that is coming from the inking unit 18 to the forme cylinder 09 .
[0039] The first roller 04 and the second roller 06 can be moved together away from the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 . For this purpose, the first roller 04 and the second roller 06 can be seated in a common support, which is not specifically shown. The common support has a rotating point, around with the support can be rotated, so that the first roller 04 and the second roller 06 together pivot away from the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 .
[0040] The surface of the first roller 04 consists, for example, of an elastomeric material, preferably rubber, and in particular consists of a material of a hardness between 20 and 30 Shore A, and preferably of approximately 25 Shore A. The surface of the second roller 06 consists of, for example, a ceramic material or of a chromium-containing material, and where a coating of a chromium-containing material has been applied to a roller core of a metallic material, for example. The surface of the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , in turn consists of, for example, an elastomeric material, preferably rubber, and in particular of a material of a hardness between 25 and 40 Shore A, and preferably of approximately 35 Shore A. The surface of the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 , is therefore made harder than the surface of the first roller 04 . The surface of the second roller 06 is preferably selected to be very much harder, for example harder by a factor of ten, than the surface of the first roller 04 or the surface of the roller 11 or 13 , which is applying the dampening agent 02 to the forme cylinder 09 . The surface of the bridge roller 14 is made of a plastic material, for example, and is preferably preferably made of Rilsan. However, the surface of the upstream located second bridge roller 23 can consist of an elastomeric material, preferably of rubber.
[0041] The ratio of the surface speed of the forme cylinder 09 with respect to the surface speed of the roller 13 applying the dampening agent 02 to the forme cylinder 09 ; with respect to the surface speed of the third roller 11 ; with respect to the surface speed of the second roller 06 ; and with respect to the surface speed of the first roller 04 are, for example, like 1 to between 1 to 0.98; to between 0.4 to 0.98; to between 0.25 to 0.4 and to between 0.08 to 0.18, and are preferably 1 to 0.99 to 0.96 to 0.33 to 0.1. If only three rollers in the roller train between the forme cylinder 09 and the dampening agent reservoir 03 are being used, the slippage ratio, which was separately mentioned above for the third roller 11 , can be omitted, because the roller 11 is now already the roller applying the dampening agent 02 to the forme cylinder 09 .
[0042] While preferred embodiments of methods for controlling both a first roller, which takes up dampening agent from a dampening agent source, as well as a second roller, and dampening systems in accordance with the present invention have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that various changes in, for example, the specific structure of the printing press, the type of material to be printed, and the like could be made without departing from the spirit and scope of the present invention which accordingly is to be limited only by the appended claims. | A first roller, which takes up dampening fluid from a dampening agent reservoir, and a second roller, are controlled. The first roller transfers the dampening fluid to the second roller. The first roller and the second roller have separate driving devices and their individual surface velocities differ from each other because of their separate driving devices. A change in the velocity of a forme cylinder results in a change in the slip between the first and second rollers. Dampening systems are also contemplated. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to the art of electrical control systems, particularly control system for comminuting apparatus. The present invention finds particular application in reprocessing vulcanized rubber by comminuting rubber pellets to micron-sized particles and will be described with particular reference thereto. It is to be appreciated, however, that the invention finds application in the comminution or size reduction of other solid materials such as synthetic and natural elastomers, plastics, coal, and the like.
Heretofore, comminuting apparatus have commonly included a pair of comminuting stones, one stationarily mounted and the other rotatably mounted, between which particles were comminuted to smaller sizes. A slurry of particles or pellets and water were pumped between the rotor and stator to be comminuted therebetween. Fluid cylinders were provided for urging the rotor and stator together with a preselected pressure or force.
In one prior art apparatus, an operator was relied upon to control and adjust the operating parameters. Human control has several drawbacks relative to automated controllers including a relatively slow response time, relatively high hourly cost, judgemental errors, and the like.
The present invention provides an automatic control system for comminuting apparatus and the like which overcomes the above-referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with the present invention, a comminuting apparatus includes a rotor and stator for comminuting pellets therebetween, a motor for causing relative rotational movement between the stator and rotor, and a pressure regulator assembly for controlling the pressure or force with which the rotor and stator are urged together. A slurry supply assembly provides a slurry of pellets to be comminuted intermixed with a fluid. A power monitor monitors the amount of power expended by the motor while causing relative rotation between the stator and rotor. A force adjusting means is operatively connected with the power monitoring means for selectively adjusting the force with which the pressure regulator assembly urges the rotor and stator together in such a manner that the expended motor power is retained in a preselected range. In this manner, the pressure between the rotor and stator is selectively adjusted to maintain the power drawn by the motor substantially constant.
In accordance with another aspect of the present invention, the control system undertakes a series of logic calculations to optimize the efficiency with which the comminuting apparatus is brought up to full operating capacity. The controller controls the concentration of pellets within the slurry and the pressure between the rotor and stator in a coordinated manner. Specifically, the controller starts a generally pellet-free slurry flowing to the rotor and stator which are rotated with relatively little pressure therebetween. The pressure between the rotor and stator is increased and the concentration of pellets in the slurry is increased until full operating conditions are achieved.
A primary advantage of the present invention is that it maximizes the overall efficiency of comminuting apparatus.
Another advantage of the present invention is that it protects against system failure attributable to operator error or lack of attention to varying operating conditions.
Another advantage of the present invention is that it increases comminution rates.
Still further advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various parts and arrangements of parts or various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment of the invention and are not to be construed as to limiting it. Wherein, the figures show:
FIG. 1 is an elevational view in partial section which diagrammatically illustrates a comminuting apparatus in accordance with the present invention; and,
FIGS. 2A and B are a wiring diagram of a preferred embodiment of the control system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a slurry feeding means A feeds a slurry of fluid and pellets of vulcanized rubber or other materials to be comminuted to a mill B. In the mill, the slurry is passed through a grinding zone in which a combination of pressure and relative movement divides the pellets into micron-sized particles in a single pass. A pressure regulating means or assembly C selectively adjusts the pressure in the grinding region. An electrical control system or means D selectively monitors operating conditions at various points in the feed means A and the mill B in order to control the operating parameters of the various components of the comminuting apparatus herein described below. Briefly stated, the control means D controls the start-up of the mill to bring the mill to its steady state comminuting condition quickly and efficiently. Further, the control means controls the steady state operating conditions to maintain high efficiency. In particular, the control means controls the concentration of pellets in the slurry supplied by the slurry feed means A and controls the pressure regulating means C to vary the pressure in the grinding zone, both in such a manner that a substantially constant amount of energy or power is drawn by the mill B to comminute the pellets. A dryer E separates the comminuted particles from the fluid to produce a dry, particulate product.
The slurry feeding means A includes a pellet feeding means 10 for supplying pellets of vulcanized rubber, plastics, synthetic rubber, other elastomers, coal, or the like at a selectable rate. The pellet feeding means includes a pellet hopper 12 which discharges the pellets into a vibratory feeder 14. The vibratory feeder includes a generally horizontal trough 16 which is vibrated by a motor 18. The vibratory feeder 14 feeds the pellets at a rate determined by the vibrational frequency or duty cycle of the motor 18 as controlled by the control means D.
A fluid or liquid feeding means 20 supplies fluid such as water, to be combined with the pellets to form the slurry. A pump 22 supplies liquid from a liquid supply 24 to a fluid pressure or presence sensing switch 26. A liquid or water supply solenoid valve 28 selectively supplies liquid to a liquid and pellet mixing region, such as a slurry reservoir 30. The pressure sensing switch 26 senses whether the liquid supply valve 28 is supplying liquid to the system. A liquid level control probe or sensor 32 senses the level of water in the slurry reservoir. The control means D monitors the liquid level sensor and controls operation of the liquid supply valve 28 such that the fluid level in the slurry reservoir is held substantially constant.
In the preferred embodiment, the pellets and fluid are mixed to form the slurry and the slurry is supplied to the mill. Optionally, the fluid and pellets could each be supplied to the mill separately in a coordinated manner such that the slurry is formed in the mill itself. An agitator 34 mixes the pellets and the liquid in the slurry supply reservoir 30 to maintain the pellets suspended in the liquid, hence maintain uniformity of the slurry.
The slurry is pumped by a positive displacement pump 40 from the slurry reservoir 30 to the mill B. A slurry feed motor 42 selectively controls the spped, hence the feed rate of the positive displacement pump 40. A pump priming solenoid 44 is selectively actuated by the control means D to prime the slurry pump 40. A slurry pump back pressure sensing switch 46 senses the pressure of the slurry at the output of the slurry pump and provides an indication of the presence thereof to the control system D.
A slurry feed line 50 is of appropriate diameter relative to the slurry fed rate such that the slurry is fed at a velocity which maintains the pellets suspended in the liquid. At the inlet of the mill B, a flow monitoring means 52 senses the flow rate of the slurry therethrough into the mill and the grinding zone. In the preferred embodiment, the flow monitoring means is an ultrasonic sensor which senses the passage of pellets therepast. A supplemental or emergency water feed valve 56 is selectively activated by the control system D to provide water to the grinding zone.
The mill B includes a mill housing 60 upon which a plurality of upward extending posts 62 are mounted. A stator mounting bracket 64 in which a stator 66 is mounted is slidably disposed on the posts 62 for longitudinal, but not rotational, movement relative thereto.
A mill or rotor motor 70, such as a 100 hp motor is mounted in the mill housing 60. The rotor motor is connected through a thrust bearing 72 with a rotor 74. A central portion of the rotor and the stator define a fluid receiving region for receiving the pellet and fluid slurry. An impeller 76 is connected with the rotor and disposed in the receiving region to urge the pellets into the grinding zone. The comminuted particles and fluid which pass from the grinding zone defined between selectively mating, peripheral portions of the rotor and stator are collected in a trough 78 and conveyed to the dryer E.
The pressure regulator assembly C includes a plurality of fluid actuated means, preferably hydraulic cylinders 90, for selectively controlling the force or pressure with which the rotor and stator. When comminuting vulganized rubber between a ten inch rotor and stator are pressed or urged together into intimate physical contact, a load of 2,000-10,000 lbs. has been found to produce satisfactory results, with about 3700-4000 lbs. being preferred.
A source of pressurized air or other gas 92, such as a compressor, selectively pressurizes a source of actuation fluid, such as a hydraulic fluid reservoir 94. An actuation fluid pressurizing means, such as a control valve 96 under the control of the control means D selectively passes and blocks the passage of the pressurized gas to the hydraulic fluid reservoir. A pressure increase limiting means or needle valve 98 slows the rate at which gas passes to the hydraulic reservoir. In this manner, the pressure increase limiting needle valve smoothly brings the hydraulic reservoir up to pressure at a controlled rate.
An actuation or hydraulic fluid pressure control means includes a fluid pressure decrease solenoid or bleed valve 100 which selectively vents the pressure from the hydraulic reservoir. A pressure reduction limiting means or restrictor valve 102 limits the rate of pressure reduction. An emergency pressure relief solenoid 104 selectively depressurizes the hydraulic fluid reservoir quickly.
In operation, the control means D opens the pressure reduction bleed valve 100 when the electric power drawn by the motor 70 reaches the top of the preselected power drawn range and closes the pressure reduction solenoid when the power drawn is safely below the top of the preselected power drawn range. The pressure increase limiting means 98 and the pressure decrease limiting means 102 limit the rate of hydraulic fluid pressure change. In this manner, varying the duty cycle of the pressure reduction bleed valve 100 selects and maintains any one of a continuum of hydraulic fluid pressures.
The control circuit D includes a slurry start-up control circuit 110 for bringing the apparatus from a stopped condition up to full operating conditions and a steady state control circuit 112 for controlling operating parameters once the apparatus is brought up to full operating conditions. The slurry start-up circuit 110 includes an electric power monitoring means or circuit 114 for monitoring the actual electrical power or watts drawn by the mill or rotor motor 70. A preselected start-up set point or memory means 116 provides an indication of a preselected start-up set point or nominal amount of electrical power to be drawn by the rotor motor.
A pellet supply rate control means causes the pellet feed means to supply pellets to the grinding zone at a rate that is inversely proportional to the difference between the actual and set point electrical power. A variable frequency means, such as a voltage to frequency converter 122, provides a vibratory pellet supply signal whose frequency approaches a steady state or limit frequency. That the concentration of pellets in the slurry increases as the actual power drawn by the rotor motor approaches the start-up set point. The pellet supply signal is conveyed to the vibratory trough motor 18. The pellet feed trough 16 conveys pellets to the slurry tank at a rate proportional to the frequency of trough vibration.
The steady state control circuit 112 includes a pressure adjusting means for causing adjustment of the force with which the pressure regulator assembly C urges the rotor and stator together in such a manner that the actual electric power drawn by the mill motor 70 is maintained generally constant. Specifically, a comparing means 130 compares the actual power drawn with a preselected pressure control power set point or memory means 132. A pressure control circuit 134 controls the duty cycle of the pressure control bleed valve 100. Specifically, when the actual power drawn by the rotor motor exceeds the preselected pressure control set point, the pressure control circuit 134 causes the pressure control bleed valve 100 to open; when the actual power drawn drops below the preselected pressure control power set point, the pressure control circuit 134 causes the pressure control bleed valve 100 to close. In this manner, the duty cycle of the pressure control bleed valve 100 is selectively adjusted to maintain the power consumption of the rotor motor substantially constant.
With particular reference to FIGS. 2A and B, the control circuit D includes a pair of electrical power leads 150, 152. A feed water start switch 154 is connected in series with the pressure switch 26 for sensing water feed to supply power to a feed water pump starter 156 for starting slurry pump motor 42. Once the slurry pump motor is started, a normally open relay contact 156a of the starter is closed to provide power to the slurry pump motor 42 and the flow monitor 52. A level controller 158 opens water valve 28 when the probe 32 senses that the water level in the slurry tank is below a preselected set point level.
The flow monitor 52 includes normally closed relay contacts 52a which actuate the pump priming solenoid 44. Once the pump is primed and the pressure of the fluid at the inlet of the mill has reached the appropriate level, the flow monitor 52 opens the contacts to the pump primer solenoid 44 and closes contacts 52b which supply power to a slurry feed flow control relay 160 and a slurry flow indicator 162. When preselected slurry feed rates are attained, the relay coil 160 closes a normally open contact 160a to enable power to be supplied to the normally open emergency water supply solenoid 56 for enabling termination of the emergency water supply.
Once the slurry feed is up to normal operating flow rates, the operator depresses a mill motor start button 170 which supplies power to a mill motor control relay 172. Optionally, the mill motor start push button 170 may be connected in series with a normally open contacts of the slurry feed control relay 160 for preventing the mill motor from being started until the slurry feed is up to the nominal flow rate. A mill motor starter 174 is connected in parallel with the mill motor control relay 172 for starting the mill motor. Once the mill motor is started, mill motor starter relay contacts 174a in parallel with the start button 170 are closed such that the mill motor continues to operate. The mill motor control relay 172 includes first normally open contacts 172a for controlling a mill motor indicator light 176 and second normally open contacts 172b for enabling the emergency water solenoid valve 56 to be closed.
A watt transducer 180 and the watt meter 114 monitor the power drawn by the mill motor 70. Closing a pellet feeder switch 182 supplies power to the start-up control circuit 110 including the voltage to frequency converter 122. The voltage to frequency converter gates an SCR 184 at a frequency which varies with the difference between the actual wattage drawn by the mill motor and the preselected set point wattage. When the mill motor is operating relay contacts 172c are closed. Until the power drawn by the mill motor reaches a preselected pellet feed set point, normally closed pellet set point relay contacts 114a are closed actuating a pellet feeder control relay 186. Actuating the pellet feeder control relay 186 closes normally open relay contacts 186a which enables a pellet feeder vibratory control relay 188. Enabling the vibrator motor control relay 188 closes normally open relay contacts 188a and 188b applying power across the SCR 184 and the vibratory pellet feed motor 18. As the power drawn by the mill motor increases, the vibrational frequency of the pellet feeder increases the concentration of pellets in the slurry until steady state operating conditions are attained.
Under steady state operating conditions, the vibratory feeder supplies pellets into the slurry tank 30 whenever the power drawn by the motor is below the pellet set point. When the power drawn exceeds the pellet set point, the pellet feeder is stopped reducing the pellet concentration in the slurry, hence the power drawn by the mill motor. When the power drawn again drops below the pellet set point, the pellet feeder is restarted.
When the slurry pump motor and the mill motor are started, normally open relay contacts 160b and 172c are closed. When an emergency head pressure release switch 190 is also closed, power is applied to the normally open emergency exhaust solenoid 104, closing it. When the power drawn by the mill motor 70 is below a preselected high limit or pressure set point, high limit relay contacts 114b are closed causing normally open bleed-off solenoid 100 to be closed. When the energy drawn exceeds the high limit, the high limit relay contacts 114b open allowing the bleed-off solenoid 100 to return to its open state reducing the pressure in the hydraulic reservoir. A relay 192 is also actuated when the high limit relay contacts 114b are closed. Normally open relay contacts 192a supply power to the normally closed main air pressure solenoid 96 when the energy drawn by the rotor motor is below the high limit causing the hydraulic reservoir to be pressurized.
In operation, the slurry pump 40 is actuated, then the mill motor 70. When the power drawn by the mill motor is below the pellet set point, relay contacts 114a are closed enabling the vibratory feeder 14 to feed pellets into the slurry. The hydraulic cylinders 90 are gradually pressurized until the energy drawn by the mill motor reaches the preselected pressure set point or high limit. When the energy drawn exceeds the pellet set point, the relay contacts 114a open stopping the pellet feed and reducing the pellet concentration in the slurry. When the power drawn also exceeds the pressure set point, high limit relay contacts 114b are opened causing the pressure bleed valve 100 to open and the air pressure supply valve 96 to close. When the pressure in the hydraulic cylinders has dropped sufficiently that the power drawn by the mill motor is below the preselected pressure set point, the air supply valve 96 opens and the bleed valve 100 closes allowing the hydraulic fluid pressure to increase gradually. Due to the pressure increase and decrease limiting means 98 and 102, the hydraulic fluid pressure remains generally constant at an equilibrium pressure as the bleed-off valve 100 cycles. When the power drawn drops to the power pellet set point, the pellet feeder is started. To hold the steady state operating conditions generally constant, the pellet set point and the pressure set point are closely adjacent. Preferrably, the difference between the pressure set point and the pellet set point is less than ten percent of the pressure set point, e.g. about 5%.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding the preceeding detailed description of the preferred embodiment. It is intended that the invention be construed as including all such alterations and modifications in so far as they come within the scope of the amended claims or the equivalents thereof. | A slurry feeding assembly (A) feeds a mixture of water and rubber pellets to a comminuting region defined between a rotor (74) and a stator (66). As an electric rotor motor (70) rotates the rotor relative to the stator, a power monitor (114) monitors of a control circuit (D) the amount of electrical power drawn thereby. The control circuit controls a pressure regulator (C) to increase and decrease the pressure between the rotor and stator in such a manner that the power drawn by the electric rotor motor remains substantially constant. The control circuit further initiates operation of various components of the comminuting apparatus in a preselected order. Specifically, the control circuit first starts the feed of water or other fluid to the rotor and stator. Thereafter, the electric rotor motor is started, followed by enabling of the pressure regulator assembly. Finally, a pellet feeding assembly (10) is initiated such that a progressively increasing concentration of pellets is introduced into the slurry until steady state operating conditions are attained. Under steady state conditions, the pellet feed rate is selectively varied to adjust the concentration of pellets in the slurry in such a manner that the power drawn by the rotor motor remains generally constant. | 1 |
1. FIELD OF THE INVENTION
[0001] The present invention relates to spout pouch ice cream and frozen yogurt manufacturing method and its device; specifically, a manufacturing process and method and its device capable of injecting ice cream, after an overrun process, through a narrow drinking tube of a spout pouch.
2. DESCRIPTION OF THE RELATED ART
[0002] Recently, manufactured ice cakes, beverages or milk shakes are injected into a spout pouch and sold to consumers similar to ice cream.
[0003] The spout pouch is held and squeezed by hand to consume. The spout pouch has advantages when compared to an existing cone type or bar type of ice cream products, the spout pouch products do not stick to a hand and can be consumed by desired amount and the leakage of the products can be prevented by the use of a closure.
[0004] The products using such a spout pouch are different from general ice cream.
[0005] Generally, the ice cream is produced utilizing a process called an overrun (to inject air into ice cream) during manufacturing of the ice cream to obtain softer texture.
[0006] U.S. Food & Drug Administration and the supervisory office of daily products have approved that the process capable of inflating the amount of products can be only applied to ice cream.
[0007] The overrun process uses a device called a freezer and all ice creams are manufactured by injecting raw materials of ice cream and air into a product container through a freezer under constant freezing temperature and pressure irrespective of their size. The working temperature of the overrun process is −30 to 50° F.
[0008] At this time, the amount of overrun (volume ratio relative to the raw materials of ice cream) is previously determined depending on the product grade.
[0009] The ice cream grade distributed in the U.S. is sorted as follows:
[0010] First grade (Super-premium): 25 to 40% overrun
[0011] Second grade (Premium): 40 to 80% overrun
[0012] Third grade (Regular): 80 to 100% overrun.
[0013] The ice cream manufactured by the process as described above is already frozen so that its viscosity is high. Therefore, it is difficult to fill the ice cream in an inner diameter (8 to 9 mm) of the drinking tube of the spout pouch.
[0014] Mixed milk shakes similar to the ice cream have been sold in Japan and Korea, wherein the mixed milk shakes are injected and frozen in the spout pouch container.
[0015] Both Japan and Korea can not use a product name of ice cream to the above product as there is also a difference in raw materials (in both Japan and Korea they use the raw materials manufactured with dried milk). Also both Japan and Korea have not developed a technology for injecting the frozen ice cream into the spout pouch container through the overrun process so that a crude liquid in a liquid state is injected and frozen into the spout pouch container.
[0016] Therefore, consumers recognize such a product as a combination of milk shake and smoothie since the moisture included in the raw materials in an ice state is frozen so that pieces of ice are included in contents. This is an alternative product manufactured due to the absence of the method of injecting the ice cream into the spout pouch as described above.
[0017] The spout pouch primarily comprises a pouch bag 10 and a drinking tube 20 fixed to an upper end of the pouch bag 10 as shown in FIG. 1 .
[0018] The drinking tube 20 comprises a closure 30 , a closure coupling part 22 coupled to the closure 30 and being a part that goes into a mouth upon drinking, a stopper 24 formed on a lower portion of the closure coupling part 22 to limit a coupling length of the closure 30 , a fixing part 29 coupled to the pouch bag 10 on an opposite side of the closure coupling part 22 , an engaging part 28 formed on an upper end of the fixing part 29 , a neck part 26 formed between the engaging part 28 and the stopper 24 .
[0019] The drinking tube 20 has an inner diameter of 5 to 15 mm and in particular, the product in the market is formed with a connecting hole having an inner diameter of 8 to 9 mm wherein the contents are injected or ingested through the connecting hole.
[0020] Filling liquid-state raw materials in the conventional spout pouch as above are not difficult.
[0021] However, filling only the liquid-state raw materials can allow manufacture of the product in the form of slush or shake, but does not allow manufacture of ice cream.
[0022] The viscosity of ice cream is very high so that it is difficult to supply the ice cream through the narrow connecting hole of the drinking tube 20 . Therefore, the spout pouch is not used as storage means for the ice cream.
[0023] Likewise, even in the case of frozen yogurt that has been widely sold, it is manufactured using the same method as ice cream. Therefore, its viscosity as in ice cream is high so that it is difficult to supply the yogurt through the narrow connecting hole of the drinking tube 20 . As a result, the spout pouch is not used as storage means for frozen yogurt.
SUMMARY OF THE INVENTION
[0024] The present invention proposes to solve the problems. It is an object of the present invention to provide a spout pouch ice cream and frozen yogurt manufacturing method and a device capable of injecting the ice cream or frozen yogurt, after overrunning, through a narrow drinking tube of the spout pouch.
[0025] In accordance, the current invention is providing a spout pouch ice cream and frozen yogurt manufacturing device comprising: a raw material supplying unit, supplying raw materials of ice cream or frozen yogurt; a freezer supplied with raw materials through a pump from the raw material supplying unit and manufacturing the ice cream or the frozen yogurt by injecting air while cooling the raw materials with coolant supplied from a refrigerator; a plurality of fillers receiving the ice cream or the frozen yogurt from the freezer and then filling the ice cream or the frozen yogurt to the spout pouch; a switching unit installed between the filler and the freezer to switch the supply or block of the ice cream or the frozen yogurt to each of the plurality of fillers; a control valve connected to a nitrogen tank to control the supply of nitrogen gas that cools a connecting pipe between the filler and the freezer; and a controller controlling the pump, the switching unit, the refrigerator, and the control valve.
[0026] Preferably, the raw material supplying unit consists of a raw material tank supplied with raw materials from the external and storing them; an agitator agitating the raw materials stored in the raw material tank; and a mixing tank temporally storing the raw materials supplied from the raw material tank.
[0027] The refrigerator is a two-stage refrigerator.
[0028] In accordance, the present invention provides a spout pouch ice cream and frozen yogurt manufacturing method using a spout pouch ice cream and frozen yogurt manufacturing device as described above, comprising the steps of: pre-cooling a connecting pipe between a plurality of fillers and a freezer to be at the same temperature as the production temperature of the ice cream or the frozen yogurt; overrunning that cools the raw materials supplied from the raw material supplying unit to the freezer and injects air by means of a pump; and filling the ice cream or the frozen yogurt, completed by overrunning, in a spout pouch mounted to the plurality of fillers.
[0029] The method further comprises the step of removing the spout pouch buffered with the ice cream or the frozen yogurt via the filling step and replacing it with a new spout pouch.
[0030] The overrunning constantly maintains the temperature of the ice cream or the frozen yogurt manufactured by means of the pressure control of an amp for a blade and the pump mounted inside the freezer.
[0031] The raw materials of the ice cream or the frozen yogurt supplied to the freezer are 36 to 38° F.
[0032] The injection amount of air of the ice cream or the frozen yogurt is 20% to 35% based on the volume of the ice cream or the frozen yogurt.
[0033] The temperature of the ice cream or the frozen yogurt discharged from the freezer is −16 to 0° F.
[0034] The pressure of the pump is 20 to 35 psi.
[0035] According to the present invention, the ice cream or the frozen yogurt can be injected into the inner diameter (8 to 9 mm) of the drinking tube of the spout pouch.
[0036] Accordingly, it is possible to manufacture the spout pouch type of ice cream or frozen yogurt that can have the advantages of the spout pouch and enjoy the inherent taste of ice cream or frozen yogurt.
BRIEF DESCRIPTION OF THE DRAWING
[0037] These and other objects, features, and advantages of preferred embodiments of the present invention will be more fully described in the following detailed description, taken in conjunction with the accompanying drawings. In the drawings:
[0038] FIG. 1 is a schematic view of a spout pouch according to the prior art.
[0039] FIG. 2 is a front view of a drinking tube of FIG. 1 .
[0040] FIG. 3 is a block diagram of a spout pouch ice cream and frozen yogurt manufacturing device according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings for instance denoting reference numerals to components of each drawing, such as denoting numerals to alike components throughout the overall drawings. The detailed description of known functions and configurations will be omitted so as not to obscure the subject of the present invention with unnecessary detail.
[0042] FIG. 3 is a block diagram of a spout pouch ice cream and frozen yogurt manufacturing device according to an embodiment of the present invention.
[0043] The spout pouch ice cream or frozen yogurt manufacturing device primarily comprises a raw material supplying unit that supplies raw materials; a freezer 140 manufacturing the ice cream or frozen yogurt with the raw materials supplied from the raw material supplying unit; and fillers 170 , 172 and 174 filling the ice cream or the frozen yogurt supplied from the freezer 140 in the spout pouch.
[0044] The raw material supplying unit comprises a raw material tank 100 supplied with the raw materials from the external and storing them, an agitator 110 agitating the raw materials stored in the raw material tank 100 , a mixing tank 120 temporally storing the raw materials supplied from the raw material tank 100 , and a pump 130 applying pressure to the ice cream raw materials in the mixing tank 120 to supply them to the freezer 140 .
[0045] The agitator 110 may comprise a motor in a known art, an agitating axis connected to the motor and agitating blades formed on outer circumference of the agitating axis, all of which are not shown in the drawing.
[0046] The agitator 110 continuously operates to serve a role of preventing several materials from being separated from each other and precipitated.
[0047] The raw material tank 100 has a receiving space larger than that of the mixing tank 120 and is supplied with milk, spices, or the like, which are raw materials of ice cream or frozen yogurt, from the external device (not shown).
[0048] The mixing tank 120 is manufactured to be smaller in size than the raw material tank 100 in order to meet the production capacity of the pump 130 and the freezer 140 and can inject a fixed quantity of additives such as food colors to the mixing tank 120 through an additive supplying source (not shown).
[0049] The freezer 140 is a device which cools the raw materials of the ice cream or the frozen yogurt and at the same time, performs the overrun process and is connected to a refrigerator 150 .
[0050] More specifically, the ice cream or the frozen yogurt is manufactured inside of the freezer 140 by freezing the raw materials through the evaporation of frozen liquid in a freezer accumulator tank installed inside the freezer 140 . At this time, the quality of product can be made uniform by controlling coolant per unit mass applied to the ice cream or the frozen yogurt by means of the control of pressure in the pump.
[0051] Also, the inside of the freezer 140 is installed with a blade (not shown). The ice cream or the frozen yogurt raw materials are agitated inside the freezer by means of the continuous rotation of the blade.
[0052] At this time, the viscosity of the ice cream or the frozen yogurt can be maintained at a constant level by means of the amount of agitation (referred to as an amp of the blade. That is, the viscosity of the ice cream or the frozen yogurt can be lowered by supplying energy to the ice cream or the frozen yogurt by agitation. In other words, the viscosity can be high by making the size of the amp large, while when the viscosity is to be lower than a certain level, the size of the amp is made small.
[0053] Therefore, the production of the ice cream or the frozen yogurt can be controlled by means of the pressure of the amp and pump 130 .
[0054] Preferably, the refrigerator 150 adopts a two-stage refrigerator to continuously supply the coolant.
[0055] The freezer 140 is connected to the plurality of fillers 170 , 172 , and 174 . At this time, the switching unit 160 is installed between the freezer 140 and the plurality (for example, three) of fillers 170 , 172 , and 174 , making it possible to selectively switch the connection of the fillers 170 , 172 , and 174 and the freezer 140 . Thus, the ice cream or the frozen yogurt from the freezer 140 is selectively supplied to each of the plurality of fillers 170 , 172 , and 174 by the switching action of the switching unit 160 .
[0056] The fillers 170 , 172 , and 174 can be mounted with the spout pouch (not shown). After the filling of the ice cream supplied from the freezer 140 is completed, it is preferable to manufacture the filler to automatically remove the mounted spout pouch and mount a new spout pouch.
[0057] Also, in order to cool a connecting pipe mounted between the freezer 140 and the fillers 170 , 172 , and 174 , the manufacturing device of the present invention is provided with nitrogen tank 180 containing nitrogen, and a control valve 162 to control the amount of nitrogen supplied from a nitrogen tank 180 .
[0058] And, the manufacturing device of the present invention further includes a controller 190 to control the operation of the pump 130 , the switching unit 160 , the refrigerator 150 , and the control valve 162 .
[0059] The spout pouch ice cream or the frozen yogurt manufacturing device according to the embodiment of the present invention is basically configured as above. Hereinafter, the spout pouch ice cream or the frozen yogurt manufacturing method using the spout pouch ice cream or the frozen yogurt manufacturing device will be described.
[0060] Each of the fillers 170 , 172 , and 174 is mounted with the spout pouch and the raw material tank 100 is filled with the raw materials of the ice cream or the frozen yogurt.
[0061] First, the connecting pipe between the fillers 170 , 172 , and 174 and the freezer 140 is pre-cooled to a temperature necessary for manufacturing the ice cream or the frozen yogurt.
[0062] At this time, the pre-cooling is performed by nitrogen gas discharging from the nitrogen tank 180 and the control valve 162 controls the supply amount of the nitrogen gas in order to control the temperature.
[0063] Such a pre-cooling process is the most important process in the spout pouch ice cream or the frozen yogurt manufacturing method of the invention. The pre-cooling process should be performed at the same temperature as the product at a production starting time or otherwise, the overrun process can not be performed by the set amount due to the temperature difference with the raw materials so that the content of ice cream finally manufactured is small and ice particles occur within the spout pouch due to the temperature difference.
[0064] Therefore, when cutting and viewing the spout pouch product manufactured without performing the pre-cooling process, it can be appreciated that the raw material separating phenomenon occurs and a phenomenon of significantly degrading the quality of product (texture as the ice cream or the frozen yogurt, not the shake or the smoothie) occurs.
[0065] When the pre-cooling process is completed, the manufacturing of the ice cream or the frozen yogurt and the filling in the spout pouch starts.
[0066] The temperature of the raw materials supplied to the freezer 140 is 36 to 38° F. and the injection amount of air upon performing the overrun process is 20 to 35% based on the volume of the raw materials of the ice cream or the frozen yogurt.
[0067] And, the product temperature at the outlet discharging the ice cream or the frozen yogurt manufactured by the freezer 140 is set to −16 to 0° F.
[0068] At this time, the pressure and temperature are controlled by the pump 130 and the refrigerator 150 to constantly maintain the temperature of the ice cream or the frozen yogurt manufactured by the freezer 140 .
[0069] In particular, it is preferable that the refrigerator 150 is the two-stage refrigerator in order to continuously supply the coolant.
[0070] Also, when continuous supplying of the ice cream or the frozen yogurt through the connecting pipe, the connecting pipe is excessively cooled over time so that overload occurs in the refrigerator 150 and the pump 130 .
[0071] Therefore, it is preferable to prevent the excessive cooling of the connecting pipe by raising the discharging temperature of the ice cream or the frozen yogurt to the connecting pipe at regular time intervals.
[0072] The control of the discharging temperature of the ice cream or the frozen yogurt is performed by means of the increase of the supply amount of raw materials and the increase of the amp for the blade according to the pressure control of the pump 130 .
[0073] The pressure control of the pump 130 is performed in the range of 20 to 35 psi.
[0074] Therefore, the product temperature of the ice cream or the frozen yogurt always reaching the spout pouch can be constantly maintained by raising the temperature of the ice cream or the frozen yogurt discharged from the freezer 130 and passing through a pipeline. The product temperature of the ice cream or the frozen yogurt reaching the spout pouch should be constantly maintained so that the amount of the overrun can be constantly maintained.
[0075] The continuously produced ice cream or frozen yogurt is filled in the spout pouch (not shown) mounted to the fillers 170 , 172 , and 174 .
[0076] At this time, the plurality of fillers 170 , 172 , and 174 and the freezer 130 are selectively selected by means of the switching unit 160 . In the buffered case, the spout pouch mounted to the plurality of fillers 170 , 172 , and 174 is removed and a new spout pouch is mounted thereto.
[0077] Therefore, the spout pouch type of ice cream or frozen yogurt can be continuously manufactured.
[0078] Those skilled in the art will appreciate that the specific embodiments disclosed in the foregoing description may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. Those skilled in the art will also appreciate that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims. | The present invention relates to a spout pouch ice cream and frozen yogurt manufacturing method and a device capable of injecting ice cream after an overrun process through a narrow drinking tube of the spout pouch. In accordance with the present invention, the ice cream or the frozen yogurt can be injected into the inner diameter (8 to 9 mm) of the drinking tube of the spout pouch. Accordingly, it is possible to manufacture the spout pouch type of ice cream or frozen yogurt that can have the advantages of the spout pouch and enjoy the natural taste of ice cream or frozen yogurt. | 0 |
The invention relates to a fuel cell system for mobile use, having a fuel cell unit for generating electrical energy and an adsorption accumulator, assigned to the fuel cell unit, for releasing heat. The invention also relates to a method for operating a fuel cell system of this type.
BACKGROUND
The storage principle of sorption or adsorption accumulators is based on the property of some highly porous materials, such as for example silica gel, of attracting water vapor and bonding to the surface of the material, releasing heat. This accumulation of water is referred to as adsorption. Adsorption accumulators of this type are often used as drying agents in packaging materials. Conversely, when the material is heated, the bonded water is released again, or desorbed, in the form of water vapor, while at the same time the accumulator is laden with thermal energy. This process can be repeated as often as desired. Adsorption accumulators can store thermal energy in a high density.
Adsorption accumulators are used in stationary heating engineering, where they are employed in particular to improve the energy balance of solar thermal installations and district heating systems, in that they are responsible for balancing the thermal energy in the event of fluctuations over the course of time.
For mobile applications, in particular to assist with what is known as a cold start, it is customary to use heating systems which are based on thermally insulated hot water reservoirs (known as sensible heat storage), on accumulators which make use of the phase change of a material (known as latent heat storage) or on mobile incineration systems or electrical heating systems (stationary heating). Laid-open specification WO 02/054520 A1 relates, for example, to the use of a latent heat store in a mobile fuel cell system.
Adsorption accumulators have also found their way into mobile application areas. For example, laid-open specification DE 43 10 836 A1 has disclosed the provision of adsorption accumulators in motor vehicles driven by internal combustion engines; the thermal energy stored by the adsorption accumulator can be utilized to heat the vehicle interior or also an internal combustion engine which drives the vehicle prior to a start.
Patent application JP 10-144333 uses an adsorption accumulator to heat a fuel cell unit of a motor vehicle. The adsorption accumulator is assigned a condenser/evaporator, in which water is available for discharging the adsorption accumulator. When the fuel cell unit has reached an appropriate operating temperature, the adsorption accumulator, together with the condenser and two downstream heat exchangers, functions as cooling for the fuel cell unit, one of the heat exchangers releasing the heat of the fuel cell unit to the ambient air. The system described, in terms of the water balance, is a closed system in which there is no exchange of water with the environment. Water for discharging the adsorption accumulator is permanently available in the condenser. For this reason, with the system described, a start is only possible at temperatures above freezing point.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a fuel cell system which is of simple construction, takes up little space and allows a rapid cold start in particular at temperatures below freezing point. A further object of the invention is to provide a method for operating a fuel cell system of this type.
The fuel cell system according to the invention comprises a fuel cell unit for generating electrical energy and an adsorption accumulator, assigned to this fuel cell unit, for releasing heat. The adsorption accumulator is in thermal terms operatively connected to a heat exchanger which is arranged in a cooling circuit assigned to the fuel cell unit, downstream of the fuel cell unit. In particular, fuel cell waste products, i.e. fuel cell exhaust gas or water in the form of water vapor, can be fed to the adsorption accumulator via a line.
According to the method of the invention, when the fuel cell system is starting up, the coolant in the cooling circuit is heated via the heat exchanger by means of the heat stored in the adsorption accumulator, with fuel cell exhaust gas products, i.e. water or water vapor, being fed to the adsorption accumulator at the same time as energy exchange medium. In the process, the adsorption accumulator is cooled. Once the cold start has ended and the fuel cell unit has reached a temperature at which no further heating is required—i.e. when the fuel cell unit is operating normally—heat is fed to the adsorption accumulator again via the heat exchanger in order to charge the adsorption accumulator, and in this way the stored water is released. The waste heat from the fuel cell unit during operation of the fuel cell system or a fuel cell vehicle is preferably used to charge the adsorption accumulator.
The use of an adsorption accumulator may provide a heat store with a high energy density and storage without heat losses which advantageously does not require any additional components, which would likewise represent energy consumers, as would be the case, for example, with an electrical heating system, a catalytic burner, stationary heating systems, etc. The fuel cell unit and any further components of the fuel cell system can be reliably and economically heated during a cold start, since the waste heat from the fuel cell system is used to charge the adsorption accumulator. The high performance of the coolant is in this way retained. The duration of heat storage is not subject to any time limitation and is independent of the ambient temperature.
On account of the increased energy density of the adsorption accumulator compared to other heat stores, which may amount to an increase of approximately 2.5 to 5 times, it is possible to save volume and weight for the heat store or the heat storage components. Further potential savings on volume and weight result from the loss-free thermochemical storage of heat inherent to the adsorption accumulator. The adsorption accumulator therefore can make do with less installation space. The storage materials or media which are used for the adsorption accumulator and preferably comprise metal hydrides, silica gels and/or zeolites, are neither corrosive, contaminating nor environmentally harmful.
The fuel cell system according to the invention—in particular also with regard to the water balance—may be an open system which involves both energy and mass exchange with the environment. In particular, water may be exchanged with the environment in the form of water vapor. There is no need for water for discharging the adsorption accumulator to be made available in an additional reservoir. As a result, freezing of the fuel cell system at temperatures below freezing point advantageously may be prevented, and the system can be started even at temperatures below freezing point.
Of course, the solution according to the invention can be used to assist cold starts even for conventional forms of internal combustion engine vehicle drives.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantageous configurations of the invention will be explained below with reference to the drawings, in which:
FIG. 1 diagrammatically depicts a fuel cell system according to the invention during the adsorption accumulator discharging or during starting, and
FIG. 2 diagrammatically depicts the fuel cell system from FIG. 1 during the adsorption accumulator charging.
DETAILED DESCRIPTION
In the figures, identical reference designations are intended to denote functionally or structurally identical components. Directions of flow are indicated by arrows.
FIG. 1 diagrammatically depicts a fuel cell system according to the invention during a start, in particular a cold start. The fuel cell system comprises a fuel cell unit or a fuel cell module 1 . The fuel cell unit comprises a plurality of fuel cells (not shown) which are connected to one another in the form of a stack. The fuel cells used are preferably polymer electrolyte membrane (PEM) fuel cells. The fuel cell unit 1 is supplied with hydrogen and oxygen in the form of air as reaction components. During the electrochemical reactions which take place in the fuel cell unit, electrical energy, heat and, as a waste product, in particular water in the form of water vapor are formed. The atmospheric oxygen is fed to the fuel cell unit 1 via a line 9 . The fuel cell waste products are discharged via a line 10 . A feed line for the hydrogen is not illustrated, for the sake of clarity.
The fuel cell unit 1 is arranged in a first cooling circuit 4 , 5 assigned to the fuel cell unit 1 ; a coolant pump 8 for delivering coolant is preferably provided upstream of the fuel cell unit 1 . Moreover, a heat exchanger 2 is provided in the first cooling circuit 4 , 5 , downstream of the fuel cell unit 1 and preferably upstream of the coolant pump 8 .
The first cooling circuit 4 , 5 is preferably coupled to a second cooling circuit 7 , which is referred to below as the main cooling circuit 7 and is used, for example, to cool or heat a vehicle interior compartment. In the first cooling circuit 4 , 5 , an actuator 6 , preferably a three-way valve, is arranged between fuel cell unit 1 and heat exchanger 2 , by means of which actuator the flow of coolant can be passed on the one hand via the heat exchanger 2 and onward in the second cooling circuit 4 , 5 or directly into the main cooling circuit 7 .
The heat exchanger 2 is thermally connected to a heat store 3 which is designed as an adsorption accumulator. The heat exchanger 2 is preferably connected, by means of its longest side, to the longest side of the adsorption accumulator 3 . An actuator 11 , preferably a three-way valve, is provided in the line 10 which carries the fuel cell waste products away from the fuel cell unit 1 , by means of which actuator the waste products can be passed through the adsorption accumulator 3 via the line 12 , which may be designed as a bypass.
During a start or cold start of the fuel cell system, the coolant flows through the heat exchanger 2 in the first cooling circuit 4 , 5 . It is preferable for no coolant to be passed into the main cooling circuit 7 , which is intended to be indicated in FIG. 1 by a corresponding cross in the line 7 . There is preferably therefore no temperature control by the main cooling circuit 7 . At the same time, fuel cell waste products and therefore water vapor are fed to the adsorption accumulator 3 via the lines 10 and 12 . The waste products are therefore passed from the line 10 into the line 12 as a result of a corresponding position of the actuator 11 , which is intended to be indicated in FIG. 1 by a cross in the line 10 downstream of the actuator 11 .
Water vapor is fed to the adsorption accumulator with the waste products or waste air from the fuel cell unit 1 . This water vapor is bonded by the adsorption accumulator 3 , releasing thermal energy, the thermal energy being fed via the heat exchanger 2 to the coolant in the first cooling circuit 4 , 5 and therefore to the fuel cell unit 1 . This facilitates a cold start. Excess fuel cell waste products or waste air are preferably released to ambient air downstream of the adsorption accumulator 3 via the line 12 and an actuator 13 , preferably an opened valve.
As an alternative or in addition to the supply of fuel cell waste products to the heat exchanger 3 , it is of course also possible to provide an evaporator which generates water vapor and makes it available to the heat exchanger 3 .
FIG. 2 diagrammatically depicts the fuel cell system from FIG. 1 during the adsorption accumulator charging. Once the fuel cell system has been successfully started and no further thermal energy is required by the adsorption accumulator 3 to heat the coolant of the first cooling circuit 4 , 5 , it may be necessary for the adsorption accumulator 3 to be loaded with thermal energy again. For this purpose, the coolant, which has now been heated by the operating fuel cell unit 1 , is passed through the heat exchanger 2 via the actuator 6 and the line 5 . It is preferable for no coolant to be passed into the main circuit 7 , which is intended to be indicated by a corresponding cross in the line 7 . On account of the thermal connection of heat exchanger 2 and adsorption accumulator 3 , this leads to heating of the material of the adsorption accumulator 3 and therefore to charging of the adsorption accumulator with thermal energy and to release of the water vapor bonded by the material. The water vapor which is released is preferably discharged to ambient air downstream of the adsorption accumulator 3 , via the line 12 and the actuator 13 .
During the charging of the adsorption accumulator 3 with heat, it is preferable for no fuel cell waste products to be supplied via the line 12 . This is indicated in FIG. 2 by a cross in line 12 .
After successful charging of the adsorption accumulator 3 , it is preferable for the supply of fuel cell exhaust gas products to the adsorption accumulator 3 and the discharge of water vapor from the adsorption accumulator 3 to be suppressed by stopping the supply to the line 12 upstream of the adsorption accumulator 3 by means of a corresponding position of the actuator 11 and the discharging from the line 12 downstream of the adsorption accumulator 3 by means of a corresponding position of the actuator 13 when no thermal energy is required to release the water vapor bonded by the material of the adsorption accumulator 3 or when there is no need for any heat stored in the adsorption accumulator 3 to heat the fuel cell system 1 via the coolant of the first cooling circuit 4 , 5 . This has the advantage that it is impossible for any ambient moisture to be drawn in by the material of the adsorption accumulator 3 . Freezing up at ambient temperatures below the freezing point is likewise ensured. The fuel cell exhaust gas products can now be discharged via the line 10 . In this operating state, in which the role of the adsorption accumulator 3 is to store the bonded thermal energy, the coolant which has been heated by the operating fuel cell unit 1 is preferably passed into the main cooling circuit 7 by means of a suitable position of the actuator 6 , the actuator 6 preferably being switched in such a manner that no coolant is fed to the heat exchanger 2 via the line 5 . By way of example, a passenger interior compartment can be heated by means of the main circuit 7 . | A fuel cell system which can be used in a mobile manner with a fuel cell unit ( 1 ) in order to produce electric energy, and an adsorption accumulator ( 3 ) which is associated with a fuel cell unit ( 1 ) are provided. The adsorption accumulator ( 3 ) is used to release heat and interacts in a thermal manner with a heat exchanger ( 2 ) which is arranged downstream from the fuel cell unit ( 1 ) in a cooling circuit ( 4, 5 ) associated with the fuel cell unit. A method for operating said type of fuel cell system, especially during a cold start is provided. | 8 |
This application is a continuation of application Ser. No. 135,335, filed 3/31/80, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for separating face-to-face pile fabrics, double plush ware or the like, into two separate panels, and in particular, to an apparatus which separates the ware into two separate panel with a minimum of rejects by maintaining the tension on both panels essentially equal.
2. Discussion of the Relevant Art
A plush cutting machine is disclosed in German Offenlegungsschrift No. 2,130,782, which corresponds to British Pat. No. 1,335,424 published Oct. 31, 1973. The apparatus disclosed therein includes a drive motor which directly drives the pull off rollers for one panel and drives the pull off roller for the other panel by means of a differential gear mechanism that may be incrementally advanced or retarded a fixed amount by means of an auxiliary motor when the pull off rollers are in a different rotational position with respect to each other because of uneven tension in the plush panels. The pull off rollers are oriented on both sides of the cutting knife and proximate thereto. The pull off rollers for each panel are individually affixed to the distal ends of a pair of levers which are biased by a pair of weights to provide tension on each of the panels. When the tension on the first panel varies, the pull off roller is caused to move and deflect the arm upon which it is mounted thereby activating a microswitch which energizes an auxiliary motor to increase or decrease the pull off roller of the other panel in an attempt to maintain the tension of both panels equal. However, by varying the tension on one of the pile panels, the double plush panel is moved laterally thereby displacing the center of the ware from being directly under the cutting knife causing uneven cuts in the pile height. Moreover, the correction of the relative rate of rotation of the pull off rollers occurs relatively slowly since the microswitch must first activate an auxiliary motor which then drives the correcting gear mechanism in the appropriate direction before the equalizing of tensions will occur. As disclosed, the system includes three different positions of the microswitch thus providing for incremental changes in position. Since the response time of this type of system is not continuous and is slow, several meters of unevenly cut pile ware may result. In addition, further problems arise when the pull off rollers are positioned adjacent to the cutting knife because any movement they are subjected to leads to an alteration of the cutting position. Furthermore, as disclosed, the double plush ware is fed to the cutting knife in a horizontal plane so that gravity also influences the tension on the panels. This is another factor that contributes to the uneven cutting of the pile.
Another pile cutting machine is disclosed in Kettenwirk-praxis No. 3 of 1969 at pages 17 through 20. The Kettenwirk-praxis iss a magazine published by Karl Mayer Textilmaschinenfabrik GmbH, of West Germany. The machine disclosed therein for cutting double plush ware has the ware fed vertically and upwardly towards a cutting band. On both sides of the cutting band are provided guide rollers which are mounted on a fixed axis. Reversing rollers are provided for the separated pile panels. The reversing rollers are provided with an axis of rotation that is vertically displaceable and are weight biased to provide a predetermined tension to both of the panels. Movement of the reversing rollers in the vertical plane caused by a change in the tension of the cut panels is automatically sensed and used to adjust the rate of rotation of the appropriate pull off rollers. In the embodiment disclosed, a belt drive is provided between the drive motor and the pull off roller for each of the panels which has their speed independently adjusted to maintain a constant tension on each panel. This system although superior to the apparatus hereinbefore discussed also requires a fixed amount of time to maintain equal tension on both panels so that several meters of defective material may be produced before the tension on both panels are made equal.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings found in the prior art by providing a plush cutting machine which is capable of providing two panels with a relatively small amount of unacceptable goods.
A slitting apparatus for separating face-to-face pile fabrics, double plush ware or the like, into two panels, according to the principles of the present invention, comprises a pair of delivery means for feeding the ware. A slitting means is disposed between the delivery means for cutting the pile to form two panels. A pair of draw roller means draws a panel of ware under tension away from the slitting means. A pair of reversing means is disposed in the draw off path of each panel between the delivery means and each of the draw roller means with the position of the reversing means being responsive to the tension of each of the panels. A pair of sensing means is provided for sensing the position of each of the reversing means and a pair of braking means is utilized to brake each of the draw roller means. The braking means is responsive to each sensing means and varies the amount of braking applied to each draw roller means, thereby maintaining the tension of each of the panels approximately equal.
A method of separating face-to-face pile fabrics, double plush ware or the like into two panels, according to the principles of the present invention, comprises the steps of feeding the ware towards a cutting means centrally disposed between the ground fabric of the ware, separately drawing both panels away from the slitting means under tension with the drawing means, sensing the tension of both panels, and braking each of the drawing means in response to the tensions sensed such that the tension of each panel is maintained approximately equal.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a schematic side view of the slitting apparatus, according to the principles of the present invention;
FIG. 2 is a cross-sectional view of a differential gear known in the prior art; and
FIG. 3 is an enlarged view of the spring loaded push rod and braking mechanism utilized in the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 in the drawing schematically discloses a side view of the slitting apparatus 10 for separating face-to-face pile fabrics, double plush ware 12 or the like, into two panels 14 and 16 according to the principles of the present invention. The double plush ware 12 is provided from a conventional storage arrangement, not shown, over feed rollers 18 and 20 and a guide roller 22 where it is lead in a vertical direction towards a cutting device 24, such as a band knife, for cutting the double plush ware into two equal panels 14 and 16.
On each side of the cutting device 24, delivery rollers 26 and 28 are provided over which pass the cut plush panels 14, 16 that move in a direction perpendicular to the direction of the cutting device 24 which moves in the direction of arrow 30. The cut pile panels 14 and 16 are led over reversing rollers 32 and 34, respectively, and then over draw or pull off rollers 36 and 38, respectively, and thence to further guide rollers 40 and 42, respectively, to winding drums 44 and 46, respectively. Winding drums 44 and 46 are rotated in the direction of arrows 48 and 50, respectively. Support rollers 52 and 54 drive winding drum 46 and, in a like manner, drum 44 is driven by a pair of support rollers, not shown.
All of the rollers discussed hereinbefore are provided with a fixed axis of rotation, that is to say, the axis of the roller is not permitted to move vertically or horizontally with the exception of reversing rollers 32 and 34 whose function and operation will be described in detail hereinafter.
A pair of drag compensating rollers 56 and 58 may be placed on both sides of the ware 12 proximate the cutting device 24. These rollers may be provided with spring tension to apply forces against both surfaces of the ware to compensate for the drag caused by the cutting device as it cuts the pile threads.
A drive motor 60, which is preferably a continuously adjustable direct current motor, drives at least one of the feed rollers 18 or 20 by means of a continuously adjustable ratio drive 62 and a chain drive 64 coupled thereto in a conventional manner. The drive motor 60 drives the input shaft 66 of a conventional differential drive mechanism 68 by means of a chain drive 70 operatively coupled to a pully 72 affixed on the output shaft of motor 60. The output bevel gears 74 or 76 of differential machanism 68 are connected, via output shafts 78 and 80, respectively, and bevel gears 82 and 84, respectively, to draw rollers 36 and 38, respectively. Thus, draw rollers 36 and 38 are differentially driven, in a conventional manner from a drive shaft 66 connected to the differential mechanism 68 and will have all of the characteristics associated with this type of drive mechanism.
Affixed on output shafts 78 and 80 are brake drums 86 and 88, respectively.
The axis 90 of reversing roller 32 is positioned proximate the distal end of a lever or bar 92 which is provided with a centrally disposed pivot or fulcrum point 94 about which the bar 92 may move in the direction of arrows 96. The axis 98 of reversing roller 34 is positioned at the other distal end of lever 92 and therefore is capable of moving in the direction of arrows 100. Proximate the left distal end of bar 92, the push rod 102 of a cooperating braking mechanism 104 is affixed. Push rod 102 cooperates with a telescopic tube 106 which has affixed thereon at one end a braking material 108 that is adapted to cooperate with brake drum 86 and apply braking forces thereto in a conventional manner. A spiral spring 110 is maintained in position on push rod 102 by support peg 112. The other end of spring 110 pushes against tube 106 permitting the braking material 108 to come into contact with drum 86. It is obvious that the braking forces applied to braking drum 86 are therefore directly related to the position of the axis 90 in lever or bar 92.
In a similar manner, on the righthand side of bar 92 proximate the distal end thereof, the push rod 114 of braking mechanism 115 is affixed. Push rod 114 cooperates with a telescopic tube 116 which has provided thereon braking material 118 that is adapted to cooperate with and apply braking pressure to brake drum 88. A spiral spring 120 is retained in position on push rod 114 by support peg 122 and pushes against tube 116.
With the construction just described, it is obvious that the tension of each of the cut pile panels 14 and 16 is compared by means of the lever or bar 92. If the tensions in both panels are not equal, the lever will move in the appropriate direction and the draw roller serving the panel under higher tension will immediately be caused to be braked. Because of the differential drive mechanism 68, the speed of rotation of the other draw roller will be correspondingly increased. Thus, almost simultaneously the tension in both panels will be made to become equal and the braking to both draw rollers 36 and 38 will be the same.
In operation, the double plush material 12 is provided with a predetermined supply velocity by means of the delivery rollers 18 and 20. The cut pile panels 14 and 16 are provided with a predetermined pull off velocity by means of draw rollers 36 and 38. Where a symmetrical double plush is being fabricated, this velocity should be the same for both pile panels 14 and 16 and, in general, it is preferably made slightly greater than the supply velocity in order to provide a certain amount of tension at the cutting point. The total speed of operation is provided by the continuously adjustable drive motor 16. The difference between the delivery speed and the pull off speed is provided by means of a continuously adjustable ratio drive 62.
If for any reason the tension in both of the cut plush panels 14 and 16 becomes unequal, it will lead to a dissymmetry at the cutting point and lever 92 will be displaced. If it is assumed that the plush panel 14 comes under greater tension then the following will occur. The lever 92 will be displaced in a clockwise direction causing the braking element 108 to contact braking drum 86 and apply braking pressure thereto. The draw roller 36 will thus be braked at the same time the rate of rotation of draw roller 38 is raised. In addition, the righthand plush panel 16 is simultaneously placed under greater tension by the displacement of the reversing roller 34 affixed to bar 92.
The combination of all these compensations provides an almost instantaneous and continous correction of the difference in tension between the panels so that the cutting device 24 will continue to cut in the center of the double plush ware 12. After the correction has occured, lever 92 will return to its original position. In the same manner, when the pile panel 16 comes under a higher tension, the mechanism will adjust accordingly.
It is to be noted that the device may be adjusted so that at the initial starting point no braking pressure is applied to both braking drums 86 and 88. However, the device will perform equally as well if the braking on both brake drums is adjusted so that some braking forces are equally applied to both brake drums 86 and 88.
It is also obvious to those knowledgeable in the art that this device includes the further advantage that it is possible to cut double pile ware wherein the left side and the right side are not worked in the same manner but, for example, carry different pile densities. In such a case, the two cut pile panels must be pulled off at a different rate in order to maintain them in the same degree of tension. This condition arises automatically in the present invention since the cut pile ware having the higher density always strives to attain the higher tension and thus the corresponding draw roller is continually braked with greater braking force. Also, it is possible to avoid errors caused by the incorrect loading of the reversing rollers by service personnel. The lever may be utilized with every type of pile ware whether it is carpeting material or wig material and whether the pile height is 1.5 millimeters or 3.0 millimeters in length.
Hereinbefore has been disclosed a slitting apparatus for separating face-to-face pile fabrics, double plush ware of the like, into two panels which operates in a continuous analog adjustable manner that is reliable and provides a minimum of unusable goods. It will be understood that various changes in the details, materials, arrangement of parts and operating conditions which have been herein described and illustrated by the nature of the invention may be made by those skilled in the art within the principles and scope of the present invention. | A slitting apparatus for separating face-to-face pile fabrics, double plush ware or the like, into two separate panels includes a closed loop feedback arrangement that maintains equal tension on both panels thereby permitting the cutting knife to sever the double plush ware exactly in the center thereof reducing panel rejects. The feedback arrangement is of the analog type thereby insuring almost instantaneous and continuous control of the tension of both panels. | 3 |
FIELD OF THE INVENTION
The invention relates to a feederhouse assembly for a combine harvester, having a housing, at the rear end of which an upper feederhouse roller is rotatably mounted, a lower feederhouse roller rotatably mounted at the front end of the housing, and an endless conveying element that is made of an inherently flexible material with slats fastened therein and circulates about the lower feederhouse roller and the upper feederhouse roller, wherein a first of the feederhouse rollers is mounted so as to be movable relative to the housing toward and away from the second feederhouse roller along an imaginary line between the feederhouse rollers.
BACKGROUND
Self-propelled combine harvesters comprise a chassis that is supported on the ground by front, driven wheels (or track drive mechanisms) and rear, steerable wheels. A feederhouse assembly, at the front end of which a harvester head is in turn mounted, is arranged on the front side of the combine harvester. The harvester head can be designed, for example, as a cutting mechanism having a mower bar and a reel arranged thereabove or a transverse conveying auger or a transverse conveyor belt, or it can be designed as a corn picker having picking units and a transverse conveying auger. During harvesting, the harvester head conveys the cut-off or taken-up crop through a rearward discharge opening onto the feederhouse assembly, which in turn conveys it into the interior of the combine harvester, where it is threshed, separated and cleaned.
The feederhouse assembly comprises a housing, in which a chain conveyor, typically operating in an undershot manner, circulates about an upper and a lower feederhouse roller, which are mounted in the housing. The lower feederhouse roller is arranged to the rear of the discharge opening of the harvester head, and the upper feederhouse roller, which cooperates with the chains of the chain conveyor by means of pinions, transfers the crop to an (axial or tangential) threshing drum or to an accelerator roller in the combine harvester.
A feederhouse assembly that operates in an undershot manner and has a rubber-fabric belt that comprises transversely arranged steel bars that engage with the crop has also been proposed (DE 10 2009 036 104 A1). The belt is likewise driven by the upper feederhouse roller, which is furnished with axially-extending cams, which engage between nubs on the inner side of the belt.
The conveyor must be tensioned sufficiently to guarantee a transmission of torque from the driven feederhouse roller to the chain conveyor and to prevent the chain from slipping over the nubs, particularly under a heavy load of crop on the feederhouse. In the prior art, feederhouses equipped with chains were tensioned by springs acting on the lower feederhouse roller, which guarantees a certain, sufficient pre-tension (DE 10 2004 036 183, U.S. Pat. No. 4,362,005), or by hydraulic cylinders (DE 199 25 691 A1, DE 10 2012 007 637 A1) or only by moving the lower feederhouse roller to a desired position and fixing it there (U.S. Pat. No. 2,858,012 A).
Because spring pre-tensioning of feederhouses having a rubber-fabric belt has the disadvantage that the tension is either not sufficient to prevent the cams of the belt from slipping on the driven feederhouse roller or must be so high that heavy wear on the belt results, it is necessary that the adjustable feederhouse roller in such feederhouses be locked in the correct position, analogously to U.S. Pat. No. 2,858,012 A, or the adjustable feederhouse roller must be prevented from approaching the other feederhouse roller any closer than a predetermined position. This correct position is determined on the basis of a measurement of the distances between the adjacent cams of the belt, which must then be converted into the target distance between the axes of rotation of the feederhouse rollers. This procedure is cumbersome, time-consuming and prone to error.
A problem addressed by the present invention is that of avoiding the aforementioned disadvantages.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a combine harvester comprises a feederhouse which further comprises a housing, at the rear end of which an upper feederhouse roller is rotatably mounted, a lower feederhouse roller rotatably mounted at the front end of the housing, and an endless conveying element that is made of an inherently flexible material with slats fastened therein and rotates about the lower feederhouse roller and the upper feederhouse roller. A first of the feederhouse rollers is mounted movably relative to the housing toward and away from the second feederhouse roller along an imaginary connecting line between the feederhouse rollers.
In order to move the first, movable feederhouse roller into a correct position more simply and precisely than previously, a spring that can be coupled to the first feederhouse roller is provided. In the coupled state, this spring pre-tensions the first feederhouse roller, otherwise movable freely along said connecting line, with a force directed away from the second feederhouse roller. At the same time, a defined tension is applied to the conveying element. In this state, the first feederhouse roller is in its target position, which it is also intended to assume in a subsequent harvesting operation. The movement of the first feederhouse roller toward the second feederhouse roller in this state is now limited to a target position of the first feederhouse roller that results from the force of the spring.
In the state in which the first feederhouse roller is tensioned by the spring and in which it is in its target position, a possible movement path of the first feederhouse roller in the direction toward the second feederhouse roller is limited to the target position. The first feederhouse roller can therefore not move past the target position in the direction toward the second feederhouse roller. This has the effect that the tension on the conveying element matches a certain desired minimum value that is necessary for transmitting the driving torque from the driven feederhouse roller to the conveying element, but does not significantly exceed that value.
The first feederhouse roller could (after the described adjusting process) move freely in the opposite direction, i.e. away from the second feederhouse roller, but it is advisable to fix it in this direction as well, i.e. locked in the target position, once the target position has been found and the movement path of the first feederhouse roller toward the second feederhouse roller has been limited to this position.
As a rule, the first feederhouse roller is the lower feederhouse roller and the upper feederhouse roller is drivable. It would be conceivable, however, to drive the lower feederhouse roller and/or to design the upper feederhouse roller to be position-adjustable.
The first feederhouse roller can preferably be limited in movement or locked at both ends and coupled to a spring at each end.
The spring can be relaxed or removed and may be loaded with a defined pre-tension by using a gauge or scale.
In one possible embodiment, a bracket extending transversely to the imaginary connecting line and furnished with an opening is attached to the outer side of the housing. The end of an axle of the first feederhouse roller can penetrate through a slotted hole extending along the imaginary connecting line in the housing. The axle of the first feederhouse roller can be connected to a front end adjusting rod extending along the connecting line, the rod penetrating the opening in the bracket and being coupled at the outer end of the rod distant from the axle to a first end of the spring, which is supported at a second end on the housing, more particularly on a U-profile coupled to the bracket. The limitation of the movement of the first feederhouse roller toward the target position can be provided between the adjusting rod and the bracket.
In particular, the spring is a helical spring operating with tensile or compressive force.
The limitation of the movement of the first feederhouse roller to the target position can be realized by a nut contacting the bracket and interacting with a thread of the adjusting rod.
A second nut interacting with a thread of the adjusting rod can be brought into contact on a second side of the bracket in order to lock the first feederhouse roller.
In accordance with another aspect of the invention, a combine harvester is provided comprising: wheels ( 14 , 16 ) for engaging the ground and carrying the combine harvester ( 10 ) through an agricultural field; a chassis ( 12 ) supported on the wheels;
a threshing drum ( 22 ) supported on the chassis ( 12 ); a threshing basket ( 34 ) wrapped around a portion of the threshing drum ( 22 ); and a feederhouse assembly ( 20 ) supported on the chassis ( 12 ) and disposed in front of the threshing drum ( 22 ), wherein the feederhouse assembly ( 20 ) comprises, a housing ( 62 ) having a front end configured to receive crop from an agricultural harvesting head and a rear end configured to transmit crop to the threshing drum ( 22 ), an upper feederhouse roller ( 64 ) rotatably mounted at the rear end of the housing ( 62 ), a lower feederhouse roller ( 80 ) rotatably mounted at the front end of the housing ( 62 ), and an endless conveying element ( 82 ) comprising an inherently flexible material, and further comprising slats ( 84 ) fastened to the inherently flexible material, wherein the endless conveying element ( 82 ) is configured to circulate about the lower feederhouse roller ( 80 ) and the upper feederhouse roller ( 64 ), wherein a first of the feederhouse rollers ( 64 , 80 ) is mounted so as to be movable relative to the housing ( 62 ) toward and away from a second of the feederhouse rollers ( 64 , 80 ) along an imaginary connecting line ( 95 ) that extends between the feederhouse rollers ( 64 , 80 ), characterized in that the first of the feederhouse rollers ( 64 , 80 ) is configured to be coupled to a spring ( 86 ), to pre-tension the first of the feederhouse rollers ( 64 , 80 ) with a force directed away from the second of the feederhouse rollers ( 64 , 80 ) and applies a defined tension to the endless conveying element ( 82 ), and in that the movement of the first of the feederhouse rollers ( 64 , 80 ) in the direction toward the second of the feederhouse rollers ( 64 , 80 ) can be limited to a target position of the first of the feederhouse rollers ( 64 , 80 ) that results from the force of the spring ( 86 ).
The first of the feederhouse rollers may be locked with respect to the housing ( 62 ) in the target position.
The first of the feederhouse rollers may be the lower feederhouse roller ( 80 ). The upper feederhouse roller may be drivable.
The first of the feederhouse rollers may be restricted in movement or locked at both ends and may be connected at each end to a spring ( 86 ).
The spring may be relaxed or removed (or both) during normal operation of the feederhouse assembly ( 20 ) and may be loaded with a defined pre-tension using a gauge ( 106 ) or a scale.
A bracket may extend transversely to the imaginary connecting line ( 95 ) between the feederhouse rollers ( 64 , 80 ) and may have an opening ( 96 ). The bracket may be mounted on the outer side of the housing ( 62 ), and a pivot axis ( 112 ) coupled by a pivoting mid floor ( 116 ) to an axle ( 88 ) of the first of the feederhouse rollers ( 64 , 80 ) may penetrate through a slotted hole ( 90 ) extending in the housing ( 62 ) along the imaginary connecting line ( 95 ). The pivot axis may be connected to an adjusting rod ( 92 ) extending along the imaginary connecting line ( 95 ). The adjusting rod may extend through the opening ( 96 ) in the bracket and an outer end of the adjusting rod that faces away from the axle, may be coupled to a first end of the spring ( 86 ). A second end of the spring may be supported on the housing ( 62 ) on a U-profile ( 100 ) that is coupled to the bracket ( 98 ). The first of the feederhouse rollers ( 64 , 80 ) may be fixed at the target position by fixing the adjusting rod ( 92 ) to the bracket ( 98 ).
The spring may be a helical (or coil) spring operating in compression or intention (i.e. the spring may be a compression spring or a tension spring.
Movement of the first of the feederhouse rollers ( 64 , 80 ) may be limited to the target position by a nut ( 108 ) that contacts the bracket ( 98 ) on a first side of the bracket and is threadedly engaged with a thread of the adjusting rod ( 92 ).
A second nut that is also threadedly engaged with a thread of the adjusting rod ( 92 ) may be brought into contact with a second side of the bracket ( 98 ) to thereby lock the first of the feederhouse rollers ( 64 , 80 ) in the target position.
These and other problems, features and advantages of the present invention will become clear to a person skilled in the art after reading the detailed description below and in view of the drawings, the reference numbers of which shall not be construed as limiting the interpretation of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a combine harvester having a feederhouse assembly.
FIG. 2 shows an enlarged side view of the lower region of the feederhouse assembly from FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows a self-propelled harvesting machine in the form of a combine harvester 10 having a chassis 12 that is supported on the ground via front wheels 14 that are driven and rear wheels 16 that are steerable and is propelled thereby. The front wheels 14 are driven by drive means, not shown in detail, in order to move the combine harvester 10 on a field to be harvested. Directional indications such as front and back refer below to the driving direction V, to the left in FIG. 1 , of the combine harvester 10 in harvesting operation. The front wheels 14 could also be replaced by track drive mechanisms.
A harvester head 18 in the form of a cutting mechanism is removably connected to the front end area of the combine harvester 10 in order to harvest crop in the form of grain or other threshable crops from the field and feed it upward and to the rear by means of a feederhouse assembly 20 , on which the harvester head 18 is removably mounted, to a multi-drum threshing mechanism that comprises, arranged in succession in the travel direction V, a threshing drum 22 , a stripper drum 24 , a drum conveyor 26 of the overshot type, a tangential separator 28 and a turning drum 30 . A straw shaker 32 is located downstream of the turning drum 30 . In its lower and rear area, the threshing drum 22 is surrounded by a threshing basket 34 . Underneath the drum conveyor 26 there is a cover 44 , with a contiguous surface or furnished with openings, while above the drum conveyor 26 there is a fixedly mounted cover, and a separating basket 36 with adjustable finger elements is located underneath the tangential separator 28 . A finger rake 38 is arranged underneath the turning drum 30 . In place of the illustrated multi-drum threshing mechanism, any other threshing and separating equipment can be used, e.g. a single tangential threshing drum with downstream straw shakers or separating rollers, or an axial threshing and separating device with one or two axial threshing and separating rotors.
The mixture containing grain and impurities that passes through the threshing basket 34 , the separating basket and the straw shaker 32 reaches a cleaning apparatus 46 via conveying floors 40 , 42 . The grain cleaned by the cleaning apparatus 46 is fed by means of a screw auger 48 to an elevator, not shown, which conveys it into a grain tank 50 . A return auger 52 passes unthreshed head parts through an additional elevator, not shown, back into the threshing process. The chaff can be ejected at the rear side of the screen device by a rotating chaff distributor, or it is ejected by a straw chopper (not drawn) arranged downstream of the straw shaker 32 . The cleaned grain can be unloaded from the grain tank 50 by a discharge system with cross augers 54 and a discharge conveyor 56 . The above-mentioned systems are driven by means of an internal combustion engine 58 and are checked and controlled by an operator from a driver's cab 60 .
The feederhouse assembly 20 comprises a housing 62 , which is rotatably articulated on the chassis 12 about the axis of an upper feederhouse roller 64 that extends horizontally and transversely to the forward direction. The feederhouse assembly 20 is swiveled about the axis of the upper feederhouse roller 64 by means of two actuators 66 in the form of hydraulic cylinders, which are articulated on either side of the feederhouse assembly 20 , at one end to the lower, front end of the chassis 12 , and at the other end, to the rear of the front, lower end of the housing 62 of the feederhouse assembly 20 . A controller (not shown) drives the actuator 66 during harvesting in such a manner that the harvester head 18 is moved at a desired height or with a desired contact force across the ground of the field to be harvested. The housing 62 of the feederhouse assembly 20 comprises, in a conventional manner, lower and upper walls that are connected to another by lateral walls.
A lower feederhouse roller 80 is rotatably mounted on the housing 62 . Its axis of rotation extends transversely to the forward direction V and horizontally. An endless conveying element 82 having slats 84 and conveying the crop in an undershot manner circulates around the feederhouse rollers 64 , 80 . The endless conveying element 82 is stretchable and preferably comprises a plurality of rubber-fabric belts 89 distributed across the width of the housing 62 that are connected to one another by the slats 84 . The endless conveying element 82 is driven via cams arranged on the interior side thereof that engage with corresponding depressions in the upper feederhouse roller 64 , which can be driven by the internal combustion engine 58 . The slats 84 are formed as U-shaped steel strips that extend across the width of the housing 62 , but could consist of some other material and have a different cross section. In order to produce an optimal connection between the slats 84 and the endless conveying element 82 , threaded bolts are vulcanized into the rubber-fabric belt 89 .
The endless conveying element 82 must be tensioned for operation in such a manner that the slats 84 do not scrape along the bottom of the housing 62 , thus minimizing wear and noise production, and it must also be ensured that the cams of the endless conveying element 82 do not slip over the complementary driving elements (i.e. teeth or cams) of the upper feederhouse roller 64 . In order to produce the required tension on the endless conveying element 82 in a simple manner, an arrangement shown in FIG. 2 , with which both sides of the lower feederhouse roller 80 can be brought by a spring 86 into a target position and locked there, is provided at both ends of the lower feederhouse roller 80 .
The lower feederhouse roller 80 comprises axle stubs 88 that do not rotate in operation, on which the lower feederhouse roller 80 is supported rotatably about the longitudinal axis via rotary bearings (not shown). The axle stubs 88 are connected to supports 114 , that are on their end connected to a pivotable mid floor 116 , which is located between the strands of the conveying element 82 and extends rearwards of the lower feederhouse roller 80 to the rear and upwards. The pivotable mid floor 116 is connected with its rear end on both sides with a pivot axis 112 , respectively, extending through a slotted hole 90 in the side wall of the housing 62 . The pivotable mid floor 116 is described in U.S. Pat. No. 7,766,736 B1, the contents of which incorporated by reference herein. The longitudinal direction of the slotted holes 90 extends along an imaginary connecting line between the feederhouse rollers 64 , 80 or at an acute angle thereto. An adjusting rod 92 is mounted at its rear end on the pivot axis 112 by means of a bearing eye 94 and extends parallel to the imaginary connecting line 95 that extends between the rotational axes of the feederhouse rollers 64 , 80 . The adjusting rod 92 penetrates an opening 96 in a bracket 98 , which is connected to the side wall of the housing 62 and extends transversely to the imaginary connecting line between the feederhouse rollers 64 , 80 , and the adjusting rod further penetrates through an additional opening in a U-profile 100 , which is connected to the bracket 98 on the side of the bracket 98 facing away from the pivot axis 112 . The bracket 98 comprises front legs 102 on either side of the slotted hole 90 . A nut 104 , which clamps a spring 86 formed as a helical compression spring between itself and the U-profile 100 , is screwed onto a thread of the adjusting rod 92 at the outer end of the adjusting rod 92 . The tension of the spring 86 can be varied by rotating the nut 104 , and a scale or gauge 106 connected to the U-profile 100 makes it possible to pre-tension the spring 86 into a desired position, which corresponds to a defined force of the spring. Additional nuts 108 , 110 , which contact both sides of the bracket 98 and lock the adjusting rod 92 on the housing 62 in the position of the nuts 108 , 110 shown in FIG. 2 , are screwed onto threaded regions of the adjusting rod 92 .
All of this results in the following procedure when the endless conveying element 82 is to be provided with a defined tension after a certain period of operation or after replacement. Any crop still present is removed from the feederhouse assembly 20 and it is then stopped. Then the springs 86 are mounted at the illustrated position and pre-tensioned with a desired force by the nuts 104 , the collars of which are made to coincide with the outer end of the gauge 106 (or with a defined point of a gauge constructed as a scale). Then the nuts 108 and 110 on both sides of the feederhouse assembly 20 are loosened, i.e. brought into position at a distance from the bracket 98 by rotation. Now the lower feederhouse roller 80 is freely movable relative to the housing 62 along the imaginary connecting line between the feederhouse rollers 64 , 80 , because the nuts 108 , 110 are loosened, but it is pulled away from the upper feederhouse roller 64 along the imaginary connecting line between the feederhouse rollers 64 , 80 forward and downward by the springs 86 , the force of which is transmitted via the U-profile 100 and the bracket 98 onto the housing 62 on the one hand, and on the other, onto the lower feederhouse roller 80 via the nut 104 , the adjusting rod 92 , the bearing eye 94 , the pivot axis 112 , the pivotable mid floor 116 , the supports 114 and the axle stub 88 . In the process, the endless conveying element 82 is tensioned with the force defined by the springs 86 , and the lower feederhouse roller 80 reaches its target position. Now the nut 108 adjacent to the pivot axis 112 on either side of the feederhouse assembly 20 is rotated such that it comes into contact with the bracket 98 . This measure has the effect that the lower feederhouse roller 80 cannot approach the upper feederhouse roller 64 more closely than the now achieved target position. In principle, the feederhouse assembly 20 would now be ready for operation. In order to avoid undesired vibrations and to be able to relieve the springs 86 , the other nuts 110 are preferably brought into contact with the bracket 98 in order to lock the lower feederhouse roller 80 on the housing 62 .
Once the proper tension has been applied to the endless conveying element 82 in this manner, and the lower feederhouse roller has been locked in place with respect to the housing 62 by tightening the nuts 108 , 110 against the bracket 98 , the springs 86 can be relaxed by loosening the nut 104 . This will lengthen the service life of the springs 86 . Alternatively, the nut 104 and the springs 86 may be removed entirely. | A combine harvester ( 10 ) has a feederhouse assembly ( 20 ) that comprises a housing ( 62 ). The housing ( 62 ) contains feederhouse rollers ( 64, 80 ), about which an endless conveying element ( 82 ) circulates. The endless conveying element ( 82 ) is made from an inherently flexible material having slats ( 84 ) fastened thereon. A first feederhouse roller ( 80 ) is mounted movably along an imaginary connecting line ( 95 ) between the feederhouse rollers ( 64, 80 ) and can be coupled to a spring ( 86 ) that pre-tensions the endless conveying element ( 82 ) and brings the first feederhouse roller ( 80 ) into a target position. The movement of the first feederhouse roller ( 80 ) toward the second feederhouse roller ( 64 ) is limited to this target position. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/971,017, filed Jan. 8, 2008, which is a divisional of U.S. application Ser. No. 09/827,641, filed on Apr. 6, 2001, now U.S. Pat. No. 7,317,698, which is a continuation-in-part of U.S. patent application Ser. No. 09/301,477, filed on Apr. 28, 1999, now U.S. Pat. No. 6,807,405, which claims priority to Canadian Patent 2,260,653, filed Feb. 2, 1999. U.S. application Ser. No. 09/827,641, filed Apr. 6, 2001, now U.S. Pat. No. 7,317,698, also claims priority to U.S. Provisional Application 60/195,387, filed Apr. 7, 2000. All sections of U.S. patent application Ser. No. 11/971,017 are incorporated herein by reference in their entirety.
FIELD OF THE DISCLOSURE
[0002] The present invention is directed to communication systems and, more particularly, to a technique for detecting, identifying, extracting and eliminating narrowband interference in a wideband communication system.
BACKGROUND OF THE DISCLOSURE
[0003] As shown in FIG. 1 , an exemplary telecommunication system 10 may include mobile units 12 , 13 , a number of base stations, two of which are shown in FIG. 1 at reference numerals 14 and 16 , and a switching station 18 to which each of the base stations 14 , 16 may be interfaced. The base stations 14 , 16 and the switching station 18 may be collectively referred to as network infrastructure.
[0004] During operation, the mobile units 12 , 13 exchange voice data or other information with one of the base stations 14 , 16 , each of which are connected to a conventional land line telephone network. For example, information, such as voice information, transferred from the mobile unit 12 to one of the base stations 14 , 16 is coupled from the base station to the telephone network to thereby connect the mobile unit 12 with a land line telephone so that the land line telephone may receive the voice information. Conversely, information, such as voice information may be transferred from a land line telephone to one of the base stations 14 , 16 , which, in turn, transfers the information to the mobile unit 12 .
[0005] The mobile units 12 , 13 and the base stations 14 , 16 may exchange information in either analog or digital format. For the purposes of this description, it is assumed that the mobile unit 12 is a narrowband analog unit and that the mobile unit 13 is a wideband digital unit. Additionally, it is assumed that the base station 14 is a narrowband analog base station that communicates with the mobile unit 12 and that the base station 16 is a wideband digital base station that communicates with the mobile unit 13 .
[0006] Analog format communication takes place using narrowband 30 kilohertz (KHz) channels. The advanced mobile phone systems (AMPS) is one example of an analog communication system in which the mobile unit 12 communicates with the base station 14 using narrowband channels. Alternatively, the mobile unit 13 communicates with the base stations 16 using a form of digital communications such as, for example, code-division multiple access (CDMA) or time-division multiple access (TDMA). Digital communication takes place using spread spectrum techniques that broadcast signals having wide bandwidths, such as, for example, 1.25 megahertz (MHz) bandwidths.
[0007] The switching station 18 is generally responsible for coordinating the activities of the base stations 14 , 16 to ensure that the mobile units 12 , 13 are constantly in communication with the base station 14 , 16 or with some other base stations that are geographically dispersed. For example, the switching station 18 may coordinate communication handoffs of the mobile unit 12 between the base stations 14 and another analog base station as the mobile unit 12 roams between geographical areas that are covered by the two base stations.
[0008] One particular problem that may arise in the telecommunication system 10 is when the mobile unit 12 or the base station 14 , each of which communicate using narrowband channels, interfere with the ability of the base station 16 to receive and process wideband digital signals from the digital mobile unit 13 . In such a situation, the narrowband signal transmitted from the mobile unit 12 or the base station 14 may interfere with the ability of the base station 16 to properly receive wideband communication signals.
SUMMARY OF THE INVENTION
[0009] According to one aspect, the present invention may be embodied in a method of detecting and eliminating narrowband interference in a wideband communication signal having a frequency bandwidth with narrowband channels disposed therein. Such a method may include scanning at least some of the narrowband channels to determine signal strengths in at least some of the narrowband channels and determining a threshold based on the signal strengths in at least some of the narrowband channels. Additionally, the method may include identifying narrowband channels having signal strengths exceeding the threshold and assigning filters to at least some of the narrowband channels having signal strengths exceeding the threshold. Furthermore, the method may include determining if the assigned filters are operating properly and bypassing any of the assigned filters that are not operating properly.
[0010] According to a second aspect, the present invention may be embodied in a system adapted to detect and eliminate narrowband interference in a wideband communication signal having a frequency bandwidth with narrowband channels disposed therein. Such a system may include a scanner adapted to scan at least some of the narrowband channels to determine signal strengths in at least some of the narrowband channels, a notch module adapted to receive the wideband communication signal and to selectively remove narrowband interference from the wideband communication signal to produce a filtered wideband communication signal and a bypass switch adapted to bypass the notch module when the bypass switch is enabled. Furthermore, the system may include a controller coupled to the scanner and to the notch module, wherein the controller is adapted to determine a threshold based on the signal strengths in at least some of the narrowband channels. Furthermore, the controller may be adapted to identify narrowband channels having signal strengths exceeding the threshold, to control the notch module to filter the wideband communication signal at a frequency corresponding to a narrowband channel having a signal strength exceeding the threshold, to determine if the notch module is operating properly and to enable the bypass switch when the notch module is not operating properly.
[0011] According to a third aspect, the present invention may be embodied in a method of detecting and eliminating narrowband interference in a wideband communication signal having a frequency bandwidth with narrowband channels disposed therein. Such a method may include scanning at least some of the narrowband channels to determine signal strengths in at least some of the narrowband channels, determining a threshold based on the signal strengths in at least some of the narrowband channels and identifying fading narrowband channels having signal strengths that do not exceed the threshold and that were previously identified as exceeding the threshold, based on how long the identified narrowband channels have not exceeded the threshold. Additionally, the method may include filtering the wideband communication signal at a frequency corresponding to a fading narrowband channel.
[0012] According to a fourth aspect, the present invention may be embodied in a system adapted to detect and eliminate narrowband interference in a wideband communication signal having a frequency bandwidth with narrowband channels disposed therein. Such a system may include a scanner adapted to scan at least some of the narrowband channels to determine signal strengths in at least some of the narrowband channels in an order representative of a probability that the narrowband channels will have interference and a notch module adapted to receive the wideband communication signal and to selectively remove narrowband interference from the wideband communication signal to produce a filtered wideband communication signal. The system may also include a controller coupled to the scanner and to the notch module, wherein the controller is adapted to determining a threshold based on the signal strengths in at least some of the narrowband channels. The controller may be further adapted to identify fading narrowband channels having signal strengths that do not exceed the threshold and that were previously identified as exceeding the threshold, based on how long the identified narrowband channels have not exceeded the threshold and to control the notch module to filter the wideband communication signal at a frequency corresponding to a fading narrowband channel.
[0013] These and other features of the present invention will be apparent to those of ordinary skill in the art in view of the description of the preferred embodiments, which is made with reference to the drawings, a brief description of which is provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an exemplary illustration of a communication system;
[0015] FIG. 2 is an exemplary illustration of a base station of FIG. 1 ;
[0016] FIG. 3 is an exemplary illustration of a frequency spectrum of a wideband signal in the absence of interference;
[0017] FIG. 4 is an exemplary illustration of a frequency spectrum of a wideband signal in the presence of three narrowband interferers;
[0018] FIG. 5 is an exemplary illustration of a frequency spectrum of a wideband signal having three narrowband interferers removed therefrom;
[0019] FIG. 6 is an exemplary illustration of one embodiment of an adaptive notch filter (ANF) module of FIG. 2 ;
[0020] FIG. 7 is an exemplary illustration of a second embodiment of an ANF module of FIG. 2 ;
[0021] FIG. 8 is an exemplary illustration of a notch module of FIG. 7 ;
[0022] FIG. 9 is an exemplary illustration of a second embodiment of a notch filter block of FIG. 8 ;
[0023] FIG. 10 is an exemplary flow diagram of a main routine executed by the microcontroller of FIG. 7 ;
[0024] FIG. 11 is an exemplary flow diagram of a setup default values routine executed by the microcontroller of FIG. 7 ;
[0025] FIG. 12 is an exemplary flow diagram of a built in test equipment (BITE) test routine executed by the microcontroller of FIG. 7 ;
[0026] FIG. 13 is an exemplary flow diagram of a signal processing and interference identification routine executed by the microcontroller of FIG. 7 ;
[0027] FIG. 14 is an exemplary flow diagram of an interference extraction routine executed by the microcontroller of FIG. 7 ;
[0028] FIG. 15 is an exemplary flow diagram of a fail condition check routine executed by the microcontroller of FIG. 7 ;
[0029] FIGS. 16A and 16B form an exemplary flow diagram of a main routine executed by the operations, alarms and metrics (OA&M) processor of FIG. 7 ;
[0030] FIG. 17 is an exemplary flow diagram of a prepare response routine executed by the OA&M processor of FIG. 7 ; and
[0031] FIG. 18 is an exemplary flow diagram of a data buffer interrupt function executed by the OA&M processor of FIG. 7 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0032] As disclosed in detail hereinafter, a system and/or a method for detecting, identifying, extracting and reporting interference may be used in a communication system. In particular, such a system or method may be employed in a wideband communication system to protect against, or to report the presence of, narrowband interference, which has deleterious effects on the performance of the wideband communication system.
[0033] As shown in FIG. 2 , the signal reception path of the base station 16 , which was described as receiving narrowband interference from the mobile unit 12 in conjunction with FIG. 1 , includes an antenna 20 that provides signals to a low noise amplifier (LNA) 22 . The output of the LNA 22 is coupled to a splitter 24 that splits the signal from the LNA into a number of different paths, one of which may be coupled to an adaptive notch filter (ANF) module 26 and another of which may be coupled to a narrowband receiver 28 . The output of the ANF module 26 is coupled to a wideband receiver 30 , which may, for example, be embodied in a CDMA receiver or any other suitable wideband receiver. The narrowband receiver 28 may be embodied in a 15 KHz bandwidth receiver or in any other suitable narrowband receiver. Although only one signal path is shown in FIG. 2 , it will be readily understood to those having ordinary skill in the art that such a signal path is merely exemplary and that, in reality, a base station may include two or more such signal paths that may be used to process main and diversity signals received by the base station 16 .
[0034] The outputs of the narrowband receiver 28 and the wideband receiver 30 are coupled to other systems within the base station 16 . Such systems may perform voice and/or data processing, call processing or any other desired function. Additionally, the ANF module 26 is also communicatively coupled, via the Internet, telephone lines or any other suitable media, to a reporting and control facility that is remote from the base station 16 . In some networks, the reporting and control facility may be integrated with the switching station 18 . The narrowband receiver 28 is communicatively coupled to the switching station 18 and may respond to commands that the switching station 18 issues.
[0035] Each of the components 20 - 30 of the base station 16 shown in FIG. 2 , except for the ANF module 26 , may be found in a conventional wideband cellular base station, the details of which are well known to those having ordinary skill in the art. It will also be appreciated by those having ordinary skill in the art that FIG. 2 does not disclose every system or subsystem of the base station 16 and, rather, focuses on the systems and subsystems of the base station 16 that are relevant to the description of the present invention. In particular, it will be readily appreciated that, while not shown in FIG. 2 , the base station 16 includes a transmission system or subsystem.
[0036] During operation of the base station 16 , the antenna 20 receives wideband signals that are broadcast from the mobile unit 13 and couples such signals to the LNA 22 , which amplifies the received signals and couples the amplified signals to the splitter 24 . The splitter 24 splits the amplified signal from the LNA 22 and essentially puts copies of the amplified signal on each of its output lines. The ANF module 26 receives the signal from the splitter 24 and, if necessary, filters the wideband signal to remove any undesired narrowband interference and couples the filtered wideband signal to the wideband receiver 30 .
[0037] FIG. 3 illustrates a frequency spectrum 40 of a wideband signal that may be received at the antenna 20 , amplified and split by the LNA 22 and the splitter 24 and coupled to the ANF module 26 . If the wideband signal received at the antenna 20 has a frequency spectrum 40 as shown in FIG. 3 , the ANF module 26 will not filter the wideband signal and will simply couple the wideband signal directly through the ANF module 26 to the wideband receiver 30 .
[0038] However, as noted previously, it is possible that the wideband signal transmitted by the mobile unit 13 and received by the antenna 20 has a frequency spectrum 42 as shown in FIG. 4 . Such a frequency spectrum 42 includes not only the wideband signal from the mobile unit 13 having a frequency spectrum similar to the frequency spectrum 40 of FIG. 3 , but includes three narrowband interferers 44 , 46 , 48 , as shown in FIG. 4 , one of which may be from the mobile unit 12 . If a wideband signal having a frequency spectrum 42 including narrowband interferers 44 , 46 , 48 is received by the antenna 20 and amplified, split and presented to the ANF module 26 , the ANF module 26 will filter the frequency spectrum 42 to produce a filtered frequency spectrum 50 as shown in FIG. 5 .
[0039] The filtered frequency spectrum 50 has the narrowband interferers 44 , 46 , 48 removed, therefore leaving a frequency spectrum 50 that is very similar to the frequency spectrum 40 , which does not include any interference. The filtered wideband signal is then coupled from the ANF module 26 to the wideband receiver 30 , so that the filtered wideband signal spectrum 50 may be demodulated. Although some of the wideband signal was removed during filtering by the ANF module 26 , sufficient wideband signal remains to enable the wideband receiver 30 to recover the information that was broadcast by a mobile unit. Accordingly, in general terms, the ANF module 26 selectively filters wideband signals to remove narrowband interference therefrom. Further detail regarding the ANF module 26 and its operation is provided below in conjunction with FIGS. 6-17 .
[0040] In general, one embodiment of an ANF module 60 , as shown in FIG. 6 , scans the frequency spectrum of the signal provided by the splitter 24 and looks for narrowband interference therein. Such scanning may be implemented by scanning to various known narrowband channels that exist within the bandwidth of the wideband signal. For example, the ANF module 60 may scan to various AMPS channels that lie within the bandwidth of the wideband signal. Alternatively, all of the frequency spectrum encompassed by the wideband signal may be scanned. Either way, when narrowband interference is detected in the wideband signal, the ANF module 60 moves the narrowband interference into the notch of a notch filter, thereby filtering the wideband signal to remove the narrowband interference.
[0041] In particular, as shown in FIG. 6 , the signal from the splitter 24 is coupled to a first mixer 62 , which receives an additional input from a voltage controlled oscillator (VCO) 64 . The first mixer 62 mixes the signal from the splitter 26 with the signal from the VCO 64 , thereby shifting the frequency spectrum of the signal from the splitter 24 and putting a portion of the shifted frequency spectrum located at intermediate frequency (IF) into a notch frequency of a notch filter 66 . Accordingly, the component of the frequency shifted signal that is at the IF is removed by the notch filter 66 having a notch frequency set at the IF.
[0042] The resulting filtered signal is coupled from the notch filter 66 to a second mixer 68 , which is also driven by the VCO 64 . The second mixer 68 mixes the notch filter output with the signal from the VCO 64 to shift the frequency spectrum of the filtered signal back to an original position that the signal from the splitter 24 had. The output of the second mixer 68 is coupled to a band pass filter 70 , which removes any undesired image frequencies created by the second mixer 68 .
[0043] In the system of FIG. 6 , the narrowband interference present in the wideband signal is mixed to the IF, which is the notch frequency of the notch filter 66 , by the first mixer 62 and is, therefore, removed by the notch filter 66 . After the narrowband interference has been removed by the notch filter 66 , the second mixer 68 restores the signal to its original frequency position, except that the narrowband interference has been removed. Collectively, the first mixer 62 , the VCO 64 , the notch filter 66 , the second mixer 68 and the band pass filter may be referred to as an “up, down filter” or a “down, up filter.”
[0044] The signal from the splitter 24 is also coupled to a bypass switch 72 so that if no narrowband interference is detected in the wideband signal from the splitter 24 , the bypass switch 72 may be enabled to bypass the notch filter 66 and the mixers 62 , 68 , thereby passing the signal from the splitter 24 directly to the wideband receiver 30 . Alternatively, if narrowband interference is detected, the bypass switch 72 is opened and the signal from the splitter 24 is forced to go through the notch filter 66 .
[0045] To detect the presence of narrowband interference and to effectuate frequency scanning, a number of components are provided. A discriminator 74 receives the output signal from the first mixer 62 and detects signal strength at the IF using a received signal strength indicator (RSSI) that is tuned to the IF. The RSSI output of the discriminator 74 is coupled to a comparator 76 , which also receives a threshold voltage on a line 78 . When the RSSI signal from the discriminator 74 exceeds the threshold voltage on the line 78 , the comparator 76 indicates that narrowband interference is present at the IF, which is the notch frequency of the notch filter 66 . When narrowband interference is detected, the sweeping action of the VCO 64 is stopped so that the notch filter 66 can remove the interference at the IF.
[0046] To affect the sweeping action of the VCO 64 , the output of the comparator 76 is coupled to a sample and hold circuit 80 , which receives input from a voltage sweep generator 82 . Generally, when no interference is detected by the comparator 76 , the output of the voltage sweep generator 82 passes through the sample and hold circuit 80 and is applied to a summer 84 , which also receives input from a low pass filter 86 that is coupled to the output of the discriminator 74 . The summer 84 produces a signal that drives the VCO 64 in a closed loop manner. As the voltage sweep generator 82 sweeps its output voltage over time, the output of the summer 84 also sweeps, which causes the frequency output of the VCO 64 to sweep over time. The sweeping output of VCO 64 , in conjunction with the discriminator 74 and the comparator 76 , scan the signal from the splitter 24 for interference. As long as the comparator 76 indicates that narrowband interference is not present, the switch 72 is held closed, because there is no need to filter the signal from the splitter 24 .
[0047] However, when the comparator 76 detects narrowband interference in the signal from the splitter 24 (i.e., when the RSSI exceeds the voltage on the line 78 ), the sample and hold circuit 80 samples the output of the voltage sweep generator 82 and holds the sampled voltage level, thereby providing a fixed voltage to the summer 84 , which, in turn, provides a fixed output voltage to the VCO 64 . Because a fixed voltage is provided to the VCO 64 , the frequency output by the VCO 64 does not change and the signal from the splitter 24 is no longer scanned, but is frequency shifted so that the narrowband interference is moved to the IF, which is the notch frequency of the notch filter 66 . Additionally, when the comparator 76 indicates that narrowband interference is present, the switch 72 opens and the only path for the signal from the splitter 24 to take is the path through the mixers 62 , 68 and the notch filter 66 .
[0048] The threshold voltage on the line 78 may be hand tuned or may be generated by filtering some received signal strength. Either way, the voltage on the line 78 should be set so that the comparator 76 does not indicate that interference is present when only a wideband signal, such as the signal shown in FIG. 3 , is present, but only indicates interference when a signal having narrowband interference is present. For example, the frequency spectrum 42 shown in FIG. 4 , shows three narrowband interferers 44 , 46 , 48 , only one of the interferers would be needed for the comparator 76 to indicate the presence of narrowband interference. As will be readily appreciated, the embodiment shown in FIG. 6 is only able to select and filter a single narrowband interferer within a wideband signal.
[0049] As shown in FIG. 7 , a second embodiment of an ANF module 100 , which may filter a number of narrowband interferers, generally includes a scanner 102 , an analog to digital converter (A/D) 104 , a microcontroller 106 , an operations, alarms and metrics (OA&M) processor 108 and notch modules, two of which are shown in FIG. 7 at reference numerals 110 and 112 . The microcontroller 106 and the OA&M processor 108 may be embodied in a model PIC 16C77-20P microcontroller, which is manufactured by Microchip Technology, Inc., and a model 80386 processor, which is manufactured by Intel Corp., respectively. Although they are shown and described herein as separate devices that execute separate software instructions, those having ordinary skill in the art will readily appreciate that the functionality of the microcontroller 106 and the OA&M processor 108 may be merged into a single processing device.
[0050] Additionally, the second embodiment of the ANF module 100 may include a built in test equipment (BITE) module 114 and a bypass switch 116 , which may be embodied in a model AS239-12 gallium arsenide single-pole, double-throw switch available from Hittite. The microcontroller 106 and the OA&M processor 108 may be coupled to external memories 118 and 120 , respectively.
[0051] In general, the scanner 102 , which includes a mixer 130 , a discriminator 132 and a programmable local oscillator 134 , interacts with the A/D 104 and the microcontroller 106 to detect the presence of narrowband interference in the signal provided by the splitter 24 . The mixer 130 and the programmable local oscillator 134 may be embodied in a model MD-54-0005 mixer available from M/A-Com and a model AD9831 direct digital synthesizer, which is manufactured by Analog Devices, Inc., respectively. Additionally, the A/D 104 may be completely integrated within the microcontroller 106 or may be a stand alone device coupled thereto.
[0052] As described in further detail below, once narrowband interference is detected in the signal from the splitter 24 , the microcontroller 106 , via serial bus 136 , controls the notch modules 110 , 112 to remove the detected narrowband interference. Although the second embodiment of the ANF module 100 , as shown in FIG. 7 , includes two notch modules 110 , 112 , additional notch modules may be provided in the ANF module 100 . The number of notch modules that may be used in the ANF module 100 is only limited by the signal degradation that each notch module contributes. Because multiple notch modules are provided, multiple narrowband interferers may be removed from the wideband signal from the splitter 24 . For example, if three notch modules were provided, a wideband signal having the frequency spectrum 42 , as shown in FIG. 4 , may be processes by the ANF module 110 to produce a filtered wideband signal having the frequency spectrum 50 , as shown in FIG. 5 .
[0053] The scanner 102 performs its function as follows. The signal from the splitter 24 is coupled to the mixer 130 , which receives an input from the programmable local oscillator 134 . The mixer 130 mixes the signals from the splitter 24 down to an IF, which is the frequency that the discriminator 132 analyses to produce an RSSI measurement that is coupled to the A/D 104 . The A/D 104 converts the RSSI signal from an analog signal into a digital signal that may be processed by the microcontroller 106 . The microcontroller 106 compares the output of the A/D 104 to an adaptive threshold that the microcontroller 106 has previously determined Details regarding how the microcontroller 106 determines the adaptive threshold are provided hereinafter. If the microcontroller 106 determines that the output from the A/D 104 , which represents RSSI, exceeds the adaptive threshold, one of the notch modules 110 , 112 may be assigned to filter the signal from the splitter 24 at the IF having an RSSI that exceeds the adaptive threshold.
[0054] The microcontroller 106 also programs the programmable local oscillator 134 so that the mixer 130 moves various portions of the frequency spectrum of the signal from the splitter 24 to the IF that the discriminator 132 processes. For example, if there are 59 narrowband channels that lie within the frequency band of a particular wideband channel, the microcontroller 106 will sequentially program the programmable local oscillator 134 so that each of the 59 channels is sequentially mixed down to the IF by the mixer 132 so that the discriminator 132 can produce RSSI measurements for each channel. Accordingly, the microcontroller 106 uses the programmable local oscillator 134 , the mixer 130 and the discriminator 132 to analyze the signal strengths in each of the 60 narrowband channels lying within the frequency band of the wideband signal. By analyzing each of the channels that lie within the frequency band of the wideband signal, the microcontroller 106 can determine an adaptive threshold and can determine whether narrowband interference is present in one or more of the narrowband channels.
[0055] Once channels having narrowband interference are identified, the microcontroller 106 may program the notch modules 110 , 112 to remove the most damaging interferers, which may, for example, be the strongest interferers. As described in detail hereinafter, the microcontroller 106 may also store lists of channels having interferers, as well as various other parameters. Such a list may be transferred to the reporting and control facility or a base station, via the OA&M processor 108 , and may be used for system diagnostic purposes.
[0056] Diagnostic purposes may include, but are not limited to, controlling the narrowband receiver 28 to obtain particular information relating to an interferer and retasking the interferer by communicating with its base station. For example, the reporting and control facility may use the narrowband receiver 28 to determine the identity of an interferer, such as a mobile unit, by intercepting the electronic serial number (ESN) of the mobile unit, which is sent when the mobile unit transmits information on the narrowband channel. Knowing the identity of the interferer, the reporting and control facility may contact infrastructure that is communicating with the mobile unit and may request the infrastructure to change the transmit frequency of the mobile unit (i.e., the frequency of the narrowband channel on which the mobile unit is transmitting) or may request the infrastructure to drop communications with the interfering mobile unit all together.
[0057] Additionally, diagnostic purposes may include using the narrowband receiver 28 to determine a telephone number that the mobile unit is attempting to contact and, optionally handling the call. For example, the reporting and control facility may use the narrowband receiver 28 to determine that the user of the mobile unit was dialing 911, or any other emergency number, and may, therefore, decide that the narrowband receiver 28 should be used to handle the emergency call by routing the output of the narrowband receiver 28 to a telephone network.
[0058] FIG. 8 reveals further detail of one of the notch modules 110 , it being understood that any other notch modules used in the ANF module 100 may be substantially identical to the notch module 110 . In general, the notch module 110 is an up, down or down, up filter having operational principles similar to the ANF module 60 described in conjunction with FIG. 6 . In particular, the notch module 110 includes first and second mixers 150 , 152 , each of which receives an input signal from a phase locked loop (PLL) 154 that is interfaced through a logic block 156 to the serial bus 136 of the microcontroller 106 . Disposed between the mixers 150 , 152 is a notch filter block 158 , further detail of which is described below. In practice, the mixers 150 , 152 may be embodied in model MD54-0005 mixers that are available from M/A-Com and the PLL 154 may be embodied in a model LMX2316™ frequency synthesizer that is commercially available from National Semiconductor.
[0059] During operation of the ANF module 100 , the microcontroller 106 controls the PLL 154 to produce an output signal that causes the first mixer 150 to shift the frequency spectrum of the signal from the splitter 24 to an IF, which is the notch frequency of the notch filter block 158 . Alternatively, in the case of cascaded notch modules, the notch module may receive its input from another notch module and not from the splitter 24 . The output of the PLL 154 is also coupled to the second mixer to shift the frequency spectrum of the signal from the notch filter block 158 back to its original position as it was received from the splitter 24 after the notch filter block 158 has removed narrowband interference therefrom. The output of the second mixer 152 is further coupled to a filter 160 to remove any undesired image frequencies that may be produced by the second mixer 152 . The output of the filter 160 may be coupled to an additional notch module (e.g., the notch module 112 ) or, if no additional notch modules are used, may be coupled directly to the wideband receiver 30 .
[0060] Additionally, the notch module 110 includes a bypass switch 164 that may be used to bypass the notch module 110 in cases where there is no narrowband interference to be filtered or in the case of a notch module 110 failure. For example, the microcontroller 106 closes the bypass switch 164 when no interference is detected for which the notch module 110 is used to filter. Conversely, the microcontroller 106 opens the bypass switch 164 when interference is detected and the notch module 110 is to be used to filter such interference.
[0061] As shown in FIG. 8 , the notch filter block 158 includes a filter 165 , which may be, for example a filter having a reject band that is approximately 15 KHz wide at −40 dB. The reject band of the filter 165 may be fixed at, for example, a center frequency of 150 MHz or at any other suitable frequency at which the IF of the mixer 150 is located.
[0062] Although the notch filter block 158 of FIG. 8 shows only a single filter 165 , as shown in FIG. 9 , a second embodiment of a notch filter block 166 may include a switch 170 and multiple filters 172 - 178 . In such an arrangement, each of the filters 172 - 178 has a notch frequency tuned to the IF produced by the first mixer 150 . Additionally, each of the filters 172 - 178 may have a different reject bandwidth at −40 dB. For example, as shown in FIG. 9 , the filters 172 - 178 have reject bandwidths of 15 KHz to 120 KHz. The use of filters having various reject bandwidths enables the ANF module 100 to select a filter having an optimal reject bandwidth to best filter an interferer.
[0063] During operation, of the second embodiment of the notch filter block 166 , the microcontroller 106 controls the switch 170 to route the output signal from the first mixer 150 to one of the filters 172 - 178 . The microcontroller 106 , via the switch 170 , selects the filter 172 - 178 having a notch switch best suited to filter interference detected by the microcontroller 106 . For example, if the microcontroller 106 determines that there is interference on a number of contiguous channels, the microcontroller 106 may use a filter 172 - 178 having a notch width wide enough to filter all such interference, as opposed to using a single filters to filter interference on each individual channel. Additionally, a single filter having a wide bandwidth may be used when two narrowband channels having interference are separated by a narrowband channel that does not have narrowband interference. Although the use of a single wide bandwidth filter will filter a narrowband channel not having interference thereon, the wideband signal information that is lost is negligible.
[0064] Having described the detail of the hardware aspects of the system, attention is now turned to the software aspects of the system. Of course, it will be readily understood by those having ordinary skill in the art that software functions may be readily fashioned into hardware devices such as, for example, application specific integrated circuits (ASICs). Accordingly, while the following description pertains to software, such a description is merely exemplary and should not be considered limiting in any way.
[0065] That being said, FIGS. 10-15 include a number of blocks representative of software or hardware functions or routines. If such blocks represent software functions, instructions embodying the functions may be written as routines in a high level language such as, for example, C, or any other suitable high level language, and may be compiled into a machine readable format. Alternatively, instructions representative of the blocks may be written in assembly code or in any other suitable language. Such instructions may be stored within the microcontroller 106 or may be stored within the external memory 118 and may be recalled therefrom for execution by the microcontroller 106 .
[0066] A main routine 200 , as shown in FIG. 10 , includes a number of blocks or routines that are described at a high level in connection with FIG. 10 and are described in detail with respect to FIGS. 11-15 . The main routine 200 begins execution at a block 202 at which the microcontroller 102 sets up default values and prepares to carry out the functionality of the ANF module 100 . After the setup default values function is complete, control passes to a block 204 , which performs a built-in test equipment (BITE) test of the ANF module 100 .
[0067] After the BITE test has been completed, control passes from the block 204 to a block 206 , which performs signal processing and interference identification. After the interference has been identified at the block 206 , control passes to a block 208 where the identified interference is extracted from the wideband signal received by the ANF module 100 .
[0068] After the interference has been extracted at the block 208 , control passes to a block 210 at which a fail condition check is carried out. The fail condition check is used to ensure that the ANF module 100 is operating in a proper manner by checking for gross failures of the ANF module 100 .
[0069] After the fail condition check completes, control passes from the block 210 to a block 212 , which performs interference data preparation that consists of passing information produced by some of the blocks 202 - 210 from the microcontroller 106 to the OA&M 108 . Upon completion of the interference data preparation, the main routine 200 ends its execution. The main routine 200 may be executed by the microcontroller 106 at time intervals such as, for example, every 20 MS.
[0070] As shown in FIG. 11 , the setup default values routine 202 begins execution at a block 220 at which the microcontroller 106 tunes the programmable local oscillator 134 to scan for interference on a first channel designated as F1. For example, as shown in FIG. 11 , F1 may be 836.52 megahertz (MHz). Alternatively, as will be readily appreciated by those having ordinary skill in the art, the first channel to which the ANF module 100 is tuned may be any suitable frequency that lies within the frequency band or guard band of a wideband channel.
[0071] After the microcontroller 106 is set up to scan for interference on a first frequency, control passes from the block 220 to a block 222 , which sets up default signal to noise thresholds that are used to determine the presence of narrowband interference in wideband signals received from the splitter 24 of FIG. 2 . Although subsequent description will provide detail on how adaptive thresholds are generated, the block 222 merely sets up an initial threshold for determining presence of narrowband interference.
[0072] After the default thresholds have been set at the block 222 control passes to a block 224 at which the microcontroller 106 reads various inputs, establishes serial communication with the notch modules 110 , 112 and any other serial communication devices, as well as establishes communications with the OA&M processor 108 . After the block 224 completes execution, the setup default values routine 202 returns control to the main program and the block 204 is executed.
[0073] FIG. 12 reveals further detail of the BITE test routine 204 , which begins execution after the routine 202 completes. In particular, the BITE test routine 204 begins execution at a block 240 , at which the microcontroller 106 puts the notch modules 110 , 112 in a bypass mode by closing their bypass switches 190 . After the notch modules 110 , 112 have been bypassed, the microcontroller 106 programs the BITE module 114 to generate interferers that will be used to test the effectiveness of the notch modules 110 , 112 for diagnostic purposes. After the notch modules 110 , 112 have been bypassed and the BITE module 114 is enabled, control passes from the block 240 to a block 242 .
[0074] At the block 242 , the microcontroller 106 reads interferer signal levels at the output of the notch module 112 via the A/D 104 . Because the notch modules 110 , 112 have been bypassed by the block 240 , the signal levels at the output of the notch module 112 should include the interference that is produced by the BITE module 114 .
[0075] After the interferer signal levels have been read at the block 242 , a block 244 determines whether the read interferer levels are appropriate. Because the notch modules 110 , 112 have been placed in bypass mode by the block 240 , the microcontroller 106 expects to see interferers at the output of the notch module 112 . If the levels of the interferer detected at the output of the notch module 112 are not acceptable (i.e., are too high or too low), control passes from the block 244 to a block 246 where a system error is declared. Declaration of a system error may include the microcontroller 106 informing the OA&M processor 108 of the system error. The OA&M processor 108 , in turn, may report the system error to a reporting and control facility. Additionally, declaration of a system error may include writing the fact that a system error occurred into the external memory 118 of the microcontroller 106 .
[0076] Alternatively, if the block 244 determines that the interferer levels are appropriate, control passes from the block 244 to a block 248 at which the microcontroller 106 applies one or more of the notch modules, 110 , 112 . After the notch modules 110 , 112 have been applied (i.e., not bypassed) by the block 248 , control passes to a block 250 , which reads the signal level at the output of the notch module 112 . Because the BITE module 114 produces interference at frequencies to which the notch filters are applied by the block 248 , it is expected that the notch modules 110 , 112 remove such interference.
[0077] After the signal levels are read by the block 250 , control passes to a block 252 , which determines if interference is present. If interference is present, control passes from the block 252 to the block 246 and a system error is declared because one or more of the notch modules 110 , 112 are not functioning properly because the notch modules 110 , 112 should be suppressing the interference generated by the BITE module 114 . Alternatively, if no interference is detected at the block 252 , the ANF module 100 is functioning properly and is, therefore, set to a normal mode of operation at a block 254 . After the block 254 or the block 246 have been executed, the BITE test routine 204 returns control to the main program 200 , which begins executing the block 206 .
[0078] As shown in FIG. 13 , the signal processing and interference identification routine 206 begins execution at a block 270 . At the block 270 , the microprocessor 106 controls the programmable local oscillator 134 so that the microcontroller 106 can read signal strength values for each of the desired channels via the discriminator 132 and the A/D 104 . In particular, the microcontroller 106 may control the programmable local oscillator 134 to tune sequentially to a number of known channels. The tuning moves each of the known channels to the IF so that the discriminator 132 can make an RSSI reading of the signal strength of each channel. Optionally, if certain channels have a higher probability of having interference than other channels, the channels having the higher probability may be scanned first. Channels may be determined to have a higher probability of having interference based on historical interference patters or interference data observed by the ANF module 100 .
[0079] Additionally, at the block 270 , the microcontroller 106 controls the programmable local oscillator 134 to frequency shift portions of the guard bands to the IF so that the discriminator 132 can produce RSSI measurements of the guard bands. Because the guard bands are outside of a frequency response of a filter disposed within the wideband receiver 30 , the block 270 compensates guard band signal strength reading by reducing the values of such readings by the amount that the guard bands will be attenuated by a receiver filter within the wideband receiver 30 . Compensation is carried out because the ANF module 100 is concerned with the deleterious effect of narrowband signals on the wideband receiver 30 . Accordingly, signals having frequencies that lie within the passband of the filter of the wideband receiver 30 do not need to be compensated and signals falling within the guard band that will be filtered by the receive filter of the wideband receiver 30 need to be compensated. Essentially, the guard band compensation has a frequency response that is the same as the frequency response of the wideband receiver filter. For example, if a wideband receiver filter would attenuate a particular frequency by 10 dB, the readings of guard bands at that particular frequency would be attenuated by 10 dB.
[0080] After the block 270 is completed, control passes to a block 272 , which selects a number of channels having the highest signal levels. Commonly, the number of channels that will be selected by the block 272 corresponds directly to the number of notch modules, 110 , 112 that are employed by a particular ANF module 100 . After the channels having the highest signal levels are selected by the block 272 , control passes from the block 272 to a block 274 .
[0081] At the block 274 , the microcontroller 106 determines an adaptive threshold by calculating an average signal strength value for the desired channels read by the block 270 . However, the average is calculated without considering the channels having the highest signal levels that were selected by the block 272 . Alternatively, it would be possible to calculate the average by including the signal levels selected by the block 272 . The block 274 calculates an average that will be compensated by an offset and used to determine whether narrowband interference is present on any of the desired channels read by the block 270 .
[0082] After the block 274 completes execution control passes to a block 276 , which compares the signal strength values of the channels selected by the block 272 to the adaptive threshold, which is the sum of the average calculated by the block 274 threshold and an offset. If the selected channels from the block 272 have signal strengths that exceeds the adaptive threshold, control passes to a block 278 .
[0083] The block 278 indicates the channels on which interference is present based on the channels that exceeded the adaptive threshold. Such an indication may be made by, for example, writing information from the microcontroller 106 to the external memory 118 , which is passed to the OA&M processor 108 . After the interferers have been indicated by the block 278 , control passes to a block 280 . Additionally, if none of the channels selected by the block 272 have signal strengths that exceed the adaptive threshold, control passes from the block 276 to the block 280 .
[0084] At the block 280 , the microcontroller 106 updates an interference data to indicate on which channels interferers were present. In particular, each frame (e.g., 20 ms) the microcontroller 106 detects interferers by comparing power levels (RSSI) on a number of channels to the threshold level. When an inteferer is detected, data for that interferer is collected for the entire time that the interferer is classified as an interferer (i.e., until the RSSI level of the channel falls below the threshold for a sufficient period of time to pass the hang time test that is described below). All of this information is written to a memory (e.g., the memory 118 or 120 ), to which the OA&M processor 108 has access. As described below, the OA&M processor 108 processes this information to produce the interference report.
[0085] Additionally, the block 280 reads input commands that may be received from the OA&M processor 108 . Generally, such commands may be used to perform ANF module 100 configuration and measurement. In particular, the commands may be commands that put the ANF module 100 in various modes such as, for example, a normal mode, a test mode in which built in test equipment is employed or activated, or a bypass mode in which the ANF module 100 is completely bypassed. Additionally, commands may be used to change identifying characteristics of the ANF module 100 . For example, commands may be used to change an identification number of the ANF module 100 , to identify the type of equipment used in the ANF module 100 , to identify the geographical location of the ANF module 100 or to set the time and date of a local clock within the ANF module 100 . Further, commands may be used to control the operation of the ANF module 100 by, for example, adding, changing or deleting the narrowband channels over which the ANF module 100 is used to scan or to change manually the threshold at which a signal will be classified as an interferer. Further, the attack time and the hang time, each of which is described below, may be changed using commands. Additionally, a command may be provided to disable the ANF module 100 .
[0086] After the block 280 has completed execution, the signal processing and interference identification routine 260 returns control back to the main routine 200 , which continues execution at the block 208 .
[0087] As shown in FIG. 14 , the interference extraction routine 208 begins execution at a block 290 , which compares the time duration that an interferer has been present with a reference time called “duration time allowed,” which may also be referred to as “attack time.” If the interferer has been present longer than the attack time, control passes to a block 292 . Alternatively, if the interferer has not been present longer than the duration time allowed, control passes to a block 296 , which is described in further detail below. Essentially, the block 290 acts as a hysteresis function that prevents filters from being assigned to temporary interferers immediately as such interferers appear. Typically, the duration time allowed may be on the order of 20 milliseconds (ms), which is approximately the frame rate of a CDMA communication system. As will be readily appreciated by those having ordinary skill in the art, the frame rate is the rate at which a base station and a mobile unit exchange data. For example, if the frame rate is 20 ms, the mobile unit will receive a data burst from the base station every 20 ms. The block 90 accommodates mobile units that are in the process of initially powering up. As will be appreciated by those having ordinary skill in the art, mobile units initially power up with a transmit power that is near the mobile unit transmit power limit. After the mobile unit that has initially powered up establishes communication with a base station, the base station may instruct the mobile unit to reduce its transmit power. As the mobile unit reduces its transmit power, the mobile unit may cease to be an interference source to a base station having an ANF module. Accordingly, the block 290 prevents the ANF module 100 from assigning a notch module 110 , 112 to an interferer that will disappear on its own within a short period of time.
[0088] At the block 292 , the microcontroller 106 determines whether there are any notch modules 110 , 112 that are presently not used to filter an interferer. If there is a notch module available, control passes from the block 292 to a block 294 , which activates an available notch module and tunes that notch module to filter the interferer that is present in the wideband signal from the splitter 24 . After the block 294 has completed execution, control passes to the block 296 , which is described below.
[0089] If, however, the block 292 determines that there are no notch modules available, control passes from the block 292 to a block 298 , which determines whether the present interferer is stronger than any interferer to which a notch module is presently assigned. Essentially, the block 298 prioritizes notch modules so that interferers having the strongest signal levels are filtered first. If the block 298 determines that the present interferer is not stronger than any other interferer to which a notch module is assigned, control passes from the block 298 to the block 296 .
[0090] Alternatively, if the present interferer is stronger than an interferer to which a notch module is assigned, control passes from the block 298 to a block 300 . The block 300 determines whether the interferer that is weaker than the present interferer passes a hang time test. The hang time test is used to prevent the ANF module 100 from deassigning a notch module 110 , 112 from an interferer when the interferer is in a temporary fading situation. For example, if a mobile unit is generating interference and a notch module 110 , 112 has been assigned to filter that interference, when the mobile unit enters a fading situation in which the interference level is detected at an ANF module 100 becomes low, the ANF module 100 does not deassign the notch module being used to filter the fading interference until the interference has not been present for a time referred to as hang time. Essentially, hang time is a hysteresis function that prevents notch modules from being rapidly deassigned from interferers that are merely temporarily fading and that will return after time has passed. Hang time may be on the order of milliseconds of seconds. Accordingly, if the interferer that is weaker than the present interferer passes hang time, control passes to a block 302 . Alternatively, if the interferer weaker than the present interferer does not pass hang time, the block 300 passes controlled to the block 296 .
[0091] At the block 302 , the microcontroller 106 deactivates the notch module being used to filter the weaker interferer and reassigns that same notch module to the stronger interferer. After the block 302 has completed the reassignment of the notch module, control passes to the block 296 .
[0092] At the block 296 , the microcontroller 106 rearranges interferers from lowest level to highest level and assigns notches to the highest level interferers. As with the block 298 , the block 296 performs prioritizing functions to ensure that the strongest interferers are filtered with notch modules. Additionally, the block 296 may analyze the interference pattern detected by the ANF module 100 and may assign filters 172 - 178 having various notch widths to filter interferers. For example, if the ANF module 100 detects interference on contiguous channels collectively have a bandwidth of 50 KHz, the 50 KHz filter 176 of the notch filter block 158 may be used to filter such interference, rather than using four 15 KHz filters. Such a technique essentially frees up notch filter modules 110 , 112 to filter additional interferers.
[0093] After the block 296 has completed execution, control passes to a block 304 , which updates interference data by sending a list of channels and their interference status to a memory (e.g., the memory 118 or 120 ) that may be accessed by the OA&M processor 108 . After the block 304 has completed execution, the interference extraction routine 208 returns control to the main module 200 , which continues execution at the block 210 .
[0094] At the block 210 , as shown in FIG. 15 , the microcontroller 106 determines if a gross failure has occurred in the ANF module 100 . Such a determination may be made by, for example, determining if a voltage output from a voltage regulator of the ANF module 100 has an appropriate output voltage. Alternatively, gross failures could be determined by testing to see if each of the notch modules 110 , 112 are inoperable. If each of the notch modules is inoperable, it is likely that a gross failure of the ANF module 100 has occurred. Either way, if a gross failure has occurred, control passes from the block 320 to a block 322 at which point the microcontroller 106 enables the bypass switch 116 of FIG. 7 to bypass all of the notch modules 110 , 112 of the ANF module 100 , thereby effectively connecting the splitter 24 directly to the wideband receiver 30 . After the execution of the block 322 , or if the block 320 determines that a gross failure has not occurred, control passes back to the main routine 200 , which continues execution at the block 212 . At the block 212 , the interference data that was written to the memory 118 or 120 , is passed to the OA&M processor 108 .
[0095] Having described the functionality of the software that may be executed by the microcontroller 106 , attention is now turned to the OA&M processor 108 of FIG. 7 . If the blocks shown in FIG. 16 represent software functions, instructions embodying the functions may be written as routines in a high level language such as, for example, C, or any other suitable high level language, and may be compiled into a machine readable format. Alternatively, instructions representative of the blocks may be written in assembly code or in any other suitable language. Such instructions may be stored within the OA&M processor 108 or may be stored within the external memory 120 and may be recalled therefrom for execution by the OA&M controller 108 .
[0096] In particular, as shown in FIGS. 16A and 16B , which are referred to herein collectively as FIG. 16 , a main routine 340 executed by the OA&M processor 108 may begin execution at a block 342 , at which the OA&M processor 108 is initializes itself by establishing communication, checking alarm status and performing general housekeeping tasks. At the block 342 , the OA&M processor 108 is initialized and passes control to a block 344 .
[0097] At the block 344 , the OA&M processor 108 determines whether there is new data to read from an OA&M buffer (not shown). If the block 344 determines that there is new data to read, control passes to a block 346 , which determines if the new data is valid. If the new data is valid, control passes from the block 346 to a block 348 , which read the data from the OA&M buffer. Alternatively, if the block 346 determines that the new data is not valid, control passes from the block 346 to a block 350 , which resets the OA&M buffer. After the execution of either the block 348 or the block 350 , control passes to a block 352 , which is described in further detail hereinafter.
[0098] Returning to the block 344 , if the block 344 determines that there is no new data to be read, control passes to a block 360 , which calculates power levels of each of the channels scanned by the ANF module 100 . The OA&M processor 108 is able to calculate power levels at the block 360 because the data generated as the microcontroller 106 of the ANF module 100 scans the various channels is stored in a buffer that may be read by the OA&M processor 108 .
[0099] After the power levels have been calculated at the block 360 , control passes to a block 362 , which determines if the any of the calculated power levels exceed a predetermined threshold. If the calculated power levels do exceed the predetermined threshold, control passes from the block 362 to a block 364 , which tracks the duration and time of the interferer before passing control to a block 366 . Alternatively, if the block 362 determines that none of the power levels calculated to the block 360 exceed the predetermined threshold, control passes from the block 362 directly to the block 366 .
[0100] The block 366 determines whether the interferer being evaluated was previously denoted as an interferer. If the block 366 determines that the interferer being evaluated was not previously an interferer, control passes to the block 352 . Alternatively, the block 366 passes control to a block 368 .
[0101] At the block 368 , the OA&M processor 108 determines whether the present interferer was a previous interferer that has disappeared, if so, the OA&M processor 108 passes control to a block 370 . Alternatively, if the present interferer has not disappeared, control passes from the block 368 to a block 372 .
[0102] At the block 370 , the OA&M processor 108 stores the interferer start time and duration. Such information may be stored within the OA&M processor 108 itself or may be stored within the external memory 120 of the OA&M processor 108 . After the block 370 has completed execution, control passes to the block 352 . At the block 372 , the duration of the interferer is incremented to represent the time that the interferer has been present. After the execution of block 372 , control passes to the block 352 .
[0103] The block 352 determines whether a command has been received at the OA&M processor 108 from the reporting and control facility. If such a command has been received, control passes from the block 352 to a block 380 . At the block 380 , the OA&M processor 108 determines if the command is for the microcontroller 106 of the ANF module 100 , or if the command is for the OA&M processor 108 . If the command is for the microcontroller 106 , control passes from the block 380 to a block 382 , which sends the command to the microcontroller 106 . After the execution of the block 382 , the main routine 340 ends.
[0104] Alternatively, if the command received by the OA&M processor 108 is not a command for the microcontroller 106 , control passes from the block 380 to a block 384 , which prepares a response to the command. Responses may include simple acknowledgments or may include responses including substantive data that was requested. Further detail on the block 384 is provided in conjunction with FIG. 17 . After the block 384 has prepared a response, a block 386 activates the serial interrupt of the OA&M processor 108 and ends execution of the main routine 340 .
[0105] Alternatively, if the block 352 determines that a command was not received, control passes from the block 352 to a block 390 , which determines if the bypass switch 116 of FIG. 7 is closed (i.e., the bypass is on). If the block 390 determines that the bypass is not on, the execution of the main routine 340 ends. Alternatively, if the block 390 determines that the bypass is on, control passes from the block 390 to a block 392 .
[0106] At the block 392 , the OA&M processor 108 determines whether there was a prior user command to bypass the ANF module 100 using the bypass switch 116 . If such a user command was made, execution of the main routine 340 ends. Alternatively, if there was no prior user command bypass the ANF module 100 , control passes from the block 392 to a block 394 , which compares the bypass time to a hold time. If the bypass time exceeds the hold time, which may be, for example, one minute, control passes from the block 394 to a block 396 .
[0107] At the block 396 , an alarm is generated by the OA&M processor 108 and such an alarm is communicated to a reporting and control facility by, for example, pulling a communication line connected to the reporting and control facility to a 24 volt high state. After the execution of the block 396 , the main routine 340 ends.
[0108] Alternatively, if the block 394 determines that the bypass time has not exceeded the hold time, control passes from the block 394 to a block 398 , which counts down the hold time, thereby bringing the bypass time closer to the hold time. Eventually, after the block 398 sufficiently decrements the hold time, the block 394 will determine that the bypass time does exceed the hold time and pass control to the block 396 . After the block 398 has completed execution, the main routine 340 ends.
[0109] As shown in FIG. 17 , the prepare response routine 384 begins execution at a block 400 . At the block 400 , the OA&M processor 108 reads information that the microcontroller 106 has written into a buffer (e.g., the memory 118 or 120 ) and calculates the duration of the interferers that are present, calculates interferer power levels and calculates the average signal power. This information may be stored locally within the ANF module 100 or may be reported back to a network administrator in real time. Such reporting may be performed wirelessly, over dedicated lines or via an Internet connection. The interferer power levels and the average signal power may be used to evaluate the spectral integrity of a geographic area to detect the presence of any fixed interferers that may affect base station performance. Additionally, such information may be used to correlate base station performance with the interference experienced by the base station. After the block 400 completes execution, control passes through a block 402 .
[0110] At the block 402 , the OA&M processor 108 adds real time markers to the information calculated in the block 400 and stores the report information including the real time markers and the information calculated in the block 400 . Such information may be stored within the OA&M processor 108 itself or may be stored within the external memory 120 of the OA&M processor 108 .
[0111] After the block 402 has completed execution, control passes to a block 404 , which determines whether a command has been received by the ANF module 100 . Such commands would be received from a reporting and control facility. If the block 404 determines that no command has been received by the OA&M processor 108 , control passes from the block 404 back to the main routine 340 , which continues execution at the block 386 .
[0112] Alternatively, if the block 404 determines that a command has been received by the OA&M processor 108 , control passes from the block 404 to a block 406 , which determines if the received command is a control command that would be used to control the operation of the ANF module 100 from a remote location, such as the reporting and control facility. If the block 406 determines that the command received is a control command, the block 406 transfers control to a block 408 which takes the action prescribed by the command. Commands may include commands that, for example, commands that enable or disable remote control of the ANF module 100 , or may include any other suitable commands. After the execution of the block 408 , control passes from the prepare response routine 384 back to the main routine 340 , which then ends execution.
[0113] Alternatively, if the block 406 determines that the command received by the OA&M processor 108 is not a control command, control passes from the block 406 to a block 410 , which determines if the received command is a report command. If the command was not a report command, the block 410 passes control back to the main routine 340 . Alternatively, if the block 410 determines that the received command is a report command, control passes from the block 410 to a block 412 , which prepares and sends out the interference report. The interference report may include information that shows the parameters of the most recent 200 interferers that were detected by the ANF module 100 and the information on which the microcontroller 106 wrote to a memory 118 , 120 that the OA&M processor 108 accesses to prepare the interference report. The interference report may include the frequency number (channel) on which interference was detected, the RF level of the interferer, the time the interferer appeared, the duration of the interferer and the wideband signal power that was present when the interferer was present.
[0114] In addition to the interference report, the OA&M processor 108 may prepare a number of different reports in addition to the interference report. Such additional reports may include: mode reports (report the operational mode of the ANF module 100 ), status reports (reports alarm and system faults of the ANF module 100 ), software and firmware version reports, header reports (reports base station name, wideband carrier center frequency, antenna number and base station sector), date reports, time reports, activity reports (reports frequency number, RF level, interferer start time, interferer duration, and wideband channel power) and summary reports.
[0115] The interference report may be used for network system diagnostic purposes including determining when the network administrator should use a narrowband receiver 28 to determine a telephone number that the mobile unit is attempting to contact and, optionally handling the call. For example, the reporting and control facility may use the narrowband receiver 28 to determine that the user of the mobile unit was dialing 911, or any other emergency number, and may, therefore, decide that the narrowband receiver 28 should be used to handle the emergency call by routing the output of the narrowband receiver 28 to a telephone network.
[0116] Additionally, the interference report may be used to determine when a network administrator should control the narrowband receiver 28 to obtain particular information relating to an interferer and retasking the interferer by communicating with its base station. For example, the reporting and control facility may use the narrowband receiver 28 to determine the identity of an interferer, such as a mobile unit, by intercepting the electronic serial number (ESN) of the mobile unit, which is sent when the mobile unit transmits information on the narrowband channel. Knowing the identity of the interferer, the reporting and control facility may contact infrastructure that is communicating with the mobile unit and may request the infrastructure to change the transmit frequency of the mobile unit (i.e., the frequency of the narrowband channel on which the mobile unit is transmitting) or may request the infrastructure to drop communications with the interfering mobile unit all together.
[0117] Further, the interference reports may be used by a network administrator to correlate system performance with the information provided in the interference report. Such correlations could be used to determine the effectiveness of the ANF module 100 on increasing system capacity.
[0118] After the block 412 has completed execution, control passes back to the main routine 340 , which continues execution at the block 386 .
[0119] Referring now to FIG. 18 , a data buffer interrupt function 500 is executed by the OA&M processor 108 and is used to check for, and indicate the presence of, valid data. The function 500 begins execution at a block 502 , which checks for data.
[0120] After the execution of the block 502 , control passes to a block 504 , which checks to see if the data is valid. If the block 504 determines that the data is valid, control passes from the block 504 to a block 506 , which sets a valid data indicator before the function 500 ends. Alternatively, if the block 504 determines that the data is not valid, control passes from the block 504 to a block 508 , which sets a not valid data indicator before the function 500 ends.
[0121] Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. For example, while the foregoing description specifically addressed the concept of eliminating interference from signals on 30 KHz narrowband channels interfering with a 1.25 MHz wideband signal, it will be readily appreciated that such concepts could be applied to wideband channels having, for example, 5, 10 or 15 MHz bandwidths or to contiguous channels that have an aggregate bandwidth of, for example, 5, 10 or 15 MHz. To accommodate such wider bandwidths, banks of downconverters may be operated in parallel to cover 1.25 MHz block of the channel. Accordingly, this description is to be construed as illustrative only and not as limiting to the scope of the invention. The details of the structure may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications, which are within the scope of the appended claims, is reserved. | A system that incorporates teachings of the subject disclosure may include, for example, a method for analyzing a wide frequency band with respect to signal power levels in specified narrow frequency bands, detecting narrow band signal power levels received in the specified narrow frequency bands, determining an average composite wideband power level from the narrow band signal power levels, determining an adaptive threshold from the average composite wideband power level, detecting narrow band interference according to the adaptive threshold, and configuring a filter to substantially suppress the detected narrow band interference. Other embodiments are disclosed. | 7 |
FIELD OF THE INVENTION
This invention relates to apparatus adapted to envelop successive portions of a bridge or other structure. The envelope provides a work station to shelter and support workers and equipment during maintenance or construction to minimize the environmental impact of such work. More particularly, the invention relates to a structure for maintaining an envelope about a portion of a bridge, motive means for positioning the envelope from time to time and scaffolding apparatus for supporting workers and equipment within the envelope.
BACKGROUND OF THE INVENTION
It is known that routine maintenance of structures is necessary to prevent them from deteriorating to a point where they must be replaced rather than repaired. Bridges, in particular, require such routine maintenance but many are in extremely poor condition. Many bridges have been closed and torn down because they are unfit for safe passage. Replacement of bridges is expensive and wasteful. Routine repair is a more economical and sensible approach.
There are two fundamental impediments to conducting routine bridge maintenance. It is difficult to put men and equipment up in the air on a large bridge structure where they are exposed to the weather without risking their safety and without interrupting traffic. It is also difficult to ensure that the detritus from cleaning, scraping and painting will not contaminate soil and water surrounding the bridge. As a result bridge maintenance is often postponed or avoided and deterioration continues. The prior art discloses some equipment and methods relating to bridge maintenance but the problem of deteriorating bridges continues.
U.S. Pat. No. 5,011,710 entitled "BRIDGE MAINTENANCE METHOD AND EQUIPMENT" dated Apr. 30, 1991, describes a method in which surfaces of a structure are treated from a walkway within an enclosure suspended from the structure. The enclosure has a downwardly-converging cross section terminating in a vacuum conveyor for collecting and removing particles accumulating from the blasting process. The enclosure is preferably provided in modules. The vacuum conveyor removes the particulate material for transfer to conventional separating and re-cycling equipment. The enclosure and walkway are movably suspended from transverse guides secured to the structure. Similarly, U.S. Pat. No. 4,854,419 entitled "PARTICULATE CONTAINMENT CONTROL METHOD AND PLATFORM DEVICE" dated Aug. 08, 1989, describes a mobile containment platform method and system for sandblasting and the like used in bridge reconditioning and painting that requires removal of paint from the support structure of the bridge. The containment platform provides an entrapment envelop for spent abrasive and removed paint residue.
U.S. Pat. No. 4,201,275 entitled "MEANS FOR THE RENOVATING AND REFURBISHING OF OVERHEAD STRUCTURES" dated May 06, 1980, describes a method for furbishing or renovating large span overhead structures, for example the roofs of railway stations, or bridges and the like. It utilizes apparatus which comprises a plurality of runway beams suspended in spaced parallel disposition from the main ribs or framework of an overhead structure, the beams spanning a plurality of said ribs or framework and being longitudinally displaceable relative thereto, and a work platform or platforms suspended from said runway beams and being displaceable along the runway beams. Thus arranged, the overhead structure can be treated for substantially its entire length by alternately advancing the work platforms along the runway beams and the runway beams relative to the structure.
U.S. Pat. No. 4,848,516 entitled "MOVABLE SCAFFOLD" dated Jul. 18, 1989, describes a movable scaffold has a pair of hanger rails attached to a construction, first hanger units movably mounted on the hanger rails, beams operatively engaged with the first hanger units and laterally disposed with respect to the hanger rails, and a floor deck mounted on the beams. Second hanger units are provided for movably suspending the beams from the first hanger units.
German patent DD 241626 dated Dec. 17, 1986, describes an apparatus to enable a bridge to be painted without erecting a complete scaffold, and enabling road and rail traffic to continue to use the bridge. A roller grid is used, which can be slid the whole length of the bridge. It has an upper frame with a fixed wheel and a lower frame supported by a fixed roller on the bridge structure and attached to the upper frame.
SUMMARY OF THE INVENTION
It is an object of the present invention to contain the debris from maintenance for protection of the environment and to shelter workers from the weather. It is a further object, in the case of bridge structures, to allow for the passage and protection of bridge traffic during maintenance, to provide scaffolding means to position workers and equipment close to all bridge surfaces to be maintained and to provide a movable envelope which can traverse a bridge structure as work progresses. It is a further object of this invention to provide a light, mobile enclosure.
In general, the work station of this invention is an envelope having a top section, a bottom section, first and second end sections, and first and second side sections. Each section is constructed of a material suitable to shelter workers and to contain debris during bridge maintenance and is suspended between a supply means and a take-up means. A plurality of support means suspend the supply means and take up means for the envelope sections about the bridge sufficiently spaced from the sides, top and bottom of the bridge to permit workers to work all about it. The support means is mounted in a motive means mounted on the bridge to permit the envelope to be repositioned from time to time along the length of the bridge. Within the envelope, scaffolding means to support workers in close proximity to bridge surfaces is suspended by cables connected to a second motive means to permit a vertical degree of freedom. The cables are mounted on one or more transverse beams for a lateral degree of freedom. The beams are mounted on a third motive means on the support means to permit a longitudinal degree of freedom of movement.
A passage is formed within the envelope to permit the passage of traffic during maintenance operations. The passage is erected with materials and construction methods that will ensure protection to vehicles from falling debris. Appropriate safety nets may be included to stop heavy objects or tools or falling workmen.
Debris collected within the envelope may be removed by forced fluid or gravity flow from the bottom of the enclosure through a duct to suitable disposal means.
The envelope is also designed to be quickly disassembled in the case of severe weather.
DESCRIPTION OF THE FIGURES
In the Figures that illustrate preferred embodiments of this invention:
FIG. 1 depicts a bridge enshrouded by the envelope of this invention;
FIG. 2 depicts an embodiment of this invention having overhead motive means viewed from within the envelope looking down the length of the bridge;
FIG. 3 depicts the embodiment of FIG. 2 from a side cross sectional view of within the envelope;
FIG. 4 depicts an embodiment of this invention having motive means mounted on a bridge deck viewed from within the envelope looking down the length of the bridge;
FIG. 5 depicts the embodiment of FIG. 4 from a side cross sectional view of within the envelope;
FIG. 6 depicts a moveable rail structure of the motive means;
FIG. 7 depicts scaffolding to surround a pillar;
FIG. 8 depicts a scaffolding roller assembly;
FIG. 9 depicts a duct in the bottom of the envelope to carry off debris.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a typical bridge 1 spanning from a north bank 2 to a south bank 3 over a river 4 supported on four pillars 5 and 6 (not shown) on the south side and 7 and 8 (not shown) on the north side. The bridge 1 has a truss structure 9 comprising steel girders an/or cables. Typically there will be an under structure 10 comprising further steel girders which supports a deck 11 and connect to the truss structure 9. Automobile traffic crosses the bridge on the deck 11. These bridge elements will normally be fabricated from steel and concrete and will deteriorate under atmospheric conditions over time.
The repair and maintenance envelope 20 of this invention surrounds a portion of the bridge 1 to protect workers and traffic and to contain debris from the maintenance work from contaminating the river 4 or the river banks 2 and 3. The envelope 20 is able to change location on the bridge 1 by means of a plurality of motive means 21 which ride on a surface of the bridge 1 during movement and may be locked in place during work. It will be seen in other figures that motive means is also provided for moving scaffolding within the envelope 20 during work. The envelope 20 is formed by a plurality of shrouds (top 30, bottom 31, north end 32, south end 33, east side 34 and west side 35) which are mounted on corresponding rollers (top north 40 and top south 40', bottom north 41 and bottom south 41', north end top 42 and north end bottom 42', south end top 43 and south end bottom 43', east side top 44 and east side bottom 44', west side top 45 and west side bottom 45') [not identified in FIG. 1--see other figures].
FIGS. 2 and 3 provide greater detail about the preferred embodiment in which the motive means 21 for the envelope 20 is mounted overhead on the top east girder 50 and top west girder 50' of the bridge 1. Tracks 51 and 51' are positioned on the girders 50 and 50' respectively and fastened temporarily in place. It will be appreciated that the construction of the motive means on the bridge will be within the skill of the art and may assume a number of different forms without departing from the scope of the invention.
One such form is shown in FIG. 6 in which the track means 51 comprises a slotted box beam 60 fabricate from a base plate 61 and two upward and inward flanges 62 and 62'. Within the slotted box beam 60, a post 63 moves along the slot on an axle 64 mounted in wheels 65 and 65'. A guide 66 is provided between the wheels 65 and 65' to maintain alignment within the box beam 60. A locking bolt 67 is provided to fix the location of the wheels 65 and 65' within the box beam 60. It will be appreciated that such a box beam 60 could be permanently welded or otherwise fastened in place. In the preferred embodiment of FIG. 6 the box beam 60 may be fastened and unfastened to the girder 50 so that new box beams 60 may be placed down as the envelope advances while those which have been passed over may be taken up and moved forward to a new position. Anchor means 68 and 68' are provided on the base plate 61 to receive a cable or chain 69 which may be looped about the girder 50 and drawn tight to secure the box beam 60 temporarily in place. Protective means for the girder 50 and tightening means are not shown and are within the art.
Returning then to FIGS. 2 and 3 it will be seen that roller 44 which carries shroud 34 is mounted on an outrigger structure 74. It will be appreciated that similar outrigger structures 70, 70' 71, 71' 72, 72' 73, 73', 74, 74', 75 and 75' are provided for the ends of respective rollers 30, 31,32, 33, 34 and 35 with suitable adaptations for their location and function. The outrigger structures can be combined to support more than one roller (see FIG. 3) but the details of the construction of the outriggers is within the art and will not be discussed at length. The rollers identified as top north 40, top south 40', north end top 42, south end top 43, east side top 44 and west side top 45 will have outrigger structures supported on posts similar to post 63 of FIG. 6 which connect into the track means 51 and 51' on the bridge girders 50 and 50'. Each of the rollers is spaced sufficiently from the top bottom and sides of the bridge to permit workers to access their outside surfaces.
The workers are supported within the envelope 20 in scaffolding means including cages 80, platforms 81 and on elevators 82. The cages 80 are supported to move vertically on cables 83 which in turn are connected to move horizontally across beams 84 in response to controls within the cage. As shown in FIG. 3, the beams 84 may be mounted to move horizontally along the length of the envelope. Mechanisms for obtaining such vertical and horizontal movement of the cages 80 are known and will not be discussed here in detail. In the preferred embodiment vertical movement would be obtained with powered pulleys and horizontal movement with a track and wheel means erected over a beam 84 and on the bridge that would be similar in structure to that shown in FIG. 6. Control within the cage would be obtained by known electronic control means and servo motors. The platforms 81 are similarly mounted for vertical and horizontal movement (although in one direction) to position workers under the bridge. More locally, workers can erect elevators 82 on a platform 81 to deal with irregular features of the under structure 10.
FIGS. 7 and 8 illustrate the novel cages 80 which are designed to obtain access to all sides of a girder. The floor plan of each cage 80 has cutout to fit about two vertical faces of a girder 90, (which may be rectangular or in the shape of an I-beam). A worker in the cage 80 is thus positioned to do maintenance work at close range on the surface of the girder 90. As shown in FIG. 8, the distance from the girder 90 is determined and controlled by a positioning arm 91 fastened to the cage 80 by vertical arm 92. The positioning arm 91 terminates at a roller 93 which rides against the girder 90 to maintain rolling contact with the girder 90. A spring/damper unit 94 absorbs dynamic loading.
A second embodiment of this invention is illustrated in FIGS. 4 and 5 in which the shroud rollers are mounted overhead from supporting structures on the bridge deck 11 in motive means 21 constructed in the same manner as described earlier for the top of the bridge 1 and as shown in FIG. 6. Similarly, the beams 84 are mounted to move along the length on the envelope in tracks on the deck 11. In one form of this embodiment the track means for the cages 80, the platforms 81 and the rollers is the same slotted box beam 60. In other forms, the track means 51 will comprise a plurality of parallel box beams or like means, each carrying different equipment to permit equipment to pass other equipment on a different track within the envelope.
A passage 100 for vehicular traffic on the deck 11 is provided in each of the above embodiments. The passage 100 is erected on the deck 11 with walls 101 and a roof 102 of materials and with a construction suitable to deflect any anticipated debris from traffic in the passage. The nature of the materials and construction will be determined by the nature of the work and is within the skill of the art. The walls 101 of the passage 100 may be mounted on the deck in a manner which permits them to be moved from time to time as the envelope 20 advances across the bridge 1.
A safety net 105 may be provided above the passage 100 across the width of the envelope 20 to catch falling objects or workers. Similarly, a safety net 106 may be provided under the bridge.
As illustrated in FIG. 9, a duct 110 may be provided in the bottom section 31 to permit the debris to be removed from the envelope through a pipe 111 to an outside disposal means 112.
It will be appreciated that the preferred embodiments described above are intended to illustrative and not limiting of the construction of this invention. Various other embodiments may be constructed by one skilled in the art, without departing from the principle of this invention, through the use of obvious mechanical equivalents or by arranging the elements of the invention in configurations different from those illustrated in the figures. The invention is more generally defined in the claims which follow. | A work station is disclosed comprising: an envelope (20) having a top section (30), a bottom section (31), first (32) and second (33) end sections, and first (34) and second (35) side sections to shelter workers and to contain debris, each section being suspended between a supply means and a take-up means on a plurality of support means (63) about a structure that are mounted in a first motive means (21) on the structure to permit the envelope to be repositioned from time to time, scaffolding means (80-81) suspended by cables on a second motive means to permit a vertical degree of freedom and on a third motive means on a transverse beam (84) for a lateral degree of freedom, each beam being mounted on a fourth motive means on the support means to permit a longitudinal degree of freedom of movement. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to drilling operations associated with the setting of piling on offshore well drilling platforms and for driving conductor pipe through templates in the jacket thereof. More particularly, this invention, in an important aspect, relates to a method for installing a pile driving atop an offshore platform for driving conductor pipe, independently of a derrick barge or drilling rig.
Heretofore offshore operations preparatory to drilling have commonly been performed by utilizing a derrick barge to transport all necessary men and equipment to the offshore drilling site at which the barge is used as a base platform for driving the pile used to stabilize the legs of the jacket and for performing many other preliminary operations such as welding the platform and driving conductor pipe. Commonly, a pile driving rig is mounted on the derrick barge to perform the pile driving function. Also, the use of drilling rigs for driving pile on the platform is not uncommon. Use of drill rigs constitutes, however, an extremely expensive method for driving pile. Similarly, although derrick barges constitute an excellent platform for a base of operations, in calm weather conditions their use for pile or conductor pipe driving is a particularly uneconomical method for the construction of an offshore drilling platform since the day-to-day cost exceeds that of the drill rig even.
Commonly, the derrick barge is used to transport the drill rig to the well site. There the drill rig may be used to pick up the deck sections and to place them on the top of the legs of the offshore platform. The barge is not uncommonly used as a base of operation for the welding process which takes place when the jacket and the platform is utilized. Also, the derrick barge may remain on site to drive conductor pipe. After the platform is secure the derrick barge generally begins the operation of placing the drilling rig onto the platform.
Since the scarcity of petroleum products began and the costs thereof have increased, the cost of exploring for and retrieving oil and gas have taken on additional importance and the industry has begun to seek ways to reduce the costs involved. One substantial potential cost reduction would take place if a method were conceived in which there were less utilization of the derrick barge and/or drill rig, at least until the time that these pieces of equipment were absolutely necessary for their basic functions. Thus, it becomes advisable, for example, to not use the derrick barge as a base for the driving of conductor pipe but to instead use a less expensive piece of equipment. An even more economical method would be to provide for emplacement of the piling and the conductor pipe without the derrick barge or the drill rig. Heretofore, no satisfactory method for accomplishing this has been known.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a method and apparatus whereby the derrick barge and drill rig are not used for driving pile and/or conductor pipe. Instead, a conventional barge or work vessel may transport the requisite equipment to the legs of the offshore platform. Included in the equipment and supplies normally transported to the site, there additionally is, in accordance with the invention, transported a pile driving rig, a module crane and a portable winch which, through the method hereof, is mounted on the platform. After establishing the winch on the platform, in any of several ways, it is used to raise the modular crane from the barge to the deck of the platform. The modular crane is then erected and is used to bring the pile driving rig to the platform deck. The pile driving rig is erected on the platform deck and skidded or moved from slot to slot for the purpose of driving pile and/or conductor pipe into the receptacles of the platform. Numerous advantages accrue from the aforementioned method.
First of all, once the platform sections are set on the jacket, the derrick barge may depart the area since the pile and conductor pipe may be driven by the present method. The ability to complete the platform in the absence of the derrick barge results in substantial savings.
Furthermore, once the pile driving machine is established on the platform the piles may be driven and the conductor pipe placed without the use of a derrick drill rig, this further resulting in substantial savings.
Still further, it will be recognized that the personnel may proceed to drive the pilings, weld the platform, set the conductor pipe and do all other necessary construction in anticipation of drilling, independently of ocean conditions such as rough seas which frequently hamper if not preclude continuous day-to-day performance of the functions when they are carried out from the deck of the derrick barge itself. Although other patents have directed themselves to accomplishment of this particular feature, (see U.S. Pat. No. 3,825,076), none have been able to do so without the continued presence of the derrick barge itself.
These and numerous features and advantages of the invention will become more readily apparent upon a reading of the following detailed description, claims and drawings.
DETAILED DESCRIPTION
With reference now to the drawings and particularly to FIGS. 1-5 there is shown a sequence of illustrations setting forth in exemplary form the steps for accomplishing the invention.
FIGS. 6 to 8 illustrate steps relating to another aspect of the invention.
In FIG. 1 there is shown a conventional barge or boat 1 which has approached and is held adjacent to the jacket legs 3 of an offshore platform. Carried on the deck of the barge is a crane module 5. The crane module includes a base means or skid 5a, a crane tower and associatad structure 5b and a block and pulley means 5c. The module is further characterized by the parallel rails 7 which serves as sides on the module base for protecting the crane tower during shipment and lifting onto the platform, see FIG. 3. Also carried on the deck of the barge 1 is a conventional power generator 9 or diesel engine.
After the barge has established its position with respect to platform legs 3 there is manually carried onto the deck 11 of the platform a plurality of machinery components constituting a portable lifting means such as block and pulley system 13. The block and pulley system is appropriately affixed on the deck and a power line 15 is connected thereto from the generator 9. The cable from the block and pulley is thereafter lowered to the barge 1 in order to be connected to the aforementioned module 5, see FIG. 3. It will be recognized that the block and pulley 13 and associated cable can of course be brought to the deck of the platform in the most facile manner so that the aforementioned manual transportation of the block and pulley up the stairs (see FIG. 2) of the platform may be replaced by utilization of a crane or other means that may exist on the deck of the barge of vessel 1.
In FIG. 3 there is shown an enlarged view of module 5, thus more clearly illustrating the side rails 7 and the crane tower 5b disposed therebetween. The crane includes connection points 5d on each side of the skid means 5a, the connection points being so disposed along the length of the skid means as to substantially coincide with the center of gravity of the module. A harness 21 is affixed to connection points 5d and includes a spreader bar 23 for keeping the harness cables in parallel relation to the skid means 5a. The cables of harness 21 meet at common point 25 at which there is also attached the moment arm cable means 27. The cable 27 extends from common point 25 to the end of the skid means 5a and has a length which is greater than the linear distance from common point 25 to the point at which cable 27 is attached to the skid means. The purpose of the moment arm cable 27 will be more clearly described hereinafter.
After the clock and pulley system, that is lifting means 13 has been properly disposed and installed on deck 11, the cable wound on the pulley is deployed over the side of the deck where it is dropped to the barge 1 and attached to the skid means 5a via the aforementioned harness 21. By utilization of the power generator 9, the module 5 is carefully lifted from the barge upwardly toward the deck 11 of the platform, see FIG. 4. In so doing, the module is adapted to hang in a substantially vertical position due to attachment of the harness 21 at the center of gravity (5d) of the module. As the module approaches the level of the platform the cables of harness 21 begin to slacken and the moment arm cable 27 begins to tighten due to the fact that the horizontal distance parallel to the deck between pulley 13 and pulley 33 is shorter than the distance between pulley 13 and module connection point 31. As connection points 5d reach the level of pulley 33, the moment arm cable 27 becomes taut and takes over the load previously carried by the harness 21. In so doing, the moment arm cable 27 beings to turn the module about its contact point with the pulley 33 thus enabling movement of the module heavy end first thereabout and toward the deck 11 of the platform. Without utilization of the harness 21 and moment arm cable 27, lifting of the module onto the deck 11 would be significantly hindered or even prevented by the inability of the lifting means or lifting cable to withstand the tension force exerted thereon between the pulleys 13 and 33. As shown in FIG. 5 therefore, the module 5 is slid onto the deck 11 and set upon the transfer skids 41 which enable movement of the crane thereon in longitudinal and lateral directions on the deck. The crane tower 5b is deployed to its operating position adjacent the edge of the deck. The power line 15 may, if necessary, be connected to the crane in order to lift a power source 43 onto the deck, after which the power line 15 is disconnected and the crane connected directly to the source of power on the deck.
After the crane is positioned on the deck it is used to sequentially lift and position the transfer skids 41 which may be used to support and enable movement of the pile driving rig. The pile driving rig is then lifted in components from the barge to the deck of the platform and assembled thereon. The pile driving rig may be adapted for movement over the deck by means of the skids or other appropriate structure. In any event, the rig 45 is adapted to be moved from slot to slot on the deck 11 in order to set the conductor pile or drive piles for the jacket legs. Similarly, it may be used to lift other equipment and even supplies and living accommodations to the platform.
From the foregoing it will be recognized that after equipment and supplies are removed from the deck of the vessel the offshore platform becomes relatively self-sufficient so that construction work on the platform may continue independently of any barge or vessel. The derrick barge, if it has been used to set platform sections, is free to depart from the offshore location and thus not be occupied with the driving of conductor pipe or pile and the welding of the legs to the jacket and platform. The barge may however be used to erect the drill rig after the platform is constructed. Thus, it is not necessary to operate the drill rig prior to the initiation of drilling operations since all of the pile driving may be conducted from the deck of the platform by the pile driving rig in accordance with the mounting method disclosed herein.
The present method of utilizing a pile driving rig not only significantly reduces the costs of construction of the offshore platform by more efficient use of the derrick barge and drill rig, but enhances the possibility of continuous operation by removing the pile setting function from the deck of the derrick barge, thus isolating the pile setting from the wave action effect to which the barge is vulnerable. Construction of the platform may thus take place more independently of the weather and surrounding water conditions thus reducing the overall construction time and construction costs.
In addition, it becomes feasible for the pile driving rig to perform any other functions, such as washing out of the pile, in preparation for the actual drilling operation, all of which facilitates construction of the offshore platform and reduces the costs thereof.
Although the present invention has been described with reference to a preferred form and sequence of steps, it will be appreciated that additions, modifications, substitutions and deletions may be made without departing from the spirit and scope of the invention as defined in the appended claims. | A method and apparatus for driving conductor pipe in an offshore drilling platform including the steps of mounting a block and tackle on the platform and then lifting a crane onto the platform with it before the drill rig is placed thereon, and driving the conductor pipe through use of a pile driver brought onto the platform with the crane, thus avoiding utilization of either a derrick barge or a drill rig for the conductor pipe driving functions. | 4 |
BACKGROUND OF THE INVENTION
Heretofore, there have been three-group zoom lenses for every type of camera. Three-group zoom lenses are compact and are widely used. Examples of such lenses are disclosed in Japanese Laid-Open Patent Publication 3-240011, Japanese Laid-Open Patent Publication 59-31922 and in U.S. Pat. No. 4,647,160. However, the rapid dissemination of digital cameras and video cameras in recent years, coupled with the increased demand for small lenses having a high picture quality and low distortion, as in general cameras, has necessitated the satisfaction of unique conditions when employing fixed photographic image elements, such as CCD arrays.
In contrast to film, CCD arrays as used in digital cameras and video cameras can receive light efficiently only when the incident luminous flux is nearly perpendicular to the photographic image plane. For example, in the case of zoom lenses with a two-group construction of a positive group and a negative group, as used frequently in 35 mm compact cameras, the incidence angle onto the photographic image plane increases as the image height reaches the periphery of the image plane. This is especially true if the distance from the exit pupil to the photographic image plane is short. When using such an optical system to image optical flux onto a CCD array, the peripheral luminance will be greatly reduced as compared to that at the center of the image, and the so-called "shading" effect occurs. Accordingly, as a condition for satisfactorily using a two-group zoom lens for photographic imaging onto a CCD array, it becomes necessary to move the exit pupil to a position sufficiently remote from the photographic image plane.
However, with digital cameras and video cameras, autofocus is commonly a feature that is desired, and high speed focusing is often favored. For this reason, what is known as the inner focusing method and the rear focusing method are frequently used as focusing methods for zoom lenses in order to allow the zoom lens to be light-weight and for easily allowing the zoom lens focus position to be driven close to the camera body side.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a three-group zoom lens, and especially to a three-group zoom lens having a fixed photographic image element for use in a digital camera or a video camera. The objects of the present invention are to provide a three-group zoom lens that is compact, has favorable aberrations that yield a high picture quality, avoids shading, and provides high-speed focusing.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more filly understood from the detailed description given below and the accompanying drawings, which are given by way of illustration only and thus are not limitative of the present invention, wherein:
FIG. 1 shows the relative positioning of the elements of the compact zoom lens according to the present invention in the maximum wide-angle state and the maximum telephoto state, respectively;
FIG. 2 shows the arrangement of the elements of the compact zoom lens according to the present invention;
FIGS. 3A and 3B illustrate the spherical aberration, astigmatism and distortion when in the maximum wide-angle state and the maximum telephoto state, respectively, for a first embodiment of the invention; and
FIGS. 4A and 4B illustrate the spherical aberration, astigmatism and distortion when in the maximum wide-angle state and the maximum telephoto state, respectively, for a second embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 illustrates the approximate relative positioning of the elements of the compact zoom lens according to the present invention when in the maximum wide-angle state and the maximum telephoto state, respectively. The three-group zoom lens of the present invention for forming an image of an object onto a fixed image element arranges, in order from the photographic object side, a first lens group G1 having a negative refractive power, a second lens group G2 having a positive refractive power, and a third lens group G3 having a positive refractive power. The present invention is comprised so that, when zooming from the maximum wide-angle state to the maximum telephoto state, each of these lens groups are moved along the optical axis X so that the spacing between the first lens group G1 and the second lens group G2 is shortened, and the spacing between the second lens group G2 and the third lens group G3 is lengthened. When focusing from an infinite distance to a near distance, the third lens group G3 moves to the photographic object side. A shutter stop 2 is arranged as part of the second lens group G2 in order to adjust the amount of light. Further, the three-group zoom lens of the present invention satisfies conditional expressions (1) and (2) below.
0.8<D.sub.wm /f.sub.3 <1.1 (1)
1.5<D.sub.ti /f.sub.3 <1.7 (2)
where
D wm is the distance from the position of the shutter stop to the on-axis position of the lens surface on the extreme image-side of the third lens group at the time of nearest focusing when in the maximum wide-angle state,
f 3 is the focal distance of the third lens group, and
D ti is the distance from the position of the shutter stop to the on-axis position of the lens surface on the extreme image-side of the third lens group at the time of infinite-distance focusing when in the maximum telephoto state.
The following conditions are recommended: at the extreme photographic object side of the second lens group G2 a shutter stop 2 should be provided for adjusting the amount of light that reaches the image plane; the third lens group should be composed of a double convex lens; and the following conditional expression (3) should be satisfied.
0.15<B.sub.ft /f.sub.3 <0.25 (3)
where
B ft is the back focus length at the time of infinite-distance focusing in the maximum telephoto state, and
f 3 is as defined above.
FIG. 2 shows the arrangement of the elements of the compact zoom lens according to the present invention. The first lens group G1 is composed of four lens elements including, in order from the photographic object side, a positive lens, a negative meniscus lens with its concave surface on the image side, a double concave lens, and a positive lens having a surface of stronger curvature on the photographic object side. The second lens group G2 is preferably composed of the shutter stop 2 at the extreme object side, and four lens elements including, in order from the photographic object side, a double convex lens, a positive meniscus lens with its convex surface on the photographic object side, a double concave lens, and a positive lens having a surface of stronger curvature on the photographic image side. The third lens group G3 is composed of a double convex lens. In addition, the zoom lens satisfies conditional expression (4) below.
2.1<f.sub.2 /f.sub.w <2.7 (4)
where
f 2 is the focal distance of the second lens group, and
f 2 is the focal distance of the three-group zoom lens when in the maximum wide-angle state.
The above conditional expressions (1) and (2) ensure a suitable magnification while providing for sufficient space between the exit pupil position and the photographic image plane to accommodate a filter component L10, such as an infra-blocking filter and/or a low pass filter. When the lower limit of conditional expression (1) is exceeded, the distance from the exit pupil to the image plane becomes too short to accommodate the filter component L10 when in the maximum wide-angle state. On the other hand, when the upper limit of conditional expression (1) is exceeded, magnification near 3× becomes very difficult to obtain. When the lower limit of conditional expression (2) is exceeded, magnification near 3× becomes very difficult to obtain. On the other hand, when the upper limit of conditional expression (2) is exceeded, the distance form the pupil exit position to the image plane becomes too short to accommodate the filter component L10 when in the maximum telephoto state.
Conditional expression (3), above, is an expression for regulating the image magnification of the third lens group when in the maximum telephoto state, thereby providing an appropriate back focus length in which to accommodate filter component L10. Further, conditional expression (3) includes a necessary condition which allows for simplification of the composition of the third lens group. When the lower limit of conditional expression (3) is exceeded, the back focus becomes too short to accommodate filter component L10 between the third lens group and the photographic image plane 1 when in the maximum telephoto state. On the other hand, when the upper limit of conditional expression (3) is exceeded, the back focus becomes too long, increasing the size of the aberration fluctuations in the image plane caused by focusing, and thereby making it difficult to construct the third lens group using only a single lens element.
Conditional expression (4), above, is an expression for insuring a suitable refraction power for the second lens group. When the lower limit of conditional expression (4) is exceeded, the length of the three-group zoom lens becomes too short, and the refractive power required of the second lens group becomes too great, thereby making it impossible to suppress the aberration fluctuations which accompany such refractive power. On the other hand, when the upper limit of conditional expression (4) is exceeded, the amount of movement of the second lens group which accompanies magnification becomes larger, and the total length of the optical system not only gets longer, but a condition is created whereby, since the amount of fluctuation in the exit pupil position due to magnification gets larger, the distance from the exit pupil to the image plane becomes too small to accommodate filter component L10.
Two embodiments of the present invention will now be described using actual numerical values.
Embodiment 1
The three-group zoom lens of the first embodiment is composed of, in order from the photographic object side, a first lens group G1 having negative refractive power, a second lens group G2 having positive refractive power, and a third lens group G3 having positive refractive power. The first lens group G1 and the second lens group G2 are moveable for zooming, and the third lens group G3 moves a minute distance for focus adjustment. No focus adjustment is required, however, when the zoom lens is in the maximum telephoto state. In addition to changing the focal distance f of the entire system by moving these three lens groups along the optical axis X, a zoom lens which allows efficient collection of the luminous flux onto the image formation plane 1 can be composed so as to satisfy the conditional expressions (1)-(4) above.
In addition, the first lens group G1 arranges, in order from the photographic object side, a first lens element L1 composed of a double convex lens with a stronger curvature surface on the photographic object side, a second lens element L2 composed of a negative meniscus lens with its concave surface on the photographic image side, a third lens element L3 composed of a double concave lens with a stronger curvature surface on the photographic image side, and a fourth lens element L4 composed of a double convex lens with a stronger curvature surface on the photographic object side. The second lens group G2 arranges, in order from the photographic object side, a shutter stop, a fifth lens element L5 composed of a double convex lens with a stronger curvature surface on the photographic object side, a sixth lens element L6 composed of a positive meniscus lens with its concave surface on the photographic image side, and a seventh lens element L7 composed of a double concave lens with a stronger curvature surface on the image side, and an eighth lens element L8 composed of a double convex lens with a stronger curvature surface on the photographic image side. The third lens group G3 arranges, in order from the photographic object side, a ninth lens element L9 composed of a double convex lens with a stronger curvature surface on the photographic object side. Furthermore, filter component L10 may be arranged between the third lens group G3 and the image plane 1 (i.e., between L9 and a CCD array which may be located at image plane 1).
Table 1, below, shows the values of the radius of curvature R (in mm) of each lens element surface, the on-axis surface spacing D (in mm), as well as the values of the index of refraction n d and the Abbe number ν d (for the sodium d line) of each lens element of the zoom lens which apply to embodiment 1. The surface numbers # in the table indicate the surface order from the photographic object side. In the lower section of Table 1, the values for the focal distance f, the F number F No . and the angle of view 2ω are given.
TABLE 1______________________________________# R D n.sub.d ν.sub.d______________________________________1 122.395 2.700 1.74399 44.82 -246.925 0.1503 42.223 1.200 1.81600 46.64 10.859 5.1475 -48.119 1.200 1.71299 53.96 30.098 0.7007 20.463 3.700 1.80099 35.08 -385.560 variable distance 19 shutter stop 1.50010 13.401 3.500 1.81600 46.611 -61.489 0.15012 16.619 2.700 1.74320 49.313 26.334 0.93614 -18.840 2.000 1.80518 25.415 10.311 1.32216 787.376 3.200 1.78800 47.417 -17.717 variable distance 218 25.182 3.500 1.51680 64.219 -38.026 variable distance 320 ∞ 4.200 1.51680 64.221 ∞f = 9.01 mm-25.23 mm F.sub.No. = 3.52-5.48 2ω = 64.9°-25.2.degree.______________________________________
Table 2, below, indicates the ranges for variable distance 1, variable distance 2, and variable distance 3 which are applicable when zooming from the maximum wide-angle state (f=9.01 mm) to the maximum telephoto state (f=25.23 mm) for both infinite distance focusing and nearest distance focusing for embodiment 1.
TABLE 2______________________________________ Infinite Distance Nearest Distance Focusing Focusing (≈1 m) maximum maximum maximum maximum wide-angle telephoto wide-angle telephoto state state state state______________________________________variable distance 1: 36.649 4.665 36.649 4.665variable distance 2: 10.108 28.190 9.904 26.766variable distance 3: 1.500 1.500 1.704 2.924______________________________________
FIGS. 3A and 3B illustrate the spherical aberration, astigmatism and distortion which occur at the maximum wide-angle state and the maximum telephoto state, respectively, of the zoom lens of embodiment 1. As is evident from FIGS. 3A and 3B, favorable aberration correction is achieved in all areas of zooming for embodiment 1.
Embodiment 2
The zoom lens of embodiment 2 has the same lens element composition description as given above for embodiment 1 and thus, the description will not be repeated. Table 3, below, shows the values of the radius of curvature R (in mm) of each lens element surface, the on-axis surface spacing D (in mm), as well as the values of the index of refraction n d and the Abbe number ν d (for the sodium d line) of each lens element of the zoom lens which apply to embodiment 2. The surface numbers # in the table indicate the surface order from the photographic object side. Further, in the lower section of Table 3, the values for the focal distance f, fnumber F No . and the angle of view 2ω are indicated.
TABLE 3______________________________________# R D n.sub.d ν.sub.d______________________________________1 120.673 2.600 1.74399 44.82 -288.617 0.1503 42.850 1.200 1.81600 46.64 11.041 4.6755 -50.663 1.200 1.71299 53.96 30.799 0.7007 20.333 3.550 1.80099 35.08 -431.518 variable distance 19 shutter stop 1.50010 13.278 3.500 1.81600 46.611 -60.221 0.15012 16.590 2.700 1.74320 49.313 25.929 0.86814 -18.929 2.000 1.80518 25.415 10.200 1.53716 1056.621 3.200 1.80400 46.617 -18.265 variable distance 218 25.528 3.500 1.51680 64.219 -39.794 variable distance 320 ∞ 4.200 1.51680 64.221 ∞f = 9.76 mm-27.33 mm F.sub.No. = 3.52-5.52 2ω = 60.6°-23.3.degree.______________________________________
Table 4, below, indicates the ranges for variable distance 1, variable distance 2, and variable distance 3 which are applicable when zooming from the maximum wide-angle state (f=9.76 mm) to the maximum telephoto state (f=27.33 mm) for both infinite distance focusing and nearest distance focusing for embodiment 2.
TABLE 4______________________________________ Infinite Distance Nearest Distance Focusing Focusing maximum maximum maximum maximum wide-angle telephoto wide-angle telephoto state state state state______________________________________variable distance 1: 34.350 3.283 34.350 3.283variable distance 2: 10.020 29.072 9.790 27.466variable distance 3: 2.000 2.000 2.230 3.606______________________________________
FIGS. 4A and 4B illustrate the spherical aberration, astigmatism and distortion at the maximum wide-angle state and the maximum telephoto state, respectively, of embodiment 2. As is evident from FIGS. 4A and 4B, favorable aberration correction is achieved in all areas of zooming for embodiment 2.
Moreover, for both embodiment 1 and embodiment 2, conditional expressions (1)-(4) above are all satisfied. The numerical values of the ratio (i.e., the middle term) of each of conditional expressions (1)-(4) are given in Table 5 below.
TABLE 5______________________________________ Embodiment 1 Embodiment 2______________________________________conditional expression (1): D.sub.wm /f.sub.3 0.96 0.94conditional expression (2): D.sub.ti /f.sub.3 1.57 1.56conditional expression (3): B.sub.ft /f.sub.3 0.19 0.20conditional expression (4): f.sub.2 /f.sub.w 2.48 2.32______________________________________
Furthermore, the three-group zoom lens of the present invention is not limited to that described in the embodiments above. For example, appropriate selection of the number of lens elements and their shapes is possible for the composition of each lens group.
As described above, by satisfying conditional expressions (1) and (2), it is possible to establish the pupil exit position in a position which is sufficiently far from the photographic image plane so as to secure a suitable magnification ratio. In this way, it becomes possible to allow the luminous flux to be incident nearly perpendicularly onto the photographic image plane, thereby making it possible to prevent shading when these rays are incident onto a CCD array located at the image plane. Furthermore, by employing the rear focusing method, high speed focusing is achieved. In addition, by satisfying conditional expressions (1)-(2), an appropriate back focus can be obtained, thereby allowing space between the exit pupil and the image plane to accommodate one or more filter components. By satisfying conditional expression (3), it is possible to construct the third lens group using only a single lens element. Further, by satisfying conditional expression (4), aberrations are suppressed, the fluctuation with zooming of the distance from the photographic image plane to the exit pupil is reduced, and a high degree of compactness for the entire zoom lens system can be achieved.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention. All such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A three-group zoom lens having lens groups, in order from the photographic object side, of negative, positive, and positive refractive power. The zoom lens is specially designed for use in a still or video camera employing a CCD array positioned at a fixed photographic image plane. Zooming is primarily performed by moving the two lens groups nearest the photographic object side, and focusing is primarily performed by adjusting the position of the lens group nearest the photographic image side. By satisfying certain conditional expressions a distance from the exit pupil to the photographic image plane is maintained to prevent shading, a back focus length sufficient to accommodate a filter component is provided, and a compact zoom lens of high quality is obtained. | 6 |
RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Patent Application No. 62/087,453, filed Dec. 4, 2014 and entitled “Conveyor System with Roller Assemblies”, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates generally to power-driven conveyors and more particularly to conveyors having rollers for manipulating the trajectory of articles through a conveyor system.
[0003] Many package- and material-handling applications require that conveyed articles be diverted to a side of a conveyor. Two examples are sorting articles off the side of a belt and registering articles against the side of the belt. U.S. Pat. No. 6,494,312, “Modular Roller-Top Conveyor Belt with Obliquely-Arranged Rollers,” Dec. 17, 2002, to Costanzo discloses a conveyor system in which cylindrical rollers mounted in a conveyor belt on axles oblique to the direction of belt travel are actuated by underlying bearing surfaces on which the oblique rollers ride as the belt advances in the direction of belt travel. The contact between the rollers and the bearing surfaces causes the rollers to rotate as the belt advances. The rotation of the oblique rollers pushes articles atop the rollers across the conveyor belt toward a side of the conveyor. These oblique-roller belts work extremely well on planar bearing surfaces as long as the rollers are arranged to rotate at an angle between the direction of belt travel (defined as a roller angle of 0°) and about 30° or so from the direction of belt travel. For roller angles greater than 30°, the rollers slip too much on the planar bearing surfaces.
[0004] U.S. Pat. No. 6,968,941, “Apparatus and Methods for Conveying Objects,” Nov. 29, 2005, to Fourney describes an improved bearing surface that accommodates a much greater range of roller angles. Instead of using a planar bearing surface, Fourney uses the outer peripheries of actuating rollers arranged to rotate on axes in the direction of belt travel. As the conveyor belt advances, the oblique belt rollers roll on the underlying actuating rollers, which are also caused to roll on their axes. Because the bearing surface on the periphery is rolling, slip is reduced and greater roller angles can be accommodated. The greater roller angles permit much sharper article-diversion trajectories than are possible with a planar bearing surface. But actuating rollers are more expensive and slightly more complicated than simple planar bearing surfaces.
[0005] U.S. Pat. No. 7,588,137, “Conveyor Belt Having Rollers that Displace Objects,” Sep. 15, 2009, to Fourney describes a conveyor belt that includes multiple roller sets used to divert objects from the conveyor belt. The angles along which articles can be diverted from the conveyor are limited.
[0006] U.S. Patent Publication 2013/0192954, published Aug. 1, 2013 and entitled “Multi-Directional Roller Assembly” (now U.S. Pat. No. 9,978,879), the contents of which are herein incorporated by reference, describes a multi-directional roller assembly that may be driven by a conveyor belt below the assembly. The same conveyor belt conveys articles to and from a roller plate housing an array of multi-directional roller assemblies. The roller assemblies manipulate the trajectory of the articles, or pass the articles straight along the roller plate and back onto the conveyor belt. The conveyor belt is diverted below the roller plate to drive the roller assemblies. The conveyor belt may experience high tensions. Furthermore, the transition of articles off the conveyor belt, onto the roller plate and back onto the conveyor belt may alter the desired spacing between articles, in addition to presenting unnecessary instability.
SUMMARY OF THE INVENTION
[0007] A conveyor system employs a roller plate housing an array of roller assemblies for manipulating the trajectory of an article and a series of narrow conveyor belts passing over the top of the roller plate between roller assemblies and back under the roller plate. The narrow conveyor belts are movable relative to the top surface of the roller plate. In a raised mode, the narrow conveyor belts convey articles over the roller plate. In a lowered mode, the narrow conveyor belts pass articles onto the roller plate and into contact with the roller assemblies, which manipulate the trajectory of the articles. Below the roller plate, the narrow conveyor belts in the returnway may help drive the roller assemblies.
[0008] According to a first aspect, a conveyance device comprises a sorting plate having an array of roller assemblies for contacting and directing an article of conveyance along a selected trajectory, at least one conveyor belt passing between two roller assemblies and an actuator for selectively raising and lowering the conveyor belt relative to the sorting plate.
[0009] According to another aspect, a conveyance device comprises a sorting plate having a plurality of rows of roller assemblies for contacting and directing an article of conveyance along a selected trajectory, a plurality of tracks passing between roller assemblies, a plurality of narrow conveyor belts contained in the tracks, and an actuator for varying the distance between the narrow conveyor belts and the roller assemblies.
[0010] According to another aspect, a method of sorting articles comprises the steps of conveying articles towards a sorting plate having a plurality of roller assemblies using a series of narrow conveyor belts and adjusting a distance between the roller assemblies and the narrow conveyor belts depending on an orientation of the roller assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These aspects and features of the invention, as well as its advantages, are explained in more detail in the following description, appended claims, and accompanying drawings, in which:
[0012] FIG. 1 is an isometric view of a sorting plate with a series of narrow belts passing between roller assemblies according to an embodiment of an invention;
[0013] FIG. 2 is a schematic side view of a conveying system including a sorting plate, narrow belts and secondary drive belt below the sorting plate;
[0014] FIG. 3A is a side view of a sorting plate with narrow belts in a raised mode according to an embodiment of the invention;
[0015] FIG. 3B is a side view of a sorting plate with narrow belts in a lowered mode according to an embodiment of the invention;
[0016] FIG. 4A is an isometric view of a rotational ramp for positioning a narrow belt in a first position;
[0017] FIG. 4B is an isometric view of a rotational ramp for positioning a narrow belt in a second position; and
[0018] FIG. 5 is a schematic view of a portion of a roller plate including a narrow belt passing between roller assemblies and having ramps on a rack gear for selectively raising and lowering the narrow belt according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A conveyor system includes an array of roller assemblies and a plurality of narrow conveyor belts passing over the roller plate between the roller assemblies. The invention will be described below relative to certain illustrative embodiments, though one skilled in the art will recognize that the invention is not limited to the illustrative embodiments.
[0020] FIG. 1 shows a conveyor system including a sorting plate 10 that comprises a plurality of roller assemblies 20 for selectively changing the trajectory of a conveyed article. The roller assemblies 20 are arranged in a pattern of alternating rows, though the sorting plate 10 may have any suitable number, size, configuration and arrangement of roller assemblies. The roller assemblies 20 are housed between upper and lower plates, as described in U.S. Patent Publication 2013/0192954, published Aug. 1, 2013 and entitled “Multi-Directional Roller Assembly”, the contents of which are incorporated herein by reference, though the invention is not limited to the multi-directional roller assemblies there described.
[0021] The sorting plate 10 includes a plurality of narrow conveyor belts 50 . The belts 50 operate in at least two modes: a raised mode and a lowered mode. In one embodiment, an actuator selectively raises or lowers the drive belts relative to the sorting plate 10 to switch between modes. In a raised mode, one or more of the drive belts is raised above the top surface of the sorting plate 10 , so that a product carried towards the sorting plate by the drive belts will pass over the sorting plate without contact with the roller assemblies 20 . In the raised mode, the belts 50 serve as the primary conveyor of articles over the sorting plate 10 . In a lowered mode, an actuator lowers the conveyor belts 50 relative to the top surface of the sorting plate, so that an article conveyed to the sorting plate 10 by the belts 50 contacts the roller assemblies 20 which then direct the article in a selected direction, depending on the orientation of the roller assemblies. In one embodiment, the belts 50 return under the sorting plates and also serve as drivers for the roller assemblies 20 . As show, the narrow conveyor belts 50 have a width sufficiently narrow to allow passage of the conveyor belt between adjacent roller assemblies 20 in the sorting plate 10 .
[0022] The individual roller assemblies 20 are arranged to allow clear passage of the narrow belts in either situation in either mode. The roller plate 10 may include tracks between different roller assemblies for containing the belts 50 . The tracks keep the belts in a straight orientation relative to the motion and support the weight of the belts and conveyed articles. In one embodiment, an actuator selectively moves the tracks up and down to expose the conveyed articles to the roller assemblies 20 . In another embodiment, the conveyor belts 50 can remain vertically stationary while the roller assemblies 20 move up and down to alternate between the two modes.
[0023] In one embodiment, the actuator moves only the top (carryway) portion of the belts 50 between raised and lowered positions. In another embodiment, the actuator moves an entire belt 50 or series of belts 50 , or the roller plate 10 may be moved relative to the top portion of the belts 50 . The tracks or the belts 50 or the roller assemblies 20 or the roller plate 10 may be raised and lowered independently of the actual roller assemblies using cams, motors, air cylinders, hydraulic cylinders, magnets, springs or any suitable combination of actuators.
[0024] FIG. 2 is a schematic side view of the conveying system of FIG. 1 . The narrow belts 50 convey an article 60 towards the sorting plate 10 . In a raised mode, the narrow belts 50 convey the article at belt speed over the sorting plate 10 . In a lowered mode, the narrow belts 50 convey the article to the sorting surface of the sorting plate 10 , where the roller assemblies act on the package. The narrow belts 50 return below the sorting plate 10 . The narrow belts may engage a secondary belt 70 below the sorting plate 10 to drive the roller assemblies 20 . Alternatively, a motor or other suitable driver may be used to drive the roller assemblies 20 .
[0025] FIG. 3A is a side view of the sorting plate 10 with the narrow belts 50 raised relative to the top surface of the roller plate 10 . In a raised mode, the top surface of the narrow belts 50 remains the conveying surface for conveyed articles. The conveyed article does not contact the roller assemblies as it passes over the sorting plate 10 .
[0026] FIG. 3B is a side view of the sorting plate 10 with the narrow belts 50 lowered relative to the top surface of the sorting plate 10 . In the lowered mode, the top surface of the belts 50 is even with or below the tops of the roller assemblies, so that the roller assemblies 20 contact the conveyed article. Each roller assembly 20 is selectively oriented and actuated to manipulate the trajectory of a conveyed article.
[0027] Any suitable means for raising and lowering the belts 50 may be used. In one embodiment, the vertical motion of the belt 50 over the roller plate 10 may be connected to the orientation of the roller assemblies 20 within the plate.
[0028] For example, FIGS. 4A and 4B show a rotational ramp 90 for guiding and changing the height of a belt 50 across a roller plate 10 . The rotational ramp 90 forms a track 91 with walls 92 for guiding a narrow conveyor belt over or through a roller plate. The rotational ramp 90 is designed so that the track 91 is in a high position ( FIG. 4A ) when the roller assemblies are in a pass-through position, so that the roller assemblies do not contact the conveyed article. When the roller assemblies are oriented in a sorting orientation, the track 91 is in a lower position ( FIG. 4B ) to lower the conveyor belt 50 passing through the track 91 , allowing an article conveyed by the conveyor belt 50 to contact the roller assemblies. The rotational ramp comprises a top portion 95 , which is fixed to the narrow belt track and a bottom portion 96 , which rotates with the roller assemblies or connected gearing. The bottom portion and top portion including bearing surfaces, such that rotation of the bottom portion 96 relative to the top portion 95 pushes the top portion 95 up to raise the track 91 .
[0029] FIG. 5 is a schematic overhead view of a belt 50 passing through a pair of roller assemblies 20 according to another embodiment of the invention. In the embodiment of FIG. 5 , each roller assembly 20 includes peripheral teeth 22 that engage a rack gear 24 or other actuator to selectively orient the roller assemblies 20 . The rack 24 includes ramps 26 for selectively raising and lowering the belt 50 relative to the roller assemblies 20 , depending on the orientation of the roller assemblies. When the roller assemblies are oriented in a pass-through orientation, the ramps 26 move inwards to push the belt 50 up so that the roller assemblies do not contact the conveyed article. When the rollers assemblies 20 are oriented in a sorting orientation, the ramps 26 pull away from the belt to lower the belt 50 .
[0030] Both the rotational ramp 90 shown in FIGS. 4A and 4B and the linear ramp 26 mechanisms can serve the dual purpose of transferring motion from one roller assembly 20 to another while also raising and lowering the belt 50 or a track containing the belt.
[0031] The narrow conveyor belts 50 allow a continuous conveying surface to be maintained. Since the belts 50 follow a much straighter path, the belt tension, belt wear and consumed power is reduced.
[0032] As these few examples suggest, the scope of the invention is meant to be defined by the claims and not limited to the details of the described versions. | A conveyance device comprises a sorting plate housing a plurality of roller assemblies and a series of narrow conveyor belts for conveying articles towards the sorting plate. In a first mode, the narrow conveyor belts bypass the roller assemblies and convey articles over the sorting plate. In a second mode, the conveyor belts bring an article into contact with the roller assemblies, which then manipulate the trajectory of the article. | 1 |
BACKGROUND
[0001] Patients suffering from chronic medical conditions may be required to perform self-care behaviors in order to manage their conditions and improve their clinical outcomes. However, individual patients may have varying determinants that influence their ability to comply with self-care behaviors, and it may be desirable to address and improve these determinants as part of a care plan in a patient-specific manner. Further, patients may not always understand the specific manner in which self-care behaviors affect their clinical outcomes, which may cause them not to comply with their self-care behaviors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 schematically illustrates a system for generating a patient-specific ordered list of determinants according to an exemplary embodiment.
[0003] FIG. 2 illustrates an exemplary method by which the system illustrated in FIG. 1 may operate.
[0004] FIG. 3 illustrates a table of self-care determinants that may be considered during the performance of the method of FIG. 2 .
[0005] FIG. 4A illustrates an exemplary result of the performance of step 210 of the method of FIG. 2 .
[0006] FIG. 4B illustrates an exemplary result of the performance of step 220 of the method of FIG. 2 .
[0007] FIG. 4C illustrates an exemplary result of the performance of step 230 of the method of FIG. 2 .
[0008] FIG. 4D illustrates an exemplary result of the performance of step 240 of the method of FIG. 2 .
[0009] FIG. 4E illustrates an exemplary result of the performance of step 250 of the method of FIG. 2 .
[0010] FIG. 4F illustrates an exemplary result of the performance of step 260 of the method of FIG. 2 .
[0011] FIG. 4G illustrates an exemplary result of the performance of step 270 of the method of FIG. 2 .
[0012] FIG. 5 schematically illustrates an exemplary system for informing patients about the effects that performance of self-care behaviors may have on their health.
[0013] FIG. 6 illustrates an exemplary method by which the system illustrated in FIG. 5 may operate.
[0014] FIG. 7 illustrates an exemplary patient profile that may be generated by the method of FIG. 6 .
[0015] FIG. 8 illustrates a portion of an exemplary database that may be used by the system of FIG. 5 during the performance of the method of FIG. 6 .
[0016] FIG. 9 illustrates a table showing adjustment of the value of patient self-care behaviors according to patient's self-management abilities according to the method of FIG. 6 .
[0017] FIG. 10 illustrates a table showing adjustment of the value of patient self-care behaviors according to input parameters according to the method of FIG. 6 .
[0018] FIG. 11 illustrates an exemplary user interface display that may be generated by the system of FIG. 5 .
DETAILED DESCRIPTION
[0019] The exemplary embodiments may be further understood with reference to the following description and the related appended drawings, wherein like elements are provided with the same reference numerals. Specifically, the exemplary embodiments relate to methods and systems for prioritizing patient self-care behaviors and providing patients with support in choosing such behaviors.
[0020] Increasing numbers of patients worldwide suffer from chronic conditions that are associated with poor outcomes such as diminished quality of life, frequent hospital readmissions, and early mortality. Self-care is useful for avoiding these poor outcomes, and, thus, is frequently recommended to patients as part of the treatment of chronic conditions. The effectiveness of such treatment relies on patients' adherence to self-care behaviors such as taking medication, maintaining an appropriate level of physical activity, consuming appropriate types and quantities of foods and beverages, cessation of smoking, managing symptoms, etc. Non-adherence to self-care behaviors is a leading cause of exacerbation of chronic conditions and poor outcomes. Therefore, it is desirable to provide patients with proper interventions to enable effective adherence to self-care behaviors, and to demonstrate to patients the effects of adherence to self-care behaviors.
[0021] Each patient will have various determinants that affect the patient's ability to adhere to self-care behaviors. Determinants may include factors such as disease burden, perceived control, self-efficacy, social support, ability to cope with problems, anxiety, depression, willingness to self-manage, comfort in a group, computer skills, etc. The patient's strength or weakness in each of the above determinants may help or hinder the patient's efforts to adhere to self-care behaviors such as those discussed above. Because this is the case, a patient's care plan (“CP”) may include efforts to address the patient's determinants and thereby improve the likelihood that the patient will adhere to self-care behaviors. For example, a patient coping with anxiety or depression may be instructed to undergo counseling; a patient with poor computer skills may not be offered an Internet-based behavior change program.
[0022] Any given chronic condition may have corresponding weights for various self-care behaviors; for example, for a patient suffering from lung cancer, smoking cessation may be a pivotal factor, whereas the same self-care behavior may be less significant for a patient having a non-cardiopulmonary ailment. Further, any given patient will have some determinants that are areas of strength for the patient, and others that are areas of weakness. Additionally, there may typically be a limited amount of time available in which to address a given patient's determinants. Therefore, it may be desirable to have a patient-specific prioritized list of determinants in order to guide clinicians in designing a CP for the patient. The exemplary embodiments described herein may generate such a patient-specific prioritized list of determinants.
[0023] FIG. 1 illustrates, schematically, an exemplary system 100 for generating a patient-specific ordered list of determinants. It will be apparent to those of skill in the art that the system 100 includes data processing elements that may be implemented through a combination of hardware (e.g., processor, memory, user interface, etc.) and software in a manner that will be understood by those of skill in the art. The operation of the system 100 will be described herein with reference to the exemplary method 200 .
[0024] The system 100 may include a Triage element 110 . The Triage 110 may perform a first portion of the tasks performed by the system 100 . In step 210 , the Triage 100 may receive, as input, a clinician's choice of determinants 20 to be used in assessing the patient. The clinician may choose a subset of all possible determinants discussed above (e.g., disease burden, perceived control, self-efficacy, social support, coping with problems, willingness to self-manage) for use in assessing the patient. The choice may be based on clinical guidelines, results of clinical trials, the clinician's experience, etc. For example, a clinician may choose to exclude “computer skills” from consideration because a patient's low level of computer skills may indicate that a telehealth system may not be an efficient use of resources for the patient; those of skill in the art that this reason is only exemplary and that various other reasons for excluding a determinant for consideration may be possible. The subset of determinants retained for subsequent analysis will be referred to hereinafter as D mod , meaning modifiable determinants.
[0025] In step 220 , the Triage 110 may also receive, as an input, data from a patient self-assessment 40 . The self-assessment 40 may be performed using a known assessment tool, such as Self-Management Assessment (“SeMaS”) or Patient Activation Measure (“PAM”) questionnaires. As a result of this self-assessment 40 , each determinant may be assigned a score which classifies a determinant as a facilitator or barrier of self-care behavior. FIG. 3 illustrates a table 300 that shows, in a first column 310 , the list of determinants selected by the clinician as the applicable subset of determinants D mod , and, in a second column 320 , possible assessment scores for each selected determinant based on the patient self-assessment 40 . Based on these scores, each determinant may be classified as either a facilitator or a barrier; for example, high self-efficacy may be classified as a facilitator, whereas low self-efficacy may be classified as a barrier.
[0026] Based on the scores for the determinants D mod included in the table 300 of FIG. 3 , in step 230 the Triage 110 assigns a weight to each determinant in the set D mod . Weights may be assigned according to the rule that a determinant with an assessment score indicating that the determinant is a facilitator of self-care behavior is assigned a low weight, while a determinant with an assessment score indicating that the determinant is a barrier to self-care behavior is assigned a high weight. This may indicate that it is more important for a CP to focus on barriers to self-care than on facilitators. The specific quantitative weights used in this step may vary among differing embodiments.
[0027] Column 330 of table 300 illustrates generalized versions of weights that may be used herein. Column 340 of table 300 illustrates a first exemplary weighting that may be applied by the Triage 110 . In the first exemplary weighting, scores are given weights from 1 to 3, with facilitators scored a 1 and barriers scored a 3. Column 350 of table 300 illustrates a second exemplary weighting that may be applied by the Triage 110 . In the second exemplary weighting, facilitators are scored a 0 and barriers are scored a 2. It will be apparent to those of skill in the art that, by weighting facilitators a 0, they may be excluded from further consideration in the modification of self-care behavior.
[0028] In step 240 , the Triage 110 creates an ordered list 120 of determinants of self-care behaviors based on the weights assigned in step 230 . This may involve ranking, by weight, the determinants D mod that remain under consideration after any potential elimination from consideration of some of the determinants due to being assigned zero weight in step 230 . This ordered list 120 of self-care determinants may be the output generated by the Triage 110 . In step 250 , the ordered list 120 is passed, by the Triage, to Quantifier element 130 of the system 100 .
[0029] In step 260 , the Quantifier 130 calculates a weight W D of each determinant from step 240 across all determinants selected for inclusion in the CP for the patient by virtue of being selected in step 210 and not assigned zero weight in step 230 . The weight for W D each determinant is calculated as:
[0000]
W
D
(
D
mod
(
i
)
)
=
weight
(
D
mod
(
i
)
)
∑
weight
(
D
mod
(
i
)
)
,
i
=
1
,
…
,
#
D
mod
[0030] In the above expression, “#D mod ” is the quantity of remaining determinants in the set D mod . In step 270 , the Quantifier 130 calculates the determines a contributions matrix 140 , in which the contribution c(i,j) of each determinant i from step 240 to the care plan for a particular self-care behavior j based on the weights W D calculated in step 260 and known weights W B (j) for each behavior. The contributions c(i,j) may be calculated as:
[0000] c ( i, j )= W D ( D mod ( i ))* W B ( j ), i= 1, . . . , # D mod ; j= 1, . . . , #Behaviors
[0031] In the above expression, “#Behaviors” is the number of self-care behaviors under consideration. After step 270 , the method 200 is complete. The set of contributions c(i,j) of the contributions matrix 140 output by the Quantifier 130 in step 270 may be the output of method 200 performed by system 100 . The matrix 140 of contributions c(i,j) is patient-specific based on the patient's self-assessment 40 , and may then be used by a clinician in devising a CP to enable important determinants to be addressed, and, in turn, to enable the patient to adhere to important self-care behaviors. It will be apparent to those of skill in the art that the division of the functions of the Triage 110 and Quantifier 130 described herein may essentially be a logical construct. Thus, they may be integrated into a single element (e.g., a software application, combination of software and hardware, etc.) without departing from the broader scope of the functions described.
[0032] FIGS. 4A-4G illustrate the results of various phases of the application of method 200 to one exemplary patient. For the condition of the patient who is the subject of these figures, the behavior weight W B for medication taking is 40%, W B for symptom management is 30%, W B for physical activity is 10%, W B for nutrition is 10%, and W B for smoking cessation is 10%, as indicated in FIG. 4F . FIG. 4A illustrates a set of determinants D mod 410 that may be received from a clinician for the patient in step 210 . As noted above, this set of determinants may be selected by the clinician based on the patient's condition and various other factors. FIG. 4B illustrates the results of the patient's self-care assessment 420 . The results shown in FIG. 4B are formatted in accordance with the SeMaS assessment tool, and it will be apparent that similar information may be where the patient's self-care assessment has been made using a different technique. In FIG. 4B , determinants with large dots are areas of strength for the patient, and will be termed facilitators of self-care, while determinants with small dots are areas of weakness and will be termed barriers.
[0033] FIG. 4C illustrates a weighted set of determinants D mod 430 that may be determined by the Triage 110 in step 230 based on the inputs shown in FIGS. 4A and 4B . The determinants 430 are weighted as shown in column 350 of FIG. 3 , described above. FIG. 4D illustrates an ordered list of determinants Dmod 120 that may be determined by the Triage 110 in step 240 , and may be the output of the Triage 110 to the Quantifier 130 .
[0034] FIG. 4E illustrates a set of weights W D 450 of each determinant from step 240 (e.g., shown in FIG. 4D ), as divided in step 260 by the Quantifier 130 across all determinants selected for inclusion in the CP for the patient. FIG. 4F illustrates a table 460 showing the calculation of the contributions of the patient's determinants to the self-care behaviors appropriate for the patient's condition. FIG. 4G illustrates a contributions matrix 140 that may be determined by the Quantifier 130 in step 270 of the method 200 , based on the inputs described above with reference to FIGS. 4A-4F . The contributions matrix 140 may be used by a clinician to determine a CP for the patient having these inputs.
[0035] As described above, self-care behaviors are an important factor in controlling the progression of chronic diseases and supporting overall wellness. The exemplary embodiments described above with reference to FIGS. 1, 2, 3 and 4A-4G present techniques by which clinicians may evaluate a patient's determinants (e.g., factors that may influence the patient's ability to adhere to self-care behaviors), and use the evaluation of determinants to shape a care plan that may enable the patient's determinants to be addressed in a manner that may improve the likelihood that the patient will adhere to self-care behaviors. However, other applications for the patient's ordered list of determinants exist. The exemplary embodiments discussed hereinafter present exemplary embodiments providing another application therefor.
[0036] One issue with self-care behaviors is that, although clinicians have a variety of ways of selecting an effective self-care behavior for a given patient, patients themselves may have difficulty integrating self-care behaviors into their daily lives. In part, this may be because it is difficult for patients to understand the level of effort that may be appropriate for a given self-care behavior, and the potential impact that such effort may have on their health. Because of this lack of understanding, patients may be discouraged from adopting new self-care behaviors into their lives. Further, a patient may find it too difficult to adopt a self-care behavior with parameters that are too challenging (e.g., an exercise regimen that is too long or performed too often).
[0037] FIG. 5 illustrates schematically an exemplary system 500 that may enable patients to more clearly understand the effect that self-care behaviors have on their health. More specifically, the exemplary system 500 may apply patient-specific parameters to general information about a condition to provide a patient with an interactive tool that may enable the patient to understand how the patient's selected manner of performing self-care behaviors affect the patient's health. The system 500 may consist of logical elements performing different tasks, in the same manner as the system 100 described above, but those of skill in the art will understand that the functions of these elements may be grouped together in other embodiments. The operation of the system 500 will be described herein with reference to the exemplary method 600 .
[0038] The system 500 may include a Profiler element 510 . In step 610 , the Profiler 510 retrieves available data about a specific patient. The data retrieved by the Profiler 510 may include results of assessment questionnaires about the patient's condition, data about the patient's self-management factors, data about the patient's communication style, data about the patient's previous clinical experiences, and data about the patient's personal preferences. It will be apparent to those of skill in the art that the specific data retrieved by the Profiler may vary among differing embodiments, and that the specific sources consulted may also vary. In one embodiment, a source of the data retrieved in step 610 may be the self-assessment 40 referred to above with reference to FIG. 1 .
[0039] Based on the data received in step 610 , in step 615 the Profiler 510 creates a profile 515 for the patient. FIG. 7 illustrates an exemplary profile 700 that may be created in step 610 . The profile 700 of FIG. 7 includes a profile element column 702 that describes the contents of each row, a value column 704 that contains the patient's value for the given row, and a type column 706 that describes the type of information contained in each row. The profile 700 includes conditions 710 , describing the conditions being experienced by the patient. The exemplary patient of the profile 700 suffers from heart failure and diabetes. The profile 700 also includes current performance 720 , describing current self-care behaviors of the patient. The exemplary patient of the profile 700 exercises once a week, skips medications once a week, and smokes five cigarettes per day. The profile 700 also includes social support 730 , describing the level of social support available to the patient.
[0040] The profile 700 also includes locus of control 740 , describing the extent to which individuals believe they themselves can control events that affect their health (e.g., internal locus of control) or that others have the main control of events that affect the individual (e.g., external locus of control). The exemplary patient of the profile 700 has an external-others locus of control. The profile 700 also includes willingness to self-manage 750 , describing the patient's willingness to self-manage his/her condition. The exemplary patient of the profile 700 has low willingness to self-manage. The profile 700 also includes patient's prioritized outcome 760 , describing the patient's outcome priority. The prioritized outcome 760 of the exemplary patient of the profile 700 is extending lifespan. It will be apparent to those of skill in the art that the profile 700 is only exemplary. The specific rows shown in the profile 700 may vary among differing embodiments, and the specific values shown in the profile 700 are only one possible patient example. The profile 700 may be stored as a computer file in any format appropriate for subsequent use as will be described hereinafter. The profile 700 may also be exported in a computer-friendly format such as XML, or in a human-readable format for display, printing, etc.
[0041] The system 500 also includes a Matcher component 520 in communication with the Profiler 510 and a Database 530 . The Database 530 stores self-care behaviors (e.g., physical activity, smoking cessation, etc.) indexed by various factors such as associated conditions, evidence of effectiveness, guidelines and recommended care plans, and population-generalized weights of the individual parameters of a behavior. In particular, the Database 530 may include, for each self-care behavior, a generalized (e.g., not patient-specific) ImpactScore for each medical condition, based only on known scientific evidence and expert opinion.
[0042] An ImpactScore quantifies the effect that a self-care behavior has on a given medical condition; the effect that self-care behavior b has on medical condition m will be referred to herein as ImpactScore bm . All ImpactScores contained in the Database 530 may be represented on a common scale; in one exemplary embodiment, this scale may be from −100 to 100, but it will be apparent to those of skill in the art that the specific scale used may vary. For example, the physical activity self-care behavior may be associated with multiple medical conditions. For conditions for which scientific evidence and expert opinion have found to be impacted positively by physical activity, a high weight (e.g., an ImpactScore of 85 on a scale from −100 to 100) may be associated with them; for those with less evidence of positive impact, a lower weight (e.g., an ImpactScore of 30 on the same scale); for those conditions where a negative impact is found, a negative weight may be designed (e.g., an ImpactScore of −20 on the same scale).
[0043] The Database 530 may also include a set of parameters describing how each self-care behavior is performed. For example, the self-care behavior or physical activity may have a parameter called “type” that may take on semantic values such as walking on a treadmill at home, attending a fitness class, walking at the mall, or following a fitness DVD at home. Another parameter may be “intensity,” which may take on semantic values such as low, moderate, or high. Another parameter may be “frequency,” which may take on values such as once per week, twice per month, three times a day, etc. It will be apparent to those of skill in the art that the specific parameters may vary for each self-care behavior contained in the Database 530 , depending on the nature of the self-care behavior. The Database 530 may also include a weight for each parameter (e.g., ranging from 0 to 1.0) describing the parameter's relative contribution to the effectiveness of the behavior, based on scientific evidence or expert opinion. The Database 530 may also include a recommended configuration of the parameters for each behavior and medical condition.
[0044] FIG. 8 illustrates a portion of an exemplary database 800 . Though FIG. 8 illustrates the contents of the entries in the database 800 for two self-care behaviors and one medical condition, it will be apparent to those of skill in the art that a real-world implementation of a database 800 may include a larger variety of both self-care behaviors and medical conditions. In the database 800 , entries for self-care behaviors 810 (in this example, taking medications) and 820 (in this example, physical activity) are provided for condition 840 (in this example, Heart Failure).
[0045] For self-care behavior 810 , data included in the database includes ImpactScore 811 , parameter 812 (in this example, frequency), recommended value 813 corresponding to parameter 812 (in this example, 80% of prescribed episodes, weight 814 corresponding to parameter 812 , parameter 815 (in this example, type), recommended value 816 corresponding to parameter 815 (in this example, all), and weight 817 corresponding to parameter 815 . For self-care behavior 820 (in this example, physical activity), data included in the database includes ImpactScore 821 , parameter 822 (in this example, intensity), recommended value 823 corresponding to parameter 822 (in this example, moderate), weight 824 corresponding to parameter 822 , parameter 825 (in this example, frequency), recommended value 826 corresponding to parameter 825 (in this example, five times per week), weight 827 corresponding to parameter 825 , parameter 828 (in this example, type), recommended value 829 corresponding to parameter 828 (in this example, walking), and weight 830 corresponding to parameter 828 . It will be apparent to those of skill in the art that the specific examples shown in FIG. 8 are only exemplary and that these may vary for differing embodiments of a database 800 .
[0046] In step 620 , the Matcher 520 receives the patient profile from the Profiler 510 and data relevant to the patient's condition from the Database 530 . This may be prompted by action by a clinician or by the patient or in any other appropriate manner. In step 625 , the Matcher 520 generates an ordered list of self-care behaviors for the patient's medical condition. The ordered list may be ordered by the ImpactScore of the behaviors corresponding to the patient's condition. At this point in the method 600 , the ImpactScores are still generalized based on the assumption that the patient carries out self-care behaviors in the optimal manner prescribed by clinical guidelines, and are not specific to the patient; in subsequent steps, the Matcher 520 will calculate updated ImpactScores that are specific to the patient.
[0047] In step 630 , the Matcher 520 scales the ImpactScores of the behaviors contained in the ordered list based on the patient's current level of performance and the corresponding parameters. In this step, an upper bound for each parameter is defined as the recommended level, as determined by clinical guidelines, and assigned a numeric value of 100. (It will be apparent to those of skill in the art that the scaling value of 100 used here is only exemplary and that the following may be performed in the same manner with a different scaling value.) A lower bound for each parameter is defined as non-performance and assigned a numeric value of zero. The patient's current level of performance is then mapped to this 0-100 scale. This process is performed for each parameter. Considering physical activity as an example, if the recommended level of physical activity is five times per week, this is defined as the upper bound and assigned a numeric value of 100. Zero times per week is identified as the lower bound and assigned a numeric value of zero. If the data received from the Profiler 510 indicates that the patient performs physical activity once per week, this may be determined to have a numeric value of 20.
[0048] In step 635 , the Matcher 520 customizes the values of some or all of the parameters based on the patient profile received from the Profiler 510 . In particular, based on elements of the patient's self-care profile (e.g., as described in the self-assessment 40 ), certain types of behavior may be more or less effective. For example, physical activity can have many types, including walking on a treadmill at home, participating in a group exercise class, etc. A patient may choose one type of physical activity, and its associated value may be used in calculation of the ImpactScore for the physical activity. If each type of physical activity is effective as any other, then each may have the same numerical value. However, in some cases, one type of physical activity may be less effective than another due to the patient's self-care barriers; for example, a patient with a low level of social support or a low willingness to self-manage may be less effective at exercising at home than at exercising in a group exercise class where their exercise can be managed by an instructor and social support can be received from the instructor and classmates. Thus, in step 635 , the values of various types of physical activity (and other self-care behaviors) may be adjusted based on the patient's self-care profile.
[0049] FIG. 9 illustrates a table 900 showing the adjustment of the value of patient self-care behaviors based on the patient's self-management abilities. Self-care behavior 910 (in this example, walking on a treadmill at home) receives an adjustment 912 of −25% due to rationale 914 of the patient's low willingness to self-manage, resulting in an adjusted value 916 of 75. Similarly, self-care behavior 920 (in this example, following a fitness DVD at home) receives an adjustment 922 of −50% due to rationale 924 of the patient's low willingness to self-manage, resulting in adjusted value 926 of 50. Conversely, self-care behaviors 930 and 940 are not impacted by the patient's willingness to self-manage and, thus, are not adjusted due to this rationale, resulting in corresponding adjusted values 932 and 942 , respectively, of 100. It will be apparent to those of skill in the art that the specific parameters used in such a table 900 may vary for different patients, different conditions, etc., and that the specific illustration of table 900 shown in FIG. 9 is only exemplary.
[0050] In step 640 , the Matcher 520 calculates adjusted, patient-specific ImpactScores for activities present in the ordered list. These revised ImpactScores are calculated so as to match the configuration and parameters specified by the patient and the patient's self-care profile. To do this calculation, a scaling factor is used. This scaling factor is calculated as:
[0000] ScalingFactor bm =Σ(weight i ×parameter i )/100 ∀ i= 1, . . . , #parameters
[0051] The scaling factor is then used to calculate adjusted ImpactScores based on the following:
[0000] ImpactScore′ bm =ScalingFactor bm *ImpactScore bm
[0052] In the above formulas, ImpactScore bm refers to the effect that self-care behavior b, when optimally configured, has on medical condition m; ImpactScore′ bm refers to the updated effect that self-care behavior b, as configured by the patient, has on medical condition m; ScalingFactor bm refers to the multiplier that scales the ImpactScore up or down based on the current configuration of the behavior b; parameter i is the value of the ith parameter, on a range from zero to 100; and weight i is a weight, ranging from 0 to 1, associated with the ith parameter, where the sum of all weights weight i is equal to 1.
[0053] Based on this model, the modification of a parameter value (equivalent to performing the corresponding self-care behavior more or less frequently, intensely, completely, etc.) will change the updated value ImpactScore′ by an amount proportional to the weight of the parameter. Separating the parameters while maintaining their relationship to the overall updated value ImpactScore′ is useful for helping the patient explore the relationship between the manner in which they carry out a self-care behavior and the effect the behavior will have on their clinical outcomes.
[0054] FIG. 10 illustrates a table 1000 showing how an updated ImpactScore′ for a given self-care behavior is determined using patient-customized parameters. For self-care behavior 1010 (in this example, physical activity), the patient responds to parameters 1020 , 1030 and 1040 with parameter values 1022 , 1032 and 1042 (in this example, once a week, moderate intensity, and walking alone, respectively). The parameters 1020 , 1030 and 1040 have corresponding unadjusted values 1024 , 1034 and 1044 (in this example, 20, 100 and 100, respectively). Values 1024 and 1034 have unchanged adjusted values 1026 and 1036 (in this example, 20 and 100, respectively), but value 1044 has a changed adjusted value 1046 (in this example, 75), for the reasons discussed above with reference to FIG. 9 . The parameters 1020 , 1030 and 1040 also have corresponding parameter weights 1028 , 1038 and 1048 (in this example, 0.60, 0.30 and 0.10, respectively). An updated ImpactScore′ value 1050 is then calculated as described above and as illustrated in table 1000 . It will be apparent to those of skill in the art that the specific values shown in table 1000 are only exemplary and that these may vary among different implementations, for different patients, for different medical conditions, etc.
[0055] In step 645 , the Matcher 520 generates a patient-specific data model 540 for use by User Interface Application 550 . The data model 540 may include any data necessary for the User Interface Application 550 to receive, from a user (e.g., the patient) one or more changes to parameters of the patient's self-care behaviors, and calculate an updated version of the updated, patient-specific ImpactScore′ bm based on those changes using the formulas described above. The data model 540 may contain only data relevant to the patient's self-care profile, medical condition, and relevant self-care behaviors and their corresponding parameters, in order to be provided to the user for interactive use through User Interface Application 550 in a comparatively small data footprint (e.g., as compared to the Database 530 containing data for a wide variety of medical conditions and the Matcher 520 capable of processing a larger quantity of data) that may be appropriate for use on an end user device such as a tablet, mobile phone, personal computer, notebook computer, desktop computer, etc. Thus, the User Interface Application 550 may use the data model 540 to calculate an updated ImpactScore for the patient without communication with other elements of the system 500 , such as the Matcher 520 or Database 530 .
[0056] In step 650 , the User Interface Application 550 presents, to a user (e.g., the patient) a display showing the user's self-care activities and the corresponding parameters for the self-care activities in an interactive manner allowing the user to vary the parameters (e.g., using known interface elements such as dropdown menus, sliders, checkboxes, etc.). FIG. 11 illustrates an exemplary User Interface Application 550 . In FIG. 11 , the User Interface Application 550 provides a display 1100 on a tablet device 1105 , but other types of devices may execute the User Interface Application 550 and receive user input in a manner appropriate for the nature of the other devices. For example, for tablet device 1105 or a mobile phone, input may be received via a touchscreen; for a personal computer, input may be received with a mouse and/or keyboard; etc.
[0057] For the patient corresponding to the User Interface Application 550 as shown in FIG. 9 , the display 1100 includes three self-care behaviors 1110 , 1120 and 1130 . In the display 1100 shown in FIG. 9 , self-care behavior 1110 is physical activity, self-care behavior 1120 is taking medication, and self-care behavior 1130 is reducing smoking, but the specific self-care behaviors displayed by User Interface Application 550 may vary depending on the patient's medical condition. For each of the self-care behaviors 1110 , 1120 and 1130 , the display 1100 includes interface elements for corresponding parameters.
[0058] For self-care behavior 1110 , which is physical activity, the display 1100 includes a dropdown menu 1111 for the user to select a type of physical activity (e.g., walking outside, walking at the mall, group exercise class, etc.). The display 1100 also includes a slider 1112 for the user to select a frequency for performing the selected physical activity. The display 1100 also includes a slider 1113 for the user to select an intensity for the selected physical activity. The display 1100 also includes an ImpactScore 1114 describing the level of effectiveness of the physical activity based on the user inputs 1111 , 1112 and 1113 , which may be determined as described above. It will be apparent to those of skill in the art that the ImpactScore 1114 and the other ImpactScores discussed hereinafter may be patient-specific adjusted ImpactScores determined as discussed above.
[0059] For self-care behavior 1120 , which is taking medications, the display 1100 includes a slider 1121 for the user to select a number of episodes of missed medication per week. The display 1100 also includes checkboxes 1122 , 1123 , 1124 and 1125 for the user to select medications he/she is willing to take. The display 1100 also includes an ImpactScore 1126 describing the level of effectiveness of the user's medication based on the user inputs 1121 , 1122 , 1123 , 1124 and 1125 , which may be determined as described above.
[0060] For self-care behavior 1130 , which is reducing smoking, the display 1100 includes a slider 1131 for the user to select a number of cigarettes smoked. The display 1100 also includes a slider 1132 for the user to select a frequency time period during which the user will smoke the number of cigarettes indicated by the slider 1131 . The display 1100 also includes an ImpactScore 1133 describing the level of effectiveness of the user's smoking reduction based on the user inputs 1131 and 1132 , which may be determined as described above. In one exemplary embodiment, the ImpactScores 1114 , 1126 and 1133 may be color-coded to more clearly indicate the level of effectiveness of the corresponding self-care behaviors 1110 , 1120 and 1130 . For example, an ImpactScore of 0 to 35 may be colored red, an ImpactScore of 36 to 70 may be colored yellow, and an ImpactScore of 71 to 100 may be colored green.
[0061] In step 655 , the User Interface Application 550 waits for changed input parameters from the user. As described above, changed input parameters may mean adjusting a dropdown menu, a slider, a checkbox, etc. If changed input parameters are received by the User Interface Application 550 , then, in step 660 , the User Interface Application 550 calculates updated ImpactScore values (e.g., ImpactScores 1114 , 1126 and 1133 of FIG. 11 ) based on the newly-received parameters and the data model 540 . After this, the method 600 returns to step 650 , where the display 1100 is updated and the new results are displayed to the user. If no new parameters are received in step 655 , then the method 600 proceeds to step 665 , where the results currently displayed may be considered to be final results for the user's selected parameters. Following step 665 , the method 600 terminates.
[0062] The exemplary embodiments of FIGS. 5-11 may provide users with the ability to visualize and dynamically modify parameters of their self-care behaviors, in order to understand the way those behaviors affect their clinical outcomes. This may be useful for patients across a wide spectrum of needs. In chronic disease management, where the trajectory of diseases is well established and the effects of self-care behaviors have been well-studied, this may be particularly useful. However, the same technique and interface may be equally applicable for choosing any health-related behavior. Some examples of this may include selection of exercise routines for general fitness purposes, selection of nutrition plans for dieting, selection of different medications, etc.
[0063] Those of skill in the art will understand that the above-described exemplary embodiments may be implemented in any number of manners, including as a software module, as a combination of hardware and software, etc. For example, the exemplary methods 200 and 600 may be embodied in a program stored in a non-transitory storage medium and containing lines of code that, when compiled, may be executed by a processor.
[0064] It will be apparent to those skilled in the art that various modifications may be made to the exemplary embodiments, without departing from the spirit or the scope of the invention. Thus, it is intended that the present invention cover modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A non-transitory computer-readable storage medium storing a set of instructions executable by a processor, the set of instructions, when executed by the processor, causing the processor to perform operations including receiving a self-care assessment from a patient having a medical condition. The self-care assessment assesses the patient's level of ability for each of a plurality of determinants. The operations also include assigning a weight to each of the plurality of determinants. The operations also include creating an ordered list including the plurality of determinants. The determinants are ordered based on the corresponding weights. The operations also include determining a plurality of behavior-specific contributions. Each of the behavior-specific contributions corresponds to one of the determinants and to one of a plurality of self-care behaviors relevant to the medical condition. | 6 |
FIELD OF INVENTION
[0001] The present invention describes certain salts of Clopidogrel including their hydrates and other solvates, both in amorphous and crystalline forms, processes for their preparation and pharmaceutical compositions containing them and their use in medicine. Clopidogrel is marketed as (S)-(+)-Clopidogrel bisulfate, useful as an antiplatelet drug for the treatment of atherosclerosis, myocardial infarction, strokes and vascular death. The present invention also describes method of treatment of such cardiovascular disorders using the salts of the present invention or mixtures thereof, and pharmaceutical compositions containing them. The present invention also relates to the use of the salts of Clopidogrel disclosed herein and pharmaceutical compositions containing them for the treatment of cardiovascular disorders.
BACKGROUND TO THE INVENTION
[0002] The compounds of the invention referred herein, are pharmaceutically acceptable salts of the compound known by its generic name Clopidogrel having structure (I)
[0000]
[0003] It is available in the market as its bisulfate salt and is marketed by Sanofi-Synthelabo as “Plavix” having the general formula (II)
[0000]
[0004] Clopidogrel is an inhibitor of platelet aggregation and is marketed as an antianginal agent, antiplatelet agent and is found to decrease morbid events in people with established atherosclerotic cardiovascular disease and cerebrovascular diseases.
[0005] The therapeutic application of Clopidogrel as blood-platelet aggregation inhibiting agents and antithrombotic agent and its preparation is disclosed in U.S. Pat. No. 4,529,596. U.S. Pat. No. 4,847,265 describes the process for the preparation of the hydrogen sulfate salt of Clopidogrel.
[0006] Polymorphs of Clopidogrel bisulfate has been described in U.S. Pat. Nos. 6,504,040 and 6,429,210. We have disclosed novel polymorphs of Clopidogrel bisulfate in our PCT International Application No. PCT/IN03/00053.
[0007] The present applicant has also disclosed novel processes for preparing Clopidogrel base in U.S. Pat. No. 6,635,763.
[0008] U.S. Pat. No. 4,847,265 discloses that the dextrorotatory enantiomer of formula (I) of Clopidogrel has an excellent antiagregant platelet activity, whereas the corresponding levorotatory enantiomer of Formula (I) is less tolerated of the two enantiomers and is less active. U.S. Pat. No. 4,847,265 also describes various other salts of the compound of formula (I), like its hydrochloride, carboxylic acid and sulfonic acids salts. Specifically, salts of acetic, benzoic, fumaric, maleic, citric, tartaric, gentisic, methanesulfonic, ethanesulfonic, benzenesulfonic and, lauryl sulfonic acids were prepared. However, according to this patent, these salts usually precipitated in amorphous form and/or they were hygroscopic making them difficult to handle in an industrial scale. Also, no data corresponding to any of these salts are reported. The specification also describes salts of dobesilic acid (m.p.=70° C.) and para-toluenesulfonic acid, having a melting point of 51° C., the purification of which, as accepted in the patent, proved to be difficult.
[0009] Thus, there remains a need to prepare salts of Clopidogrel which are stable, easy to handle, can be purified and can be exploited on an industrial scale.
[0010] We hereby disclose certain pharmaceutically acceptable salts of Clopidogrel particularly the salts of p-toluenesulfonic acid, benzenesulfonic acid and methanesulfonic acids both in crystalline and amorphous forms, including their hydrates and other solvates which are well characterized, free flowing, easy to handle and having high purity.
OBJECTS OF THE INVENTION
[0011] It is therefore, an object of the present invention to prepare new pharmaceutically acceptable salts of Clopidogrel. More particularly, the present invention aims to provide new forms of Clopidogrel p-toluenesulfonate, Clopidogrel benzenesulfonate and Clopidogrel methanesulfonate, including their hydrates and other solvates in both crystalline and amorphous forms.
[0012] Another object of the present invention is to provide processes for preparing the new salts described herein.
[0013] A further object of the present invention is to provide the salts in pure, easy to handle, free flowing and stable form.
[0014] A further object is to provide a process of preparation of the pharmaceutically acceptable salts of the present invention on an industrial scale.
[0015] It is also an object of the present invention to provide for pharmaceutical compositions of the pharmaceutically acceptable salts of Clopidogrel of the present invention, as described herein.
[0016] Another object is to provide a method of treatment of cardiovascular disorders, comprising administering, for example, orally a composition containing the pharmaceutically acceptable salts of the present invention in a therapeutically effective amount.
SUMMARY OF THE INVENTION
[0017] The present invention describes certain pharmaceutically acceptable salts of Clopidogrel including their hydrates and other solvates, both in crystalline and amorphous forms, process for their preparation and pharmaceutical compositions containing them and their use in medicine. More particularly, the present invention describes new forms of Clopidogrel p-toluenesulfonate (or Clopidogrel tosylate), Clopidogrel benzenesulfonate (or Clopidogrel besylate) and Clopidogrel methanesulfonate (or Clopidogrel mesylate). Also described are processes for their preparation and pharmaceutical compositions containing the same and their use in medicine.
DESCRIPTION OF FIGURES
[0018] FIG. 1 : XRD of amorphous Clopidogrel besylate
[0019] FIG. 2 : XRD of crystalline Clopidogrel besylate
[0020] FIG. 3 : DSC of crystalline Clopidogrel besylate
[0021] FIG. 4 : XRD of amorphous Clopidogrel mesylate
[0022] FIG. 5 : XRD of amorphous Clopidogrel tosylate
DETAILED DESCRIPTION
[0023] The present invention provides certain pharmaceutically acceptable salts of Clopidogrel having the general formula (III) given below:
[0000]
[0000] wherein R represents 4-methylphenyl, phenyl or a methyl group.
[0024] More particularly, the present invention describes stable forms of Clopidogrel p-toluenesulfonate, Clopidogrel benzenesulfonate and Clopidogrel methanesulfonate. These salts in their hydrated or other solvated forms is also encompassed within the present invention. The salts may be present either in crystalline or amorphous form. The salts may be prepared by reacting Clopidogrel base with the corresponding acids (p-toluenesulfonic acid, benzenesulfonic acid and methanesulfonic acid respectively) in a suitable solvent, at a temperature ranging from −30° C. to 50° C., and subsequently, removing the solvent. The suitable solvents can be water, methanol, ethanol, acetone, propanol, n-butanol, n-pentanol, n-hexanol, n-heptanol, dichloromethane, dimethyl formamide, dimethyl acetamide, 1,4-dioxane, tetrahydrofuran, ether, hexane, heptane, acetonitrile or mixtures thereof. The removal of the solvent can be done preferably at reduced pressure.
[0025] In a preferred embodiment, the Clopidogrel base may be prepared according to the processes disclosed in U.S. Pat. No. 6,635,763.
[0026] The salts may exist in a solvent-free form or it may be isolated as a hydrate or a solvate. The hydrates and solvates of the salts of the present invention form another aspect of the invention.
[0027] The salts can be characterized by suitable techniques known in the art.
[0028] The amorphous Clopidogrel p-toluene sulfonate (Clopidogrel tosylate) has a melting point in between the range of 70-95° C.
[0029] The amorphous Clopidogrel benzene sulfonate (Clopidogrel besylate) of the present invention has a melting point in between the range of 85° C.-95° C.
[0030] The crystalline Clopidogrel benzene sulfonate (Clopidogrel besylate) of the present invention has a melting point in between the range of 124° C.-132° C.
[0031] The amorphous Clopidogrel methane sulfonate (Clopidogrel mesylate) has a melting point of in between the range of 60° C.-70° C.
[0032] The following non-limiting examples illustrate the inventor's preferred methods for preparing the different salts of S(+) Clopidogrel discussed in the invention and should not be construed to limit the scope of the invention in any way.
Example 1
Preparation of Clopidogrel Tosylate Amorphous Form
[0033] Clopidogrel base was dissolved in acetone to obtain a clear solution. To it was added p-toluene sulfonic acid at room temperature. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain amorphous Clopidogrel tosylate.
[0034] m.p.: 75-93° C. (soften)
[0035] XRD: Amorphous
[0036] DSC: No melting peak
[0037] % water: 0.5-4% by weight (obtained in different batches).
Example 2
Preparation of Clopidogrel Tosylate Amorphous Form
[0038] Clopidogrel base was dissolved in methanol to obtain a clear solution. To it was added p-toluenesulfonic acid at 20° C. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain a powder.
[0039] m.p: 73-93° C. (soften)
[0040] XRD: Amorphous
[0041] DSC: No melting peak
[0042] % water: 0.5-4% by weight (obtained in different batches).
[0043] Similarly, the same salt was prepared using THF, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Example 3
Preparation of Clopidogrel Tosylate Amorphous Form
[0044] Clopidogrel base was dissolved in methanol. p-Toluene sulphonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 hrs. The solution was cooled to room temperature and was added drop-wise to diethyl ether. The suspension was stirred at RT. The solid was filtered and dried at about 50° C. in a vacuum oven to give Clopidogrel tosylate similar to that obtained above.
[0045] Similarly, same salt was prepared using acetone, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Example 4
Preparation of Clopidogrel Tosylate Amorphous Form
[0046] Clopidogrel base was dissolved in methanol, p-Toluene sulphonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 hrs. The solution was cooled to room temperature and the methanolic solution was added dropwise to hot toluene. The resulting solution was refluxed for an additional 20 minutes. The solution was cooled to room temperature and was stirred for 24 hrs. The solvent was evaporated under reduced pressure to dryness to obtain Clopidogrel tosylate, similar to that obtained above.
[0047] Similarly, the same salt was prepared using acetone, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Experiment 5
Preparation of Clopidogrel Besylate Amorphous Form
[0048] Clopidogrel base was dissolved in acetone to obtain a clear solution. Then benzenesulfonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain the title salt as a powder.
[0049] m.p: 86-95° C. (soften)
[0050] XRD: Amorphous
[0051] DSC: No melting peaks
[0052] % water: 0.5-4% by weight, (obtained in different batches).
Example 6
Preparation of Clopidogrel Besylate Amorphous Form
[0053] Clopidogrel base was dissolved in methanol to obtain a clear solution. Benzenesulfonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain the title compound.
[0054] m.p.: 84-93° C. (soften)
[0055] XRD: Amorphous
[0056] DSC: No melting peak
[0057] % water: 0.5-4% by weight (obtained in different batches).
[0058] Similarly, the same salt was prepared in THF, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Example 7
Preparation of Clopidogrel Besylate Amorphous Form
[0059] Clopidogrel base was dissolved in methanol. Benzene sulphonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 hrs. The solution was cooled to room temperature and was added drop-wise to diethyl ether. The suspension was stirred at RT. The solid was filtered and dried in a vacuum oven to give Clopidogrel besylate, similar to that obtained above.
[0060] Similarly, the same salt was prepared using acetone, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Example 8
Preparation of Clopidogrel Besylate Amorphous Form
[0061] Clopidogrel base was dissolved in methanol. Benzene sulphonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 hrs. The solution was cooled to room temperature and the methanolic solution was added drop-wise to the boiling toluene. The resulting solution was refluxed for an additional 20 minutes. The solution was cooled to room temperature and was stirred at this temperature for extended hours. The solvent was evaporated under reduced pressure to dryness to obtain Clopidogrel besylate, similar to that obtained above.
[0062] Similarly, the same salt was prepared using acetone, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
Example 9
Preparation of Clopidogrel Besylate Crystalline Form
[0063] Clopidogrel besylate amorphous was stirred in diethyl ether at 20° C. The obtained white solid was collected by filtration, washed with diethyl ether and dried, in a vacuum oven to obtain Clopidogrel besylate in crystalline form.
[0064] m.p.: 126-130° C. (range obtained from different batches).
[0065] XRD: Crystalline
[0066] DSC: 127.5-132.9° C.
[0067] % water: 0.1-0.3% by weight (range obtained from different batches).
[0068] The above process for preparing clopidogrel besylate crystalline form, is carried out using different ethers wherein each alkyl radical of the ether is independently selected from the group consisting of methyl, ethyl, propyl, isopropyl, butyl, 1-butyl, 2-butyl and t-butyl or mixtures thereof.
Example 10
Preparation of Clopidogrel Besylate Crystalline Form
[0069] Clopidogrel besylate amorphous was stirred in n-heptane at 20° C. The obtained white solid was collected by filtration, washed with n-heptane, and dried in a vacuum oven to obtain clopidogrel besylate in crystalline form.
[0070] m.p: 125-130° C. (range obtained from different batches).
[0071] XRD: Crystalline
[0072] DSC: 125.5-130.9° C.
[0073] % water: 0.1-0.3% by weight (range obtained from different batches).
[0074] Similarly, Clopidogrel besylate crystalline form was prepared in hexane, n-heptane, cyclohexane, petroleum ether as solvents as well as their mixtures.
Example 11
Preparation of Clopidogrel Besylate Crystalline Form
[0075] Clopidogrel base was dissolved in diethyl ether at 20-25° C. To this was added benzene sulphonic acid dissolved in diethyl ether. The reaction mixture was stirred at 25-30° C. for 24-30 hrs. The white solid was collected by filtration, washed with diethyl ether, and dried at 50-60° C. in a vacuum oven to obtain Clopidogrel besylate crystalline form.
[0076] m.p.: 124-130° C. (range obtained from different batches).
[0077] XRD: Crystalline
[0078] DSC: 128.9-132.7° C.
[0079] % water: 0.2%
[0080] The above process for preparing clopidogrel besylate crystalline form, is carried out using different ethers wherein each alkyl radical, of the ether is independently selected from the group consisting of methyl, ethyl, propyl, isopropyl, butyl, 1-butyl, 2-butyl and t-butyl or mixtures thereof.
Example 12
Preparation of Clopidogrel Mesylate Amorphous Form
[0081] Clopidogrel base was dissolved in acetone to obtain a clear solution. Methanesulfonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain the title compound.
[0082] m.p: 60-70° C. (soften)
[0083] XRD: Amorphous
[0084] DSC: No melting peak
[0085] % water: 0.5-4% by weight (obtained from different batches).
Example 13
Preparation of Clopidogrel Mesylate Amorphous Form
[0086] Clopidogrel base was dissolved in methanol to obtain a clear solution. Methanesulfonic acid was added to the solution at 20° C. The reaction mixture was heated to reflux temperature for 2 to 10 hrs. The solvent was evaporated to dryness under reduced pressure to obtain the title compound.
[0087] m.p: 60-70° C. (soften)
[0088] XRD: Amorphous
[0089] DSC: No melting peak
[0090] % water: 0.5-4% by weight. (obtained from different batches).
[0091] Similarly, the same salt was prepared in THF, acetonitrile and other similar solvents either alone or as a mixture of two or more solvents described elsewhere in the specification.
[0092] All these salts are free flowing, easy to handle and can be manufactured in large scale as well as can be used in the preparation of suitable pharmaceutical compounds or dosage forms. The salts of the present invention may also exist as different solvates corresponding to the different solvents used in their preparation. Such obvious solvates are also intended to be encompassed within the scope of the present invention.
[0093] The salts of Clopidogrel drug substance of the present invention prepared according to any process described above or any other process can be administered to a person in need of it either without further formulation, or formulated into suitable formulations and dosage forms as are well known.
[0094] In another embodiment of the present invention a method of treatment and use of the pharmaceutically acceptable salts of Clopidogrel described in the present invention for the treatment of cardiovascular disorders & inhibiting platelet aggregation is provided, comprising administering, for example, orally or in any other suitable dosage forms, a composition containing the new salts of the present invention in a therapeutically effective amount. | Disclosed are new salts of Clopidogrel viz. Clopidogrel mesylate, Clopidogrel besylate and Clopidogrel tosylate, methods for their preparation and pharmaceutical compositions containing them and their use in medicine. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of U.S. patent application Ser. No. 09/843,053, filed on Apr. 26, 2001, now U.S. Pat. No. 6,535,374, which is a division of U.S. patent application Ser. No. 09/165,848, filed on Oct. 2, 1998, now issued as U.S. Pat. No. 6,275,729, the specifications of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention concerns electrolytic capacitors, particularly those for use in medical devices, such as implantable defibrillators.
Every year more than half a million people in the United States suffer from heart attacks, more precisely cardiac arrests. Many of these cardiac arrests stem from the heart chaotically twitching, or fibrillating, and thus failing to rhythmically expand and contract as necessary to pump blood. Fibrillation can cause complete loss of cardiac function and death within minutes. To restore normal heart contraction and expansion, paramedics and other medical workers use a device, called a defibrillator, to electrically shock a fibrillating heart.
Since the early 1980s, thousands of patients prone to fibrillation episodes have had miniature defibrillators implanted in their bodies, typically in the left breast region above the heart. These implantable defibrillators detect onset of fibrillation and automatically shock the heart, restoring normal heart function without human intervention. A typical implantable defibrillator includes a set of electrical leads, which extend from a sealed housing into the heart of a patient after implantation. Within the housing are a battery for supplying power, heart-monitoring circuitry for detecting fibrillation, and a capacitor for storing and delivering a burst of electric charge through the leads to the heart.
The capacitor is typically an aluminum electrolytic capacitor, which includes two long strips of aluminum foil with two long strips of paper, known as separators, in between them. One of the aluminum foils serves as a cathode (negative) foil, and the other serves as an anode (positive) foil. Each foil has an aluminum tab, extending from its top edge, to facilitate electrical connection to other parts of the capacitor.
The foil-and-paper assembly, known as the active element, is rolled around a removable spindle or mandrel to form a cylinder and placed in a round tubular case, with the two tabs extending toward the top of the case. The paper is soaked, or impregnated, with a liquid electrolyte—a very electrically conductive solution containing positive or negative ions. And, the tubular case is sealed shut with a lid called a header. Extending from the header are two terminals connected respectively to the anode foil and cathode foil via the aluminum tabs.
In recent years, manufacturers of aluminum electrolytic capacitors have focused almost single-mindedly on improving the active element by developing aluminum foils, electrolytes, and multiple-anode arrangements that improve capacitor performance, specifically energy density—the amount of energy or charge a capacitor stores per unit volume. For example, because energy density is directly proportional to the surface area of the aluminum foil making up the capacitive element, manufacturers have focused on methods of etching microscopic hills and valleys into foils to increase their effective surface area.
In comparison, capacitor manufacturers have made little, if any, effort to improve packaging of the active element. For example, three leading manufactures of electrolytic capacitors—Rubycon, United Chemicon, and Roederstein—presently provide 330-360 volt, dual-anode aluminum electrolytic capacitors which have total volumes greater than about 6.5 cubic-centimeters (which is roughly the same size as a AA battery.) Yet, when the present inventors studied how this space was used, they determined that the ratio of the volume of the active element to the overall volume of these capacitors was only about 40 percent. Thus, the inventors concluded that about 60 percent of the total capacitor volume was wasted in the sense of failing to directly contribute to the performance of these electrolytic capacitors.
Accordingly, the inventors identified an unmet need to reduce the size of electrolytic capacitors, especially those intended for implantable defibrillators, through better packaging.
SUMMARY OF THE INVENTION
To address this and other needs, the inventors devised several improvements intended to reduce the overall size of electrolytic capacitors, particularly those intended for implantable defibrillators. With these improvements, the inventors built an exemplary 360-volt operating, 390-volt surge, 190-microfarad, 15.9-Joule aluminum electrolytic capacitor about 33 percent smaller than conventional capacitors with comparable electrical traits.
One improvement contributing to this size reduction is the use of one or more separators having a thickness less than the standard one-thousandth of an inch used in conventional electrolytic capacitors. The exemplary embodiment uses combinations of paper separators with thicknesses of 0.000787, 0.0005, and 0.00025 inches. For conventional cylindrically wound active elements, reducing separator thickness reduces the space necessary to contain the separators. In turn, this allows one to reduce the diameter and volume of the active element and thus the total volume of the capacitor, or alternatively to increase the size of other components of the active element to increase energy density for a given total volume.
In devising this improvement, the inventors recognized that the conventional practice of using thick paper separators stems from at least three design objectives that are of lesser relevance to implantable defibrillators. The first is that thicker paper reduces electrolyte depletion, or evaporation, and thus generally increases capacitor life. However, the inventors determined that electrolyte depletion has much less effect on capacitor life in medical device applications than it does in the typical applications that govern how conventional electrolytic capacitors are built. In particular, implanted defibrillators are generally not subject to the same long-term temperature variations and extremes that conventional capacitors are designed to withstand.
Secondly, conventional manufacturers used the standard thick paper because it is less likely to tear or break during fabrication, particularly during the conventional high-speed process of winding the foil-and-paper assembly around a spindle. Thus, using the thick paper allows conventional manufacturers to make capacitors faster. However, manufacturing speed is not very important to defibrillator makers who need to make many fewer capacitors than conventional manufacturers and thus can generally afford more time making them.
Thirdly, conventional manufacturers use the thick papers to reduce the chance of anode and cathode foils contacting each other and therefore causing capacitor failure during functional testing. Since failed capacitors are generally discarded or recycled, using thick papers ultimately reduces manufacturing waste. However, waste is of less concern when making a small number of capacitors for implantable defibrillators than it is when making millions of capacitors as do most conventional manufacturers.
Another improvement contributing to the 33-percent size reduction is the use of separators with end margins less than two millimeters. The end margins are the portions of the separators which extend beyond the width of the cathode and anode foils. Conventional paper separators are about four-to-six millimeters wider than the aluminum foils of the active element, with the excess width typically divided to form equal top and bottom margins of two-to-three millimeters. Thus, when wound into a roll and stood up on one end, the top and bottom margins increase the overall height of the active element and the overall height of the case needed to contain the active element.
Conventional manufacturers use the large end margins for at least two reasons: to protect the foils from damage during high-speed manufacturing processes, and to insulate the foils of the active element from an aluminum case after insertion into the case. In particular, during high-speed winding, the foil and paper can easily become misaligned or skewed so that the edges of the foil extend beyond the edges of the papers, making them prone to bending, creasing, or tearing. The large, conventional end margins allow room for misalignment while also protecting the foil edges during high-speed winding. After insertion into a tubular case, the end margins separate the edges of the rolled foil from the top and bottom of the case, preventing the electrically conductive case from shorting the anode and cathode foils.
In devising this improvement, the inventors determined that the end margins could be greatly reduced, even eliminated completely in some embodiments, by more carefully winding the foils and separators during manufacture. Additionally, the inventors devised other ways of insulating foils from cases, while reducing capacitor size.
Specifically, the exemplary embodiment of the invention, which has little or no end margins, includes insulative inserts, for example, flat paper disks, between the bottom of the active element and the bottom of the case and between the top of the active element and the underside of a lid on the case. Other embodiments enclose substantially all of the active element within an insulative bag.
Other improvements include reducing the thickness of the capacitor lid, or header, by about 50 percent, reducing the space between the underside of the lid and the top of the active element, reducing the diameter of the normally empty mandrel region of the active element, and reducing thickness of the aluminum tube. Like the use of thinner separators, smaller end margins, and insulative inserts, these ultimately allow reductions in the size of electrolytic capacitors and implantable defibrillators which incorporate them.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary aluminum electrolytic capacitor 10 incorporating various space-saving features to achieve a 33-percent size reduction over conventional electrolytic capacitors;
FIG. 2 is a cross-sectional view of electrolytic capacitor 10 taken along line 2 — 2 of FIG. 1 ;
FIG. 3 is a cross-sectional view of a layered capacitive assembly 21 used to form active element 20 of FIG. 2 ;
FIG. 4 is a perspective view of a unique foil structure 33 included within some alternative embodiments of capacitive assembly 21 ;
FIG. 5 is a partial cross-sectional view of an insulative bag 40 enclosing active element 20 in an alternative embodiment of capacitor 10 ; and
FIG. 6 is a block diagram of generic implantable defibrillator 50 including a capacitor that has one or more of the novel features of capacitor 10 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description, which references and incorporates FIGS. 1-6 , describes and illustrates one or more specific embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach, are shown and described in sufficient detail to enable those skilled in the art to implement or practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
FIG. 1 shows a perspective view of an exemplary 360-volt operating, 390-volt surge, 190-microfarad, 15.9-Joule (stored) electrolytic capacitor 10 which incorporates various space-saving features of the present invention. Capacitor 10 has a diameter 10 d of about 14.5 millimeters and a total height 10 h of about 30 millimeters, and a total volume of about five cubic-centimeters. Thus, capacitor 10 has an energy density of about 3.2 Joules per cubic-centimeter.
In contrast, conventional electrolytic capacitors with comparable electrical characteristics and of about the same diameter have heights greater than or equal to about 40 millimeters and total volumes greater than or equal to about 6.6 cubic-centimeters, with energy densities around 2.4 Joules per cubic-centimeter. Thus, the exemplary capacitor is about 33 percent smaller than conventional capacitors with similar electrical traits.
More specifically, capacitor 10 includes a cylindrical aluminum case 12 , a header (or lid) 14 , and two aluminum terminals 16 and 18 . Two rivets 15 and 17 fasten terminals 16 and 18 to header 14 . Aluminum case 12 , which houses an active element 20 (not visible in this view), includes a circumferential seating groove 12 a and a rolled lip 12 b , both of which secure header 14 to case 12 .
FIG. 2 , a cross-section taken along line 2 — 2 in FIG. 1 , shows that case 12 has a thickness 12 t and that groove 12 a is spaced a distance 12 d from lip 12 b . In the exemplary embodiment, thickness 12 t is about 0.010 inches, and distance 12 d is about 0.145 inches. Additionally, groove 12 a has a radius of about 0.035 inches, and lip 12 b , which is formed by rolling over the top edge of case 12 , has a radius of about 0.015 inches. Groove 12 a and lip 12 b each have a smaller radius than the corresponding features of conventional capacitors. In another embodiment, case 12 is vertically compressed to completely flatten or reduce the height of groove 12 a and thus to further reduce the height and volume of capacitor 10 .
FIG. 2 also shows that header 14 comprises two bonded layers 14 a and 14 b and has a total thickness 14 t . Layer 14 a consists of rubber, and layer 14 b consists of a phenolic resin. Although thickness 14 t is about two millimeter in the exemplary embodiment, it ranges inclusively between 0.5 to 2 millimeters in other embodiments. In contrast, conventional aluminum electrolytic capacitors use headers that are about three to four millimeters thick.
FIG. 2 also shows that capacitor 10 includes an active element 20 comprising about 19 turns of a layered capacitive assembly 21 around mandrel region 28 and two pairs of insulative inserts 30 a - 30 b and 32 a - 32 b separating the top and bottom of active element 20 from interior surfaces of case 12 . For clarity, FIG. 2 omits a plastic insulative sheath that surrounds the vertical surfaces of active element 20 . In the exemplary embodiment, this sheath is a piece of transparent tape having a width of 1.125 inches (or 28.6 millimeters).
FIG. 3 , a cross sectional view of layered capacitive assembly 21 , shows that it includes a cathode 22 , a three-foil anode 24 , and four electrolyte-impregnated separators 26 a , 26 b , 26 c , and 26 d . Cathode 22 and anode 24 each have a width (or height) 22 w , which partly determines a minimum height of case 12 . Though not shown in FIG. 3 for clarity, cathode 22 and anode 24 also include insulative or dielectric coatings, for example aluminum or tantalum oxide, on at least their facing surfaces. In this exemplary embodiment, cathode 22 and three constituent foils 24 a , 24 b , and 24 c of anode 24 are about 24 millimeters wide and 100 micrometers thick. Cathode 22 is about 422 millimeters long and anode 24 is about 410 millimeters long.
Although not shown in FIG. 3 , anode foils 24 a , 24 b , and 24 c are connected to a single aluminum anode tab 25 (which is shown in FIG. 2 ). Alternatively, individual anode tabs can be connected to each anode members, and to each other to form a joint or composite anode tab. For more details on these or other types of tabs incorporated in other embodiments of the invention, see U.S. Pat. Nos. 6,249,423 and 6,110,233, which are respectively entitled Electrolytic Capacitor and Multi-Anodic Attachment and Wound Multi-Anode Electrolytic Capacitor with Offset Anodes and which are incorporated herein by reference.
Anode tab 25 , shown in FIG. 2 , is ultrasonically welded to rivet 15 and thus electrically connected to terminal 16 . In this embodiment, anode tab 25 is folded over itself; however, other embodiments omit this fold to reduce the space between header 14 and the top of active element 20 . Though not visible in FIG. 2 or FIG. 3 , cathode 22 includes a cathode tab which is similarly connected via rivet 17 to terminal 18 .
Cathode 22 and anode foils 24 a , 24 b , and 24 c are made of an electrically conductive material, such as aluminum or tantalum foil, with the anode etched to enhance its effective surface area. Examples of suitable etched foil structures include conventional core-etched and tunnel-etched foils, and a novel perforated-core-etched foil as well as various combinations of these foils. For instance, one embodiment forms anode 24 by stacking a core-etched or tunnel-etched foil with two perforated-core-etched foils. FIG. 4 shows an example of a perforated-core-etched foil 33 .
Foil 33 includes two opposing surfaces 33 a and 33 b that define an average foil thickness 33 t and a number of perforations, or holes, 33 p that extend all the way through the foil. Surfaces 33 a and 33 b include respective sets of surface cavities 34 a and 34 b , which have respective average maximum depths Da and Db and respective average cross-sectional areas Sa and Sb (measured in a plane generally parallel to the foil). In the exemplary embodiment, the perforations, which are formed using laser, etch, or mechanical means, have an average cross-sectional area that is 2-100 times larger than the average cross-sectional areas of the cavities. Depths Da and depths Db are approximately equal to one third or one quarter of thickness 33 t , and cross-sectional areas Sa and Sb are equal and range inclusively between about 0.16 and 0.36 square-microns. The layout or arrangement of perforations can take any number of forms, including, for example, a random distribution or a specific pattern with each perforation having a predetermined position relative to other perforations. Perforations 33 p , which can be any shape, for example, circular, have a cross-sectional area ranging between approximately 500 square-microns and 32 square-millimeters in the exemplary embodiment. Additionally, the exemplary embodiment limits the total surface area of perforations 10 p to about 20 percent of the total area of foil 33 .
The perforated-coil-etched foil can be made either by perforating a conventional core-etched foil or core-etching a perforated foil. Further details of the perforated core-etched foil are disclosed in co-pending U.S. patent application Ser. No. 09/165,779, filed on Oct. 2, 1998, entitled High-Energy Density Capacitors for Implantable Defibrillators. This application was filed on the same day as the present application and is incorporated herein by reference.
In addition to cathode 22 and three-part anode 24 , FIG. 3 shows that capacitive assembly 21 includes thin electrolyte-impregnated separators 26 , specifically 26 a , 26 b , 26 c , and 26 d . Separators 26 a , 26 b , 26 c , and 26 d , each of which consists of kraft paper impregnated with an electrolyte, such as an ethylene-glycol base combined with polyphosphates or ammonium pentaborate, distinguish in at least two ways from separators used in conventional electrolytic capacitors.
First, in contrast to conventional separators which are one-thousandth of an inch or more in thickness to improve fabrication yield and reduce electrolyte depletion, separators 26 a - 26 d are each less than one-thousandth of an inch in thickness. In the exemplary embodiment, each of the separators has one of the following thicknesses: 0.000787, 0.0005 inches, and 0.00025 inches, with thicker papers preferably placed nearer the center of the active element to withstand the greater tensile stress that interior separators experience during winding.
However, various other embodiments of the invention use combinations of these thicknesses, combinations of these thickness with other thicknesses, and combinations of other thicknesses. Additionally, other embodiments of invention combine one or more thin separators with one or more conventional separators. Ultimately, the use of one or more thinner separators reduces the diameter of the active element for a given length of separator (assuming all other factors are equal).
Second, in contrast to conventional separators which are about four to six millimeters wider than the anode and cathode foils to provide large two to three millimeter end margins, separators 26 have a width 26 w which is less than four millimeters wider than cathode 22 and anode 24 to provide smaller end margins 27 a and 27 b . For example, in the exemplary embodiment, width 26 w is about 27 millimeters, or three millimeters wider than cathode 22 and anode 24 , to provide end margins 27 a and 27 b of about 1.5 millimeters. Other embodiments of the invention provide at least one end margins of about 1.75, 1.25, 1, 0.75, 0.5, 0.25, and even 0.0 millimeters.
The large end margins of conventional separators are necessary to prevent damage to foil areas during high-speed fabrication and to insulate the cathode and anode foils from case 12 . However, the inventors recognized that they are not necessary in all applications, particularly defibrillator applications, where high-speed fabrication is of little concern or where the inventors have devised other ways of insulating the foils from the top and bottom of aluminum case 12 .
In particular, FIG. 2 shows that the exemplary embodiment provides two pairs of insulative inserts 30 a - 30 b and 32 a - 32 b , which prevent other conductive portions of capacitor 10 , specifically anode tab 25 and rivets 15 and 17 and the interior surface of case 12 , from shorting cathode 22 and anode 24 . In the exemplary embodiment, these inserts are two pairs of paper disks, with each disk having a thickness of one one-thousandth of an inch and a diameter of about 14 millimeters. However, other embodiments of the invention use not only thinner or thicker inserts, but also different insert materials and numbers of inserts. For example, in one alternative embodiment, one or both pairs of inserts 30 a - 30 b and 32 a - 32 b consist of a polymeric insulator, and in another embodiment, inserts 30 a and 30 b consist of different material combinations, such as paper and a polymeric insulator.
As an alternative to insulative inserts, other embodiments enclose substantially all of active element 20 within an insulative bag. FIG. 5 shows an exemplary embodiment of an insulative bag 40 enclosing substantially all of active element 20 , with the exception of the anode and cathode tabs. In this embodiment, bag 40 comprise materials similar to the insulative inserts.
FIG. 2 also shows that capacitive assembly 21 of active element 20 is wound around a mandrel (not shown), which has been removed after winding to leave an empty mandrel region or cavity 28 . In this exemplary embodiment, mandrel region 28 has a width or diameter of about 2.5 millimeters, or more generally less than about 3.5 millimeters. In contrast to conventional electrolytic capacitors which have mandrels or mandrel regions with 3.5-millimeter diameters, the smaller mandrels of the present invention allow use of about 2-5 percent more aluminum foil without increasing the total volume of the capacitor. Another embodiment of the invention uses about the same amount of foil as conventional capacitors with the smaller mandrel region, thereby reducing the diameter of the active element without reducing energy density.
Mandrels with diameters less than 3.5 millimeters are not used in manufacturing conventional electrolytic capacitors primarily because they increase the difficulty in rolling the cathodes, anodes, and separators around them. Indeed, a smaller-diameter mandrel increases the tensile stress on the cathode, anode, and separators, leading them to break or tear during high-speed winding and thus to increase manufacturing waste. In addition, the smaller diameter mandrels tend to break and require replacement more often than larger mandrels. Thus, conventional capacitor manufactures avoid smaller mandrels to increase manufacturing yield and to accelerate manufacturing. However, these conventional objectives are of lesser importance when making small numbers of capacitors for implantable medical devices, specifically defibrillators.
Exemplary Embodiment of Implantable Defibrillator
FIG. 6 shows one of the many applications for space-saving electrolytic capacitor 10 : a generic implantable defibrillator 50 . More specifically, defibrillator 50 includes a lead system 52 , which after implantation electrically contacts strategic portions of a patient's heart, a monitoring circuit 54 for monitoring heart activity through one or more of the leads of lead system 52 , and a therapy circuit 56 which delivers electrical energy through lead system 52 to the patient's heart. Therapy circuit 56 includes an energy storage component 56 a which incorporates at least one capacitor having one or more of the novel features of capacitor 10 . Defibrillator 50 operates according to well known and understood principles.
In addition to implantable defibrillators, the innovations of capacitor 10 can be incorporated into other cardiac rhythm management systems, such as heart pacers, combination pacer-defibrillators, and drug-delivery devices for diagnosing or treating cardiac arrhythmias. They can be incorporated also into non-medical applications, for example, photographic flash equipment. Indeed, the innovations of capacitor 10 are pertinent to any application where small, high energy, low equivalent-series-resistance (ERS) capacitors are desirable.
Conclusion
In furtherance of the art, the inventors have devised unique space-efficient packaging for aluminum electrolytic capacitors which allows either reduction of the actual size (total volume) of capacitors with specific electrical traits or improvement in the electrical traits of capacitors of a specific total volume. For example, in their exemplary embodiment, the inventors use thinner and narrower separators and top and bottom insulative inserts to achieve a capacitor which is about 33 percent smaller than conventional capacitors having similar electrical traits.
The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the concepts and principles of the invention, is defined only by the following claims and their equivalents. | Implantable defibrillators are implanted into the chests of patients prone to suffering ventricular fibrillation, a potentially fatal heart condition. A critical component in these devices is an aluminum electrolytic capacitors, which stores and delivers one or more life-saving bursts of electric charge to a fibrillating heart. These capacitors make up about one third the total size of the defibrillators. Unfortunately, conventional manufacturers of these capacitors have paid little or no attention to reducing the size of these capacitors through improved capacitor packaging. Accordingly, the inventors contravened several conventional manufacturing principles and practices to devise unique space-saving packaging that allows dramatic size reduction. One embodiment of the invention uses thinner and narrower separators and top and bottom insulative inserts to achieve a 330-volt operating, 390-volt surge, 190-microfarad, 30-Joule aluminum electrolytic capacitor which is 33 percent smaller than conventional capacitors having similar electrical traits. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to expandable particulate styrene polymers which have been provided with halogen-free flame retardants.
DISCUSSION OF THE BACKGROUND
Molded polystyrene foams are widely used to insulate buildings and components of buildings. For this application they must be flame-retardant. The flame retardants usually used for rendering polystyrene foams flame retardant comprise halogens. For environmental reasons the use of halogens in foams should be reduced.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide expandable polystyrene particles which can be processed to give foams which achieve fire classifications B 1 and B 2 and which have been produced without the use of halogen-containing flame retardants.
We have found that this object is achieved by a process for preparing particulate expandable styrene polymers by polymerizing styrene, where appropriate together with comonomers, in aqueous suspension with use of blowing agents prior to, during, or after the polymerization, where the polymerization is carried out in the presence of from 5 to 50% by weight, based on the monomers, of expanded graphite.
The invention also provides particulate, expandable styrene polymers which comprise from 5 to 50% by weight, based on the styrene polymer, of uniformly distributed expanded graphite with an average particle size of from 20 to 100 μm, preferably from 30 to 80 μm
Expanded graphite is described in the literature in combination with red phosphorus and/or with phosphorus-containing compounds as a flame retardant for compact polystyrene. However, it has been found in previous experiments that halogen-free flame retardants which can be used for compact polystyrene cannot be used in foam production, since there is either a severe adverse effect on the foaming process or an excessive reduction in the heat resistance of the foam. Surprisingly, however, this is not the case in the present invention.
U.S. Pat. No. 3,574,644 describes the addition of expanded graphite as flame retardant for combustible materials, inter alia for foams in which the amounts of expanded graphite present are to be from 20 to 40% by weight. The expanded graphite may either be incorporated into the expandable material prior to expansion or coated on to this material after the expansion process. The preparation of expandable polystyrene particles by polymerizing styrene in the presence of expanded graphite is not described.
JP-A 03-167 236 describes a polystyrene foam which comprises, as flame retardant, expanded graphite whose surface was entirely coated with a film-forming resin. This coating is indicated as being necessary to prevent corrosion of processing machinery by acids always present in the expanded graphite. However, it requires an additional and complicated operation. Besides the expanded graphite, the polystyrene foam may also comprise conventional flame retardants, e.g. halogenated organic phosphates. The polystyrene foam is preferably prepared by mixing polystyrene foam particles with an adhesion promoter and with the coated expanded graphite. The particle size of the expanded graphite is preferably to be from 30 to 120 mesh, corresponding to a diameter of from about 120 to 540 μm. At particle sizes below 150 mesh (104 μm) it is said that the flame-retardant action of the expanded graphite is markedly reduced.
DETAILED DESCRIPTION OF THE INVENTION
The layered lattice structure of graphite enables it to form specific types of intercalation compounds. In these compounds, which are known as interstitial compounds, foreign atoms or foreign molecules have been absorbed into the spaces between the carbon atoms, sometimes in stoichiometric ratios. These graphite compounds, e.g. with sulfuric acid as the foreign molecule, are also prepared on an industrial scale and are termed expanded graphite. The density of this expanded graphite is from 1.5 to 2.1 g/cm 3 , and its average particle size is generally from 20 to 2000 μm, in the present case preferably from 20 to 100 μm, and in particular from 30 to 80 μm.
Phosphorus compounds which may be used are inorganic or organic phosphates, phosphites or phosphonates, and also red phosphorus. Examples of preferred phosphorus compounds are diphenyl phosphate, triphenyl phosphate, diphenyl cresyl phosphate, ammonium polyphosphate, resorcinol diphenyl phosphate, melamine phosphate, dimethyl phenylphosphonate, and dimethyl methylphosphonate.
In the suspension polymerization of the invention, it is preferable to use only styrene as monomer. However, up to 20% of the weight of styrene may have been replaced by other ethylenically unsaturated monomers, such as alkylstyrenes, divinylbenzene, acrylonitrile, diphenyl ether, or α-methylstyrene.
During the suspension polymerization, use may be made of the usual auxiliaries, e.g. peroxide initiators, suspension stabilizers, blowing agents, chain transfer agents, expansion auxiliaries, nucleating agents, and plasticizers. The expanded graphite is added during the polymerization in amounts of from 5 to 50% by weight, preferably from 8 to 30% by weight, and the phosphorus compound in amounts of from 2 to 20% by weight, preferably from 3 to 10% by weight. Blowing agents are added in amounts of from 3 to 10% by weight, based on monomer. They may be added prior to, during, or after the polymerization of the suspension. Suitable blowing agents are aliphatic hydrocarbons having from 4 to 6 carbon atoms. It is advantageous for inorganic Pickering dispersants to be used as suspension stabilizers, e.g. magnesium pyrophosphate or calcium phosphate. It has been found that when expanded graphite of relatively low particle size is used, i.e. expanded graphite with an average diameter of from 20 to 100 μm, preferably from 30 to 80 μm, the stability of the suspension is better than when using coarser expanded graphite particles, and the particles produced have lower internal water content.
The suspension polymerization produces bead-shaped, essentially round particles with an average diameter in the range from 0.2 to 2 mm. They may be coated with the usual coating agents, e.g. metal stearates, glycerol esters, or fine-particle silicates.
The expandable polystyrene particles may be prepared not only by the suspension polymerization of claim 1 but also, as in claim 7, by mixing styrene polymer melt and blowing agent with expanded graphite whose average particle size is from 20 to 100 μm, and also, where appropriate, with the phosphorus compound, extruding, cooling, and pelletizing. Subsequent impregnation of styrene polymer pellets comprising expanded graphite is also possible.
The expandable polystyrene particles may be processed to give polystyrene foams with densities of from 5 to 100 g/l, preferably from 10 to 50 g/l. For this, the expandable particles are prefoamed. This mostly takes place by heating the particles with steam in what are known as prefoamers. The resultant prefoamed particles are then fused to give moldings.
For this, the prefoamed particles are introduced into non-gas-tight molds, and the particles are brought into contact with steam. The moldings may be removed after cooling.
EXAMPLE 1
61.0 g of dicumyl peroxide and 20.2 g of dibenzoyl peroxide are dissolved in 18.0 kg of styrene, and 900 g of dimethyl phenylphosphonate are added (5% by weight, based on styrene). The organic phase is introduced into 20.2 l of demineralized water in a 50 l mixing vessel. The aqueous phase comprises 35.0 g of sodium pyrophosphate and 70.0 g of magnesium sulfate (Epsom salt). The suspension is heated rapidly to 90° C. and then, within a period of 4 hours to 130° C. 1 hour after 90° C. has been reached, 1.8 g of emulsifier K 30 (Bayer AG) are metered in. After a further hour, 2.7 kg of expanded graphite (UCAR, Grafguard 160-80, average particle size 100 μm), suspended in 2.0 kg of styrene, are added to the reaction mixture. After a further 30 minutes, 1.6 kg of pentane are metered in. Finally, completion of polymerization takes place at the final temperature of 130° C. The resultant polystyrene beads comprising blowing agent are isolated by decanting, washed, and dried to remove internal water. They are foamed by conventional processes to give foam beads and then sintered to give foam blocks or moldings.
The resultant foam blocks or moldings fulfill the requirements of fire classifications B 1 and B 2.
EXAMPLE 2
3.6 kg of polystyrene (VPT, BASF Aktiengesellschaft), 61.0 g of dicumyl peroxide and 20.2 g of tert-butylperoxy 2-ethylhexanoate are dissolved in 14.4 kg of styrene, and 900 g of dimethyl phenylphosphonate are added (5% by weight, based on styrene and polystyrene). 2.7 kg of an expanded graphite with an average particle size of 45 μm are then suspended, with stirring. The organic phase is introduced into 20.2 l of demineralized water in a 50 l mixing vessel. The aqueous phase comprises 35.0 g of sodium pyrophosphate and 70.0 g of magnesium sulfate (Epsom salt). The suspension is heated rapidly to 90° C. and then, within a period of 4 hours to 130° C. 60 minutes after 90° C. has been reached, 1.8 g of emulsifier K 30 (Bayer AG) are metered in. After a further 90 minutes, 1.6 kg of pentane are metered in. Finally, completion of polymerization takes place at the final temperature of 130° C. The resultant polystyrene beads comprising blowing agent are isolated by decanting, washed, and dried to remove internal water. They are foamed by conventional processes to give foam beads and then sintered to give foam blocks or moldings.
The resultant foam blocks or moldings fulfill the requirements of fire classifications B 1 and B 2.
EXAMPLE 3
A mixture made from polystyrene, and also 15% by weight of expanded graphite (average particle size 45 μm) and 5% by weight of red phosphorus was continuously introduced into an extruder with an internal screw diameter of 53 mm, and melted. 6% by weight of pentane is injected continuously into the extruder as blowing agent, via an inlet appature in the extruder, and is incorporated into the melt. The melt was pelletized to give bead-shaped particles, via an underwater pelletizer attached to the die plate of the extruder and operating under pressure.
Foam beads of bulk density 15 g/l were obtained by foaming twice, using steam. These foam beads, and a foam molding produced therefrom, met the requirements of fire classifications B 1 and B 2 to DIN 4102. | A process for preparing expandable particulate styrene polymers wherein from 5 to 50% by weight of expanded graphite and also, if desired, from 2 to 20% by weight of a phosphorus compound, are present as flame retardants, by suspension polymerization of styrene in the presence of the flame retardants. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an automatic apparatus for the manufacture of mattress-sacks.
As is known, mattresses of the type having springs and the like are outwardly lined by a sack generally consisting of a pair of quilted panels joined by a perimetral band. The sack containment borders are provided by strips sewn astride the adjacent borders of the panels and of the perimetral band.
In order to manufacture said mattress-sacks, conventional sewing machines are usually employed. This entails by no means small difficulties for the operator assigned to the manufacture operation, due to the considerable dimensions and to the weight of the parts to be joined. It is in fact obvious that it is necessary to rotate the quilted panels perpendicularly more than once on the work plane, in order to sew the perimetral band along their various sides. It is furthermore often observed that during sewing, creases form between the panels and the perimetral band such as to compromise the quality of the product.
SUMMARY OF THE INVENTION
The aim of the present invention is to eliminate the above described disadvantages by devising an apparatus which allows to perform the manufacture of mattress-sacks in an automatic manner, allowing in particular to easily perform their perimetral sewing.
Within the scope of this aim, a further object of the invention is to provide an apparatus which is simple in concept as well as safely reliable in operation and versatile in use.
This aim and this object are both achieved, according to the invention, by the present automatic apparatus for the manufacture of mattress-sacks, characterized in that it comprises a base plane for the sack to be manufactured provided with a work side, a sewing machine is supported and overhanging by said side and adapted to operate along a border of said sack parallel to said side, an auxiliary work plane rotatable on said base plane about a vertical axis, and presser elements rotatably supported about the same axis and adapted to secure on said rotatable plane said border of said sack being sewn so as to allow its rotation for the sewing of a following border perpendicular to said border.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of the invention will become apparent from the detailed description of a preferred embodiment of the apparatus for the manufacture of mattress-sacks, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a top plan view of the apparatus according to the invention;
FIG. 2 is a side elevation view thereof in partial cross section; and
FIGS. 3 and 4 are, respectively, a vertical cross section and a top plan detail view of the sewing region.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With particular reference to said figures, the reference numeral 1 generally indicates the apparatus for the manufacture of mattress-sacks substantially consisting of a pair of panels 2, for example of the quilted type, perimetrally joined by a band 3. FIG. 3 illustrates the step in which the band 3 is superimposed on a panel 2 so that the borders are perfectly overlapping in order to be covered by a strip 4.
The apparatus 1 comprises a base plane 5, for the sack being manufactued, which is rectangular and is mounted on an adapted base 6. A bracket 7 extends co-planar and centrally with respect to the work side 5a of the base plane 5, and is apapted to support a sewing machine 8 actuated by an adapted drive element 9. The sewing machine 8 is therefore arranged overhanging from the base plane 5, with the arm which supports the operating head arranged perpendicular to the work side 5a and the needle 10 vertically aligned with said side 5a.
An upright 11 is rigidly associated with the bracket 7, and a pair of horizontally parallel arms, upper 12 and lower 13 with respect to the bracket, extend from said upright. The arms 12, 13 are provided, at their ends, with respective brackets 14, 15 adapted to support related small shafts 16, 17 which are both coaxial to the needle 10 of the sewing machine, the small shaft 16 being rotatable, while the small shaft 17 is fixed.
The small shaft 16 is rigidly associated with a frame 18 which is horizontally V-shaped and provided at its ends with a pair of jacks 19 with a vertical axis which are adapted to actuate respective downwardly directed presser elements 20. The small shaft 16, rotatable on adapted bearings, is controlled in its rotation in alternate directions by a gear, composed of a pinion keyed to the small shaft 16 and of a rack provided on the stem of a double cylinder 21 rigidly associated with the bracket 14.
When lowered, the pressers 20, abut on an auxiliary work plane 22 rotatable about an axis defined by the small shaft 17. The rotatable plane 22 is constituted by a circular sector slightly wider than a quarter of a circle, conveniently inserted in a semicircular recess 23 of the resting plane 5. The recess 23 is adapted to allow the rotatable plane 22 to rotate through 90°, this rotation being limited by a shoulder 24 arranged along the work side 5a of the base plane 5.
The rotatable plane 22 is rigidly associated by means of a lower flap 25 with a sleeve 26 which is mounted rotatable, by means of bearings, on the small shaft 17. A flexible plate 27 is radially associated with the fixed shaft 17 and is provided, at its end, with a slot 27a in which a head-shaped pivot 25a engages and is rigidly associated with the flap 25. The flexible plate 27 acts as a spring to return back the flap 25, and therefore the plane 22, at the end of each rotation.
The strip 4 is fed by a reel 28 mounted on the bracket 7 and is driven through a creaser 29 adapted to arrange it in a known manner on the overlapping borders of the quilted panel 2 and of the perimetral band 3 at the sewing region of the needle 10.
The panel 2 and the band 3 are made to advance on the base plane 5 in the direction indicated by the arrow A in FIG. 1, advantageously guided by the shoulder 24. Once the sewing of one side of the sack has been completed, leaving the needle 10 stuck in the fabric of the sack, the lowering of the pressers 20 is actuated, so as to secure said sack on the rotatable plane 22, and the angular rotation of said plane 22 is subsequently actuated in the direction indicated by the arrow B. The rotation of the rotatable plane 22 is actuated by the double cylinder 21, which positively controls the frame 18 which is in turn rigidly associated with the plane 22 by the pressers 20.
The rotatable plane 22 rotates from the work position illustrated in FIG. 1 to an orthogonal position defined by the abutment on the shoulder 24. Thus the sack secured by the pressers 20 is also forced to rotate through 90°, so as to offer a new side to the sewing line of the machine 8. It should be particularly noted that the axis of rotation of the plane 22 and of the frame 18, defined by the small shafts 16 and 17, is coaxial to the needle 10 of the machine 8, so that said needle can remain engaged in the sack without interrupting the sewing, and acting as a rotation pivot for the sack.
Once the rotation of the sack has been performed, the raising of the pressers 20 and the return of frame 18 and of the rotatable plane 22 to their initial positions are actuated. The return of the frame 18 is actuated by the cylinder 21, while the return of the plane 22 is actuated by the flexible plate 27. At this point it is possible to resume the sewing of the strip 4 to the borders of the panel 2 and of the band 3 to continue the sewing along a new side of the sack.
The apparatus described therefore allows to manufacture mattress-sacks in a simple and rapid manner, in particular freeing the operator, who conveniently sits on a chair 30 in front of the sewing machine, from the task of rotating the sack. By means of adapted sensors it is furthermore possible to make the various functions of the apparatus completely automatic.
The invention described is susceptible to numerous modifications and variations. For example, the small shafts 16, 17, instead of being coaxial to the needle 10 of the sewing machine, may be fixed along an axis parallel to that of the needle. In this manner it is possible to produce an arc-shaped sewing.
According to another aspect, instead of the rack-and-pinion gear actuated by a double cylinder, the use is provided of an electromechanical system such as a clutch/free-wheel assembly. Similarly, the rotatable plane 22 can be actuated in its return stroke by an electromechanical device replacing the spring 27.
In the practical embodiment of the invention, the materials employed, the shapes and the dimensions may be any according to the requirements. | The automatic apparatus for the manufacture of mattress-sacks includes: a base plane supporting the sack to be manufactured and having a work side, a sewing machine overhanging by said side and adapted to operate along a border of the sack parallel to said side, an auxiliary work plane rotatable on said base plane about a vertical axis, and presser elements rotatably supported about the same vertical axis and adapted to secure on said rotatable plane the border of the sack being sewn so as to allow its rotation for the sewing of a following border perpendicular to the preceding one. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for, and a method of, making a hard carbon film, or a so-called diamond-like carbon film, having various physical properties comparable to those of a diamond.
2. Description of the Prior Art
Since it has been discovered that a diamond could be synthesized by means of a low-pressure vapor deposition process, numerous reports have been made on various methods for the formation of diamond films and the synthesis of diamond-like carbon films, an example of which includes that made by H. Vora and T. J. Moravec (J. Appl. Phys. 52 6151, 1981). Any of those prior art methods comprises the use of a gaseous hydrocarbon such as, for example, CH 4 or C 2 H 6 which is transformed into a plasma so that radicals and/or ions contained in the plasma can be utilized to synthesize a diamond film or a diamond-like carbon film. In recent years, various improved systems and apparatuses have been suggested whereby a diamond film or diamond-like carbon film can be fabricated by various devices.
The inventors have suggested in, for example, U.S. Pat. No. 4,645,977, a plasma injection CVD (chemical vapor deposition) method effective to synthesize the diamond-like carbon film on a film-like substrate continuously at a high speed. The plasma injection CVD apparatus used to carry out this method is schematically illustrated in FIG. 9. As shown therein, the apparatus comprises a plasma tube 25, equipped with a plasma generating means, and a vacuum vessel 27 for accommodating a substrate 26. The plasma tube 25 and the vacuum vessel 27 communicate with each other so that a gaseous medium introduced into the plasma tube can flow into the vacuum vessel 27 through a nozzle 28. The gaseous medium introduced into the plasma tube 25 is transformed into a plasma by means of an RF power applied to an RF coil 30, and the plasma is then blown onto the substrate 26 by the effect of a pressure difference between the plasma tube 25 and the vacuum vessel 27. At this time, ions contained in the plasma are accelerated by the difference in potential between an accelerator electrode 29, installed inside the plasma tube 25, and the substrate 26 to impinge the substrate 26. Thus, the flow of the plasma of the hydrocarbon gas containing the accelerated ions makes it possible to maximize the use of the ions and radicals in forming the diamond-like carbon film at a high speed.
However, the plasma injection CVD method has been found to have the following problem. The speed at which the diamond-like carbon film is synthesized depends on the number of the ions and radicals that reach the substrate. On the other hand, the number of the ions and radicals is based on the pressure of the plasma tube, the type of the gaseous medium used and the electric power invested. Therefore, in order to increase the speed at which the diamond-like carbon film is synthesized, the plasma tube should be evacuated to a pressure as low as possible. In addition, since the plasma injection CVD method makes use of the difference in pressure between the plasma tube and the vacuum vessel to cause the radicals of the plasma to flow this pressure difference should be as large as possible in order to increase the speed at which the diamond-like carbon film is synthesized.
However, since the difference in pressure between the plasma tube and the vacuum vessel is limited by the flow resistance imposed by the nozzle, in order for the pressure difference between the plasma tube and the vacuum vessel to be increased while the pressure inside the plasma tube is maintained low, the flow resistance imposed by the nozzle must be increased. Because of this, the opening of the nozzle must be as small as possible and this is limited due to the incompatibility between the increase in speed at which the diamond-like carbon film is synthesized and a large surface area over which the diamond-like carbon film is to be synthesized.
Also, according to the plasma injection CVD method, in order to accelerate the ions, a mesh-like electrode is installed within the plasma tube and a positive potential is applied to the electrode. At this time, the plasma exhibits a potential substantially equal to that developed at the mesh-like electrode and the plasma ions are accelerated by the effect of a potential difference between the plasma and the substrate. When the plasma is blown from the nozzle onto the substrate, a portion of the plasma diffuses into the vacuum vessel and this may often constitute a cause of an abnormal discharge. The lower the vacuum exhibited by the pressure inside the plasma tube, the greater the amount of the plasma diffused into the plasma tube and, hence, the more often does the abnormal discharge occur. Since the plasma injection CVD method entails blowing the plasma onto the substrate, the uniformity of pressure at a film forming portion is limited, and it has been found that the uniformity of the film thickness was limited to ±5% at an area corresponding to the cross-section of the nozzle. Because of this, in applications in which uniformity is an important factor (for example, when providing a protective film on a magnetic tape), a further improvement in uniformity of the film thickness is desired.
SUMMARY OF THE INVENTION
The present invention has been devised to substantially eliminate the above discussed problems and is intended to provide an improved plasma CVD apparatus capable of synthesizing a diamond-like carbon film of uniform film thickness and of a relatively large surface area at a high speed and which operates stably with a minimized possibility of an abnormal discharge.
To this end, the present invention provides a plasma CVD apparatus which comprises a first vacuum vessel enclosing a substrate on which a film is desired to be formed; a second vacuum vessel fluid-connected with a source of a raw gaseous medium and having a gas outflow port from which a plasma of the raw gaseous medium introduced into the second vacuum vessel is discharged; and plasma generating means for transforming the raw gaseous medium, introduced from the raw gaseous medium source into the second vacuum vessel, into plasma within the second vacuum vessel.
The gas outflow port is so shaped as to conform to the shape of the surface of the substrate, while the second vacuum vessel is accommodated within the first vacuum vessel with the gas outflow port oriented towards and spaced apart from the surface of the substrate with a gap formed therebetween. The gap is of a size small enough to permit the pressure of the plasma, discharged from the gas outflow port into the gap, to be uniform at any location within the gap.
The apparatus also comprises electric field generating means for directing ions of the plasma, discharged from the gas outflow port into the gap, towards the substrate.
The present invention also provides a method of forming, by the use of a plasma CVD technique, a film on a surface of a substrate within a vacuum vessel. This method comprises supplying a plasma into the vacuum vessel under a pressure higher than the pressure inside the vacuum vessel; developing an electric field acting on the plasma gas for directing ions of the plasma towards the substrate; and forming the film of elements of the plasma.
The plasma supply is carried out by passing the plasmas through a plasma gas outflow port of a shape conforming to the shape of the surface of the substrate and disposed proximate the surface of the substrate while leaving a sufficiently small gap therebetween such that, within the gap, the plasma gas has a substantially uniform pressure higher by at least one figure (an order of ten) than the pressure inside the vacuum vessel.
According to the present invention, the surface of the substrate on which the film is desired to be formed and the gas outflow port of a shape conforming to the surface of the substrate are spaced apart by a small distance. Since the gas outflow port has a shape conforming to the surface of the substrate, the gap therebetween is uniform.
Since the substrate surface and the gas outflow port are close, the amount of plasma emerging outwardly from the gas outflow port can be controlled to a properly selected small value as compared with the amount of the plasma generated. Therefore, a sufficient amount of the plasma gas accumulates within the gap and the plasma pressure is increased. In other words, because a proper amount of the plasma is accumulated in the gap, the plasma is stably supplied to the substrate surface and the pressure of the plasma within the gap is substantially uniform and higher by at least one figure (an order of ten) than the pressure inside the vacuum vessel. Therefore, film forming conditions under which the film is formed on the substrate surface are stable.
Also, because the rate of flow of the plasma from the plasma outflow port is so controlled as described above, the diffusion of the plasma is advantageously minimized thereby minimizing the possibility of an abnormal discharge which would otherwise occur as a result of the diffusion of the plasma. When the pressure of the plasma is higher by one or more figures than the pressure inside the vacuum vessel and the pressure inside the vacuum vessel is lower than that at which the discharge can be maintained, any undesirable discharge within the vacuum vessel can be avoided.
When a diamond-like carbon film is to be formed with the use of the above discussed plasma CVD method, the radicals of the plasma increase and, therefore, the film quality tends to be deteriorated. The diamond-like carbon film is generally regarded as a structure in which diamond bonds (SP3 bonds) and graphite bonds (SP2 bonds) are mixed, and the greater the number of the SP3 bonds, the more the structure is characteristic of a diamond. Since under ordinary environments the SP2 bonds are rather stable, energy is required to render the carbon ions of the plasma into the SP3 bonds.
In the present invention, an electric field accelerates the ions of the plasma to increase the energy of ion bombardment to thereby correspondingly increase the SP3 bonds for the purpose of providing a diamond-like carbon film of high quality.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clear from the following description taken in conjunction with preferred embodiments thereof with reference to the accompanying drawings, in which like parts are designated by like reference numerals and in which:
FIG. 1 is a schematic diagram of one preferred embodiment of a plasma CVD apparatus according to the present invention;
FIG. 2 is a schematic diagram of a modified form of the plasma CVD apparatus shown in FIG. 1;
FIG. 3 is a schematic diagram of a second preferred embodiment of the plasma CVD apparatus according to the present invention;
FIG. 4 is a schematic diagram of a modified form of the plasma CVD apparatus shown in FIG. 3;
FIG. 5 is a schematic diagram of another modified form of the plasma CVD apparatus shown in FIG. 3;
FIG. 6 is a schematic diagram of a further modified form of the plasma CVD apparatus shown in FIG. 3;
FIG. 7 is a schematic diagram of a third preferred embodiment of the plasma CVD apparatus according to the present invention;
FIG. 8 is a schematic diagram of a modified forth of the plasma CVD apparatus shown in FIG. 7; and
FIG. 9 is a schematic diagram of the prior art plasma CVD apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the present invention is shown as applied to the formation of a diamond-like carbon film on a magnetic tape and, for this purpose, there is provided a magnetic tape transport system for transporting a continuous length of magnetic tape to a thin film forming unit where a diamond-like film is formed over a magnetic layer of the magnetic tape.
Specifically, a first vacuum vessel 1 has a tape transport system accommodated therein and including a supply roller 5 supporting a roll of magnetic tape 8, a drum 3 adapted to be driven at a peripheral speed substantially equal to the speed of transport of the magnetic tape 8 and around which the magnetic tape 8 drawn from the supply roller 3 is guided, a take-up roller 4 for winding up the magnetic tape 8 having been guided by the drum 3, and a tensioning roller 6 for imparting a proper tension to the magnetic tape 8 while the latter is guided around the drum 3.
The length of magnetic tape 8 is drawn from a supply roller 5 and is wound around a take-up roller 4 after having travelled around the drum 3. As a matter of course, the drum 3 is ordinarily cooled by a known cooling means such as, for example, a water cooling system, to prevent an increase of temperature thereof during an operation of the apparatus.
As shogun in FIG. 1, the tensioning roller 6 which is electrically grounded contacts the magnetic layer of the magnetic tape 8 to connect the magnetic layer of the magnetic tape 8 electrically to the ground. The other component parts of the tape transport system including the drum 3 are electrically insulated.
In the illustrated embodiment, the drum 3 has a diameter of about 800 mm and a length of about 280 mm as measured in a direction parallel to the axis of rotation of the drum 3, that is, in a direction perpendicular to the sheet of FIG. 1. A second vacuum vessel 2 (hereinafter referred to as a plasma generating tube because plasma necessary to form a diamond-like thin film is generated in this vessel) is positioned immediately beneath the drum 3 and has a gas outflow port 9 defined therein. The gas outflow port 9 in the illustrated embodiment has a width of about 600 mm as measured in a direction conforming to the curvature of the drum 3 and a length of about 250 mm as measured in a direction parallel to the axis of rotation of the drum 3. As will be described later, the plasma generating tube 2 is so positioned that the distance of separation between the outer peripheral surface of the drum 3 and the gas outflow port 9 is uniform over the entire surface area of the gas outflow port 9.
The plasma generating tube 2 is supported on a positioning mechanism comprising a motor 12, gears 13, a movable platform 14, and a support framework 15, and which mechanism is so designed as to adjust the distance of separation between the peripheral surface of the drum 3 and the gas outflow port 9 of the plasma generating tube 2. The plasma generating tube 2 has an electrode 7 installed therein and connected with an electric power source 10 to produce a potential difference between the electrode 7 and the magnetic layer of the magnetic tape 8.
As a raw gaseous material, C 6 H 6 gas is used and is introduced into the plasma generating tube 2 through a gas supply line 11. At this time, the distance of separation between the gas outflow port 9 and the peripheral surface of the can roller 3 and the flow rate of the C 6 H 6 gas are adjusted so that the pressure difference between the plasma generating tube 2 and the vacuum vessel 1 can attain a value in the order of more than a single figure. If this pressure difference is insufficient, not only would an uneven pressure be developed at the gas outflow port 9, but also a portion of the plasma generated within the plasma generating tube 2 would flow into the vacuum vessel 1, thereby causing film to form at an unwanted area and an abnormal discharge.
After the pressure inside the plasma generating tube 2 has been stabilized, an electric potential required to cause the electrode 7 to have a positive potential is applied between the electrode 7 and the magnetic layer of the magnetic tape 8 to cause the plasma generating tube 2 to generate the plasma. Ions contained in the plasma so generated are accelerated by the effect of the potential difference between the electrode 7 and the magnetic layer of the magnetic tape 8 to impinge on the magnetic layer of the magnetic tape 8 thereby forming a diamond-like carbon film together with radicals contained in the plasma.
One example of film forming conditions is shown in Table 1. In Table 1, the current density in the magnetic layer refers to the amount of ions flowing into that portion of the magnetic layer of the magnetic tape 8 which is then situated within a gap between the gas outflow port 9 and the outer peripheral surface of the drum 3.
TABLE 1______________________________________Pressure inside Tube 2 10 to 15 PaPressure inside Vessel 1 0.1 PaC.sub.6 H.sub.6 Flow Rate 12 SCCMPotential Difference between 6 and 7 3 kVCurrent Density in Magnetic Layer 0.1 mA/cm.sup.2______________________________________
As a result of the film formation under the above tabulated conditions, over the entire area of the gas outflow port 9 (250 mm in length and 600 mm in width), a film of 3,000 kg/mm 2 in Vickers hardness could be synthesized at a speed higher than 300 nm per minute. Consequently, it has become possible to form the diamond-like carbon film of 10 nm in thickness uniformly (with ±2% in variation in film thickness) over a surface of the length of magnetic tape 8 transported at a speed of 18 m per minute.
An important aspect of the present invention lies in that the pressure of the plasma generated from the plasma generating tube 2 and flowing into the first vacuum vessel 1 through the gas outflow port 9 is maintained at a uniform value at any local portion of the gap between the peripheral surface of the drum 3 and the gas outflow port 9. This can be accomplished by using the positioning mechanism comprising the motor 12 to adjust the gap between the peripheral surface of the drum 3 and the gas outflow port 9. If the gap between the gas outflow port 9 and the peripheral surface of the drum 3 is too large as compared with the flow rate of the gas discharged from the gas outflow port 9, the flow of the plasma emerging outwardly from the gas outflow port 9 will become unstable, making it difficult to achieve a uniform pressure over the entire area of the gap.
Accordingly, in order to achieve the uniform pressure over the entire area of the gap, it is necessary to set the distance of separation between the peripheral surface of the drum 3 and the gas outflow port 9 to a relatively small value. By selecting the distance of separation to be of the small value, the gas flow from the plasma generating tube 2 can be properly controlled to a small value as compared with the amount of the plasma produced within the plasma generating tube 2 and, consequently, not only can a sufficient amount of plasma be accumulated within the plasma generating tube as compared with the amount of the plasma discharged outwardly from the gas outflow port 9, but the gas pressure of the plasma can also be increased. Therefore, while the proper amount of the plasma is accumulated within the plasma generating tube 2, the amount of the plasmas produced and the amount of the plasma discharged are balanced with each other, making it possible to accomplish a stabilized supply of the plasma gas to the gap while the gas pressure at the gap is kept uniform.
So far as the illustrated embodiment is concerned, the distance of separation is deemed optimum if it is about 0.3 μm, but not exceeding 1 μm. Since in the illustrated embodiment the radius of curvature of the gas outflow port 9 and the radius curvature of the peripheral surface of the drum 3 are identical with each other, the distance of separation is not uniform if strictly measured in a direction lengthwise of the drum 3. However, in terms of the purpose of equalizing the pressure of the plasma gas at any local positions within the gap between the peripheral surface of the drum 3 and the gas outflow port 9, the distance of separation of about 0.3 mm may be regarded as a uniform gap size.
As hereinabove described, the foregoing embodiment of the present invention is effective to form a diamond-like film of uniform film thickness at a high speed. The diamond-like film formed on the surface of the magnetic layer has shown no problem in bondability thereof with the magnetic layer, and has shown an excellent wear resistance, proving that the resultant diamond-like film could be used as a sufficient and effective protective layer.
It is to be noted that the magnetic layer of the magnetic tape 8 has been electrically grounded through the tensioning roller 6. However, it need not be held at a ground potential, but may be connected with a direct current source 16 such as shown in FIG. 2. In the modification shown in FIG. 2, since the potential difference is produced between the magnetic layer and the drum 3 (ground potential), this potential difference assists the magnetic tape 8 to strongly adhere to the drum 3. While the drum 3 is notionally water-cooled to prevent an increase of temperature during the film formation and to prevent the magnetic tape 8 from being thermally damaged and an emission of gases therefrom, the application of an electric potential to the magnetic layer to cause the magnetic tape 8 to stick to the drum 3 is effective to stabilize the film forming conditions.
Also, while in the embodiment shown in and described with reference to FIG. 1 a ratio between the pressure inside the first vacuum vessel and that inside the plasma generating tube has been chosen to be in the order of two figures, the ratio of pressure in the order of a single figure is sufficient to accomplish the formation of the diamond-like carbon film at a high speed as compared with the prior art method with the resultant diamond-like film being advantageously usable as a protective layer.
FIG. 3 illustrates the second embodiment of the plasma CVD apparatus according to the present invention. While in the foregoing embodiment a direct current power source 10 is employed as means for generating the plasma, the plasma CVD apparatus according to FIG. 3 employs an alternating current of a frequency at 13.56 kHz. In this embodiment, the magnetic layer of the magnetic tape is impressed with a negative potential from the direct current power source 17 through the tensioning roller 6. One example of film forming conditions is shown in Table 2 and, as shown in Table 2, the ratio between the pressure inside the plasma generating tube 2 and that inside the vacuum vessel 1 is in the order of two figures.
TABLE 2______________________________________Pressure inside Tube 2 10 PaPressure inside Vessel 1 0.1 PaC.sub.6 H.sub.6 Flow Rate 8 SCCMPotential of Magnetic Layer -2 kVCurrent Density in Magnetic Layer 0.05 mA/cm.sup.2AC Power applied to Electrode 7 150 W______________________________________
As a result of the film formation under the conditions tabulated in Table 2, over the entire area of the gas outflow port 9 (250 mm in length and 600 mm in width), a film of 2,500 kg/mm 2 in Vickers hardness could be synthesized at a speed higher than 400 nm per minute. Consequently, it has become possible to form the diamond-like carbon film of 10 nm in thickness uniformly (with ±2% or smaller in variation in film thickness) over a surface of the length of magnetic tape 8 travelling at a rate higher than 24 m per minute.
In the practice of the second embodiment of the present invention, the negative potential need not always be impressed on the magnetic layer by a direct current power source, as an alternating current potential may be impressed instead so that a self-biasing effect thereof can be utilized. Also, the frequency of the alternating current to be applied to the electrode 7 is not limited.
Similar effects can be obtained even when the AC potential superimposed with a negative DC potential is applied to the electrode 7 such as shown in FIG. 4. This can be accomplished by superimposing a DC potential, supplied from a direct current power source 18 through a low-pass filter 17, on the DC potential supplied from the AC power source 16 and, in this instance, the magnetic layer of the magnetic tape may be grounded.
In the practice of the second embodiment of the present invention, a favorable film formation is possible particularly if the pressure ratio between the first and second vacuum vessels is in the order of one or more figures.
It is to be noted that the plasma generating tube 2 in its entirety may not be completely enclosed within the vacuum vessel 1, but a portion thereof may be situated outside the vacuum vessel 1 as shown by 2-a in FIG. 5, and even this arrangement is free from problems. The arrangement in which a portion of the plasma generating tube 2 is situated outside the vacuum vessel 1 as shown in FIG. 5 is particularly advantageous where the AC power source is employed as means for generating the plasma, an example of which is shown in FIG. 6.
According to the modification shown in FIG. 6, that portion of the plasma generating tube 2 which protrudes outwardly from the vacuum vessel 1 is exteriorly wrapped with a high frequency coil 21 which is in turn electrically connected through a matching box 20 with an AC power source for applying an AC potential to the high frequency coil 21. If the plasma is produced by the application of the AC potential while the plasma generating tube 2 is disposed completely within the vacuum vessel 1, not only the interior of the plasma generating tube 2, but also the high frequency coil 21 will provide a trigger by which an abnormal discharge is likely to occur. This problem is obviated if the high frequency coil 21 is positioned outside the vacuum vessel 1 such as shown in FIG. 6 and, therefore, while the uniformity of the resultant film is ensured, the possibility of an abnormal discharge which would result in damage to the magnetic tape 8 can be eliminated.
Although the plasma CVD apparatus of the present invention has been described as carrying out the formation of the diamond-like carbon film on the surface of the magnetic layer of the magnetic tape, the apparatus of the present invention may be used in forming the diamond-like carbon film on substrates other than the magnetic tape. Also, the present invention is not limited to forming a diamond-like carbon film, but may be employed in forming any other thin film provided that the raw gaseous material and the film forming conditions are properly selected. The present invention can also be equally applied to the sputtering of a substrate surface with the use of an inert gas such as Ar gas and the oxidization or nitriding of a surface with the use of O 2 gas or N 2 gas.
Furthermore, by modifying the shape of the gas outflow port, the present invention can be used for forming a thin film on a three-dimensional substrate, an example of which will now be described in connection with a third preferred embodiment of the present invention with reference to FIG. 7. In describing the third embodiment of the present invention, reference is made to the synthesis of a diamond-like thin film on a surface of a sliding member employed in a machine for guiding a movement of a movable member. An example of this sliding member includes the one used to linearly guide tool carriage of a table-top machine tool. As is well known to those skilled in the art, the linear motion of the tool carriage directly affects the machining precision of a workpiece and is therefore maintained at a high level of preciseness. In view of this, a sliding surface supporting of the tool carriage must have a sufficient wear resistance and a sufficiently low coefficient of friction. The diamond-like thin film satisfies these requirements and, if it is formed on the sliding surface, an excellent sliding member can be obtained.
The present invention may also be used to form a diamond-like film on members other than the sliding member, such as a surface of a shaft supported by a slide bearing or any other bearing, a surface of any other tool or any other surface requiring wear resistance.
The plasma CVD apparatus according to the present invention and shown in FIG. 7 may be advantageously employed for forming a diamond-like film on the surface of a sliding member 23. The plasma CVD apparatus shown therein comprises a vacuum chamber 1 in which the sliding member 23 is supported, and a plasma generating tube 2. The plasma generating tube 2 has a gas outflow port 22 so designed and so sized in consideration of the size of a film forming portion 23-a that the distance of separation between the sliding member 23 and the gas outflow port 22 is uniform over the entire area of the gas outflow port 22. In the illustrated embodiment, the film forming portion 23-a is flat and rectangular and, therefore, the gas outflow port 22 has a rectangular shape.
A substrate to be coated with the diamond-like film in accordance with the third embodiment of the present invention is not a band-like medium such as employed in the previously described embodiments, but a sliding member made of metal and is therefore fixed in position inside the vacuum vessel 1 during the formation of the diamond-like film on the surface of the sliding member 23. Hence, the third embodiment of the present invention does not require the use of the transport system such as required in any one of the foregoing embodiments of the present invention.
Where the surface on which the diamond-like film is to be formed is a curved surface such as shown by 24-b in FIG. 8, a gas outflow port 24 must be correspondingly shaped to follow the curved surface 23-b. Machine settings and operating means employed therein are substantially similar to those used in any one of the foregoing embodiments. As a raw gaseous material, C 6 H 6 gas is used and is introduced into the plasma generating tube 2 through the gas supply line 11. At this time, the distance of separation between the gas outflow port 22 and the sliding member 23 and the flow rate of the C 6 H 6 gas are adjusted so that the pressure difference between the plasma generating tube 2 and the vacuum vessel 1 can attain a value in the order of more than a single figure. If this pressure difference is insufficient, not only is an uneven pressure developed at the gas outflow port 22, but also a portion of the plasma generated within the plasma generating tube 2 flows into the vacuum vessel 1, thereby causing a film to form at an unwanted area and an abnormal discharge.
After the pressure inside the plasma generating tube 2 has been stabilized, an electric potential required to cause the electrode 7 to have a positive potential is applied between the electrode 7 and the sliding member 23 to cause the plasma generating tube 2 to generate the plasma. Ions contained in the plasma so generated are accelerated by the effect of the potential difference between the electrode 7 and the sliding member 23 to impinge on the film forming portion 23-a of the sliding member 23 to thereby form a diamond-like carbon film together with radicals contained in the plasma.
One example of film forming conditions is shown in Table 3.
TABLE 3______________________________________Pressure inside Tube 2 10 to 15 PaPressure inside Vessel 1 0.1 PaC.sub.6 H.sub.6 Flow Rate 12 SCCMVoltage of Power Source 10 3 kVCurrent Density in Magnetic Layer 0.1 mA/cm.sup.2______________________________________
As a result of the film formation under the above tabulated conditions, over the entire area of the gas outflow port 22 (50 mm in length and 80 mm in width), a film of 4,000 kg/mm 2 in Vickers hardness could be synthesized at a speed higher than 150 nm per minute. Consequently, it has become possible to form the diamond-like carbon film of 1 μm in thickness uniformly (with ±2% in variation in film thickness) over the film forming portion 23-a of the sliding member 23. It is to be noted that modifications described in connection with any one of the first and second preferred embodiments of the present invention can be equally employed in the practice of the third embodiment of the present invention.
In the illustrated embodiment, the potential difference between the electrode within the plasma generating tube 2 and the magnetic layer of the magnetic tape 8 or the sliding member 23 is chosen to be within a range of 0.3 to 5.0 kV and, preferably, within a range of 0.5 to 3.0 kV. If this potential difference is lower than 0.3 kV, the ion bombardment energy will be reduced resulting in a film similar to an organic film that is soft and easily be damaged. On the other hand, if the potential difference is higher than 5.0 kV, the ion bombardment energy will be excessive enough to sputter and/or damage the formed film.
The inside the vacuum vessel is preferably under a vacuum higher than 0.5 Pa and more preferably 0.2 Pa. If the vacuum inside the vacuum vessel is lower than 0.5 Pa, the potential applied to the magnetic layer may cause an abnormal discharge to take place within the vacuum vessel. Once the abnormal discharge occurs within the vacuum vessel, not only may foreign matter be undesirably deposited on the surface of the magnetic tape 8, but the magnetic layer of the magnetic tape may be damaged.
The pressure inside the plasma generating tube is preferably higher than 10 Pa and, more preferably within the range of 10 to 50 Pa. If the pressure inside the plasma generating tube is lower than 10 Pa, the film forming speed will be considerably reduced. On the other hand, if the pressure inside the plasma generating tube is higher than 50 Pa, the plasma generating tube is susceptible to an abnormal discharge when the potential is applied to the electrode. Also, an average stroke of free movement of ions is reduced accompanied by a reduction in bombardment energy and, therefore, the quality of the resultant film will be lowered (that is, the SP2 bonds are increased to provide a soft film).
Again, although reference has been made to the use of C 6 H 6 gas as the raw gaseous material, the present invention is not limited thereto, but may employ any gaseous medium provided that it contain carbon elements. The raw gaseous material used in the present invention may contain any one of Ar gas and H 2 gas.
While various embodiments of the present invention have fully been described, the present invention is characterized in that the distance of separation between the gas outflow port and surface of the substrate on which the film is desired to be formed is so chosen that the pressure of the plasma generated by the plasma generating tube 2 and emerging outwardly through the gas outflow port into the first vacuum vessel 1 is uniform over the entire area of the gas outflow port, that is, at any location over the gas outflow port. If the distance of separation is great as compared with the rate of flow of the gas emerging outwardly through the gas outflow port, the flow of the gas emerging from the gas outflow port is so unstable that no uniform pressure can be created in the gap between the gas outflow port and the substrate.
When the distance of separation between the gas outflow port and the substrate is chosen to be a proper value, the amount of gas emerging outwardly from the gas outflow port of the plasma generating tube is so small compared to the amount of plasma generated within the plasma generating tube that not only is a sufficient amount of the plasma accumulated within the plasma generating tube, but the gas pressure thereof is increased. Consequently, while a proper amount of the plasma is accumulated in the plasma generating tube, the amount of the plasma generated and the amount of the plasma flowing outwardly from the tube are properly balanced with each other to such an extent that the plasma is stably supplied to the gap and the pressure in the gap is maintained uniform.
In the practice of the present invention, the pressure inside the plasma generating tube is higher than that inside the first vacuum vessel. It has, however, been found that, in order to create uniform gas pressure over the entirety of the gap between the substrate and the gas outflow port in order to form a high quality film, the pressure inside the plasma generating tube, that is, the second vacuum vessel, should be higher on the order of one, or preferably one to two, figures than the pressure inside the first vacuum vessel.
Although the present invention has been described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they otherwise depart therefrom. | A plasma CVD apparatus for continuously forming a diamond-like film on a length of magnetic tape, includes a first vacuum vessel, a plasma generating vessel for transforming a gaseous medium into a plasma, and an electrode for accelerating ions of the plasma toward the substrate. The plasma generating vessel has a gas outflow port of a shape complementary to that of the portion of the magnetic tape readied for deposition. A portion of the plasma generating vessel is disposed within the vacuum vessel, with the gas outflow port facing the substrate. A gap between the substrate and the gas outflow port is set to maintain the pressure of plasma in the gap uniform. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for providing a nuclear fuel and a fuel element provided with a nuclear fuel made by such a method.
2. Description of the Related Art
It is known to produce nuclear fuels containing relatively low densities of highly enriched uranium. Highly enriched uranium (HEU) has the disadvantage that for political reasons, the use of this material is undesirable, because it can not only be deployed for peaceful purposes but can also be used for less peaceful applications, as for perpetrating terrorist attacks and/or manufacturing atomic bombs. For this reason in recent years the use of low enriched uranium (LEU), which has a 235-U content of less than 20%, is strongly encouraged. In view of the above-mentioned disadvantage of HEU, a nuclear fuel preferably comprises uranium not highly enriched in the 235-U isotope. A disadvantage of such a fuel, however, is that the total uranium content (the sum of all isotopes) in an LEU-containing fuel element must be much higher than that in an HEU-containing fuel element, in order to obtain a similar reactivity. However, metallic uranium inherently has insufficient mechanical stability during irradiation to be used in elemental form.
It is known to impart stability to the uranium by using it in a chemical composition with silicon, e.g. U 3 Si 2 . In this composition, however, the density of the uranium still cannot always attain the desired higher value to be able to provide a reactivity sufficiently high to enhance the utility or the economics of the reactor. For this reason a new class of nuclear fuels for use in research, test and radioisotope-production reactors is being developed based on uranium-molybdenum alloys. The high uranium density of these alloys should make it possible to fuel these reactors using LEU instead of HEU, without causing a large decrease of the neutron flux in these reactors. These uranium-molybdenum alloys offer the further advantage of being able to be reprocessed in currently operating reprocessing plants.
Uranium-molybdenum alloys are currently being tested as dispersions of alloy fuel particles in a non-fissionable matrix material, such as aluminum, and as a monolithic fuel. Both types of fuel are enclosed in a cladding such as aluminum. U.S. Pat. No. 5,978,432 describes one method of producing a dispersion fuel using uranium-molybdenum alloys. The most common design of a Material Test Reactor (MTR) fuel element using U—Mo fuel and U—Mo fuel plates is as follows. U—Mo particles are dispersed into an aluminum matrix. The dispersed particles and the aluminum matrix make up a thin fuel layer, which is placed between two thin cladding plates of aluminum alloy. Such a cladding is, for example, described in the U.S. Pat. No. 4,963,317. In the present invention, the aluminum matrix is to be understood to comprise the aluminum of the fuel only. Therefore, the bulk of the aluminum cladding does not form part of the matrix in the present invention.
The thus-obtained fuel plates, each comprising a fuel layer enclosed by cladding plates, are either curved or flat. Approximately 20 of such plates form a fuel element together with structural components. Cooling water that flows between the plates cools the fuel plates fuelling a reactor during the operation thereof.
Although the use of uranium-molybdenum alloys makes it possible to increase the uranium density in the nuclear fuel for research and test reactors, the use of molybdenum carries the penalty of a significant neutron absorption, which decreases the effect of the added uranium, resulting in a relatively low reactivity. Therefore, the application of molybdenum in a nuclear fuel has been unfavourable albeit its advantages.
SUMMARY OF THE INVENTION
It is an aspect of the present invention to overcome the problems described above of providing a nuclear fuel that comprises an uranium-molybdenum alloy, in particular it is an aspect of the present invention to increase the reactivity of such a fuel.
To that end, the present invention provides a nuclear fuel including an alloy of metallic uranium and molybdenum, the uranium being enriched in the isotope 235-U, while the molybdenum is depleted in the isotope 95-Mo.
The present invention is based on Applicant's discovery that the use of molybdenum depleted in 95-Mo, which absorbs less neutrons compared to natural molybdenum, results in a higher reactivity of the nuclear fuel. This effect is explained below. The higher reactivity can be used to render a number of advantages, depending among others on the specific design of the fuel element to be used and the manner in which the fuel element is used. Possible advantages of using molybdenum depleted in 95-Mo are: high reactivity; increased flux; achieving a higher concentration of molybdenum in the fuel in case of 95-Mo-depleted molybdenum, while retaining identical flux, which may render an increasingly stable fuel; identical flux, but with a longer cycle, which allows for consumption of a smaller quantity of fuel elements; and/or smaller quantity of expensive enriched uranium per fuel element to retain identical flux.
DETAILED DESCRIPTION
The reasons for the effect of the use of molybdenum depleted in 95-Mo instead of natural molybdenum, are shown in Table 1 below, which includes the thermal neutron absorption cross section (D) and the resonance integral of various molybdenum isotopes. The thermal neutron absorption cross section and the resonance integral are measures for the amount of thermal neutrons and epi-thermal neutrons absorbed by the molybdenum respectively. The thermal neutron cross section data in Table 1 originate from the 81 st edition of the Handbook of Chemistry and Physics (2000–2001), CRC Press, Robert C. Weast et al, page 11–165/166. The resonance integral data are a typical example of the results of neutronics computations.
Molybdenum Resonance isotope Abundant atomic % D (barns) Integral (barns) 92-Mo 14.84 0.06 0.8 94-Mo 9.25 0.02 0.8 95-Mo 15.92 13.4 109 96-Mo 16.68 1.5 17 97-Mo 9.55 2.2 14 98-Mo 24.13 0.14 7.2 100-Mo 9.63 0.19 3.6 Natural Mo — 2.7 23.8
Table 1. Effective cross section of molybdenum isotopes for neutrons. The values for natural Mo have been computed using the weighed averages of the data for the isotopes.
Table 1 shows that 95-Mo has both the highest thermal neutron absorption cross section (D) and the highest resonance integral. Therefore the presence of the considerable fraction 95-Mo in natural molybdenum (about 16%) has a significant negative impact on the reactivity of U—Mo fuel containing natural Mo. Comparing the computed D-value and the computed resonance integral for natural molybdenum with those for the isotopes 92-Mo, 94-Mo, 96-Mo, 97-Mo, 98-Mo and 100-Mo shows that all these isotopes have a lower computed D-value and a lower computed resonance integral compared to natural molybdenum. This shows that the use of all these isotopes will increase the reactivity compared to the use of natural molybdenum. The data in Table 1 show that 92-Mo and 94-Mo have the lowest values for the thermal neutron absorption cross section (D) and the resonance integral of all molybdenum isotopes. The data in Table 1 show that 96-Mo and 97-Mo have values for the thermal neutron absorption cross section (D) and the resonance integral which are only somewhat lower than those for natural molybdenum. The data in Table 1 show that 98-Mo and 100-Mo have values for the thermal neutron absorption cross section (D) and the resonance integral which are intermediate between those of 92-Mo and 94-Mo on the one hand and 96-Mo and 97-Mo on the other hand. The isotopic composition that will be applied in practical applications will depend on various parameters, such as the costs of enrichment of the molybdenum in 92-Mo and 94-Mo compared to the costs of enrichment of the molybdenum in 98-Mo and 100-Mo.
The impact of the use of molybdenum depleted in 95-Mo in U—Mo fuel in a test reactor can lead to an annual savings of 2.5 to 3 fuel elements. This means that fewer fuel elements must be purchased at high cost and fewer spent fuel elements must be disposed of at even higher cost.
The production of molybdenum which does not contain any 95-Mo is not feasible from a technical point of view. Therefore, the 95-Mo-depleted molybdenum will still contain some 95-Mo. The 95-Mo concentration that will be used for practical application will depend on various parameters, such as: the costs of the enrichment of uranium in 235-U and the costs of depletion of molybdenum in 95-Mo; the costs for the production of fuel plates and fuel elements; and/or the costs of disposing of spent fuel elements.
According to a further embodiment of the present invention, the depleted molybdenum contains less than 15% by weight, more particularly approximately 5% by weight, of the molybdenum isotope 95-Mo. With these percentages by weight of the molybdenum isotope 95-Mo, relatively high reactivity values are obtained.
According to an even further embodiment of the present invention, the content of molybdenum in the uranium-molybdenum alloy is in the range of 2–20% by weight, more particularly in the range of 5–10% by weight. When the fuel contains such an amount of molybdenum, a relatively high concentration of uranium can be incorporated therein without the uranium becoming mechanically unstable during irradiation. In particular, at a content of 5–10% by weight, sufficient uranium can be present in the fuel to obtain a neutron yield useful for the purposes mentioned earlier. In a preferred embodiment, the fuel contains more than 3 grams/cm 3 , more particularly more than 4 grams/cm 3 , of uranium. More preferably, the fuel contains more than 5 grams/cm 3 , more particularly more than 7.5 grams/cm 3 , of uranium. Such densities of enriched uranium provide relatively high neutron yields and high reactivity values. A fuel that comprises uranium in such relatively high densities can comprise an aluminum matrix embedding the alloy of uranium and molybdenum, so that a stable fuel meat is formed.
The present invention further provides a fuel element. Such a nuclear fuel element can be made by a method according to the invention. Such a fuel element is relatively simple to recycle, compared with, for instance, fuel elements containing uranium-silicon compounds. Since the fuel element is not provided with highly enriched uranium, production, transport and use of such a fuel element is preferable, from a non-proliferation point of view, to fuel elements that do contain highly enriched uranium.
The advantages discussed above of using molybdenum depleted in the isotope 95-Mo result for any level of uranium enrichment, although in different degree. Therefore, the present invention is applicable to all levels of uranium enrichment. The enriched uranium can for example contain 2–40% by weight, in particular 10–20% by weight, of the isotope 235-U. On the other hand, a fuel comprising an alloy of a higher enriched uranium, such as HEU, and Mo-95 depleted molybdenum is also within the scope of the present invention. Enrichment of this uranium can be implemented in different ways, for example by utilizing ultracentrifuges, by gas diffusion, or by a combination of these or other methods. Besides, the enriched uranium can be obtained from the mixing of highly enriched uranium with lowly enriched or natural uranium. This is also known as HEU downblending.
Further, the depleted molybdenum can have been obtained in different ways, for example by utilizing ultracentrifuges.
The molybdenum can also be enriched in the isotope 92-Mo, 94-Mo, 96-Mo, 97 Mo, 98-Mo and/or 100-Mo, resulting in molybdenum which is effectively depleted in 95-Mo.
To those skilled in the art, it will be clear that various modifications are possible within the scope of the present invention. | A method for providing a nuclear fuel includes forming a uranium-molybdenum alloy that provides an enhanced reactivity in research, test and radioisotope production nuclear reactors. In this uranium-molybdenum alloy, the uranium is enriched in the isotope 235-U, while the molybdenum is depleted in the isotope 95-Mo. The thus obtained enhanced reactivity can have at least two advantages, depending on the exact use of the fuel element: a requirement for less uranium in the fuel and the use of the fuel elements during a longer period in the reactor. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a microcomputer provided with a monitor circuit for tracing, i.e., keeping track of operations of a central processing unit (CPU) disposed in the microcomputer.
2. Description of the Prior Art
In order to develop computer systems, it is necessary to implement development work accompanied by verification of whether or not software programs to control operations of the CPU are executed properly. Furthermore, a single chip microcomputer having a built-in monitor circuit for monitoring instructions or the like provided by the CPU has been used recently.
Referring now to FIG. 6, there is illustrated a block diagram showing the structure of such a prior art microcomputer. In the figure, reference numeral 100 denotes a single chip microcomputer, 110 denotes a CPU, 120 denotes a memory for storing a software program for controlling operations of the CPU 110, data and the like, 130 denotes a bus interface unit for linking buses of the CPU 110 to buses of the memory 120, and 140 denotes a monitor unit for keeping track of the execution of an instruction by the CPU 110. Furthermore, reference numeral 150 denotes a tristate buffer, 160 denotes a flag register for storing a flag determining whether or not the monitor unit keeps track of operations of the CPU, 170 denotes a storage unit for storing trace information obtained by the monitor unit 140, and 180 denotes an external terminal through which a signal for setting the flag in the flag register 160 is applied to the flag register 160 from outside the microcomputer. In addition, reference numeral 191 denotes a data bus, 192 denotes an address bus, 193 denotes a group of control signal lines, 194 denotes a CPU data bus, and 195 denotes a CPU address bus.
Next, a description will be made as to the operation of the prior art microcomputer. The monitor unit 140 can latch signals on the CPU address bus 195 and CPU data bus 194 connecting the CPU 110 to the bus interface unit 130 according to a signal on the group 193 of control signal lines and furnish a piece of trace information about the type of an instruction executed by the CPU 110, the address specifying a memory location in the memory in which the instruction is stored and data processed by the instruction. When the flag register 160 is set to "High" state by way of the external terminal 180, that is, when the monitor unit is allowed to store such a piece of trace information in the storage unit 170, the trace information furnished by the monitor unit 140 is written into the storage unit 170 by way of the tristate buffer 150. When the summation of all pieces of trace information sequentially stored in the storage unit exceeds the storage capacity of the storage unit 170, the oldest piece of trace information is erased so that a new piece of trace information can be stored in the storage unit. On the other hand, when the flag register 160 is set to "Low" state, a piece of trace information from the monitor unit 140 cannot be stored in the storage unit 170.
Therefore, a problem with such a prior art microcomputer having the structure mentioned above is that in order to check the main stream of an operation of a software program, that is, check the operation of the program from a broad perspective, the amount of information to be traced is increased and therefore a storage unit having a large amount of memory is needed.
SUMMARY OF THE INVENTION
The object of the present invention is to overcome the above problem. More precisely, it is an object of the present invention to provide a microcomputer capable of checking the main stream of the operation of a software program even though the storage capacity of a storage unit for storing trace information about an operation of a software program is not sufficient.
In accordance with the present invention, there is provided a microcomputer comprising a central processing unit (CPU) for sequentially executing instructions according to a software program and for, when the CPU decodes a marker indicating its location within the software program, furnishing a marker decoding signal showing that the CPU has decoded the marker, and a monitor unit, responsive to the marker decoding signal, for obtaining CPU operation information about operations of the CPU and furnishing the CPU operation information and a marker identifier showing that the marker has been decoded.
In accordance with a preferred embodiment of the present invention, the microcomputer further comprises a storage unit for storing the CPU operation information and the marker identifier furnished by the monitor unit.
Preferably, the CPU operation information can include at least addresses specifying memory locations in which instruction codes that respectively correspond to instructions executed and included in the software program are stored.
In accordance with another preferred embodiment of the present invention, when the CPU decodes the marker, the CPU also furnishes the value of an accumulator thereof via a data bus disposed within the microcomputer, and the monitor unit obtains and furnishes the value of the accumulator on the data bus as a piece of the CPU operation information in response to the marker decoding signal from the CPU.
In accordance with another preferred embodiment of the present invention, the microcomputer further comprises a user-programmable register for storing a specific address and an address comparator for comparing an address on an address bus of the CPU with the specific address stored in the user-programmable register and furnishing a control signal when the address on the address bus of the CPU is coincident with the specific address. Furthermore, when the monitor unit receives the control signal, from then on, it is enabled to obtain and furnish detailed trace information about operations of the CPU including at least addresses indicating memory locations in which instruction codes that respectively correspond to instructions executed and included in the software program are stored and the types of the instructions executed.
Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of a microcomputer according to a first embodiment of the present invention;
FIG. 2 is a view showing a part of a software program source file written in the assembler language;
FIG. 3 is a timing diagram showing the timing of signals which appear within the microcomputer of the first embodiment shown in FIG. 1 when the CPU executes a write instruction;
FIG. 4 is a timing diagram showing the timing of signals which appear within the microcomputer of the first embodiment shown in FIG. 1 when the CPU decodes the instruction code of a marker in the case of where a monitor unit is allowed to keep track of an operation of a software program;
FIG. 5 is a block diagram showing the structure of a microcomputer according to a second embodiment of the present invention; and
FIG. 6 is a block diagram showing the structure of a prior art microcomputer provided with a monitor unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring next to FIG. 1, there is illustrated a block diagram showing the structure of a microcomputer according to a first embodiment of the present invention. In the figure, reference numeral 200 denotes a single chip microcomputer, 210 denotes a CPU, 220 denotes a memory for storing a software program for controlling operations of the CPU 210, data and the like, 230 denotes a bus interface unit for linking buses of the CPU 210 to buses of the memory 220, and 240 denotes a monitor unit for tracing or keeping track of the execution of an instruction by the CPU 110. Furthermore, each of reference numerals 250 and 251 denotes a tristate buffer, 260 denotes a trace flag register for storing a flag determining whether or not the monitor unit keeps track of operations of the CPU, 261 denotes a detailed trace flag register for storing a flag determining whether or not the monitor unit keeps detailed track of operations of the CPU, 270 denotes a storage unit for storing trace information about operations of the CPU (i.e. an operation of a software program executed by the CPU) obtained by the monitor unit 240, 280 denotes an external terminal through which a signal for setting the first flag in the trace flag register 260 is applied to the trace flag register 260 from outside the single chip microcomputer 200, and 281 denotes another external terminal through which a signal for setting the second flag in the detailed trace flag register 261 is applied to the detailed trace flag register 261 from outside the single chip microcomputer 200. In addition, reference numeral 291 denotes a data bus, 292 denotes an address bus, 293 denotes a group of control signal lines, 294 denotes a CPU data bus, 295 denotes a CPU address bus, and 296 denotes a control signal line through which when the CPU 210 decodes a marker which is a specific instruction, it furnishes a pulse signal for showing the decoding of the marker to the monitor unit 240.
Next, a description will be made as to the operation of the microcomputer of the first embodiment. Referring next to FIG. 2, there is illustrated a view showing a part of a software program source file written in the assembly language which is to be executed by the CPU 210. In the figure, (A) shows addresses, and (B) shows instructions. Actually, the CPU 210 executes a set of machine codes which correspond to such a source program written in the assembly language. For example, the instruction "STA A, ADRS1" specified by the address "4000H" states that the value of an accumulator A in the CPU 210 is written into a memory location specified by the address ADRS1. Furthermore, the instruction "MRK" specified by the address "400BH" is a marker showing its location within the software program. When the CPU 210 decodes the instruction code of the marker, it furnishes a pulse for showing the decoding of the instruction code that corresponds to the marker to the monitor unit 240 by way of the control signal line 296.
When the flag stored in the trace flag register 260 is set to "Low", the tristate buffer 250 switches to the OFF state. As a result, the monitor unit 240 is disabled to store trace information about an operation of the software program executed by the CPU 210 in the storage unit 270.
On the other hand, when the flag stored in the trace flag register 260 is set to "High" by way of the external terminal 280, and the flag stored in the detailed trace flag register 261 is set to "Low", the monitor unit 240 does not trace detailed data about an operation of the software program executed by the CPU, but stores only a marker and the address of the marker in the storage unit 270. That is, when the flag in the detailed trace flag register 261 is set to "Low", the tristate buffer 251 switches to the OFF state and hence a control signal from the CPU 210 cannot be delivered to the monitor unit. Accordingly, the monitor unit 240 is disabled to latch the detailed information on the address specifying a memory location in which an instruction code executed by the CPU 210 is stored, data output by the CPU, and the like, and therefore the information cannot be transferred to the storage unit 270. In this case, when the CPU decodes a marker and furnishes a pulse showing the decoding of the marker to the monitor unit 240 via the control signal line 296, the monitor unit 240 latches and delivers the address of the marker to the storage unit 270.
When the flag stored in the trace flag register 260 is set to "High" by way of the external terminal 280, and the flag stored in the detailed trace flag register 261 is set to "High" by way of the external terminal 281, the monitor unit 240 keeps track of detailed information about an operation of the software program executed by the CPU and stores a marker and the address of the marker as well as the detailed information in the storage unit 270. That is, when the flag in the detailed trace flag register 261 is set to "High", the tristate buffer 251 switches to the ON state and hence a control signal from the CPU 210 can be delivered to the monitor unit 240 by way of the group of control signal lines 293. Accordingly, in response to the control signal, the monitor unit 240 latches an address which appears on the CPU address bus 295 and data which appears on the CPU data bus 294, and transfers detailed information about the type of an instruction code executed by the CPU 210, the address specifying a memory location in which the instruction code is stored, the data that has been processed by the instruction, and the like to the storage unit 270. Furthermore, when the CPU 210 decodes the instruction code of a marker, it furnishes a pulse showing that the instruction code of the marker has been delivered thereto, by way of the control signal line 296. When the monitor unit 240 receives the pulse, it latches the address of the marker on the CPU address bus 295 and delivers data indicating the marker as well as the address of the marker to the storage unit 270. The storage unit 270 stores the information delivered thereto therein. Thus, the trace information stored in the storage unit can be used for checking the operation of the software program.
Referring now to FIG. 3, there is illustrated a timing diagram showing the timing of signals which appear within the microcomputer when the CPU 210 executes a write instruction such as "STA A, ADRS1" in the case of where the flag in the detailed trace flag register 261 is set to "High". In the figure, the uppermost waveform CLK shows a reference clock signal, the next waveform ADR shows an address on the CPU address bus 295, the next waveform DATA1 shows data on the CPU data bus 294, the next waveform CONT1 shows a pulse signal which is delivered by the CPU 210 via one of the group of control signal lines 293 when a write instruction is executed by the CPU, the next waveform CONT2 shows a pulse signal which is delivered by the CPU 210 via one of the group of control signal lines 293 when the address of a memory location into which data is to be written is output by the CPU, the next waveform CONT3 shows a pulse signal which is delivered by the CPU 210 via one of the group of control signal lines 293 when the data to be written into the above memory location is output by the CPU, and the next waveform DATA2 shows trace information which is delivered to the storage unit 270 by the monitor unit 240.
When the CPU 210 delivers an address 301 specifying the memory location of a write instruction in the memory by way of the CPU address bus 295, the write instruction 302 stored in the memory location specified by the address 301 is furnished via the CPU data bus 294 by the bus interface unit 230 or the memory 220. Furthermore, the CPU 210 furnishes a pulse 303 showing that the write instruction has been delivered thereto. When the monitor unit 240 receives the pulse transferred thereto via the group 296 of control signal lines, it delivers a write instruction identifier such as "W" to the storage unit 304.
After that, the CPU 210 delivers a memory address 305 indicating the memory location into which data is to be written, by way of the CPU address bus 295. Then, the CPU 210 furnishes a pulse 306 showing that the CPU has delivered the memory address 305 indicating the memory location into which data is to be written. When the monitor unit 240 receives the pulse 306, it latches the memory address 305 delivered by way of the CPU address bus 295 and delivers it as a memory address 307 into which data is to be written to the storage unit 270. Then, the CPU 210 delivers data 308 which is to be written into the memory location via the CPU data bus 294 and furnishes a pulse 309 showing that the CPU has delivered the data to the monitor unit 240. When the monitor unit 240 receives the pulse 309, it latches the data 308 which is to be written into the memory and delivers it as data 310 which is to be written into the memory to the storage unit 270.
Thus, when a write instruction is executed by the CPU, the identifier showing the execution of the write instruction, the address specifying the memory location into which data is written, and the data to be written into the memory location from the monitor unit 240 are transferred to and are stored as trace data in the storage unit 270. Similarly, when a read instruction to read data from the memory 220 or a jump instruction to cause a jump to another address is executed, the trace data about the instruction from the monitor unit 240 are delivered to and are stored in the storage unit 270.
Referring next to FIG. 4, there is illustrated a timing diagram showing the timing of signals which appear within the microcomputer when the CPU 210 decodes the instruction code of a marker in the case of where the flag in the trace flag register 260 is set to "High", that is, the monitor unit keeps track of an operation of the software program. In the figure, the uppermost waveform CLK shows a reference clock signal, the next waveform ADR shows an address on the CPU address bus 295, the next waveform DATA1 shows data on the CPU data bus 294, the next waveform CONT1 shows a pulse signal showing that the CPU 210 has delivered the address specifying a memory location in which the instruction code of a marker is stored via one of the group of control signal lines 293, the next waveform CONT2 shows a pulse signal which is delivered by the CPU 210 via the control signal line 296 when the CPU identifies the instruction code of a marker, and the next waveform DATA2 shows a marker identifier showing that the CPU has identified a marker and the address of the marker which are sequentially delivered by the monitor unit 240 when the CPU identifies the command of a marker.
When the CPU 210 identifies a marker, it delivers a marker address 401 specifying a memory location in which the instruction code of the marker is stored, by way of the CPU address bus 295 and a pulse 403 showing that the CPU 210 has delivered the marker address 401 by way of the group 293 of control signal lines. When the monitor unit 240 receives the pulse 403, it latches the marker address 401 on the CPU address bus 295. Then, when the marker instruction 402 from the bus interface unit 230 or memory 220 is transferred to the CPU 210 by way of the CPU data bus 294, the CPU 210 decodes the instruction code of the marker and furnishes a pulse 404 showing the decoding of the marker to the monitor unit 240 via the control signal line 296. When the monitor unit 240 receives the pulse 404, it furnishes an identifier showing that the marker instruction has been executed, such as "M", and the marker address 406 that the monitor unit has latched to the storage unit 270.
Thus, the microcomputer according to the first embodiment of the present invention is adapted to execute a software program including markers and store only the identifier and addresses of the markers in the storage unit. Accordingly, the microcomputer can keep track of the main stream of an operation of software programs without having to use a storage unit having a large amount of memory.
As previously explained, when the CPU 210 decodes the instruction code of a marker, the monitor unit is adapted to store the marker identifier and the address specifying a memory location in which the instruction code is stored in the storage unit 270. Alternatively, the CPU 210 is adapted to deliver the value of the accumulator thereof by way of the CPU data bus 294 when it decodes the instruction code of a marker, and the monitor unit 240 is adapted to latch the value of the accumulator on the CPU data bus 294 and furnish it as well as the identifier and address of the marker. In this variant, since the content of the accumulator, which is of importance to the operation of the software program, can be verified, the efficiency of developments of software programs can be improved.
Referring next to FIG. 5, there is illustrated a block diagram showing the structure of a microcomputer according to a second embodiment of the present invention. The same components as those shown in FIG. 1 are designated by the same reference numerals, and the duplicated description about the components will be omitted hereinafter. In the figure, reference numeral 200a denotes a single chip microcomputer, 297 denotes a use-programmable address register for storing a specific (or predetermined) address which is to be compared with an address delivered via the CPU address bus 295, 298 denotes an address comparator which compares the address in the address register 297 with an address on the CPU address bus 295, 299 denotes an AND gate, and 299a denotes a latch circuit. The address register 297 can be set by a signal delivered from outside the microcomputer applied to a terminal not shown in the figure. Alternatively, the value of the address register 297 can be defined by a software program executed by the CPU 210.
Next, a description will be made as to the operation of the microcomputer of this embodiment. In the first embodiment, only when the flag in the detailed trace flag register 261 is set to "High", the tristate buffer 251 allows the monitor unit 240 to furnish detailed trace information. On the contrary, in accordance with the second embodiment, when the value of an address on the CPU address bus 295 exceeds a predetermined value and the CPU 210 identifies a marker, the monitor unit 240 is enabled to obtain and furnish detailed trace information to the storage unit 270.
To this end, a marker is inserted into the top of a part of a software program the operation of which is to be traced and the address of the marker is written into the address register 297 first. Then, when the CPU 210 starts to execute the software program, the address comparator 298 starts to compare an address on the CPU address bus 295 with the address of the marker stored in the address register 297.
When the value of the address on the CPU address bus 295 is smaller than the value stored in the address register 297, the address comparator 298 furnishes a signal at "Low" level. Therefore, the output of the AND gate 299 becomes "Low" state regardless of the state of a control signal on the control signal line 296. As a result, the tristate buffer 251 switches to the OFF state and the monitor unit 240 furnishes only information about the marker to the storage unit 270.
On the other hand, when the value of the address on the CPU address bus 295 reaches the value stored in the address register 297, the address comparator 298 furnishes a signal at "High" level. Then, when the CPU decodes the marker, it furnishes a control signal at "High" level via the control signal line 296, so that the output of the AND gate 299 changes to "High" state. When the output of the AND gate 299 changes from "Low" state to "High" state, the latch circuit 299a keeps a signal delivered to the tristate buffer 251 in "High" state. After that, a control signal from the CPU 210 can be furnished to the monitor unit 240, and the monitor unit 240 operates so as to deliver detailed trace information to the storage unit 270.
Thus, the microcomputer according to the second embodiment of the present invention is adapted to store only the identifier and addresses of markers in the storage unit 270 during the execution of a part of a software program which is not of importance, and store detailed trace information in the storage unit 270 during the execution of the part of the software program which is of importance. Accordingly, the microcomputer can keep track of the main stream of an operation of a software program and check the trace information about a important part of the software program. Thereby, software programs can be developed with efficiency.
As previously explained, the present invention offers the following advantages.
In accordance with a preferred embodiment of the present invention, there is provided a microcomputer comprising a monitor unit, when the CPU executes a software program including a marker, for obtaining CPU operation information or trace information about operations of the CPU upon decoding the marker and furnishing a marker identifier showing that the marker has been decoded as well as the information. Therefore, the embodiment offers the advantage of being able to easily check the main stream of an operation of a software program.
In accordance with another preferred embodiment of the present invention, the microcomputer further comprises a storage unit for storing the CPU operation information and the marker identifier furnished by the monitor unit. Therefore, the embodiment offers the advantage of being able to easily check the main stream of an operation of a software program without having to use a storage unit having a large amount of memory.
In accordance with a preferred embodiment of the present invention, the CPU operation information can include addresses indicating memory locations in the memory in which instruction codes of instructions included in the software program are stored. Therefore, the embodiment offers the advantage of being able to easily check the main stream of an operation of a software program.
In accordance with another preferred embodiment of the present invention, when the CPU decodes the marker, the CPU also furnishes the value of an accumulator thereof via a data bus disposed within the microcomputer, and the monitor unit obtains and furnishes the value of the accumulator on the data bus as a piece of the information about operations of the CPU in response to the marker decoding signal showing that the CPU has decoded a marker from the CPU. Therefore, the embodiment offers the advantage of being able to easily check the operational condition of software programs.
In accordance with another preferred embodiment of the present invention, when an address furnished via the address bus of the CPU is coincident with a specific address stored in a user-programmable address register, the monitor unit obtains and furnishes detailed trace information about operations of the CPU including at least addresses specifying memory locations in the memory in which instruction codes which respectively correspond to instructions in the software program are stored and the types of the instructions. Therefore, the embodiment offers the advantage of being able to provide the user with detailed information about an operation of a part of a software program which is of importance to the user, and hence develop software programs with efficiency.
Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims. | A microcomputer includes a central processing unit for sequentially executing instructions according to a software program. When the CPU decodes a marker, the CPU determines the location of the marker within the software program and produces a marker decoding signal showing that the CPU has decoded the marker. A monitor unit obtains CPU operation information about operation of the CPU in response to the marker decoding signal. The monitor unit provides to a storage unit the CPU operation information and a marker identifier showing that the marker has been decoded. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to plant for use in carrying out the separation of the impurity content of impure water by the immiscible refrigerant freeze process. The said process broadly comprises boiling the immiscible refrigerant in impure water to be processed, separating the ice crystals formed and melting the ice crystals to produce water purified to an acceptably low inorganic salt concentration. A plant for the said process must comprise a plurality of plant components each carrying out one or more process steps and thus provision must be made for transferring process materials between one component and the next. In attempting to reduce capital costs, designers' attention has been directed to the formulation of an integral design of plant so avoiding the need to duct process fluids between spaced apart plant components and at the same time easing thermal insulation problems. However this integral concept has not so far been achieved without compromising to some degree the operational efficiency of one or other of the plant components to the detriment of overall performance. This is a disincentive to integrate for, in plant of this kind, there is a definite relationship between the outline shape of a conventionally designed plant component and its efficient functioning which imposes constraints on the ultimate outline which the plant may assume.
The present invention aims to produce an integrated plant which compromises little, if at all, with operational efficiency.
Considering now the specific plant components of an immiscible refrigerant freeze separation plant, these comprise a crystalliser in which ice crystals are formed in the liquid to be treated by boiling in it a liquid refrigerant, a wash column in which an ice column is formed from compacted ice crystals, a condenser/melter in which refrigerant vapour is condensed in melting compacted ice scraped from the top of the ice column and a decanter in which the condensed refrigerant separates from the product water and is poured off the top of underlying water. Thus, whilst the wash column and condenser/melter are vertically orientated plant components which may be reasonably evenly matched in height, the crystalliser must be strictly limited in height. In practice; too deep a fluid flow in the crystalliser does not allow the secondary refrigerant liquid to evaporate on injection into the impure liquid due to the latter's hydrostatic head unless a very low refrigerant inlet pressure is to be employed. The decanter also tends towards a horizontal axis so that the fluids may lose velocity, separate and the less dense liquid may be decanted successfully.
SUMMARY OF THE INVENTION
According to the present invention plant for reducing the impurity content of impure water by the immiscible refrigerant freeze process includes a crystalliser component for producing ice crystals by boiling immiscible refrigerant in the water, the crystalliser component taking the form of a plurality of tiers, so that its overall height matches that of those plant components which tend towards a vertical outline shape whereby the plant components may be integrated in a single vessel of regular outline. The improvement in the crystalliser configuration leads to an advantageous sub-division of plant construction by which there is provided a freezer section for producing ice crystal slurry by boiling immiscible refrigerant in the impure water followed by a disengagement section in which entrained refrigerant separates from ice crystals, the freezer section taking the form of a number of tiers. Preferably each tier comprises an annular, endless, approximately horizontally extending passageway along which the impure liquid may be circulated, with the process liquid inlet, a refrigerant gas inlet, an ice slurry outlet disposed at spaced parts of the passageway. The subdivision of the crystalliser into tiers enables the superimposed annular passageways to circumscribe a central conduit for accommodating ducting and pipework. Conveniently, the central conduit may communicate at its base with one or more radial conduits which interconnect it to one end of the outer annulus which may contain plant auxiliaries. Pipework may occupy a part of these inter-connecting radial conduits.
The disengagement, region may comprise a helical tray or trays beneath, and co-axial with, the annular passageways.
Advantageously the single vessel serves as an insulated containment for the integrated plant and comprises an upstanding cylinder accommodating the multi-tiered crystalliser as a plurality of superposed annular passageways in structure defining a central duct which extends co-axially of the cylinder, the vessel having an outer annulus containing the wash column and an intermediate annulus housing the melter/condenser. The decanter then occupies a lower region of the vessel.
The vessel may be constructed in steel but concrete is to be preferred with the crystalliser passageways formed in massive concrete as cored holes or precast sections in block form. The disengagement zone may then occupy a special cavity formed in the concrete below the passageways.
DESCRIPTION OF THE DRAWINGS
In order that the invention may be better understood one embodiment thereof as applied to a brine desalting plant will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a block diagram showing how the components of the plant are integrated into a single cylindrical vessel,
FIG. 2 is a diagrammatic form of the preferred embodiment.
FIG. 3 is a section on the line III--III of FIG. 2, and
FIG. 4 is a perspective view of the plant in part broken away to show the interior.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a freeze plant is integrated into a single, upstanding cylindrical reinforced concrete vessel 1 in the following manner:
A crystalliser 2 is housed in an inner annulus, a washer 4 arranged in an outer annulus and a melter/condenser 3 in an annulus intermediate these two. A decanter 5 for separation of liquid refrigerant from the product is situated beneath the crystalliser and melter/condenser. In the compact arrangement described below, a cylindrical vessel of less than 90 foot external diameter and an overall height of about 60 feet may accommodate a plant having an output of 21/2 MIGD of desalted water.
This compactness is attributable at least in part to the provision of a crystalliser operable in the "stirred tank " mode, yet is built to a height corresponding to that of each of the washer and the melter/condenser and circumscribing a central axial gas duct 7 also useful for service and process piping. Communicating with the bottom of the duct 7 are a number of radial access conduits 8, leading to an annulus 6 below the washer 4.
Reference to FIG. 2 shows how the crystalliser 2 which normally tends to a horizontal configuration is constructed to fit a vertical annulus. As shown, the cylindrical vessel 1 is reinforced concrete and has its central axial duct 7 defined by a concrete wall 9 integral with bulk concrete in which three tiers of separate horizontal passages 2a form a freezer section of crystalliser. Each tier comprises a pair of concentric horizontal tracks (FIG. 3) which unite at 2b to form an endless passageway around which brine may circulate whilst it is cooled by the boiling of a liquid refrigerant, in this case butane. Each passage 2a has its liquid butane inlet 2c in its base, its butane vapour outlet 2d near its top, its tangential raw brine inlet 2e and its ice/brine slurry outlet 2f. The butane vapour discharges directly into the central duct 7 whilst the other outlets/inlets are served by pipes extending within the duct 7. Vapour from duct 7 is taken via one of the radial ducts 8 to a primary compressor 27a.
A secondary crystalliser or disengagement section is housed in a cavity beneath the lowermost tier and receives ice/brine slurry from outlets 2f. This section comprises three helical trays 10 arranged as a three start helix around the duct 7 so constituting three parallel flow paths in which ice crystals may grow and butane vapour disengage from the slurry.
Raw brine feed is pumped up to each brine inlets 2e through three separate feedpipes one of which is shown at 11 and supplied in parallel to each of the separate tiers via branch pipes 12 arranged to lie in a common vertical plane. Liquid butane is pumped through three pipes as at pipe 13 one for each tier into ring mains 14 communicating with inlets 2c. Outlets 2f for the slurry from each tier also lie in a common vertical plane, the outlet pipes only one of which is shown at 15 being bent round to suit this configuration.
The effluent from the trays 10 is a slushy ice brine mixture. A pipe such as pipe 15a from each of the three trays 10 leads to a slurry pump 16 located in the annulus 17. The slurry pump 16 lifts the slurry below the outer annulus 17 where it enters the washer 4. The washer is of known construction and is similar to that described in the following reference Proc of the 3rd International Symposium on Fresh Water from the Sea Vol 3 pp 51-69 1970. Suffice to say here that an annular inlet plenum chamber 19 which is defined between a pair of annular horizontal, vertically spaced walls 19a 19b receives the slurry from the pumps 16. The lower wall 19b supports the base of elongated vertical thimble or drain tubes 20 with closed upper ends; towards the upper end the tube walls are peppered with perforations forming drain screens for the brine. The tubes 20 pass with clearances 21 through holes in the upper wall 19a and centred by radial fins (not shown). Below the wall 19b, the tubes 20 communicate with a header pipe 22 leading to a downcomer 23. The latter leads brine washed off ice crystals to the inlet of a brine pump 24 for re-circulation via pipe 11. Make-up brine may be added from supply 25. As will be understood from the aforementioned reference, the brine/ice mixture rises in the annulus 17 and the ice compacts as an annular column in the form of a porous solid and the brine flows upwardly through this column and eventually through the perforations in the thimble tubes 20. Thence the brine flows through the bores of tubes 20 into the header pipe 22.
Mounted above the annulus 17 are a number of co-planar scraper blades 26 forming an annular scraper blade assembly whose function is to harvest the ice off the top of the outer annulus and to move it into the top of the intermediate annulus 3. To provide a large surface area for melting, the greater part of annulus 3 is filled with small plastics artefacts of saddle-like shape. Butane vapour from a primary compressor 27a outside the vessel is delivered into a radial duct 3 which is inter-connected with a plastics lined annular duct 29. The latter extends within the partition wall separating annuli 3 and 4 and at its upper end leads through the partition wall to annulus 3. In an ante chamber 31 above the melter/condenser, the ice is mixed with a bleed of product water so that it is reslurried by admixture with product water, delivered via pipe 31a, so that the slurry is fluid enough to be distributed over the whole cross section of the intermediate annulus 3. The reconstituted slurry flow is distributed by trays 30 and then con-currently with butane vapour over the plastics artefacts, the slurry melting and the butane condensing. The resulting mixture of product water and butane liquid pass through outlets 32 into the annulus 5 shaped to act as a decanter. To this end an arcuate wall 33 is upstanding from the floor of the annulus 5, so that, as the circulatory flow of fluids results in the less dense butane rising to an upper layer above the denser water, so the butane flows over the wall 33 into an inner volume 34 whence, separated now from the product water it can be withdrawn via outlet pipe 35 leading to a secondary butane compressor 27b. Product water on the other hand is withdrawn from the decanter through downcomer pipe 36 into product water main 37. The butane is delivered as liquid from the decanter 5 into risers 13 for re-use in the crystalliser. The scraper blade assembly comprises six helical blades 26. The blades which are carried by a common carriage 40 have cone wheels 41 running on circular rails 42. On the upper part of the carriage are mounted a series of reaction plates 43 which serve as armatures with respect to stators 44 of linear electric motors which are themselves carried at spaced intervals on the underside of the roof of the vessel 1. The motors are energised from a supply S outside the vessel and fed to the motors via cables 46 which extend through a sealed penetration in the vessel roof.
A linear drive to the reaction plates is permissible owing to the large diameter of the track and scraper blade carriage. By the use of linear motors the need for supporting a rotary motor centrally of the vessel is obviated rotary and seals for the motor drive are thus obviated. | A plant for reducing the impurity content of impure water by the immiscible refrigerant freeze process, for example a secondary refrigerant freezing plant employed for desalination, has its crystallizer sub-divided into a plurality of tiers of passageways and supplied in parallel with impure water. Thus the crystallizer may be built to a height which matches the configuration of the usual wash column so that together the two components can be housed in a conveniently cylindrical shell along with the decanter and the melter/condenser. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to microscopic imaging and, more specifically, to three-dimensional (“3D”) sub-100 nanometer resolution by biplane microscope imaging.
BACKGROUND OF THE INVENTION
Until about a decade ago, resolution in far-field light microscopy was thought to be limited to ˜200-250 nanometers in the focal plane, concealing details of sub-cellular structures and constraining its biological applications. Breaking this diffraction barrier by the seminal concept of stimulated emission depletion (“STED”) microscopy has made it possible to image biological systems at the nanoscale with light. Additional details are provided in an article titled “Far-Field Optical Nanoscopy by Stefan W. Hell (316 Science, 1153-1158, May 25, 2007), which is incorporated herein by reference in its entirety. STED microscopy and other members of reversible saturable optical fluorescence transitions (“RESOLFT”) family achieve a resolution >10-fold beyond the diffraction barrier by engineering the microscope's point-spread function (“PSF”) through optically saturable transitions of the (fluorescent) probe molecules.
Lately, an emerging group of localization-based techniques has obtained similar resolution in the lateral plane. This group includes fluorescence photoactivation localization microscopy (“FPALM”), photoactivation localization microscopy (“PALM”), stochastic optical reconstruction microscopy (“STORM”), and PALM with independently running acquisition (“PALMIRA”). FPALM is described in more detail in an article titled “Ultra-High Resolution Imaging by Fluorescence Photoactivation Localization Microscopy” by Samuel T. Hess et al. (91 Biophysical Journal, 4258-4272, December 2006), which is incorporated herein by reference in its entirety. PALM is described in more detail in an article titled “Imaging Intracellular Fluorescent Proteins at Nanometer Resolution” by Eric Betzig et al. (313 Science, 1642-1645, Sep. 15, 2006), which is incorporated herein by reference in its entirety. STORM is described in more detail in an article titled “Sub-Diffraction-Limit Imaging by Stochastic Optical Reconstruction Microscopy” by Michael J. Rust et al. (Nature Methods/Advance Online Publication, Aug. 9, 2006), which is incorporated herein by reference in its entirety. PALMIRA is described in more detail in an article titled “Resolution of λ/10 in Fluorescence Microscopy Using Fast Single Molecule Photo-Switching” by H. Bock et al. (88 Applied Physics A, 223-226, Jun. 1, 2007), and an article titled “Photochromic Rhodamines Provide Nanoscopy With Optical Sectioning” by J. Folling et al. (Angew. Chem. Int. Ed., 46, 6266-6270, 2007), each of which is incorporated herein by reference in its entirety. As referred to in the current application, the term photo-sensitive refers to both photo-activatable (e.g., switching probes between an on state and an off state) and photo-switching (e.g., switching between a first color and a second color).
While utilizing similar optical switching mechanisms, this latter group of microscopes circumvents the diffraction limit by basing resolution improvement on the precise localization of spatially well-separated fluorescent molecules, a method previously used to track, for example, conventionally labeled myosin V molecules with 1.5 nanometers localization accuracy. This method is described in more detail in an article titled “Myosin V Walks Hand-Over-Hand: Single Fluorophore Imaging With 1.5-nanometers Localization” by Ahmet Yildiz et al. (300 Science, 2061-2065, Jun. 27, 2003), which is incorporated herein by reference in its entirety.
To resolve complex nanoscale structures by localization-based methods, the sample is labeled with photo-sensitive probes, such as photo-activatable (“PA”) fluorescent probes (e.g., PA proteins or caged organic dyes). Activation of only a sparse subset of molecules at a time allows their separate localization. By repeated bleaching or deactivation of the active molecules in concert with activation of other inactive probe molecules, a large fraction of the whole probe ensemble can be localized over time. The final sub-diffraction image of the labeled structure is generated by plotting the positions of some or all localized molecules.
Based on the rapid development in both RESOLFT and localization-based techniques, the impact of super-resolution far-field fluorescence microscopy on the biological sciences is expected to increase significantly. Within 2007 alone subdiffraction multi-color imaging has been reported for the first time for STED microscopy, PALMIRA, STORM, and FPALM has successfully been demonstrated in live cells. Some of these reports are included in an article titled “Two-Color Far-Field Fluorescence Nanoscopy” by Gerald Donnert et al. (Biophysical Journal, L67-L69, Feb. 6, 2007), in an article by M. Bates, B. Huang, G. T. Dempsey, and X. Zhuang (Science 317, 1749-1753, 2007), and in an article titled “Dynamic Clustered Distribution of Hemagglutinin Resolved at 40 nanometers in Living Cell Membranes Discriminates Between Raft Theories” by Samuel T. Hess et al. (Proc. Natl. Acad. Sci. USA 104, 17370-17375, Oct. 30, 2007), each of which is incorporated herein by reference in its entirety.
However, the slow progress in 3D super-resolution imaging has limited the application of these techniques to two-dimensional (“2D”) imaging. The best 3D resolution until recently had been 100 nanometers axially at conventional lateral resolution. Achieved by the combination of two objective lens apertures in 4Pi microscopy, it has been applied for more than a decade. This is described in more detail in an article titled “H2AX Chromatin Structures and Their Response to DNA Damage Revealed by 4Pi Microscopy” by Joerg Bewersdorf et al. (Proc. Natl. Acad. Sci. USA 103, 18137-18142, Nov. 28, 2006), which is incorporated by reference in its entirety. Only lately first 3D STED microscopy images have been published exceeding this resolution moderately with 139 nanometer lateral and 170 nanometer axial resolution. These images are presented in more detail in an article by K. I. Willig, B. Harke, R. Medda, and S. W. Hell (Nat. Methods 4, 915-918, 2007), which is incorporated by reference in its entirety. While this represents a ˜10-fold smaller resolvable volume than provided by conventional microscopy, it is still at least 10-fold larger than a large number of sub-cellular components, for example synaptic vesicles. Recently, an article (Huang et al., Science 2008) has reported first 3D STORM of thin optical sections (<600 nanometers) with sub-100 nanometer 3D resolution under reducing (low oxygen) conditions.
Moreover, current understanding of fundamental biological processes on the nanoscale (e.g., neural network formation, chromatin organization) is limited because these processes cannot be visualized at the necessary sub-millisecond time resolution. Current biological research at the sub-cellular level is constrained by the limits of spatial and temporal resolution in fluorescence microscopy. The diameter of most organelles is below the diffraction limit of light, limiting spatial resolution and concealing sub-structure. Recent developments (e.g., STED, FPALM, STORM, etc.) have dramatically enhanced the spatial resolution and even overcome the traditional diffraction barrier. However, comparable improvements in temporal resolution are still needed.
Particle-tracking techniques can localize small objects (typically<diffraction limit) in live cells with sub-diffraction accuracy and track their movement over time. But conventional particle-tracking fluorescence microscopy cannot temporally resolve interactions of organelles, molecular machines, or even single proteins, which typically happen within milliseconds.
The spatial localization accuracy of single particles in a fluorescence microscope is approximately proportional to d/√{square root over (N)} (d=spatial resolution; N=total number of detected fluorescence photons from the particle) in the absence of background and effects due to finite pixel size. For longer acquisition times more signal can be accumulated, hence increased temporal resolution requires a trade-off of decreased spatial localization accuracy. For bright organelles containing a few hundred fluorescent molecules, (or future fluorescent molecules with increased brightness), sufficient signal can be accumulated quickly. However, especially for 3D localization where data acquisition is far more complicated than in 2D, technical constraints arising from axial scanning and/or camera readout times limit the recording speed, and therefore, the temporal resolution.
For example, a particular 3D particle-tracking technique can track particles only with 32 milliseconds time resolution. This technique scans a 2-photon excitation focus in a 3D orbit around the fluorescent particle and determines its 3D position by analyzing the temporal fluorescence fluctuations. The temporal resolution is ultimately limited by the frequency with which the focus can revolve in 3D around the particle. This technique is described in more detail in an article titled “3-D Particle Tracking In A Two-Photon Microscope: Application To The Study Of Molecular Dynamics IN Cells” by V. Levi, Q. Ruan, and E. Gratton (Biophys. J., 2005, 88(4): pp. 2919-28), which is incorporated by reference in its entirety.
In another example, another current 3D particle-tracking technique combines traditional particle-tracking with widefield “bifocal detection” images. Particles are simultaneously detected in one plane close to the focal plane of the particle and a second plane 1 micrometer out of focus. The lateral and axial coordinates are derived from the 2 images. In accordance with this technique, the temporal resolution is limited to the 2-50 milliseconds range, and the localization accuracy is limited to the 2-5 nanometer range. Additional details are described in an article titled “Three-Dimensional Particle Tracking Via Bifocal Imaging” by E Toprak et al. (Nano Lett., 2007, 7(7): pp. 2043-45), which is incorporated by reference in its entirety. As such, advances in temporal resolution to sub-millisecond levels have been limited only to 2D imaging.
Thus, there is a need for a microscopy system that can provide 3D imaging with resolution below 100 nanometers in all three dimensions. Another need is directed to achieving particle-tracking in 3D with a temporal resolution below 1 millisecond for enabling visualization of dynamic sub-cellular processes. The present invention is directed to satisfying one or more of these needs and solving other problems.
SUMMARY OF THE INVENTION
According to one embodiment, a microscopy system is configured for creating 3D images from individually localized probe molecules. The microscopy system includes a sample stage, an activation light source, a readout light source, a beam splitting device, at least one camera, and a controller. The activation light source activates probes of at least one probe subset of photo-sensitive luminescent probes, and the readout light source causes luminescence light from the activated probes. Optionally, the activation light source and the readout light source is the same light source. The beam splitting device splits the luminescence light into at least two paths to create at least two detection planes that correspond to the same or different number of object planes of the sample. The camera detects simultaneously the at least two detection planes, the number of object planes being represented in the camera by the same number of recorded regions of interest. The controller is programmable to combine a signal from the regions of interest into a 3D data set.
According to another embodiment, a method for creating 3D images from individually localized probe molecules includes mounting a sample on a sample stage, the sample having a plurality of photo-sensitive luminescent probes. In response to illuminating the sample with an activation light, probes of at least one probe subset of the plurality of photo-sensitive luminescent probes are activated. In response to illuminating the sample with a readout light, luminescence light from the activated probes is caused. The luminescence lights is split into at least two paths to create at least two detection planes, the at least two detection planes corresponding to the same or different object planes in the sample. At least two detection planes are detected via a camera. The object planes are recorded in corresponding recorded regions of interest in the camera. A signal from the regions of interest is combined into a 3D data stack.
According to yet another embodiment, a microscopy system is configured for tracking microscopic particles in 3D. The system includes a sample, a sample stage, at least one light source, a beam-steering device, a beam splitting device, at least one camera, and a controller. The sample, which includes luminescence particles, is mounted to the sample stage. The light source is configured to illuminate an area of the sample to cause luminescence light, primarily, from one tracked particle of the luminescence particles. The beam-steering device is configured to selectively move a light beam to illuminate different areas of the sample such that the luminescence light is detected. The beam splitting device, which is located in a detection light path, splits the luminescence light into at least two paths to create at least two detection planes that correspond to different object planes in the sample. The camera is positioned to detect simultaneously the at least two detection planes, the number of object planes being represented in the camera by the same number of recorded regions of interest. The controller is programmable to combine a signal from the recorded regions of interest, determine a 3D trajectory of the particle at each time point of a recorded data sequence, and move the beam-steering device to illuminate the different areas of the sample in accordance with corresponding positions of the one tracked particle.
According to yet another embodiment, a method for tracking microscopic particles in 3D includes mounting a sample on a sample stage, the sample including luminescent particles. A small area of the sample is illuminated to cause luminescence light from primarily one particle of the luminescent particles. The light beam is selectively moved to illuminate different areas of the sample to track movement of the one particle, the different areas including the small area of the sample and corresponding to respective positions of the one particle. The luminescence light is split into at least two paths to create at least two detection planes that correspond to the same or different number of object planes in the sample. The at least two detection planes are detected simultaneously. The number of object planes is represented in a camera by the same number of recorded regions of interest. Based on a combined signal from the recorded regions of interest, a 3D trajectory of the one particle is determined at each time point of a recorded data sequence.
Additional aspects of the invention will be apparent to those of ordinary skill in the art in view of the detailed description of various embodiments, which is made with reference to the drawings, a brief description of which is provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating a biplane microscope setup for Fluorescence Photoactivation Localization Microscopy (FPALM), according to one embodiment.
FIG. 2 is a schematic view illustrating a biplane microscope setup, according to an alternative embodiment.
FIG. 3 is a schematic view illustrating a fluorescent particle image on a CCD chip.
FIG. 4A is a graph representing an axial resolution measured from an axial profile of caged fluorescein-labeled antibodies.
FIG. 4B is a representative image showing added-up projections of a data set in three different orientations for the axial resolution measured in FIG. 4A .
FIG. 5A is a representative image of a data set for beads labeled with caged fluorescein at an axial position of 300 nanometers.
FIG. 5B illustrates a representative image of a resulting data set for the beads of FIG. 5A at an axial position of 100 nanometers.
FIG. 5C illustrates a representative image of a resulting data set for the beads of FIG. 5A at an axial position of −100 nanometers.
FIG. 5D illustrates a representative image of a resulting data set for the beads of FIG. 5A at an axial position of −300 nanometers.
FIG. 5E illustrates a representative image of a resulting data set for the beads of FIG. 5A at an axial position of −500 nanometers.
FIG. 5F illustrates a volume-rendered representation of the data set illustrated in FIGS. 5A-5E .
FIG. 6 is a schematic view illustrating adjustment of a biplane microscope setup, according to an alternative embodiment.
FIG. 7A is a schematic view illustrating a fluorescent particle image on a CCD chip when the particle is in focus, in a first position.
FIG. 7B is a schematic view illustrating the fluorescent particle image of FIG. 7A when the particle is out of focus, in a second position.
FIG. 7C is a schematic view illustrating the fluorescent particle image of FIG. 7B when the particle is in focus, in a third position.
DETAILED DESCRIPTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
Referring to FIG. 1 , a biplane (“BP”) microscope system 100 allows 3D imaging at an unmatched resolution well below 100 nanometers in all three dimensions, resulting in at least a 100-fold smaller resolvable volume than obtainable by conventional 3D microscopy. The BP microscope system 100 is optionally a BP FPALM system, which is generally based on a conventional FPALM design. However, in contrast to conventional FPALM design, the BP microscope system 100 includes a modified detection path that allows the simultaneous detection from two focal planes. The simultaneous detection of two planes for localization-based super-resolution microscopy speeds up the imaging process by making axial scanning unnecessary, and more importantly, in contrast to scanning-based systems, eliminates localization artifacts caused by abrupt blinking and bleaching common to single molecules. The BP microscope system 100 can optionally be located on an air-damped optical table to minimize vibrations.
In addition to achieving 3D particle localization down to the nanometer range accuracy, the BP microscope system 100 can also achieve temporal resolution <1 milliseconds. As such, in addition to being a BP FPALM system, the BP microscope system 100 can also be a next-generation 3D particle-tracking microscope (“3D PTM”) for providing unprecedented temporal and spatial resolution when tracking fluorescent particles in live cells in 3D. FPALM and particle-tracking are just some exemplary applications of the BP microscope system 100 . To achieve unprecedented temporal resolution at least as short as 0.3 milliseconds, the BP microscope system 100 tracks one particle at a time (in contrast to conventional 2D and 3D tracking techniques that visualize the entire field). Additionally, the BP microscope system 100 can include a detection scheme without any moving parts that detects simultaneously two axially shifted detection planes.
In contrast to current PTM techniques, the BP microscope system 100 can include a focused laser beam for excitation combined with spatially limited detection. Background light is filtered out to avoid localization disturbances and to increase sensitivity in samples thicker than about 1 micrometer. This enables particle-tracking even in tissue sections. To follow a particular particle over several microns in 3D, the BP microscope system 100 can include, for example, high-speed piezo-mirrors and a fast piezo-driven sample stage. The combination of focused excitation and feedback-driven beam-tracking reduces the background and enhances the speed limit by approximately one order of magnitude. Optionally, a second (different) luminescence color can be detected to enable correlative studies of the movement of the tracked particle.
Illumination for readout and activation can be provided by a readout laser 102 , operating typically at 496 nanometers, and an activation laser 104 (e.g., 50 mW, Crystalaser), operating typically at 405 nanometers. The readout laser 102 is optionally a water-cooled Argon laser (e.g., Innova 70, coherent Inc.) that can provide 458, 472, 488, 496, or 514 nanometers for readout illumination. Optionally, the wavelength of the readout laser 102 is selected to minimize activation of inactive probes of a plurality of photo-sensitive probes of a sample 124 . Optionally yet, the readout laser 102 and the activation laser 104 can be the same source. For example, the readout laser 102 can perform both the readout functions and the activation functions, without requiring the use of the activation laser 104 . According to one embodiment, at least one illuminated area of the sample 124 is a relatively small area, having, for example, a general diameter that is less than about three times an Airy disk diameter.
Both lasers 102 , 104 are combined, via a first dichroic beam splitter 110 , and coupled, via a second dichroic beam splitter 120 , into a microscope stand 106 equipped with a 63× 1.2NA water immersion tube lens 108 after passing through a field aperture 107 . Both lasers 102 , 104 can be switched on and off by software-controlled electrical shutters (e.g., SH05, Thorlabs). Other components that may be included along the path between the lasers 102 , 104 and the microscope stand 106 are a first mirror 112 and a first lens 114 .
The microscope stand 106 can have a plurality of components, including a sample stage 116 and an objective 118 . The sample 124 , including for example a biological cell 124 a is generally positioned on the sample stage 116 . The sample stage 116 can be a mechanical stage or a three-axis piezo stage (e.g., P-733.3DD, Physik Instrumente). Other components, which are not shown, may include shutters in front of the lasers 102 , 104 and further optics for folding the beam path.
Fluorescence is collected by the objective 118 , passes through a second dichroic beam splitter 120 (which reflects the laser light) and is focused by the tube lens 108 via an optional second mirror 122 (e.g., a piezo-driven mirror) into an intermediate focal plane 140 . The focal plane 140 is imaged by two lenses—a second lens 128 and a third lens 132 —onto a high-sensitivity EM-CCD camera 126 (e.g., DU897DCS-BV iXon, Andor Technology). Scattered laser light is attenuated by bandpass and Raman edge filters (e.g., Chroma and Semrock), such as filter 130 .
The detection scheme can be achieved by moving the CCD camera 126 out of the standard image plane closer to the tube lens 108 and thereby shifting the corresponding focal plane ˜350 nanometers deeper into the sample. A beam splitter cube 134 is placed into a focused light path 136 a in front of the CCD camera 126 . The beam splitter cube 134 redirects a reflected light path 136 b via a third mirror 138 towards the CCD camera 126 to form a second image in a different region of the same CCD. Due to the longer optical path, this second image corresponds to a focal plane ˜350 nanometers closer to the objective 118 than the original focal plane.
The BP microscope system 100 , using a single camera, is straightforward to implement and avoids synchronization problems between separate cameras. The BP microscope system 100 features a reasonable field of view of ˜20×50 micrometers 2 (pixel size corresponding to ˜100 nanometers in the sample 124 ; 512×512 pixels), sufficient to image large portions of a cell. The BP microscope system 100 is able to image 100 frames per second with a field of view of 10 to 20 micrometers in length and 2×2 binning. The use of the CCD camera 126 , which features negligible readout noise due to its on-chip electron multiplication, avoids additional noise that would otherwise result from splitting the light up into two fields as required for BP detection. Combined with the fact that there is minimal loss of fluorescence detection efficiency, this exemplary BP microscope system 100 expands conventional FPALM to 3D imaging without significant drawbacks.
BP FPALM technology is compatible with live cell imaging and can be expanded to multicolor imaging (even realizable on the same CCD detector). BP FPALM can record 3D structures in a ˜1 micrometer thick z-section without scanning. Larger volumes can be recorded by recording BP FPALM data at different sample positions. To minimize activation of out of focus PA molecules, BP FPALM can be combined with a 2-photon (“2P”) laser scanner. 2P excitation-mediated activation is directed to diffraction-limited planes of 800 nanometers thickness, a thickness that is compatible with the axial detection range of BP FPALM. BP FPALM therefore has the potential of imaging specimens such as cell nuclei or tissue sections far exceeding 1 micrometer in thickness.
Moreover, combined with or without 2P excitation, BP FPALM can be readily implemented in practically every existing FPALM, PALM, PALMIRA or STORM instrument. BP FPALM therefore provides the means to investigate a large variety of biological 3D structures at resolution levels previously far out of reach.
Optionally, BP FPALM detected luminescence from activated probes is fluorescence or scattered light. In an alternative embodiment, the activation of activated probes is achieved via a non-linear process that limits the activation to a plane of diffraction-limited thickness.
For PSF measurement, according to one example, 100 nanometer diameter yellow-green fluorescent beads (Invitrogen, F-8803) can be attached to a poly-L-lysine coated cover slip. The sample can be mounted on a piezo stage and imaged in the BP FPALM setup with 496 nm excitation. Typically, 101 images at z-positions ranging from −2.5 to +2.5 micrometers with 50 nanometers step size are recorded. The same bead is imaged 2 to 3 times to check for drift and to correct for bleaching. To reduce noise, the data set can be smoothed in Inspector with a Gaussian filter of sub-diffraction size. Additionally, the data set can be corrected for mono-exponential bleaching, cropped to appropriate size and to be centered and normalized to 1.
Use of two focal planes for z-position determination is generally sufficient for particle localization under the constraints that (1) a sparse distribution of particles is analyzed (no overlapping signal within the size of one PSF) and (2) the axial position of the particle is close to one of the detection planes or lies between them. For example, to evaluate the range and accuracy of z-localization, 40 nanometers diameter fluorescent beads (FluoSpheres, F8795, Invitrogen) were imaged on a cover slip over 1,000 frames. A piezo-driven sample stage was moved by one 100 nanometers z-step every 100 frames. Localization analysis of the BP images reproduced that z-movement very accurately with σ≈6 to 10 nanometers axial localization accuracy. The beads could be localized over a range of 800 nanometers exceeding the distance between the two detection planes (in this case 500 nanometers) by more than 50%.
In one example, the accumulation time per frame is typically 10 milliseconds. In this example, electron multiplying gain is set to 300, the readout is 2×2 binned, only the region occupied by two recorded regions of interest (“ROIs”) is read out, and, typically, 5,000 to 50,000 frames are recorded.
Optionally, at least some of the ROIs are detected at different wavelengths by including suitable detection filters in the BP microscope system 100 . In alternative embodiments, at least some of the ROIs are detected at different polarization directions by including suitable polarization optics in the BP microscopy system 100 .
Referring to FIG. 2 , a BP microscope system 200 is shown according to an alternative embodiment. The BP microscope system 200 includes a microscope stand 202 having a piezo-driven sample stage 204 on which a sample 206 is positioned. The sample 206 includes a plurality of fluorescent particles 206 a - 206 d . The microscope stand 202 further includes an objective 208 and a first lens 210 .
Additional components are positioned between a focal plane 212 and the CCD camera 214 along a fluorescence light path 215 . Specifically, the components include a second lens 216 , a beam-steering device 281 (e.g., a piezo-driven mirror), a dichroic beam splitter 220 , a bandpass filter 222 , a third lens 224 , a neutral 50:50 beam splitter 226 , and a mirror 228 . Optionally, the beam-steering device 218 can include generally a focusing optical element that moves illumination and detection focal planes axially to follow the tracked particle. In yet another example, the beam-steering device 218 can include a phase-modulating device that moves an illuminated area laterally and illumination and detection focal planes axially to follow the tracked particle. Optionally yet, more than one piezo-driven mirror 218 can be included in the BP microscope system 200 .
A polarized laser beam from a laser 229 is coupled into the microscope stand 202 and focused into the sample 206 by the objective 208 . A fourth lens 230 and a λ/4 plate 232 are positioned between the laser 229 and the dichroic beam splitter 220 .
The focus can be positioned in the region of interest by moving the sample stage 204 and the beam-steering device 218 . The fluorescence emerging from the focal region is collected by the objective 208 and is imaged onto the CCD camera 214 via the first lens 210 , the second lens 216 , and the third lens 224 . The dichroic beam splitter 220 and the bandpass filter 222 filter out scattered excitation light and other background light.
The neutral 50:50 beam splitter 226 splits the fluorescence light into two beam paths, a transmitted beam 215 a and a reflected beam 215 b . The transmitted beam 215 a images light emitted from a plane deeper in the sample onto one area of the CCD chip. The reflected beam 215 b images light from a plane closer to the objective onto another well-separated area to avoid cross-talk.
Referring to FIG. 3 , two ROIs on the CCD chip represent two focal planes in the sample 206 (illustrated in FIG. 2 ), typically 700 nanometers apart, arranged like wings of a biplane. The two ROIs include a transmitted ROI 300 and a reflected ROI 302 , each having nine pixels showing an image of the fluorescent particle 206 b from the sample 206 . The dashed areas 304 a - 304 i , 306 a - 306 i depict the pixels that are used for tracking the fluorescent particle 206 b . Thus, the two 9-pixel-areas 304 a - 304 i , 306 a - 306 i represent in general the position of the particle 206 b in 3D.
The fluorescent particle 206 b , which is generally smaller than the laser focus and located in the focal region, is excited homogeneously and 3 (binned) lines (i.e., the two 9-pixel-areas represented by dashed areas 304 a - 304 i , 306 a - 306 i ) of the CCD chip arranged around the laser focus image are read out at every time point. Particles laterally shifted with respect to the laser focus center will appear shifted on the CCD chip. For the z direction, the two 9-pixel-areas 304 a - 304 i , 306 a - 306 i act in the same was as two confocal pinholes in different planes: if the particle 206 b moves axially, the signal will increase in one of the 9-pixel-area and decrease in the other 9-pixel-area. An axial shift will be represented by a sharper intensity distribution in one of the two 9-pixel-areas depending on the direction of the shift.
The 3D position can be determined by subtracting different pixel values of the two 9-pixel-areas from each other. For the axial coordinate (z-axis), the sum of all pixels from one 9-pixel-area can be subtracted from the other 9-pixel-area. The fact that the lateral information is preserved in the 9-pixel-areas allows for lateral localization of the particle 306 b at the same time. For the lateral x-axis (or y-axis) direction, the signal collected in the left columns 304 a , 304 d , 304 g , 306 a , 306 d , 306 g (or upper rows: 304 a , 304 b , 304 c and 306 a , 306 b , 306 c ) of both 9-pixel-areas 300 and 302 can be subtracted from the one in the right columns 304 c , 304 f , 304 i , 306 c , 306 f , 306 i (or lower rows: 304 g , 304 h , 304 i and 306 g , 306 h , 306 i ). Calculations show that the determined values are approximately proportional to the particle position offset of the center as long as the position stays in a range of +/−250 nanometers axially and +/−100 nanometers laterally. In a simple feedback loop, these values can be fed back to piezo controllers tilting piezo mirrors and moving the sample stage piezo to re-center the particle in the 9-pixel-areas after every measurement. Optionally, for larger movements up to about double the linear ranges, the position can be determined by taking the image shape and brightness into account in the data analysis to increase the tracking range.
According to an alternative embodiment, the pixels of the transmitted ROI 300 (on the left) show a brighter image than the pixels of the reflected ROI 302 (on the right). For example, the top-right dashed areas 304 b , 304 c , 304 e , 304 f of the transmitted ROI 300 are generally brighter than the other 5 pixels in the same ROI 300 and than all pixels of the reflected ROI 302 As such, the fluorescent particle 206 b is located axially more towards the focal plane 140 imaged on transmitted ROI 300 and is shifted by about half the diffraction limit toward the right and top relative to the excitation focus.
The signal from the two ROIs 300 , 302 can also be combined into a 3D data stack (2 pixels in z; x and y dimensions are determined by the size of the ROIs 300 , 302 ). Data analysis is a generalization of standard FPALM methods to 3D. Instead of a Gaussian, an experimentally obtained 3D-PSF can be fit to each data set consisting of the pixels around each detected probe molecule. The x, y and z-coordinates of each molecule are determined from the best fit of the molecule image with the PSF.
For BP FPALM, typically but not necessarily, larger ROIs 300 , 302 are used to allow localization of particles over a larger field of view. Also, several particles can be present in the same ROI and still be analyzed separately. Slight variations in the magnification and rotation between the two detection areas may be corrected by software before combination of the two ROIs 300 , 302 into a 3D data stack. The slight difference in the tilt of the focal planes between the two ROIs 300 , 302 is negligible because of the large axial magnification (proportional to the lateral magnification squared). The analysis of the 3D data can be seen as the generalization of standard 2D FPALM analysis to 3D. Particles are identified in the z-projected images by iteratively searching for the brightest pixels and eliminating this region in the subsequent search until a lower intensity threshold has been reached. The raw data may be cut out in each ROI 300 , 302 around each found particle in a square window of, for example, 10-19 pixels long and wide. Instead of a 2D Gaussian, a theoretical or experimentally obtained 3D-PSF can be fitted to the data sets in this cutout window using a simplex fitting algorithm adapted from Numerical Recipes in C, or a different algorithm. From the resulting best fitting x, y and z-coordinates, the localized position is extracted and stored. Additionally, amplitude, background, the deviation from the cutout windows center, the number of iterations and the chi square value are stored, which allow later determination of the quality of the fit. The stored list of fit results is analyzed and translated into 3D data sets of customizable voxel sizes. The fit amplitude is used as the voxel intensity for every molecule found that fulfills the user-defined quality criteria. For operation without the piezo stage, the camera software (Solis, Andor Technology) is used for data recording. Software to operate the microscope with the piezo stage, for fitting, and to create 3D data sets, may be programmed in LabView 8.2 (National Instruments). Inspector (Andreas Schoenle, Max Planck Institute for Biophysical Chemistry, Goettingen, Germany) is used for display and analysis of 3D data sets. 3D rendered images may be created using Amira.
Referring to FIG. 4A , a graph illustrates the axial resolution measured using a BP FPALM setup. Specifically, the axial resolution is measured from an axial profile of caged fluorescein-labeled antibodies on a covers slip and embedded in 87% glycerol. The black line represents raw data and the dashed line represents a Gaussian fit.
From the axial profile, a full-width-at-half-maximum (“FWHM”) distribution of 75 nanometers is measured, which is about 10-fold below the axial FWHM of measured PSF (which represents the axial resolution of conventional diffraction-limited microscopy). Since localization-based resolution is proportional to the diffraction-limited PSF size and the axial FWHM of a widefield 1.2NA PSF is ˜250% larger than the lateral FWHM, the measured z-localization precision is consistent with x and y-resolution of 20 to 40 nanometers previously obtained in FPALM and PALM.
Referring to FIG. 4B , an inset shows added-up projections of the data set (of FIG. 4A ) in three different orientations. The white box marks the region used to generate the axial profile. The scale bar of the original images was 2 micrometers.
Referring to FIGS. 5A-5E , 3D BP FPALM imaging of 2 micrometers diameter beads labeled with caged fluorescein shows data sets at different axial positions. Specifically, representative 100 nanometer thick xy images of the resulting data set are illustrated at z=+300 nanometers, +100 nanometers, −100 nanometers, −300 nanometers, and nanometers, respectively. The data shown in all planes 5 A- 5 F is recorded simultaneously without scanning. Especially to image samples thicker than 1 micrometer, the sample stage can be moved after finishing recording at one sample position to access different sample depth positions and the data recording process is repeated until all sample positions of interest have been recorded.
Referring to FIG. 5F , a volume-rendered representation is shown based on the data sets of FIGS. 5A-5E . The curved surface of the bead is nicely reproduced over nearly 1 μm in depth without scanning. The optical images show well-below 100 nanometers resolution in all three dimensions. With approximately 30×30×80 nanometers 3 , the resolvable volume is ˜500-fold below the diffraction-limited observation volume and represents the smallest observation volume achieved in a far-field light microscope.
Referring to FIG. 6 , a BP microscope system 600 is illustrated to show the tracking of a single particle 606 positioned on a sample stage 604 . The BP microscope system 600 is generally similar to the BP microscope system 300 described above in reference to FIG. 3 .
As the single particle 606 moves relatively to the sample stage 604 from a first position (indicated in solid line) to a second position (indicated in dashed line), the fluorescence light beam is adjusted by tilting one or more piezo-mounted mirrors or adjusting alternative beam-steering devices 618 . In the exemplary scenario, the piezo-mounted mirror 618 is tilted counterclockwise from a first position (indicated in solid line) to a second position (indicated in dashed line). The rotation of the mirror 618 steers the fluorescence light beam on the camera as well as the excitation light beam focusing into the sample and coming from the laser to correct for sideways movement of the particle 606 . The mirror 618 is rotated until the excitation light beam is again centered on the particle 606 .
Optionally, the sample stage 604 is moved up or down to correct for vertical movement. Alternatively, a suitable beam-steering device 618 refocuses the beam vertically. After the necessary adjustments are made to track the particle 606 , the positions of the piezo and stage are recorded to reconstruct large scale movement in post-processing.
Referring to FIGS. 7A and 7B , two insets show the images recorded when a particle moves from a first position to a second position as described above in reference to FIG. 6 . In FIG. 7A , a transmitted ROI 700 a and a reflected ROI 700 b are recorded on a CCD chip when the particle is in the first position. The pixels of the transmitted ROI 700 a show the same focus and intensity as the pixels in the reflected ROI 700 b . A black box surrounds a general 5×5 pixel area of interest.
When the particle moves to the second position, as shown in FIG. 7B , the transmitted ROI 700 a and the reflected ROI 700 b change such that the respective pixels in the area of interest are now out of focus and of different intensity. For example, the pixels of the transmitted ROI 700 a are now generally brighter (i.e., more intense) than in the first position, and off-center with respect to the area of interest (i.e., up and to the right). Similarly, the pixels of the reflected ROI 700 b are now generally less bright (i.e., less intense) than in the first position, and off-center with respect to the area of interest (i.e., up and to the right).
Referring to FIG. 7C , the fluorescence light beam has now been steered to center it on the particle 606 in the second position. The pixels of the transmitted ROI 700 a and of the reflected ROI 700 b are generally similar, if not identical, to the pixels illustrated in the first position of the particle 606 (shown in FIG. 7A ). Specifically, the pixels are generally centered within the area of interest and are now of similar intensity in both the transmitted ROI 700 a and the reflected ROI 700 b.
Various aspects of the present invention may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described in the foregoing, and the aspects of the present invention described herein are not limited in their application to the details and arrangements of components set forth in the foregoing description or illustrated in the drawings. The aspects of the invention are capable of other embodiments and of being practiced or of being carried out in various ways.
Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. | A microscopy system is configured for creating 3D images from individually localized probe molecules. The microscopy system includes a sample stage, an activation light source, a readout light source, a beam splitting device, at least one camera, and a controller. The activation light source activates probes of at least one probe subset of photo-sensitive luminescent probes, and the readout light source causes luminescence light from the activated probes. The beam splitting device splits the luminescence light into at least two paths to create at least two detection planes that correspond to the same or different number of object planes of the sample. The camera detects simultaneously the at least two detection planes, the number of object planes being represented in the camera by the same number of recorded regions of interest. The controller is programmable to combine a signal from the regions of interest into a 3D data. | 6 |
FIELD OF THE INVENTION
[0001] This invention generally relates to semiconductor wafer cleaning and more particularly to a cleaning procedure for removing residual contamination from semiconductor wafer surface including metal nitride particles, following semiconductor device manufacturing processes.
BACKGROUND OF THE INVENTION
[0002] In semiconductor fabrication, various layers of insulating material, semiconducting material and conducting material are formed to produce a multilayer semiconductor device. The layers are patterned to create features that taken together, form elements such as transistors, capacitors, and resistors. These elements are then interconnected to achieve a desired electrical function, thereby producing an integrated circuit (IC) device. The formation and patterning of the various device layers are achieved using conventional fabrication techniques, such as oxidation, implantation, deposition, epitaxial growth of silicon, lithography, etching, and planarization.
[0003] For example, in creating a multiple layer semiconductor device on a semiconductor wafer, each layer making up the device may be subjected to one or more deposition processes, for example by chemical vapor deposition (CVD), and usually including one or more etching procedures by either a dry (plasma) or wet (chemical) etching process. A critical condition in semiconductor manufacturing is the absence of contaminants on the wafer processing surface, as contaminants including, for example, microscopic particles, may interfere with and adversely affect subsequent processing steps leading to device degradation and ultimately semiconductor wafer rejection.
[0004] While the wafer cleaning process has been always been a critical step in the semiconductor wafer manufacturing process, ultra clean wafers are becoming even more critical to device integrity. For example, as semiconductor feature sizes decrease, the detrimental affect of particle contamination increases, requiring removal of ever smaller particles. For example, particles as small as 20 nm may be unacceptable in many semiconductor manufacturing processes. Further, as the number of device layers increase there is a corresponding increase in the number of cleaning steps and the potential for device degradation caused by contamination. To adequately meet requirements for ultra clean wafers in ULSI and VLSI the wafer surface must be free of particles, organic contamination, metal contamination, surface micro roughness and native oxide.
[0005] Common processes in use for cleaning wafers include cleaning solutions based on hydrogen peroxide. At high pH values (basic) organic contamination and oxidizable particles, are removed by an oxidation process. At low pH (acidic) metal contamination is desorbed from the wafer surface by forming a soluble complex.
[0006] Common particle removal mechanisms which may be exploited, depending on the particle and how it adheres to the surface, include dissolution, oxidizing degradation and dissolution, physical removal by etching, and electrical repulsion between a particle and the wafer surface.
[0007] Standard wafer cleaning processes include mechanical scrubbing or and ultrasonic agitation of the wafer surface in the cleaning solution or in deionized water (particulate removal). Typical chemical cleaning solutions include solutions of “piranha”, RCA cleanup, and choline. Piranha is a solution of hydrogen peroxide (H 2 O 2 ) and sulfuric acid (H 2 SO 4 ). Choline cleaning solution includes hydrogen peroxide with choline ((CH 3 ) 3 N(CH 2 CH 2 OH)OH) at 50° C. followed by an ultrasonic agitation in deionized water and a deionized water rinse followed by a spin dry. The RCA cleaning process has up to three steps; a removal of gross organics with perchloroethylene; a removal of residual organic films with a basic solution of H 2 O 2 and NH 4 OH followed by deionized water rinse and spin dry; and, a removal of metal particles with an acidic solution of H 2 O 2 and HCl again followed a deionized water rinse and spin dry. The cleaning solutions are typically used at about 75° C. to about 80° C. and essentially provide an oxidizing and complexing treatment which does not attack silicon or silicon dioxide (oxide). The basic solution cleanup is frequently referred to as SC- 1 and the acidic solution cleanup is referred to as SC- 2 .
[0008] One shortcoming with cleaning process of the prior art using cleaning solutions based on hydrogen peroxide, is the failure to adequately remove metal nitride particles as acceptable particle sizes decrease. Metal nitrides are used in semiconductor processing for numerous portions of a semiconductor device. For example, metal nitrides including silicon nitride, silicon oxynitride, and titanium nitride are widely used as barrier layers in metal interconnects such as vias and trench lines to prevent metal fill diffusion into adjacent insulating layers.
[0009] Another example includes the use of metal nitrides, for example, silicon nitride, as a hard mask or etch stop overlying, for example, an insulating layer in which features are anisotropically etched using the metal nitride as a hard mask during reactive ion etching (RIE). The metal nitride layers are typically deposited by a CVD process such as plasma enhanced CVD (PECVD) and low pressure CVD (LPCVD). Metal nitride particles contaminate the process wafer surface during both the CVD process and the RIE process. For example, metal nitride particles remaining on the wafer surface after the CVD process may degrade subsequent process steps including photolithographic patterning of a photoresist layer deposited over a metal nitride layer in preparation for etching. As a further example, metal nitride particles remaining over a barrier layer following a CVD deposition could interfere with the adhesion or step coverage of, for example, a metal seed layer for a subsequent electrodeposition process.
[0010] Yet another example where metal nitride particles are left on a semiconductor processing surface includes chemical mechanical polishing (CMP). Frequently in semiconductor processing steps, following RIE etching and backfilling with metal of vias and trench lines, a CMP process is performed to planarize the semiconductor surface, frequently removing not only metal but a portion of the metal nitride etch stop layer overlying the insulating layer. As such, both metal particles and metal nitride particles must be removed from the semiconductor surface before forming the next series of device layers.
[0011] At least two major difficulties are presented in using hydrogen peroxide based cleaning solutions of the prior art, such as SC- 1 and SC- 2 , to clean metal nitride surfaces. One difficulty is that both basic and acidic versions of hydrogen peroxide based solutions may tend to attack the metal nitride surface resulting in micro roughness due to oxidation and etching of the surface thereby unacceptably degrading electrical properties in many emerging applications of metal nitrides, for example, as gate materials in CMOS gate structures.
[0012] Another difficulty is due to what are believed to be electrical repulsion effects or electrical double layer effects resulting from smaller metal nitride particles, making the electrical repulsion effect from, for example, cleaning solutions SC- 1 or SC- 2 , less effective with metal nitride particles.
[0013] There is therefore a need in the semiconductor processing art to develop cleaning methods that are able to effectively clean metal nitride particle residues from semiconductor wafer surfaces without creating a micro roughened metal nitride surface.
[0014] It is therefore an object of the invention to provide a cleaning method that will effectively clean metal nitride particle residues from semiconductor wafer surfaces creating a micro roughened metal nitride surface while overcoming other shortcomings and deficiencies in the prior art.
SUMMARY OF THE INVENTION
[0015] To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention provides a method of removing residual contamination including metal nitride particles from semiconductor wafer surfaces.
[0016] In a first embodiment according to the present invention, includes the steps of: providing at least one semiconductor wafer with metal nitride particles adhering to the at least one semiconductor wafer surface thereto; subjecting the at least one semiconductor wafer to at least one mechanical brushing process while a cleaning solution including a carboxylic acid is supplied to the at least one semiconductor wafer surface; and, subjecting the at least one semiconductor wafer to an a sonic cleaning process including the carboxylic acid cleaning solution.
[0017] In related embodiments, the cleaning solution includes at least one of formic acid, acetic acid, propionic acid, valeric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, maleic acid, fumaric acid, phthalic acid, glycolic acid, lactic acid, citric acid, tartaric acid, gluconic acid, and adipic acid. Further, the cleaning solution comprises from about 2 to about 10 weight percent carboxylic acid. Further yet the cleaning solution has a temperature of from about 20° C. to about 90° C.
[0018] In other related embodiments, the metal nitride particle source includes at least one of a chemical vapor deposition process, a plasma etching process, a chemical mechanical polishing process, and an ion implantation process. Further, the metal nitride includes at least one of silicon nitride, silicon oxynitride, titanium nitride, and tantalum nitride.
[0019] In yet other related embodiments, the mechanical brushing process includes using brushes that comprise polyvinylacetal (PVA) bristles. Further, the mechanical brushing process includes at least one rotary brush applied to the at least one semiconductor surface. Further yet, the sonic cleaning process comprises a megasonic cleaning process. Further, the method according to the present invention includes immersing the at least one semiconductor wafer in the carboxylic acid cleaning solution such that the at least semiconductor wafer surface is oriented parallel to an ultrasonic energy source.
[0020] In another embodiment the step of subjecting the at least one semiconductor wafer to a sonic cleaning process is performed prior to the step of subjecting the at least one semiconductor wafer to a mechanical brushing process.
[0021] These and other embodiments, aspects and features of the invention will be better understood from a detailed description of the preferred embodiments of the invention which are further described below in conjunction with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1 A- 1 C are representative cross sectional side views of a portion of a dual damascene structure at different stages of manufacture.
[0023] FIGS. 2 A- 2 C are graphical representations of a carboxylic acid cleaning process according to the present invention.
[0024] FIGS. 3 A- 3 C are graphical representations of machanical brushing and megasonic cleaning processes used according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The method according to the present invention is more clearly described by referring to FIGS. 1 A- 1 C, FIGS. 2 A- 2 C, FIGS. 3 A- 3 C.
[0026] In the method according to the present invention the method is explained by an exemplary reference to manufacturing a dual damascene structure where metal nitride layers are advantageously used. It will be appreciated, however, that the method according to the present invention may be used in any semiconductor wafer cleaning process where metal nitride particles are advantageously be removed.
[0027] In a typical damascene process, for example, a dual damascene manufacturing process known in the art as a via-first-trench process, conventional photolithographic processes using a photoresist layer is first used to expose and pattern a metal nitride etching mask overlying an insulating (IMD/ILD) layer, for etching via openings through the insulating layer. Subsequently a similar process is used to define trench openings that are formed substantially over the via openings which in turn define metallic interconnect lines. The via openings and trench openings are subsequently filled with metal to form metallization vias and metal interconnect lines. The surface may then be planarized by conventional techniques to better define the metal interconnect lines and prepare the substrate for further processing.
[0028] As an example of a typical damascene process, for example, a via-first process, referring to FIG. 1A a substrate having a first conductive layer 10 , for example copper or aluminum is provided. Next, an insulating layer 12 is formed over the substrate by, for example, plasma enhanced chemical vapor deposition (PECVD) followed by planarization so that the insulating layer thickness matches the depth of the desired via openings. Thereafter, a metal nitride etching stop layer 14 of, for example, silicon nitride or silicon oxynitride, is formed over the insulating layer by a conventional CVD process such as low pressure CVD (LPCVD), PECVD, or high density plasma CVD (HDPCVD). Following the deposition of the metal nitride etching stop layer, the semiconductor wafer may be subjected to a wafer cleaning process to remove contaminants including residual metal nitride particles remaining on the semiconductor wafer surface.
[0029] Next, a dielectric anti-reflectance coating (DARC) layer 16 , for example, silicon oxynitride or titanium nitride, is formed over the etching stop layer 14 to reduce undesired light reflections from the surface and underlying interfaces in a subsequent photolithographic process. Again, the semiconductor wafer may be subjected to a wafer cleaning process at this point to remove contaminants including residual metal nitride particles. Next, a photoresist layer 18 is formed over the DARC layer, which is subsequently patterned for reactive ion etching (RIE) through the metal nitride layers at e.g., opening 20 to form a via opening through the metal nitride layers and insulating layer. The patterned photoresist layer 18 is then used as a mask to anisotropically etch through the underlying layers 16 , 14 to include etching through the insulating layer 12 to conductive layer 10 to form via opening 22 as shown in FIG. 1B. Again, the semiconductor wafer at this point is advantageously subjected to a wafer cleaning process to remove contaminants including residual metal nitride particles remaining on the semiconductor surface or within the etched features from the etching process.
[0030] After etching the via opening 22 , the photoresist layer 18 is stripped and the process is repeated to form a trench line 24 in insulating layer 26 overlying via opening 22 as shown in FIG. 1C. Referring to FIG. 1C, a metal nitride barrier layer 28 , for example, silicon nitride or titanium nitride, may be advantageously deposited by a conventional CVD process, for example, LPCVD, to cover the via walls and via floor to prevent diffusion of subsequently deposited metal filling the via opening 22 and trench opening 24 into the insulting layers 10 and 26 . Again, a wafer cleaning process may be advantageously used to remove residual metal nitride particles remaining from the metal nitride CVD process to deposit the metal nitride layer 28 . Subsequently the via and trench openings are filled to form vias and trench lines (metal interconnects) followed by a chemical mechanical polishing (CMP) step to planarize the semiconductor surface 30 , removing excess metal including a portion of uppermost metal nitride layers, which is again followed by a wafer cleaning process.
[0031] In the wafer cleaning process according to the present invention, it has been found that carboxylic acids may be advantageously used in a wafer cleaning process to remove metal nitride particles from a semiconductor wafer surface. In one embodiment, a carboxylic acid solution of between about 2 to about 10 weight percent carboxylic acid is advantageously used according to the present invention. More preferably, the carboxylic acid solution is about 4% by weight. The solution preferably includes deionized water as a solvent.
[0032] Referring FIG. 2A, in one embodiment according to the present invention, the semiconductor wafer is immersed in the carboxylic acid solution of the present invention together with a source of agitation, such as mechanical brushing or ultrasonic energy. In FIG. 2A a carboxylic acid molecule 201 releases hydrogen ions 202 to form a carboxylate anion group. The weakly acidic solution is believed to alter the surface charge state of the semiconductor wafer surface 204 thereby weakening the adherence of metal nitride particles e.g., 206 . While it is believed alteration of the charge state of the semiconductor surface 204 is not sufficient by itself to repel adhering metal nitride particles e.g., 206 , it is believed the negatively charged carboxylate anions are able to weakly complex with the metal nitride particles at the surface e.g., 206 as shown in FIG. 2B. As a result of electrostatic repulsion effects and complexing effects it is believed that the metal nitride particles adherence to the wafer surface is weakened, thereby allowing a sufficient agitation applied to the wafer surface by, for example, mechanical brushing and sonic energy to dislodge the particles from the surface. It is believed the particles e.g., 206 , after dislodging, as shown in FIG. 2C are thereafter kept from re-depositing on the semiconductor wafer surface 204 by electrostatic repulsion forces. In order to perform the complexing function, the cleaning solution must have at least one carboxylate group. It is believed weak complexes are formed between the metal nitride and carboxylate anions through hydrogen bonding mechanisms. Exemplary acids carboxylic acids include formic acid, acetic acid, propionic acid, valeric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, maleic acid, fumaric acid, phthalic acid, glycolic acid, lactic acid, citric acid, tartaric acid, gluconic acid, adipic acid, and combinations thereof. Preferably, however, a carboxylic acid such as citric acid, which contains more than one carboxylic acid group is preferred as it is believed the complexing function is improved thereby. Preferably the cleaning solution according to the present invention is within a temperature range of from about 20° C. to about 90° C.
[0033] It has been found according to the present invention that using a carboxylic acid, for example, a citric acid cleaning solution, that a mechanical brushing (scrubbing) process alone is insufficient to remove metal nitride particles from the semiconductor wafer surface. In addition, the use of sonic energy, such as a megasonic cleaning process, is likewise by itself insufficient to dislodge the metal nitride particles from a semiconductor wafer surface. It has been unexpectedly found, however, that a mechanical brushing cleaning procedure in addition to a megasonic cleaning procedure using the carboxylic acid solution of the present invention act together synergistically to increase the removal of metal nitride particles compared to either mechanical brushing or megasonic cleaning alone. For example, the mechanical brushing procedure in addition to a megasonic procedure using a carboxylic acid solution of the present invention significantly increases the removal of metal nitride particles from about 82 percent, using cleaning solutions of the prior art including ammonium hydroxide containing solutions, to about 95.8 percent using the carboxylic acid solution of the present invention. The mechanical brushing procedure is preferably carried out prior to the sonic cleaning procedure, but the present invention may additionally be practiced by carrying out the sonic cleaning procedure prior to the mechanical brushing procedure, or by carrying out the sonic, for example megasonic, and the mechanical brushing procedure simultaneously.
[0034] Preferably, a conventional sonic cleaning procedure referred to as a megasonic cleaning process is used as the sonic cleaning process which includes a transducer producing sonic energy at a frequency of about 850 to 900 kHz. The sonic energy is preferably directed parallel to the semiconductor wafer surfaces. In operation, referring to FIG. 3A, semiconductor wafer surfaces e.g., 302 held in cassette 303 , are immersed in carboxylic acid cleaning solution 304 such that semiconductor wafer surfaces e.g., 302 are oriented parallel to the direction of travel of the sonic waves e.g., 306 produced by the transducer 308 , typically mounted against the outside of a cleaning solution container 310 . Fresh cleaning solution including one or more carboxylic acids, may be added at the top portion of container 310 through solution supply feeds e.g., 312 . Both automated megasonic cleaning devices and automated mechanical brushing devices are commercially available and exemplary apparatus are outlined, for example, in U.S. Pat. No. 5,762,084 by Kreuss et al. which is incorporated herein by reference. It will be appreciated, however, that any conventional mechanical brushing device and megasonic cleaning device may be utilized according to the present invention. Preferably, the mechanical brushing cleaning procedure and the megasonic cleaning procedure according to the present invention, are performed either separately or together, and are each carried out for a period of from about 30 to 220 seconds and more preferably about 45 seconds, but the time period may vary depending on the mechanical brushing procedure used and the megasonic cleaning procedure used.
[0035] According to the present invention, the mechanical brushing procedure may be applied to one or both of the semiconductor surfaces, but preferably is applied to both surfaces. The mechanical brushing may be applied by any conventional brush equipped with bristles that will not damage the surface such as a plastic material including, for example, a porous polyvinyl acetal (PVA). Preferably the PVA bristles have a porosity of from about 85 percent to about 95 percent. However, other materials such as nylon, mohair or a polishing pad material can be used. Suitable pressures applied by the brushes to the wafer surface may be within a range of 1 PSI to about 10 PSI, but are preferably about 5 PSI.
[0036] The mechanical brushing action on the semiconductor surface is preferably supplied by a rotary type brush either immersed in the cleaning solution or equipped with commercially available brushes that include a spraying source for the cleaning solution. As shown in FIG. 3B both semiconductor wafer surfaces e.g., 320 A and 320 B may be contacted with one or more rotary brushes e.g., 322 A and 322 B while the semiconductor wafer surfaces are, for example, mounted on rollers 324 A and 324 B with the wafer oriented for example, horizontally, such that both the rotary brush and the semiconductor wafer rotate to allow for the entire wafer surface to be brushed. The wafer may either be immersed in the carboxylic acid containing cleaning solution or have the cleaning solution supplied by cleaning solution feeds located near the wafer surface or included as pat of the brushing fixture. The wafer may further be optionally oriented in other directions such as vertically with rotary brushes contacting the top and bottom surfaces of the wafer while the wafer is rotated. It will be further appreciated that other types of brushing action, such as vertically directed or horizontally directed may be advantageously used according to the present invention.
[0037] In another embodiment, the ultrasonic cleaning process and the sonic cleaning process according to the present invention are carried out simultaneously. Preferably the sonic energy source is a megasonic source in the range of 850 kHz to about 900 kHz. For example, the semiconductor wafer surfaces 330 A and 330 B are contacted by one or more rotary brushes e.g., 332 A and 332 B mounted on brush holders e.g. 334 A and 334 B. The semiconductor wafer is mounted on rollers 336 A and 336 B for rotating the semiconductor wafer while applying rotary brush action. The semiconductor wafer surfaces 330 A and 330 B are oriented such that they are parallel to the direction of travel e.g., 338 of sonic energy produced waves introduced into cleaning solution 340 by transducer 342 mounted adjacent to container 344 .
[0038] The preferred embodiments, aspects, and features of the invention having been described, it will be apparent to those skilled in the art that numerous variations, modifications, and substitutions may be made without departing from the spirit of the invention as disclosed and further claimed below. | A method of removing residual contamination including metal nitride particles from semiconductor wafer surfaces including the steps of: providing at least one semiconductor wafer with metal nitride particles adhering to the at least one semiconductor wafer surface thereto; subjecting the at least one semiconductor wafer to at least one mechanical brushing process while a cleaning solution including a carboxylic acid is supplied to the at least one semiconductor wafer surface; and, subjecting the at least one semiconductor wafer to an a sonic cleaning process including the carboxylic acid cleaning solution. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cooling system for an automobile etc., and more particularly to a cooling system equipped with a device for preventing a bad odor from circulating after starting.
2. Description of the Prior Art
In a cooling system which has a refrigeration cycle with a compressor and an evaporator, and a blower for supplying air to the evaporator of the refrigeration cycle, it is widely known that air with a bad odor due to dust clinging to the evaporator is circulated into a room if the blower is rotated immediately after the starting of the compressor. Devices for preventing such bad odor from circulating have been disclosed in Japanese Utility Model Publication (KOKOKU) No. 55-44652 and Japanese Utility Model Publication (KOKOKU) No. 56-1447, for example. In the device disclosed in the former, first and second thermoswitches are provided on or near the evaporator. The compressor is turned on and off by the first thermoswitch so as to be at a temperature in the vicinity of the freezing temperature. The compressor is then controlled by the second thermoswitch instead of the first thermoswitch, after the starting of the cooling system, so as to drive the compressor to a temperature lower than the freezing temperature, and so as to stop the operation of the blower throughout the period of the drive of the compressor to sufficiently dew the evaporator to prevent the flying-away of the odor molecules clinging to the evaporator. In the device disclosed in the latter, a single thermoswitch is provided so as to drive the compressor to the vicinity of the freezing temperature, regardless of a set temperature, at the first action of the thermoswitch to produce the same effect as mentioned above.
In both prior art devices mentioned above, the temperature at which the compressor is turned on and off is only lowered at the time of the starting of the cooling system, and the capacity of the compressor is not changed. For that reason, the speed of the cooling of the evaporator is low. As a result, the time of the stoppage of the blower is long, and the hot environment at the time of the starting of the cooling system lasts for a long time, and the cooling speed of the system is low.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a cooling system which can solve the abovementioned problems. More specifically, the speed of the cooling of the evaporator is increased at the time of the starting of the cooling system to shorten the time of the stoppage of the blower to quickly cool a room while preventing a bad odor from circulating.
According to the present invention, there is indicated a cooling system comprising a refrigeration cycle having a compressor and an evaporator, and is equipped with a means for adjusting the capacity of the compressor, and a means for stopping the blower until the evaporator is substantially dewed after starting the compressor, and a means for driving the compressor at maximum capacity under the action of the adjusting means until the stoppage of the blower is nullified under the action of the stop means. The r.p.m. or discharge volume of the compressor can be changed by the adjusting means. The stop means can be provided with a manual switch for enabling it to stop the blower or disabling it so as not to stop it at all.
Consequently, after starting the cooling system, the blower is stopped by the stop means and the compressor is driven at the maximum capacity by the driving means until the evaporator is substantially dewed. As a result, the speed of the cooling of the evaporator is maximized, so that the problems are solved.
Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying drawings in which preferred structural embodiments incorporating the principles of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a cooling system which is an embodiment of the present invention.
FIG. 2 is an electric circuit of a control circuit of the cooling system.
FIG. 3 is an electric circuit of a control circuit which is used in another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a cooling system having an air duct 3 which is provided with an air inlet port 1 and an air outlet port 2. A blower 4 and an evaporator 5 are disposed in the air duct 3. When electricity is applied to the motor 4a of the blower 4, its fan 4b is rotated to introduce air into the air duct 3 through the air inlet port 1 and to blow of the air into a room through the evaporator 5 and the air outlet port 2. The evaporator 5 and a compressor 6 constitute a conventional refrigeration cycle. A coolant flowing in the refrigeration cycle is evaporated to perform a heat exchange with the air passing through the evaporator 5 so as to cool the air. The compressor 6 includes a motor 6a, by which the r.p.m. of the compressor is adjusted. The motor 4a of the blower 4 and that 6a of the compressor 6 are controlled by output signals of a control circuit 7. The control circuit 7 receives signals from a blower switch 9 and a temperature sensor 8 which detects the temperature of the evaporator 5.
FIG. 2 shows the electric circuitry including the control circuit 7. The blower switch 9 is connected to the positive terminal of a power supply unit 10 such as a battery. The blower switch 9 comprises a movable contact 9a, and a common contact 9b and four fixed contacts OFF, LOW, MED and HI. The common contact 9b is connected to one terminal of a main switch 11. The fixed contact OFF is connected to nowhere. The fixed contact LOW is connected to one terminal of a series circuit consisting of resistors 12 and 13 used for controlling the r.p.m. of the blower 4. The fixed contact MED is connected to the middle point of the series circuit of the resistors 12 and 13. The fixed contact HI is connected to other terminal of the series circuit. The latter terminal of the series circuit is connected to a positive terminal of the motor 4a of the blower 4 via a normally closed contact 15a, which is opened and closed via a first relay coil 15 in a circuit 14 used for controlling the blower 4 at the time of the starting of the system. The negative terminal of the motor 4a is grounded.
The circuit 14 has a timer comprising a capacitor 16 and resistors 17 and 18. The positive terminal of the capacitor 16 is connected to the main switch 11. One terminal of the resistor 17, whose other terminal is connected to the negative terminal of the capacitor 16, is grounded. One terminal of the resistor 18 is connected to a junction point P which connects the capacitor 16 and the resistor 17, and the other terminal of the resistor 18 is connected to the base of a transistor 19, whose collector is connected to the relay coil 15 and whose emitter is grounded. Immediately after the starting of the charging of the capacitor 16, the potential at the point P is high enough to turn on the transistor 19. However, the potential on the point P gradually falls as the capacitor 16 is increasingly charged, so that the transistor 19 is turned off after a prescribed time. The prescribed time is set by the timer so that the time lasts from immediately after the starting of the cooling operation of the system to the dewing of the surface of the evaporator if the compressor is driven at maximum capacity.
The circuit 14 for controlling the blower at the time of the starting of the system also includes a manual switch 20, which is provided on a operating panel and can be manually turned on and off. The manual switch 20 is connected between the main switch 11 and the relay coil 15. When the manual switch 20 is open, the relay 15 remains unexcited, regardless of the action of the transistor 19. When the manual switch 20 is closed, the supply of electricity to the relay coil 15 is controlled depending the action of the coil 15. A diode 21 for the absorption of the counter electromotive force is connected in parallel with the relay coil 15.
A circuit 22 for controlling the compressor includes a detection circuit comprising a resistor 23 and a temperature sensor 8 which are connected in series between the main switch 11 and ground, and a series circuit comprising resistors 24 and 25 which are also connected between the main switch and ground. The conjointly coupled point of the temperature sensor 8 and the resistor 23 is connected to a non-inverting input terminal of an operational amplifier 26, and the conjointly coupled point of the resistors 24 is connected to an inverting input terminal of the operational amplifier 26, so that a bridge type temperature comparison circuit is constructed. When the temperature of the the evaporator is higher than a reference level (2° C., for example) which is predetermined by the resistors 24 and 25, the operational amplifier 26 sends out an "H" signal. When the temperature is not higher than the reference level, the operational amplifier 26 sends out an "L" signal. These signals are supplied to the base of a transistor 27, whose collector is connected to the main switch 11 via a second relay coil 28 and whose emitter is grounded. A normally open contact 28a, which is opened and closed by the second relay coil 28, has one terminal connected to the main switch 11 and has the other terminal connected to the positive terminal of the motor 6a of the compressor via a parallel circuit consisting of a normally open contact 15 b and a resistor 29 for controlling the r.p.m. of the compressor. The negative terminal of the motor 6a is grounded. The normally open contact 15b is opened and closed by the first relay coil 15. When the normally open contact 28a is closed by energizing the second relay coil 28, the r.p.m. of the motor 6a is controlled depending on opening or closing of the normally open contact 15b so that when the contact 15b is closed, the r.p.m. of the motor 6a is put at the maximum to drive the compressor at the maximum capacity, and when the contact 15b is open, the motor is supplied with electricity via the resistor 29 to make the r.p.m. lower to drive the compressor at a lower capacity. A diode 30 for the absorption of counter electromotive force is connected in parallel with the relay coil 28.
At the first stage of the cooling operation of the system started by connecting the movable contact 9a of the blower switch 9 to a fixed contact other than the OFF contact, and the main switch 11 and the manual switch 20, the potential on the point P of the timer is so high that the transistor 19 is turned on to energize the first relay coil 15 to open the normally closed contact 15a and close the normally open contact 15b. For that reason, the motor 4a of the blower 4 is not supplied with electricity, so that the rotation of the blower remains stopped. At that time, the evaporator 5 is not yet cooled, so that the operational amplifier 26 sends out an "H" signal to turn on the transistor 27 to energize the second relay coil 28 to close the normally open contact 28a. As a result, the maximum voltage is applied to the motor 6a of the compressor 6 to drive it at maximum capacity to quickly lower the temperature of the evaporator 5 to dew it in a short time. When the prescribed time corresponding to the short time has elapsed, the potential on the point P of the timer in the circuit 14 for controlling the blower 4 at the time of the start of the system falls so that the transistor 19 is turned off to de-energize the first relay coil 15 to close the normally closed contact 15a. As a result, electricity is supplied to the motor 4a of the blower 4 to start blowing air. At the same time, the normally open contact 15b is to supply electricity to the motor 6a of the compressor 6 via the resistor 29 to drive the compressor 6 at a lower capacity. After that, the motor 6a is turned on or off depending on the output of the temperature sensor 8.
If the manual switch 20 is open, the normally closed contact 15a remains closed, regardless of the action of the transistor 19, so that the blower 4 is rotated even immediately after the start of the system to enhance its cooling speed although a bad odor is likely to circulate. One of the above-mentioned two cases can thus be manually selected by closing or opening the manual switch 20 depending on the desire of the operator.
FIG. 3 shows the other embodiment of the present invention, which is appropriate particularly to a cooling system for an automobile. A compressor 6 includes an electromagnetic clutch 6b. The compressor 6 is put into and out of operation by applying and not applying electricity to the electromagnetic clutch 6b. The compressor 6 is provided with a by-pass 31 for connecting the suction port and discharge port of the compressor to each other, and with a solenoid valve 32 in the by-pass 31. When electricity is supplied to the electromagnet of the solenoid valve 32, the valve 32 is closed so that the discharge volume of the compressor becomes a maximum. When no electricity is supplied to the electromagnet of the valve 32, the valve 32 is opened so that the discharge volume of the compressor is decreased. A circuit for controlling the discharge volume of the compressor is connected in parallel with normally open contact 15b, which is opened and closed by a first relay coil 15. In the circuit, a series circuit consisting of a temperature setting device 33 and a room temperature sensor 34 and another series circuit consisting of resistors 35 and 36 are provided between the main switch 11 end ground. The conjointly coupled point of the temperature setting device 33 and the room temperature sensor 34 is connected to a non-inverting input terminal of an operational amplifier 37. The conjointly coupled point of the resistors 35 and 36 is connected to an inverting input terminal of the operational amplifier 37. The output terminal of the amplifier 37 is connected to the base of a transistor 38, whose collector is connected to the main switch 11 via a third relay 39 and whose emitter is ground. A open contact 39a, which is opened and closed by the relay coil 39 is connected in parallel with normally open contact 15b. A diode 40 for the absorption of counter electromotive force is connected in parallel with the third relay coil 39.
When the room temperature detected by the sensor 34 is higher than a prescribed temperature value which is set by the temperature setting device 33, the operational amplifier 37 sends out an "H" signal to turn on the transistor 38 so as to energize the third relay coil 39 to thereby close the normally open contact 39a. As a result, electricity is supplied to the solenoid valve 32 to drive the compressor at a high capacity. If the difference between the detected room temperature and the set temperature is small, the operational amplifier 37 sends out an "L" signal to drive the compressor 6 at such an appropriate capacity as not to cause a loss.
To control the capacity of the compressor without using the above-mentioned two embodiments, the r.p.m. of the compressor may be adjusted by a two-step pulley, or the angle of the swash plate of the compressor, if it is of the swash plate type, may be changed, or the number of effective vanes of the compressor, if it is of the vane type, may be changed, so as to adjust the discharge volume of the compressor. Although the time that takes the evaporator to be dewed is set by the timer in the two embodiments, it may be detected by a temperature sensor or a dew sensor which sense that the evaporator has actually reached a dewing temperature or has been actually dewed. | A cooling system includes a circuit for the adjusting of the capacity of a compressor of a refrigeration cycle, and a circuit for stopping a blower until an evaporator of the refrigeration cycle is substantially dewed after the starting of the compressor and a circuit for driving the compressor at the maximum capacity until the blower has begun to be driven. The evaporator is cooled quickly because the compressor is driven at its maximum capacity, so that the time of the stoppage of the blower can be short while preventing a bad odor from circulating. | 1 |
CROSS REFERENCED TO RELATED APPLICATION
This is a continuation of application Ser. No. 07/607,217, filed on Oct. 30, 1990 pending.
BACKGROUND OF THE INVENTION
The present invention relates to a system for detecting changes in mechanical impedance and, more particularly, for tracing uterine contractions.
Uterine contraction, although a gross mechanical phenomenon, has proved awkward to measure. Typically, uterine contractions are traced by measuring the spring resistance to a toco-transducer probe which pushes against the maternal abdomen, as disclosed in Hewlett-Packard, "Cardiotocograph", Application Note 700 F., 1979. The probe is typically held in place and against the maternal abdomen by an elastic belt. When contractions occur, the probe encounters a more resistive medium and it moves orthogonal to the abdominal surface. This method generally suffices to trace uterine contraction. However, it is awkward to position the elastic belt and probe properly. Furthermore, the pressure of the elastic belt and probe are a source of discomfort to the subject.
Another widely employed method of tracing contractions is even more intrusive. Intrauterine measurement of contractions can be performed using a balloon-tipped or open-ended fluid filled catheter, as disclosed by D. O. Thorne, I. Assadi, J. Flores, and J. Seitchik, "The relationship of the maximum amplitude and the maximum and minimum slope of the intrauterine pressure waveform in late pregnancy and labor", IEEE Transactions on Biomedical Engineering., vol. BME-19, p. 388, 1972.
More recently, changes in the electrical activity of tissue during contractions have been employed in tracing contractions, as disclosed by C. Marque, J. M. G. Duchene, S. Leclercq, G. S. Panczer, and J. Chaumont, in "Uterine EHG Processing for Obstetrical Monitoring", IEEE Transactions on Biomedical Engineering, Vol. BME-33, No. 12, December 1986. The electrical activity is recorded as a electromyogram, also referred to as a "electrohysterogram" or "EHG".
EHG measurements can be made using intrauterine or abdominal electrodes. Electrical signals at several frequencies have been observed to correlate with contractions. The main problems with EHG measurements are that the signals are not strong, so that they are easily interfered with by electrical signals from spurious physiological activity, and that their correlation with contractions is not very strong. Furthermore, intrauterine electrodes are more intrusive than desired. Abdominal electrodes are less intrusive, but pick up electrical activity resulting from other sources, such as skin stretching, respiratory movements, and movement of abdominal muscles. Because of the weakness of the electrical signals being monitored and the susceptibility of the signals to noise from sources other than the contractions of interest, the sensitivity and validity of abdominal EHG measurements are limited.
What is needed is an improved system and method for tracing uterine contractions which provides accurate tracing and which is also non-intrusive, comfortable and easy to use.
SUMMARY OF THE INVENTION
In accordance with the present invention, changes in mechanical impedance are traced by monitoring their effect on the resonant frequency of a mechanically oscillating system. Since intrauterine contractions are inevitably accompanied by changes in the mechanical impedance of abdominal tissue, they can be traced using this system and method.
The mechanically oscillating system comprises a probe, or other transducer assembly, including a mechanical interface and an electro-mechanical resonant transducer. The resonant transducer has a resonant frequency at which it vibrates preferentially; this resonant frequency varies with the mechanical impedance of a mechanically interfaced body. The mechanical interface can be simply a surface which can be adhered or otherwise positioned against an abdomen or other body of interest. This surface can be part of a probe housing which encloses the electro-mechanical transducer.
The electro-mechanical transducer can be implemented by taking advantage of a variety of phenomena, including the piezo-electric effect and electro-magnetic effects. In the latter case, the transducer can include a permanent magnet, an electro-magnet, and a spring for regulating their relative positions. An electric signal applied to the electro-magnet causes relative displacement of the magnets. By rigidly attaching one of the magnets to the mechanical interface, the latter can be made to displace adjacent tissue.
The transducer has a resonant frequency which is a function of the mechanical impedance of the spring and effective masses and mechanical impedances associated with each magnet. When the mechanical interface is adhered to an abdomen, the resonant frequency varies sensitively with the "spring constant" of the abdominal tissue. Preferably, the transducer is designed so that the range of resonant frequencies is spanned by the "low sonic" frequencies, i.e., 20 Hz to 200 Hz.
Resonant frequency is monitored using a feedback circuit which drives the transducer at its resonant frequency. The output of the feedback circuit is then a signal at the current resonant frequency of the transducer. By tracking the frequency of this output, changes in resonant frequency, and thus changes in the mechanical impedance of an abdomen, and thus, contractions can be monitored. The frequency of the feedback circuit output can be monitored using a frequency counter and display and/or using a frequency-to-voltage converter to drive a standard strip-chart recorder.
A major advantage of the present invention is that it employs an active measurement system. Instead of relying on the subject to provide the energy, whether mechanical or electrical, for the measurement system, the present invention supplies a signal which is merely modulated by the subject. In the preferred embodiment, the parameter being monitored is frequency. Frequency is easily measured with precision and is less vulnerable to interference than alternative parameters. In contrast, EHG systems depend on the passive detection of a weak electrical signal which is subject to interference by other electrical signals. Also, since contractions inevitably are accompanied by significant changes in mechanical impedance, there is no doubt as to the validity of the parameter being measured. Conveniently, the present invention disposes of the elastic belt required of typical abdominal toco-transducers. Consequently, measurement is less effected by shifting of such a belt when the subject shifts body position.
Thus, the present invention provides a system and method for tracing uterine contractions which is convenient, accurate and reliable. Furthermore, it is readily apparent that the present invention is applicable to the measurement of changes in mechanical impedance associated with other tissue changes and to a wide variety of other subjects, not necessarily living, in which changes in mechanical impedance are of interest. These and other features and advantages of the present invention are apparent from the description below with reference to the following drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a system for tracing uterine contractions in accordance with the present invention.
FIGS. 2A and 2B are plan and sectional views, respectively, of a probe of the system of FIG. 1 with its cover removed.
FIG. 3 is a circuit diagram of a drive circuit of the system of FIG. 1 shown in relation to the probe of FIGS. 2A and 2B.
FIG. 4 is a schematic diagram of a mechanical model of the probe of FIGS. 2A and 2B.
FIG. 5 is a block diagram of an alternative uterine contraction tracing system in accordance with the present invention.
In the figures, for elements referred to by a three-digit reference numeral, the first digit of the reference numeral is the figure number in which that element is first depicted.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, a uterine contraction tracing system 100 comprises a probe 101 and an electronics module 103. Probe 101, can be attached to a body 99 with medical-grade, double-sided adhesive tape 105. Electronics module 103 includes a drive circuit 107 and an output section 109. Probe 101 and drive circuit 107 are electrically coupled by a cable 110 and constitute an oscillator. Output section 109 includes a frequency display 111 and a frequency-to-voltage converter 113 for driving a strip chart recorder 115.
Probe 101 incorporates a electro-mechanical ("E/M") resonant transducer 117, i.e., a transducer which has a resonant frequency enclosed by a housing 119 and a cap 121. A surface 120 of housing 119 serves, along with tape 105, as a mechanical interface with body 99. When driven by a cyclical drive signal, transducer 117 can cause probe 101 to vibrate. While not attached to a substantial object, probe 101 can be made to vibrate at a free-space resonant frequency by drive circuit 107. While attached to a substantial object, probe 101 is driven at a different resonant frequency. The instantaneous value of this frequency is a function of the mechanical impedance of body 99. Thus, by monitoring this resonant frequency, the mechanical impedance of body 99 can be traced. Since, contractions are accompanied by changes in mechanical impedance, they can be detected and characterized using uterine contraction tracing system 100.
Transducer 117 comprises a permanent magnet 223 and an electro-magnet 225, shown in FIGS. 2A and 2B. Permanent magnet 223 is bonded at the free end 227 of a leaf spring 229 cantilevered from a support post 231 rigidly attached to housing 119. Electro-magnet 225 comprises a plastic bobbin 233 and a conductive coil 235 which surrounds permanent magnet 223 as shown in FIG. 2B. Coil 235 has a signal lead 237 and a ground lead 239 which extend through cable 110 to electronics module 103.
The degree to which permanent magnet 223 extends into electro-magnet 227 depends on the forces applied by the latter and by leaf spring 229. A cyclical electric signal through coil 235 causes permanent magnet 223 to oscillate relative to the rest of probe 101, causing housing 119 to vibrate. These vibrations can be damped by body 99 when attached by tape 105 to the mechanical interface surface 120 of housing 119. This damping action determines the degree to which the frequency of the vibrations differ from the free-space resonant frequency of probe 101.
Drive circuit 107 is designed to drive probe 101 at its resonant frequency, as modified by the mechanical impedance of body 99 when attached. Drive circuit 107 comprises a differential amplifier 341, a positive feedback resistor 343, a negative feedback resistor 345 and an AC-coupling capacitor 347, as shown in FIG. 3. Lead 237 from coil 235 of probe 101 is coupled to node A of drive circuit 107, while lead 239 is coupled to node D, which is at ground. Node A is coupled to the "+" input of differential amplifier 341. The "-" input of differential amplifier 341 is AC-coupled to ground via capacitor 347.
The output of differential amplifier 341 at node C is fed back to node A and thus to "+" terminal of amplifier 341 via a positive feedback loop 349 including resistor 343. The output at node C is also fed back to node B and thence to the "-" input of amplifier 341 via a negative feedback loop 351 including resistor 345. In the illustrated embodiment, positive feedback resistor 343 is nominally 100 kΩ, negative feedback resistor 345 is nominally 500 kΩ, and capacitor 347 is nominally 10 μF. By contrast, the DC resistance of the transducer is of the order of 5 Ω. At the resonant frequency of the transducer, the voltage swings at the "+" terminal of amplifier 341 due to the positive feedback signal are larger than the voltage swings at the "-" terminal of amplifier 341 due to the negative feedback signal. Thus, although the amplifier is stably biased, the system oscillates at the resonant frequency.
The amplifier output not only drives probe 101 according to the signal at node A, but also provides via node C a buffered signal at node E, shown in FIG. 1, of output section 109 for driving frequency display 111 and frequency-to-voltage converter 113 for driving strip-chart recorder 115.
The action of probe 101 can be further understood with reference the mechanical model of FIG. 4. Probe 101 can be represented by a mass M 1 , corresponding collectively to housing 119, cap 121 and electro-magnet 225, a mass M 2 corresponding to permanent magnet 223, and a spring force 453, corresponding to leaf spring 229. In addition, mechanical resistance of probe 101 is represented by dashpot 455. Body 99 is modelled by an infinite rigid mass 457, variable spring 459 and dashpot 461. (In a more complete model, M 1 would include a component representing bodily tissue displaced by the action of probe 101.) The spring constant of variable spring 459 varies with changes in mechanical impedance of body 99 which occur during contractions.
When not attached to body 99, probe 101 has a free-space resonant frequency of:
f.sub.fs =[K(M.sub.1 +M.sub.2)/(M.sub.1 M.sub.2)].sup.1/2.
If attached to a rigid body of infinite mass, probe 101 would have a resonant frequency of:
f.sub.∞ =(K/M.sub.2).sup.1/2.
The preferred range of oscillation frequencies is from about 20 Hz to 80 Hz. F fs for the illustrated embodiment is about 50 Hz. In the cases of interest, the resonant frequency is intermediate between f fs and f.sub.∞ and varies with the mechanical impedance of body 99.
In uterine contraction tracing system 100 described above, changes in resonant frequency are detected by driving transducer 117 at resonant frequency and monitoring the drive frequency. In an alternative uterine contraction tracing system 500, shown in FIG. 5, a drive signal is maintained at a constant frequency and changes in resonant frequency are detected by monitoring the phase relationship between the current and the voltage across a transducer 501.
System 500 comprises transducer 501, an AC voltage source 503, a resistor 505 and a phase meter 507. Transducer 501 and resistor 505 constitute a transducer assembly. Voltage source 503 drives transducer 501 at a constant frequency. Phase meter 507 detects the voltage across transducer 501 via lines 509 and 511 and the voltage across resistor 505 via lines 513 and 515 and measures the phase differential between the two voltages. The voltage across resistor 505 is in phase with the current through transducer 501 so that the phase differential measured by phase meter 507 is the difference between the phases of the voltage and current through transducer 501.
When transducer 501 is interfaced with a body and the mechanical impedance of that body changes, the resonant frequency of transducer 501 changes. Because AC voltage source 503 drives transducer 501 at a constant frequency, the difference between the drive frequency and the resonant frequency changes with resonant frequency. This frequency difference results in a phase difference measured by phase meter 507. Thus, phase meter 507 can be used to indicate changes in mechanical impedance, for example, such as those caused by uterine contractions.
An alternative embodiment employs a transducer with two electromagnets, rather than one electromagnet and one permanent magnet. Another embodiment uses a transducer fabricated by modifying an small, inexpensive loudspeaker by cutting away portion of the cone and adding mass to lower its resonant frequency to about 50 Hz. Also, when a body is appropriately positioned, the incorporated probe can be held in position by gravity so that tape is not required.
In the illustrated embodiment, contractions are detected because changes in mechanical impedance of the contracting tissues affect the frequency output from a resonant circuit. However, the present invention provides for non-resonant circuit. However, the present invention provides for non-resonant circuits as well. In an alternative embodiment, a motor drives an eccentric shaft, e.g., a shaft with an off-center weight attached. A constant current drives the motor at a constant rotational rate. The eccentric shaft causes an attached frame to vibrate. The motor thus serves as a non-resonant electro-mechanical transducer. When the frame is pressed against a body, the rotation rate of the motor varies with changes in the mechanical impedance of the body during contractions. Thus, one can monitor contractions by observing changes in the motor rotation rate.
The foregoing discussion has focussed on frequency as the parameter of interest in detecting contractions. However, other parameters can be used. For example, changes in mechanical impedance can affect the amplitude of a current through an electro-magnetic resonator.
While contractions can be detected by examining the effect of changes in mechanical impedance on an electro-mechanical transducer, it is also possible to characterize contractions by their effect on the signal generated from such a transducer. During a contraction, there is a change in the effect of bodily tissue on signal amplitude and phase. These changes can be detected as the signal is received after being transmitted through or reflected by the body. One embodiment uses pseudo-random numbers to generate a signal. An advantage of this pseudorandom approach is that the resulting signal is broad spectrum and thus minimally disturbing to a subject. In addition, such signals are easily distinguished from noise, even where the latter's amplitude is relatively high. Alternatively, the generated signal can be pulses generated by a series of taps. The changing delays in the transmitted or reflected signal can be used to characterize a contraction.
In related embodiments, the tendency of a change in mechanical impedance to change frequency can be compensated by changing another variable, e.g., drive current. In this case, contractions are not reflected in frequency changes since frequency is held constant. However, contractions can be traced by tracking the drive current required to maintain constant amplitude or, in the eccentric shaft embodiment, rotation rate.
While tracing system 100 detects changes in mechanical impedance by monitoring the drive signal, the present invention provides alternatives. For example, a separate acoustic receiver can be used to detect acoustic waves transmitted through or reflected by a body.
A uterine contraction system can incorporate multiple probes for current detection of changes in mechanical impedance at several locations on a body. Multiple probes cannot be used conveniently with the current method, because multiple belts would be required. The present invention provides for a multiple probe system which can be used to monitor the progress of single contractions. This monitoring can be used to distinguish contractions from localized false labor contractions which could confuse a single probe system. In addition, while a single probe system might fail to detect contractions due to probe misplacement, a multiple probe system would be much less susceptible to this problem.
The present application is described above as applied to the detection of uterine contractions. More generically, the principles involved in the present invention include the modulation of signals by changes in mechanical impedance of a body. With appropriate modifications, the system and method of the present invention can be used to detect changes in mechanical impedance in tissue reflecting other physiological events, such as voluntary muscular activities. Furthermore, applications of the present invention are not limited to physiological phenomena, but can include measurement of tension, rigidity and viscosity where desired. These and other modifications and variations are provided for by the present invention, the scope of which is limited only by the following claims. | A system for tracing uterine contraction is disclosed. The system comprises a probe and an electronics module. The electronics module includes a drive circuit and an output section having a frequency counter. The output section also includes a strip-chart recorder driven by a frequency-to-voltage converter. The probe includes an electro-mehanical transducer which is driven at resonance by the action of the drive circuit. When the probe contacts the abdomen of a pregnant subject, changes in the mechanical impedance of bodily tissue during a contraction affect the resonant frequency of the probe and thus the frequency output by the drive circuit. This frequency can be read directly from the frequency counter and recorded on the strip-chart so that contractions can be traced. | 0 |
CLAIM TO PRIORITY OF PROVISIONAL APPLICATION
[0001] The application claims priority under 35 U.S.C. § 119(e)(1) of provisional application Ser. No. 60/458,859, attorney docket number TI-36131PS, entitled Low-Current, Area-Efficient and Flicker Noise Free Bias CMOS Voltage Control Oscillator, filed Mar. 28, 2003, by Abdellatif Bellaouar and See Taur Lee.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to voltage control oscillators (VCO), and more particularly to a system and method for implementing a current bias to a VCO core via a resistor rather than a more conventional transistor.
[0004] 2. Description of the Prior Art
[0005] Radio frequency systems-on-chip have a very bright future, especially if they are capable of providing a very low-cost solution. Such RF systems have however, posed tremendous design challenges, for example, in the design of VCOs, low-noise amplifiers and power amplifiers.
[0006] A significant effort has been devoted in the VCO art to the design of CMOS VCOs in order to replace bipolar circuits with low-cost CMOS solutions and maintain acceptable phase noise performance. Illustrated in FIG. 1 is one of the prior art differential CMOS VCO 100 solutions. It consists of transistors M 1 -M 2 102 , 104 and current source IB 106 as the current source to the VCO core, inductances L 1 -L 2 108 , 110 and capacitance C 1 112 as the LC-tank circuit, and a cross-coupled differential transistor pair M 3 -M 4 114 , 116 that provides the negative resistance.
[0007] In a fully integrated CMOS VCO, the main sources of phase noise have been shown by B. Razavi, “Study of phase noise in CMOS oscillators,” IEEE J. Solid - State Circuits , vol. 31, pp. 331-343, March 1996, and H. Wang, “A 50 GHz VCO in 0.25 um CMOS,” ISSCC Digest of Technical Papers , pp. 372-373, February 2001, to be the thermal noise of the passive and active devices, flicker noise of the transistor and supply and substrate noise.
[0008] Numerous techniques have been proposed to reduce the thermal noise of passive devices. H. Jiang, et al., “Electromagnetically shielded high-Q CMOS-compatible copper inductors,” ISSCC Digest of Technical Papers , pp. 330-331, February 2000, for example, proposed a high-Q electromagnetically shielded inductor showing that it is possible to achieve an inductor Q higher than 30.
[0009] The two remaining noise sources then are attributable to the cross-coupled transistor pair M 3 -M 4 noises and the bias current transistor noises. Efforts to push the phase noise of the CMOS VCO to even lower levels have shown the only noise sources that can be eliminated or reduced are the bias current transistor noises. An analysis by E. Hegazi, H. Sjoland, A. Abidi, “A filtering technique to lower oscillator phase noise,” ISSCC Digest of Technical Papers , pp 364-365, February 2001, showed that the commutating differential pair translates noise from the current source at frequencies around the second harmonics to the oscillation frequency and to the third harmonic and half of the translated noise at the fundamental frequency contributes phase noise. The authors also suggested that the differential cross-coupled pair upconverts the baseband noise in the current source into amplitude noise across the resonator. A filtering technique to lower the VCO phase noise has been proposed by these authors.
[0010] One of the drawbacks of the foregoing proposed technique is that more area is needed by the additional L-C noise filter. The present inventors believe that proper design of the current source using bigger size transistors can actually achieve a comparable phase noise. Another alternative is shown in FIG. 2, that shows additional filtering to reduce the noise contribution from the current source. Noises from the current source can be reduced; and thus phase noise at low frequency offset can be minimized simply by adding transistor M 5 118 .
[0011] Thus far, all the proposed or published techniques to push for lower VCO phase noise can only reduce or minimize the noises contributed from the current source. In view of the foregoing, it is highly desirable and advantageous to provide a technique for providing a flicker noise free current source to achieve a low VCO phase noise at low frequency offset.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to a system and method for implementing a low-current, area-efficient and flicker noise free bias CMOS voltage control oscillator. In contradistinction with prior art techniques, the present system and method do not require any L-C noise filter or use of huge transistor sizes to reduce the noise contributions from the current source. The CMOS VCO employs but a simple resistor as a bias current source with an optional capacitor (i.e., MOS transistor) to act as a filtering capacitor to stabilize the biasing voltage and to reduce the effect of junction capacitance variations from the cross-coupled transistor pair. Since the current source to the VCO core employs only a resistor, the only noise source is the thermal noise from the resistor. With proper design, low supply pushing can also be achieved. The CMOS VCO advantageously requires no reference current source, resulting in at least a 10-20% current saving over known techniques. Further, noise amplification from the reference current source is eliminated. A low noise reference current source is therefore not required in the present CMOS VCO. A programmable current source to the CMOS VCO can be easily obtained via adding resistors in parallel. Either one or two cross-coupled pairs can be used in association with the CMOS VCO. The simple current source allows a compact and area-efficient CMOS VCO.
[0013] According to one embodiment, a voltage control oscillator (VCO) comprises an L-C tank circuit; a negative resistance generator operational to oscillate at a frequency determined by the L-C tank circuit, the L-C tank circuit and the negative resistance generator together forming a VCO core; and a VCO core current source comprising at least one passive resistor, and devoid of capacitors, inductors and active components.
[0014] According to another embodiment, a voltage control oscillator (VCO) comprises a tuning circuit; a negative resistance generator operational to oscillate at a frequency determined by the tuning circuit, the tuning circuit and the negative resistance generator together forming a VCO core; and a VCO core current source comprising at least one passive resistor, and devoid of capacitors, inductors and active components, wherein the current source operates to provide a VCO bias current.
[0015] According to yet another embodiment of the present invention, a voltage control oscillator (VCO) comprises oscillating means for oscillating at a desired frequency; tuning means for controlling the desired frequency, the oscillating means and the tuning means together forming a VCO core; and biasing means for providing a VCO core bias current, wherein the biasing means is devoid of capacitors, inductors and active components.
[0016] According to still another embodiment of the present invention, a method of controlling a voltage control oscillator (VCO) phase noise comprises the steps of providing a VCO core; and generating a self-bias current for the VCO core via a resistor bias current source that is devoid of capacitors, inductors and active components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] 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 drawings in which like reference numerals designate like parts throughout the figures thereof and wherein:
[0018] [0018]FIG. 1 is a schematic diagram illustrating a prior art differential CMOS voltage control oscillator;
[0019] [0019]FIG. 2 is a schematic diagram showing the prior art differential CMOS voltage control oscillator shown in FIG. 1 with additional filtering to reduce the noise contribution from the current source;
[0020] [0020]FIG. 3 is a schematic diagram illustrating a resistor bias CMOS VCO according to one embodiment of the present invention;
[0021] [0021]FIG. 4 is a schematic diagram illustrating a resistor bias CMOS VCO according to another embodiment of the present invention having CMOS cross-coupled pairs;
[0022] [0022]FIG. 5 is a schematic diagram illustrating a resistor bias CMOS VCO according to yet another embodiment of the present invention having an optional power down transistor; and
[0023] [0023]FIG. 6 is a schematic diagram illustrating a resistor bias CMOS VCO according to still another embodiment of the present invention having a programmable current source.
[0024] While the above-identified drawing figures set forth alternative embodiments, 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
[0025] Low phase noise at low offset frequency has become a very important factor in the design of a VCO. Since a VCO consists of three major parts, namely the LC-tank, negative resistance generator and the current source, the only noise source that can be further minimized to implement a low phase noise oscillator is the current source as discussed herein before. FIG. 3 shows a schematic diagram illustrating the most preferred embodiment of the present CMOS VCO 200 . It consists of a resistor R 1 202 as the current source to the VCO core, inductances L 1 -L 2 204 , 206 and capacitor C 1 208 that form the LC-tank, a cross-coupled CMOS pair M 3 -M 4 210 , 212 that provides the negative resistance and to maintain oscillation and transistor M 5 214 that acts as a capacitor. A varactor can be added to tune the center frequency of the oscillator 200 , which is not shown in FIG. 3. In operation, the center frequency is fixed by the differential inductances and capacitances. The amount of current required by the VCO core can be adjusted by changing the resistance of the resistor R 1 202 . Transistor M 5 214 has been added to act as a capacitor and provides filtering to the noise from the power supply VDD. It also stabilizes the dc voltage and minimizes the effect of capacitance variation from the junction capacitance of the cross-coupled pair M 3 -M 4 210 , 212 .
[0026] Another important factor to be considered in the design of a VCO is the effect of supply pushing, especially when the VCO is integrated with noisy circuits. A simple analysis on the frequency sensitivity to the power supply has been performed. Indirectly, the frequency sensitivity to the supply can be found by obtaining the current variation in the resistor 202 due to supply variation. The current in the bias resistor 202 can be expressed as
I = Vdd - Vgs R ( 1 )
[0027] where I, Vdd, Vgs and R are the current through resistor R 1 202 , supply voltage, gate-to-source voltage of the cross-coupled pair 210 , 212 and resistance of R 1 202 respectively. The current through the cross-coupled transistors 210 , 212 can be written as
I = k ′ 2 ( Vgs - Vth ) 2 . ( 2 )
[0028] Thus, the current through resistor R 1 202 can be found to be
I = Vdd R - 1 R ( α I + Vth ) where α = 2 k ′ . ( 3 )
[0029] In order to find the current sensitivity to the power supply, a partial derivative can be performed and it can be found to be
∂ I ∂ Vdd = 1 R ( 2 R I 2 R I + α ) = 1 R ( 2 R I 2 R I + 2 k ′ ) ( 4 )
[0030] From this simple analysis, one concludes that in order to get good power supply rejection, the resistance of the bias resistor has to be relatively big. In other words, to design a VCO with resistor bias current source and to obtain good supply pushing, the resistance of the bias resistor 202 has to be increased.
[0031] For comparison purposes, two CMOS VCOs as shown in FIG. 2 and FIG. 3 and that have almost the same operation conditions have been built and simulated by the present inventors. The parameters used for simulations are summarized in the Table 1 below.
TABLE 1 Parameters used in simulation for phase noise comparison between the prior art and embodiments of the present invention. Parameters Value used Inductor Q 20 Capacitor Q 40 Differential inductance (nH) 1.3 Differential capacitance (pF) 1.35 Cross-coupled transistor sizes (M3-M4) 8 (2 um/0.2 um) M5 60 (20 um/5 um) M1 (20 um/2 um) M2 10 (20 um/2 um) R1 1.39 kΩ Vdd 2.7 V Differential capacitive load 375 fF
[0032] The simulated results of the two VCOs are summarized in Table 2 below.
TABLE 2 Performance comparison between the prior art VCO in FIG. 2 and the embodiment shown in FIG 3. Comparison parameters Prior art in FIG. 2 Embodiment in FIG. 3 Bias current (mA) 1.504 1.508 Highest voltage swing (mV) 771.520 772.077 Lowest voltage swing (mV) 435.404 434.965 Peak-to-peak voltage (mV) 336.117 337.148 Center frequency (GHz) 3.41371 3.41369 Phase noise @ 1 kHz −56 dBc/Hz −58 dBc/Hz Supply pushing (MHz/V) 3.7 3.3
[0033] Both VCOs have been properly biased and each consumes about 1.5 mA of current. The single-ended peak-to-peak voltage swing is about 336 mV and the center frequency of both oscillators is about 3.4 GHz. The prior art in FIG. 2 shows 2 dB higher phase noise at 1 kHz offset compared to the embodiment shown in FIG. 3. From the noise summary, the main contribution of phase noise at 1 kHz offset frequency originates from the flicker noise of the current source. One can reduce the flicker noise from the current source by using huge transistor sizes. By changing the transistor M 1 -M 2 sizes such that they are 100 times bigger, the simulation results show that one embodiment of the present invention using a resistor bias current source is still better than the prior art. An area-efficient VCO can therefore be realized using the inventive principles set forth herein.
[0034] The above phase noise simulation assumes that the reference bias current IB is an ideal current source. If a non-ideal reference current source were used, the phase noise of the VCO will become worse since the noises from the reference current source will be multiplied by the ratio of the current mirror. Thus, using a resistor as a current bias to replace the prior art current source, a lower-current, area-efficient and flicker noise free bias VCO can be implemented. The foregoing simulation was not optimized for very low phase noise at low offset frequency. By proper design and optimization, the embodiments described herein can be found to have promising results.
[0035] Another important design parameter for VCOs is supply pushing. This is because for a system-on-chip (SOC) approach, a clean supply for the VCO is very difficult to achieve. The simulation results show that the present inventive embodiments have better supply pushing than that achievable using prior art techniques. By proper design, experimental results by the present inventors have shown that a resistor bias VCO in the preferred embodiment can achieve supply pushing of 1.5 MHz/V.
[0036] In summary, the preferred embodiment shows good performances in phase noise at low offset frequency, low supply pushing, lower area and lower current consumption compared to that achievable using prior art techniques. The present inventors believe the inventive embodiments described herein should exhibit nearly identical performance if one were to move the bias resistor R 1 202 and connect it between the sources of the cross-coupled transistors and ground and connect the center taps of inductors L 1 -L 2 to the VDD supply. One can also use a PMOS cross-coupled pair instead of the NMOS cross-coupled pair or CMOS cross-coupled pairs such as shown in FIG. 4.
[0037] Power down capability of a building block is usually a very important function in a system-on-chip design. FIG. 5 illustrates one embodiment 300 to add a power down option by adding an additional transistor M 6 302 in series with resistor R 1 202 . By controlling the gate of the transistor M 6 302 , the VCO can be either turning off or on. Since transistor M 6 302 is in its linear region during operation, any flicker noise contribution is insignificant. The gate to source capacitance of M 6 302 can advantageously also provide some decoupling between the power supply and ground.
[0038] Another capability that many VCO designers desire is current programmability. Since the present invention employs a resistor as a current source to the VCO core, one can implement a programmable current source 400 such as shown in FIG. 6 simply by paralleling a plurality of resistors 404 . By turning the control bits at the gate of PMOS transistors MO-Mn 402 either on or off, the bias current to the VCO core can be easily programmed.
[0039] In view of the above, it can be seen the present invention presents a significant advancement in the art of voltage control oscillator design. This invention has been described in considerable detail in order to provide those skilled in the VCO 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 of implementing a low-current, area-efficient and flicker noise free bias CMOS voltage control oscillator (VCO) 200 employs a resistor 202 as a current source to the VCO core. By eliminating the transistor current source as employed in conventional designs, the CMOS VCO 200 does not require any reference current source, and thus achieves at least a 10-20% current savings over that achievable using prior art techniques. Further, noise amplification issues from the reference current source do not exist since only a resistor 202 is used as a current source, yielding only resistor thermal noise. The method employed allows low supply pushing, an important factor to be considered in VCO designs. | 7 |
RELATED APPLICATIONS
This application is a National Phase application of PCT/FR2008/052251, filed on Dec. 9, 2008, which in turn claims the benefit of priority from French Patent Application No. 07 59808, filed on Dec. 13, 2007, the entirety of which are incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to a method of preparing a transparent polymer material comprising a thermoplastic polycarbonate and nanoparticles, as well as to a transparent polymer material obtained by said method.
The invention typically applies, but not exclusively, to the fields of optics, in particular to optical articles of the aiming instrumentation lens type, helmet visor type, or ophthalmic lens type, and to optical articles of the automobile glass type.
More particularly, the term “ophthalmic lens” means lenses that are in particular suitable for mounting in eyeglasses, having the function of protecting the eye and/or correcting vision, such lenses being selected from afocal, single-vision, bifocal, trifocal and progressive lenses.
More particularly, the term “automobile glass” not only means external transparent bodywork elements such as rear lights, side panels, side windows, glazed roofs, headlight or sidelight glazing, but also transparent elements for the interior, such as dashboard, dial, or screen glazing.
2. Description of Related Art
Polycarbonate enjoys advantages that render it particularly advantageous for optics, in particular excellent transparency, excellent resistance to impacts, a high refractive index, and being very lightweight. In contrast, its principal disadvantages lie in it not being very rigid and being sensitive to scratching and abrasion.
In order to improve the mechanical properties of a polymer, in particular its rigidity and its abrasion and scratch resistance, it is known to add mineral nanoparticles to the polymer. Typically, said mineral nanoparticles are incorporated directly into the polymer in the molten state. However, that process applied to a thermoplastic polycarbonate does not guarantee good dispersion of the nanoparticles in the thermoplastic polycarbonate matrix and frequently results in degradation of said matrix.
The material obtained thereby is thus less transparent and less impact resistant compared with a thermoplastic polycarbonate material including no nanoparticles.
OBJECTS AND SUMMARY
The aim of the present invention is to provide a method of preparing a transparent polymer material comprising both a thermoplastic polycarbonate and nanoparticles, and that does not suffer from the above-mentioned disadvantages.
Thus, the invention provides a method of preparing a transparent polymer material, the method comprising the following steps:
i) mixing mineral nanoparticles selected from nanoparticles of alkaline-earth metal carbonates, alkaline-earth metal sulfates, metallic oxides, oxides of metalloids, and siloxanes, and a composition A including at least one thermoplastic polymer in the molten state selected from polycarbonate (PC), polystyrene (PS), and polymethyl methacrylate (PMMA) in order to obtain a master-batch, the mixture of step i) including at least 25% and at most 75% by weight of said mineral nanoparticles; and
ii) mixing the master-batch obtained in step i) with a composition B comprising a thermoplastic polycarbonate matrix (PCm) in the molten state, to obtain a transparent polymer material including at most 10% by weight of said mineral nanoparticles, preferably at most 5% by weight of said mineral nanoparticles.
The preparation method of the present invention can significantly limit degradation of the PCm matrix when nanoparticles have been incorporated. It can also limit the phenomenon of aggregation of the nanoparticles during their incorporation into the PCm matrix, guaranteeing a homogeneous dispersion of said nanoparticles in said matrix.
In particular, it means that the light transmission and impact resistance are maintained as much as possible compared with a thermoplastic polycarbonate material per se, and it means that the mechanical properties of the transparent polymer material are improved during incorporation of the mineral nanoparticles into the polycarbonate matrix (PCm).
The material obtained by the preparation method of the invention thus has improved rigidity as well as improved abrasion and scratch resistance compared with a thermoplastic polycarbonate material in routine use in the field of optics.
The term “transparent polymer material” means a material through which an image is observed with no significant loss of contrast. In other words, interposing said transparent polymer material between an image and an observer thereof does not significantly reduce the quality of the image.
The term “molten state” means a state in which the thermoplastic polymer of step i) or the thermoplastic polycarbonate matrix of step ii) is in a malleable state. This malleable state, well known to the skilled person, may conventionally be obtained when the polymer in question is heated to a temperature above its glass transition temperature, or softening temperature.
In the text of the present invention, the expression “in the range value x to value y” means that the values x and y are included in this range of values.
The thermoplastic polycarbonate (PC) used in step i) and the thermoplastic polycarbonate (PCm) used in step ii) may be identical or different. Preferably, the sources of the polycarbonate used in step i) and in step ii) are identical.
In the context of the invention, the mixture of step i) may preferably include at least 40% and at most 60% by weight of mineral nanoparticles, and more preferably 50% by weight of mineral nanoparticles.
Typically, at least one of the dimensions of the mineral nanoparticles of the present invention is nanometric (10 −9 meter) in scale.
The term “dimension” means the number average dimension of the set of nanoparticles of a given population, said dimension being determined conventionally using methods that are well known to the skilled person.
According to said methods of determining the size of the nanoparticles, the “dimension” of the nanoparticles according to the present invention makes reference either to the Stokes diameter (if the method used is that of sedimentation by centrifuging and X ray analysis) or to the diffusion diameter (if the method used is that of diffusion of light by laser granulometry), or to the diffraction diameter (if the method used is that of diffraction of light by laser granulometry), or to the width (l) of nanoparticles defined as the smallest dimension of the nanoparticles (if the method used is that of electron microscopy, such as scanning electron microscopy (SEM) or transmission electron microscopy (TEM)); the latter method is preferred.
These four methods of determining the dimension of the nanoparticles may produce substantially different results. For this reason, the results obtained must satisfy the nanometric dimension condition for the nanoparticles of to the invention for at least one of the four above-mentioned methods, preferably at least two of these methods, preferably at least three of these methods, and more preferably these four methods.
The dimension of the mineral nanoparticles of the invention is in particular at most 400 nanometers (nm), preferably at most 300 nm, and more preferably at most 100 nm.
Particularly preferably, this dimension is at least 0.1 nm and at most 80 nm, more preferably at least 10 nm and at most 70 nm, for example equal to 40 nm.
The mineral nanoparticles of the mixture of step i) may also be defined by their form factor, corresponding to the ratio between a specified “largest dimension” (L) of a particle, generally termed the “length”, and a specified “smallest dimension” of the particle, generally termed the “width” or “diameter”, mentioned below by the letter “l”.
The form factor is conventionally determined by analyzing microscopy images, in particular by electron microscopy (SEM or TEM). The largest dimension L as well as the smallest dimension l of a nanoparticle are measured directly by SEM or by TEM and thus can be used to calculate the ratio L to l.
The mean form factor for a population of nanoparticles in accordance with the present invention is defined as the number average of the form factors for each nanoparticle taken individually, or in other words the number average of the ratio of the length L to the width l of each nanoparticle.
The form factor of the mineral nanoparticles of the present invention is equal to 1.0.
Advantageously, prior to their incorporation into the mixture of step i), the mineral nanoparticles of the present invention may undergo a “surface” treatment to improve their dispersion in said mixture and thus to limit aggregation thereof.
By way of example, the surface treatment may consist in pre-coating the nanoparticles with a layer of a polyacrylate, polybutadiene type polymer grafted with maleic anhydride, methacrylsilane, or aminosilane.
Other types of surface treatment of said nanoparticles may be envisaged, in particular the functionalization or grafting of said nanoparticles, said surface treatments being well known to the skilled person.
Of the mineral nanoparticles in accordance with the present invention, the nanoparticles of alkaline-earth metal carbonates may be nanoparticles of calcium carbonate, those of alkaline-earth metal sulfates, nanoparticles of barium sulfate, those of metallic oxides, nanoparticles of alumina, of zinc oxide, or of titanium dioxide, those of oxides of metalloids, nanoparticles of silicon dioxide and those of siloxanes, nanoparticles of silsesquioxanes, and more particularly nanoparticles of trisilanolphenyl polyhedral silsesquioxane (TP-POSS). Preferred mineral nanoparticles from this list are nanoparticles of calcium carbonate.
In order to further improve the mechanical and optical properties of the polymer material of the present invention, the mixture of step ii) may further include at least one antioxidant.
In accordance with a first variation, composition B is prepared prior to step ii) by mixing the antioxidant or antioxidants with the thermoplastic polycarbonate matrix (PCm) in the molten state.
In accordance with a second variation, composition A is prepared prior to step i) by mixing the antioxidant or antioxidants with the thermoplastic polymer in the molten state (PC, PS or PMMA), preferably with the polycarbonate (PC).
In accordance with a third variation, the antioxidant or antioxidants may be added directly during step ii), or in other words to the mixture of step ii).
In accordance with a fourth variation, the antioxidant or antioxidants may be added directly during step i), or in other words to the mixture of step i).
The antioxidant or antioxidants used in these four variations are at least partially soluble in the thermoplastic polycarbonate matrix of step ii), and in the second or fourth variation at least partially soluble in the thermoplastic polymer of step i).
Preferably, and in particular when the thermoplastic polymer of composition A is polycarbonate, the master-batch and composition B include at least one antioxidant. The antioxidant or antioxidants present in the master-batch and composition B may be identical or different. Preferably, the antioxidants present in the master-batch and the composition B are identical.
Particularly preferably, the agent or agents are added to compositions A and B during an additional step.
Advantageously, composition A may include at most 15% by weight of antioxidant, and more particularly at least 0.5% by weight of antioxidant.
Preferably, composition A may include a quantity in the range 2% to 12% by weight of antioxidant, more preferably at most 10% by weight of antioxidant, and still more preferably 5% by weight of antioxidant.
Advantageously, composition B may include at most 5% by weight of antioxidant, preferably at least 0.5% and more particularly at least 0.1%.
Preferably, composition B may include in the range 0.5% to 2% by weight of antioxidant.
Thus, in accordance with the implementation carried out in the context of the invention, the mixture of step ii) may include at most 5% by weight of antioxidant, preferably in the range 1% to 2% by weight of antioxidant. Beyond such a quantity of antioxidant in the mixture of step ii), the transparent polymer material obtained may suffer degraded mechanical properties.
For this reason, whatever the variation or variations for adding the antioxidant, the transparent polymer material of the present invention may include at most 5% by weight of antioxidant, preferably in the range 1% to 2% by weight of antioxidant, in order to guarantee the best compromise between optimal rigidity and almost non-existent coloration.
The antioxidant or antioxidants of the invention may be any type of antioxidant that is well known to the skilled person. Preferably, the antioxidant used comprises a phosphite. Examples of antioxidants that may be mentioned are Ultranox® 626, Irgafos® 168, and Irganox® HP2921.
In accordance with a particular implementation, the mixture of step ii) may further comprise a compatibilizing agent when the mixture of step i) comprises polystyrene (PS) and/or polymethyl methacrylate (PMMA).
The term “compatibilizing agent” means any polymeric or mineral element with a certain affinity of the miscibility and/or reactivity type with both the thermoplastic polymer of step i) and the PCm matrix. The compatibilizing agent may in particular improve the rigidity of the transparent polymer material of the present invention.
The compatibilizing agent of the polymeric element type may be a block, graft, or random copolymer, in which one of its constituents has a specific affinity of the miscibility type for the polymer of step i), while another has a miscibility and/or reactivity type affinity for the PC matrix. Particularly preferably, the components of the compatibilizing copolymer are constituted by the same monomeric motifs as those of the polymers to be compatibilized, or at least one of them. By way of example, the compatibilizing agent of the polymeric element type is a copolymer of polystyrene, in particular a copolymer of polystyrene and maleic anhydride.
A preferred mineral element type compatibilizing agent that may be used is a natural montmorillonite that is surface-modified with functional hydroxyl type groups.
In order to guarantee the optimal mechanical properties of the transparent polymer material of the present invention, it is preferable for the mixture of step ii) to include at most 5% by weight of compatibilizing agent, preferably in the range 0.1% to 2% by weight of compatibilizing agent, and more preferably in the range 0.3% to 1% by weight of compatibilizing agent.
The mixing method used for the various steps of the method of preparing a transparent polymer material may be an extrusion method. However, this method is not in any way limiting and any other method that is well known to the skilled person may be employed.
The present invention also provides a transparent polymer material obtained by the preparation method defined above, having remarkable mechanical and optical properties.
A first technical feature of this polymer material is that it has a light transmission loss, in particular at 650 nm, compared with a reference material obtained solely from the thermoplastic polycarbonate matrix (PCm), of at most 25%, preferably at most 10%, and more preferably in the range 1% to 3%.
A second technical feature of this material is that it has an increase in the bending modulus compared with a reference material obtained solely from the thermoplastic polycarbonate matrix (PCm), of at least 10%, preferably in the range 20% to 60%.
A third technical feature of this material is that it has a molecular weight loss compared with a reference material obtained solely from the thermoplastic polycarbonate matrix (PCm), induced by incorporation of the mineral nanoparticles, of at most 30%, preferably at most 20%, and more preferably at most 10%.
The present invention also provides the use of said transparent polymer material for the manufacture of optical articles of the aiming instrumentation lens type, helmet visor type, or ophthalmic lens type, and to optical articles of the automobile glass type.
By way of example, the thickness of the optical articles may be at most 15 millimeters (mm), preferably in the range 0.1 mm to 5 mm, and more preferably in the range 0.5 mm to 4 mm.
Typically, the optical article may be manufactured from said transparent polymer material using any forming method that is well known to the skilled person, such as thermoforming, extrusion, calendaring, drawing, injection, injection-compression, or blow molding; the optical article retains all of the mechanical and optical properties of said polymer material.
DETAILED DESCRIPTION
Other characteristics and advantages of the present invention become apparent from the following examples; said examples are given by way of non-limiting illustration.
EXAMPLES
The origins of the various constituents used are as follows:
the polycarbonate used (PC or PCm), whether in the mixture of step i) or in the mixture of step ii), was a thermoplastic polycarbonate with reference Makrolon® A12647 marketed by Bayer AG; the polystyrene was Empera® 251N, marketed by NOVA Innovene International SA; the polymethyl methacrylate was marketed with reference 200336 by Sigma-Aldrich Co; the nanoparticles were precipitated calcium carbonate particles with a dimension of approximately 60 nm sold by Solvay France under the trade name SOCAL® 31; the antioxidant used in the various steps of the method was Ultranox® 626, marketed by Crompton N.V.; the compatibilizing agent AgCp1 was a copolymer of polystyrene and maleic anhydride comprising 7% maleic anhydride, marketed under reference 426946 by Sigma-Aldrich Co; the compatibilizing agent AgCm1 was Cloisite® 20A, marketed by Southern Clay Products, Inc; the compatibilizing agent AgCm2 was Cloisite® 30B, marketed by Southern Clay Products, Inc.
In more detail, the dimension of the SOCAL® 31 particles was determined by TEM using a magnification of 40000 measured on about twenty images, dispersing these nanoparticles initially in ethanol then placing them on a copper screen and finally covering them with a transparent amorphous polymer film. This gave a width l, or number average dimension, as well as a length L, of 60 nm for these nanoparticles. Thus, according to the TEM analysis and direct measurements, the form factor L/l for these nanoparticles was of the order of 1.0.
Prior to preparing the polymer materials, the mineral nanoparticles and the polycarbonate, the polymethyl methacrylate and the polystyrene used in the examples below were oven dried at 120° C. for at least 12 hours (h).
The various samples were produced from said polymer materials extruded into a rod, cooled and then granulated.
The mixing steps detailed in the preparation methods P0 to P4 below were carried out using a twin screw re-circulation type micro-extruder with reference DSM micro 15 marketed by DSM Explore, with a shear rate of 40 revolutions per minute (rpm).
Example 1
Prior Art Preparation Method P0: Direct Incorporation of Nanoparticles Into a PC Matrix
In accordance with a prior art preparation method P0, 0.45 grams (g) of mineral nanoparticles and 8.55 g of polycarbonate were mixed at 260° C. for 14 minutes (min).
A polymer material PM0 was thus obtained, including 5% by weight of mineral nanoparticles.
Example 2
Preparation Method P1, in Accordance with the Invention
According to a first preparation method P1 in accordance with the present invention, 4.5 g of mineral nanoparticles were mixed (step i)) with 4.5 g of polystyrene (PS) or polycarbonate (PC) at 260° C. for approximately 5 min to obtain the respective master-batches. Next, 0.9 g of each master-batch was mixed (step ii)) with 8.1 g of a polycarbonate matrix at 260° C. for 15 min. A polymer material PM1 PS was thus obtained when the polymer of mixture i) was PS and a polymer material PM1 PC was obtained when the polymer of mixture i) was PC.
The polymer materials obtained (PM1 PS and PM1 PC ) comprised 5% by weight of mineral nanoparticles.
Example 3
Preparation Method P2, in Accordance with the Invention
According to a second preparation method P2 in accordance with the present invention, 4.5 g of mineral nanoparticles was mixed (step i)) with 4.5 g of polystyrene (PS) or polymethyl methacrylate (PMMA) or a composition A2 comprising a polycarbonate (PC) and an antioxidant, at 260° C. for 5 min, to obtain respective master-batches.
In this context, said composition A2 was prepared prior to step i) by mixing, at 260° C. for 5 min, 90 parts by weight of polycarbonate with 10 parts by weight of antioxidant per 100 parts by weight of composition A2.
A composition B2 was prepared by mixing, at 260° C. for 3 min, 98.9 parts by weight of polycarbonate and 1.1 parts by weight of antioxidant per 100 parts by weight of composition B2. Next, 0.9 g of each master-batch was mixed (step ii)) with 8.1 g of composition B2, at 260° C. for 10 min, in order to disperse the nanoparticles properly in said mixtures. A polymer material PM2 PS was obtained when the polymer of the mixture i) was PS, a polymer material PM2 PMMA was obtained when the polymer of the mixture i) was PMMA and a polymer material PM2 PC was obtained when the polymer of mixture i) was PC.
The polymer materials obtained (PM2 PS , PM2 PMMA , PM2 PC ) comprised 5% by weight of mineral nanoparticles.
Example 4
Preparation Method P3, in Accordance with the Invention
In accordance with a third preparation method P3 in accordance with the present invention, 4.5 g of mineral nanoparticles was mixed (step i)) with 4.5 g of polystyrene (PS) at 260° C. for 5 min, to obtain a master-batch. A composition B3 was prepared by mixing, at 260° C. for 3 min, 97.8 parts by weight of polycarbonate, 1.1 parts by weight of antioxidant and 1.1 parts by weight of polymeric type compatibilizing agent AgCp1 per 100 parts by weight of composition B3. Next, 0.9 g of master-batch was mixed (step ii)) with 8.1 g of composition B3, at 260° C. for 11 min, in order to properly disperse the nanoparticles in said mixture.
A polymer material PM3 AgCp1 was obtained comprising 5% by weight of mineral nanoparticles.
Example 5
Preparation Method P4, in Accordance with the Invention
In accordance with a fourth preparation method P4 of the present invention, 4.5 g of mineral nanoparticles was mixed (step i)) with 4.5 g of polymethyl methacrylate (PMMA) at 260° C. for 5 min to obtain a master-batch.
A composition B4 was prepared by mixing, at 260° C. for 3 min, 98.9 parts by weight of polycarbonate and 1.1 parts by weight of antioxidant per 100 parts by weight of composition B4. Next, 0.9 g of said master-batch was mixed (step ii)) with 0.03 g of a AgCm1 or AgCm2 type compatibilizing agent and with 8.07 g of composition B4 at 260° C. for 11 min in order to disperse the nanoparticles properly in said mixture. A polymer material PM4 AgCm1 was obtained when the polymeric type compatibilizing agent was AgCm1, and a polymer material PM4 AgCm2 was obtained when the polymeric type compatibilizing agent was AgCm2.
The various polymer materials obtained (PM4 AgCm1 , PM4 AgCm2 ) comprised 5% by weight of mineral nanoparticles.
Physico-Chemical Characteristics of Materials Obtained:
The various physico-chemical characteristics studied were light transmission, bending modulus and molecular weight.
A material termed a reference material (RM) was also produced uniquely from the polycarbonate used in the various methods P0 to P4, in the form of samples.
Light Transmission:
The light transmission characterizes the transparency of the polymer material. The higher the light transmission, the better the transparency of said material.
The light transmission measurements were carried out on samples in the form of disks 25 mm in diameter and 1.5 mm in thickness using a Cary 50 spectrometer marketed by Varian. The disks were obtained from granules of polymer materials RM and PM0 to PM4 shaped by injection molding using a DSM 5 cubic centimeter (cm 3 ) micro-injector marketed by DSM Explore. The temperature of the micro-injector cylinder was fixed at 290° C. and the temperature of the mold was fixed at 60° C.; the granules were heated for 2 min prior to injection.
Molecular Weight:
The molecular weight measurements were carried out on samples in the form of powders. The powder was obtained by milling granules of polymer materials RM and PM0 to PM4 using a cryogenic mill. A quantity of 50 milligrams (mg) of said powder was then dissolved in 10 milliliters (mL) of tetrahydrofuran (THF) and filtered at 0.45 micrometers (μm).
The molecular weight was determined using a chromatograph provided with a Waters SIS-HPLC pump, a Waters 410 differential refractometer, Styragel 5 μm HR4 and HR3 columns marketed by Waters, and a PI-gel 5 μm column marketed by Polymer Laboratories.
The measurement processing software was Millennium 32 software marketed by Waters.
Bending Modulus:
The bending modulus characterizes the rigidity of a polymer material. The higher the bending modulus, the better the rigidity of said material.
The bending modulus measurements were carried out on samples in the form of 4 mm×40 mm×1.5 mm bars.
The bars were obtained from granules of polymer materials RM and PM0 to PM4 formed using a hydraulic thermo-compression press with heated plates from DARRAGON. The bending modulus of said bars was determined using a VA4000 visco-analyzer marketed by Metravib.
The sample was heated to a temperature of 30° C. at a heating rate of 3 degrees Celsius per minute (° C./min). Next, the modulus was measured at a 30° C. constant temperature stage over 10 min. The applied oscillation frequency was 1 hertz (Hz) and the dynamic movement (amplitude of oscillations) was 5 μm.
The results obtained are shown in the table below. The transmission values are given for a wavelength of 650 nm.
Light
Molecular
Bending
Preparation
Polymer
transmission
weight
modulus
method
material
(%)
(g · mol −1 )
(GPa)
/
RM
87.8
52500
2.35
P0
PM0
19.4
22400
NM*
P1
PM1 PC
65.2
36200
2.61
PM1 PS
65.9
50700
2.96
P2
PM2 PC
68.4
47300
3.11
PM2 PS
72.2
49700
2.94
PM2 PMMA
71.1
47200
2.92
P3
PM3 AgCp1
65.2
50700
3.28
P4
PM4 AgCm1
71.0
46500
2.92
PM4 AgCm2
70.0
45300
3.45
*NM: not measured since too brittle
It can thus be seen that methods P1 to P4, compared with direct incorporation in accordance with method P0, can significantly reduce the loss of light transmission induced by the presence of nanoparticles. The loss of light transmission of the polymer materials PM1 to PM4 relative to the reference material RM is at most 25% compared with the reference material RM. The polymer material PM0 has a loss of transmission of more than 40% compared with the reference material RM. The polymer materials PM1 to PM4 thus have very satisfactory transparency.
It can also be seen that the values for the bending modulus for the polymer materials PM1 to PM4 exhibit a significant increase in said modulus relative to the value for the bending modulus of the reference material RM. Thus, incorporating nanoparticles using the preparation methods of the present invention can substantially increase the rigidity of the polymer materials by more than 20%.
Furthermore, it can be seen that the polymer materials PM1 to PM4 have a molecular weight that tends significantly towards the value 52500 grams per mole (g/mol −1 ), the value of the molecular weight of the reference material RM, in contrast to the polymer material PM0 for which the value drops by more than 50%. Too large a drop in the molecular weight, i.e. more than 30%, signifies a major degradation of the matrix.
Furthermore, the polymer materials PM2 show that adding an antioxidant indirectly to the mixture of step ii) (methods P2, P3 and P4) significantly improves the physico-chemical characteristics of said materials.
Finally, using a compatibilizing agent can also optimize the bending modulus, and in particular can increase said modulus by approximately 46% (PM4 AgCm2 ).
Thus, the results of the above table show that preparation methods P1 to P4 can produce transparent polymer materials PM1 to PM4 with optimal transparency while improving the mechanical properties. | A method of preparing a transparent polymer material includes mixing mineral nanoparticles selected from nanoparticles of alkaline-earth metal carbonates, alkaline-earth metal sulfates, metallic oxides, oxides of metalloids, and siloxanes, and a composition A including at least one thermoplastic polymer in the molten state selected from polycarbonate (PC), polystyrene (PS) and polymethyl methacrylate (PMMA) in order to obtain a master-batch, the mixture of step i) including at least 25% and at most 75% by weight of the mineral nanoparticles. The master-batch obtained in step i) is mixed with a composition B of a thermoplastic polycarbonate matrix (PCm) in the molten state, to obtain a transparent polymer material including at most 10% by weight of the mineral nanoparticles, preferably at most 5% by weight of the mineral nanoparticles. | 2 |
FIELD OF THE INVENTION
[0001] A DNA polymerase from Geobacillus stearothermophilus has been described in Kong, et al., U.S. Pat. No. 5,814,506 (1998). This enzyme, which is a Bst DNA polymerase, belongs to DNA polymerase Family A and shares about 45% sequence identity with its better known relative Taq DNA polymerase. Whereas Taq DNA polymerase is from a hyperthermophilic organism and is able to survive the high temperatures of the polymerase chain reaction, the Bst DNA polymerase reported in Kong, et al., is from a thermophilic organism, is optimally active between 60-70° C., but does not survive the high temperatures of PCR. The full length (FL) Bst DNA polymerase is 876 amino acid residues and has 5′-3′ endonuclease activity but not 3′-5′ exonuclease activity. The large fragment (LF) of Bst DNA polymerase lacks both 5′-3′ exonuclease activity and 3′-5′ exonuclease activity and is only 587 amino acid residues with 289 amino acids being deleted from the N-terminal end. The FL Bst DNA polymerase and the LF Bst DNA polymerase have been found to be useful for isothermal amplification techniques and DNA sequencing.
SUMMARY OF EMBODIMENTS OF THE INVENTION
[0002] Compositions and methods are described herein that relate to variants of DNA polymerases belonging to Family A DNA polymerases.
[0003] In embodiment 1, a variant Family A DNA polymerase comprises two or more amino acid sequence motifs selected from 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569, where the number preceding the amino acid in the motif corresponds to the location of that amino acid in the amino acid sequence of FIG. 1 , wherein the two or more motifs confer improved reaction speed in an amplification reaction and/or improved stability compared to the reaction speed and/or stability of any of SEQ ID NOs:1-23.
[0004] Other embodiments are defined in claims 2 - 49 appended hereto.
[0005] In embodiment 2, a variant polymerase of embodiment 1 has at least 75% but less than 100% identity to any of SEQ ID NOs:1-23.
[0006] In embodiment 3, a variant polymerase of embodiment 1 or 2 comprises at least three or four or five or six or seven or eight or nine or ten or eleven or twelve of the motifs.
[0007] In embodiment 4, a variant polymerase of any one of the preceding embodiments further comprises one or more mutations selected from the group of mutations consisting of (a)-(f) where the mutations in (a)-(f) are:
(a) A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V; (b) E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P); (c) Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, 5135(E or P), V144A, 5147(P or A), L148(D or V), Q152(L or P); (d) T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M); (e) A193(I or S), A194(L, S or T), N205(D or K), S216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R; and (f) A330T, D357L, D378N, D380E, I383A, Q387R, L390M; 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R).
[0014] In embodiment 5, a variant polymerase according to embodiment 4, comprising at least one mutated amino acid selected from each of groups (a)-(f).
[0015] In embodiment 6, a variant polymerase of embodiment 4 further comprises two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, fifteen, sixteen, seventeen, eighteen, nineteen, or twenty mutant amino acids at the same position as the corresponding amino acids in (a)-(f) of SEQ ID NO:1.
[0016] In embodiment 7, a variant polymerase of any one of the preceding embodiments is described wherein said sequence motif(s) confer one or more improved properties selected from at least one of specific activity; reaction speed; thermostability; storage stability; dUTP tolerance and salt tolerance; increased performance in isothermal amplification; non-interference of pH during sequencing; improved strand displacement; altered processivity; altered ribonucleotide incorporation; altered modified nucleotide incorporation; and altered fidelity when compared to the corresponding parent polymerase.
[0017] In embodiment 8, a variant polymerase of any one of the preceding embodiments is described wherein a peptide is fused to one end of the variant polymerase directly or by means of a linker sequence.
[0018] In embodiment 9, an enzyme preparation comprises a variant polymerase according to any one of the preceding embodiments and a buffer.
[0019] In embodiment 10, an enzyme preparation according to embodiment 8 or 9 comprises a temperature dependent inhibitor of polymerase activity.
[0020] In embodiment 11, an enzyme preparation according to any of embodiments 8 through 10, further comprises dNTPs.
[0021] In embodiment 12, a DNA encodes a variant polymerase as described in any of preceding embodiments.
[0022] In embodiment 13, a host cell comprises the DNA according to embodiment 12.
[0023] In embodiment 14, a process for preparing a variant of a parent Family A DNA polymerase having improved polymerase activity compared with the parent polymerase, comprises synthesizing a polypeptide as defined in any one of embodiments 1-8; and characterizing the polymerase activity.
[0024] In embodiment 15, the process of embodiment 14 is described wherein characterizing the polymerase activity, further comprises: determining in comparison with the parent polymerase, at last one of: thermostability; stability in storage; tolerance to salt; performance in isothermal amplification; strand displacement; kinetics; processivity; fidelity; altered ribonucleotide incorporation; altered dUTP incorporation; and altered modified nucleotide incorporation.
[0025] In embodiment 16, a variant Family A DNA polymerase is obtainable by the process of embodiment 14 or embodiment 15.
[0026] In embodiment 17, a variant polymerase of any of embodiments 1 through 7 wherein the one or more motifs or one or more mutations selected from the group of mutations consisting of (a)-(f) have improved reverse transcriptase (Rtx) activity.
[0027] In embodiment 18, a method for reverse transcribing an RNA of interest, comprises combining an RNA with a DNA polymerase variant or preparation thereof according to embodiments 1-11 to form a complementary DNA (cDNA).
[0028] In embodiment 19, a method according to embodiment 18 further comprises amplifying the cDNA by means of the DNA polymerase variant or preparation thereof according to claims 1 - 11 , to produce amplified DNA.
[0029] In embodiment 20, a method for amplifying DNA comprises combining a target DNA with a DNA polymerase variant or preparation thereof according to embodiments 1-11, to produce amplified DNA.
[0030] In embodiment 21, a variant protein comprises: an amino acid sequence with at least 75% or 80% or 85% or 90% or 95% but less than 100% sequence identity to any of SEQ ID NOs:1-23, wherein the variant protein further comprises at least one mutated amino acid having a position corresponding to SEQ ID NO:1 selected from the group of mutated amino acids consisting of (a)-(f) where the mutations in (a)-(f) are:
(a) A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V; (b) E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P); (c) Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, 5135(E or P), V144A, 5147(P or A), L148(D or V), Q152(L or P); (d) T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M); (e) A193(I or S), A194(L, S or T), N205(D or K), 5216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R; and (f) A330T, D357L, D378N, D380E, I383A, Q387R, L390M; 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R).
[0037] In embodiment 22, the variant may contain at least one amino acid corresponding to a mutated amino acid in SEQ ID NO:1 selected from each of groups (a) through (f).
[0038] In embodiment 23, the variant protein according to embodiment 21, further comprises at least one amino acid motif or at least two amino acid motifs selected from the group consisting of: from 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0039] In embodiment 24, a variant protein according to any of embodiments 21-23, further comprises two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, fifteen, sixteen, seventeen, eighteen, nineteen, or twenty amino acids at the same positions as the corresponding mutant amino acids in (a)-(f) of SEQ ID NO:1.
[0040] In embodiment 25, the variant protein of embodiment 24 is described wherein the amino acid sequence is at least 80% identical to any one of SEQ ID NOs:1-23.
[0041] In embodiment 26, a variant protein according to embodiment 25 is described, wherein the amino acid sequence is at least 90% identical to any one of SEQ ID NOs:1-23.
[0042] In embodiment 27, a variant protein according to embodiment 26, is described wherein the amino acid sequence is at least 95% identical to any one of SEQ ID NOs:1-23.
[0043] In embodiment 28, a non-naturally occurring synthetic protein comprises: a fragment 1, a fragment 2, a fragment 3, a fragment 4, a fragment 5, a fragment 6, a fragment 7 and a fragment 8 wherein the fragments are covalently linked in numerical order, and wherein:
[0044] the fragment 1 is selected from Segment 1 having an amino acid sequence selected from the group consisting of SEQ ID NOs:24-39;
[0045] the fragment 2 is selected from Segment 2 having an amino acid sequence selected from the group consisting of SEQ ID NOs:40-56;
[0046] the fragment 3 is selected from Segment 3 having an amino acid sequence selected from the group consisting of SEQ ID NOs:57-72;
[0047] the fragment 4 is selected from Segment 4 having an amino acid sequence selected from the group consisting of SEQ ID NOs:73-87;
[0048] the fragment 5 selected from Segment 5 having an amino acid sequence selected from the group consisting of SEQ ID NOs: 88-99;
[0049] the fragment 6 selected from Segment 6 having an amino acid sequence selected from the group consisting of SEQ ID NOs:100-111;
[0050] the fragment 7 selected from Segment 7 having an amino acid sequence selected from the group consisting of SEQ ID NOs:112-125;
[0051] the fragment 8 selected from Segment 8 having an amino acid sequence selected from the group consisting of SEQ ID NOs:126-138; and;
[0052] wherein the covalently linked fragments has an amino acid sequence that does not have 100% identity to SEQ ID NOs:1-23.
[0053] In embodiment 29, a synthetic protein according to embodiment 28 is described, wherein the amino acid sequence of the synthetic protein comprises at least one amino acid sequence motif selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0054] In embodiment 30, the synthetic protein of embodiment 28 is described, wherein the amino acid sequence comprises at least two or three or four or five or six or seven or eight or nine or ten or eleven or twelve of the amino acid sequence motifs selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0055] In embodiment 31, a protein comprises at least 75% or 80% or 85% or 90% or 95% sequence identity with SEQ ID NOs:1 and further comprises one or more mutations (such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, or 79 mutations) selected from the group consisting of A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V, E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P), Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, 5135(E or P), V144A, 5147(P or A), L148(D or V), Q152(L or P), T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M): A193(I or S), A194(L, S or T), N205(D or K), 5216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R, A330T, D357L, D378N, D380E, I383A, Q387R, L390M, 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R); and optionally a sequence motif at a specified position in SEQ ID NO:1 selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0056] In embodiment 32, a variant protein or a synthetic protein according to any of embodiments of 21-31 is described, wherein a peptide is fused to one end of the variant protein. For example, the peptide may be fused to one end of the variant protein either directly or by means of a linker.
[0057] In embodiment 33, an enzyme preparation comprises a variant protein or a synthetic protein according to any of embodiments 21-31 and a buffer.
[0058] In embodiment 34, an enzyme preparation according to embodiment 33 further comprises a plurality of proteins.
[0059] In embodiment 35, an enzyme preparation according to embodiment 33 or 34 further comprises a reversible inhibitor of polymerase activity.
[0060] In embodiment 36, an enzyme preparation according to embodiment 33 or 34 further comprises dNTPs.
[0061] In embodiment 37, DNA encodes a variant protein or synthetic protein described in any of embodiments 21-36.
[0062] In embodiment 38, a host cell comprises the DNA according to embodiment 37.
[0063] In embodiment 39, a method for obtaining a variant of a parent protein has improved polymerase activity compared with the parent protein, comprises synthesizing a protein from any of embodiments 21-36; and characterizing the polymerase activity.
[0064] In embodiment 40, which is a method according to embodiment 39, characterizing the polymerase activity further comprises: determining in comparison with the parent protein, at least one of: thermostability; stability in storage; tolerance to salt; performance in isothermal amplification; strand displacement; kinetics; processivity; fidelity; altered ribonucleotide incorporation; altered dUTP incorporation; and altered modified nucleotide incorporation. Additionally, characterizing the polymerase activity includes detecting an increase in Rtx activity.
[0065] In embodiment 41, a method comprises:
(a) synthesizing a protein wherein the protein has an amino acid sequence which is capable of being generated from single selected protein fragments obtainable from 8 different segments described in FIG. 2 ; and (b) assaying the synthetic protein for polymerase activity.
[0068] In embodiment 42, a method according to embodiment 41 is provided, wherein the protein is synthesized by cloning a DNA sequence encoding the protein.
[0069] In embodiment 43, a method comprises:
(a) selecting a protein variant or synthetic protein according to any of claims embodiments 21-36 having an amino acid sequence; and (b) expressing the protein variant or synthetic protein as a fusion protein with an additional peptide at an end of the amino acid sequence.
[0072] In embodiment 44, a method of isothermal amplification comprises:
(a) providing a preparation comprising a variant protein or synthetic protein according to any of claims 21 - 36 ; (b) combining a target DNA with the preparation; and (c) amplifying the target DNA at a temperature less than 90° C.
[0076] In embodiment 45, a method according to embodiment 44 is described, wherein the amplification reaction results in a quantitative measure of the amount of target DNA in the preparation.
[0077] In embodiment 46, a DNA polymerase having one or more improved properties for isothermal amplification compared with SEQ ID NO:1, where the one or more improved properties are selected from the group consisting of:
(a) an increased reaction speed where the increase is at least 10% and as much as 200%; 500% or 1000%; (b) an increased temperature stability in the range of 50° C. to 100° C., 50° C. to 90° C., or 60° C. to 90° C.; (c) an increased salt tolerance in the range of 10 mM-1 M, or 20 mM-200 mM or 500 mM monovalent salt; (d) an increase in storage stability at 25° C., retaining at least 50% activity over 45 weeks, over 1 year or over 2 years; (e) an enhanced dUTP tolerance of the range of an increase of 50% to 100% dUTP; and (f) an increased reverse transcriptase activity by at least 2 fold; wherein the DNA polymerase is a non-naturally occurring mutant of a wild type Bst DNA polymerase.
[0084] In embodiment 47, a DNA polymerase according to embodiment 46 is described having at least two or three or four or five or six of the improved properties.
[0085] In embodiment 48, a DNA polymerase according to embodiments 46 or 47 having at least 80% amino acid sequence identity but less than 100% amino acid sequence identity with any of SEQ ID NOs:1-23 and containing at least 12 artificially introduced single amino acid mutations that occur within a three amino acid motif that differs from a three amino acid motif in the corresponding site of a naturally occurring Bst polymerase.
[0086] In embodiment 49, a DNA polymerase according to embodiment 48 is described wherein at least one of the three amino acid motifs is selected from the group consisting of 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0087] In general in one aspect, the composition includes a variant protein, having an amino acid sequence with at least 75% or 80% or 85% or 90% or 95% but less than 100% identity to any of SEQ ID NOs:1-23. The variant protein may include at least one amino acid identified by a position in its amino acid sequence and an identity corresponding to any of the mutated amino acids in the corresponding position in SEQ ID NO:1 and listed in (a)-(f) as provided below, wherein the at least one amino acid is selected from the group consisting of:
(a) A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V; (b) E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P); (c) Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, 5135(E or P), V144A, 5147(P or A), L148(D or V), Q152(L or P); (d) T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M); (e) A193(I or S), A194(L, S or T), N205(D or K), 5216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R; and (f) A330T, D357L, D378N, D380E, I383A, Q387R, L390M; 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R).
[0094] In another aspect, the variant may contain at least one amino acid corresponding to a mutated amino acid in SEQ ID NO:1 and selected from each of groups (a) through (f).
[0095] In another aspect, the variant protein may include in addition to the amino acids specified above, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, fifteen, sixteen, seventeen, eighteen, nineteen, or twenty amino acids at the same positions and identities as the corresponding mutant amino acids in (a)-(f) of SEQ ID NO:1.
[0096] In another aspect, the variant protein may include at least one or two or three or four or five or six or seven or eight or nine or ten or eleven or twelve amino acid sequence motifs selected from 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569, where the number preceding the amino acid in the motif corresponds to the location of that amino acid in the amino acid sequence as determined from FIG. 1 . The variant protein may include at least one or two or three or four or five or six or seven or eight or nine or ten or eleven or twelve of these motifs in addition to one or more mutations in (a)-(f).
[0097] In another aspect, the variant protein has an amino acid sequence that is at least 80%, or at least 85% or at least 90% or at least 95% but less than 100% identical to any one of SEQ ID NOs:1-23.
[0098] In another aspect, the variant protein of the sort described above has an amino acid sequence that is at least 80%, or at least 85% or at least 90% or at least 95% but less than 100% identical to any one of SEQ ID NOs:1-23.
[0099] In another aspect, a DNA polymerase is provided that comprises or consists of a plurality of peptide fragments selected from segments 1-8 covalently linked to form a single polypeptide that has less than 100% amino acid sequence identity with any of SEQ ID NOs:1-23.
[0100] In another aspect, a non-naturally occurring synthetic protein is provided that includes 8 fragments wherein the fragments include a Fragment 1 selected from Segment 1 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:24-39; a Fragment 2 selected from Segment 2 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:40-56, a Fragment 3 selected from Segment 3 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:57-72, a Fragment 4 selected from Segment 4 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:73-87, a Fragment 5 selected from Segment 5 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:88-99; a Fragment 6 selected from Segment 6 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:100-111; a Fragment 7 selected from Segment 7 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:112-125; and a Fragment 8 selected from Segment 8 and having an amino acid sequence selected from the group consisting of SEQ ID NOs:126-138. Fragments 1-8 are covalently linked preferably in numerical order so as to form a single protein wherein the single protein is not any of SEQ ID NOs:1-23.
[0101] In another aspect, the amino acid sequence of the synthetic protein comprises at least one or at least two or at least three or at least four or at least five or at least six or at least seven or at least eight or at least nine or at least ten or at least eleven amino acid sequence motifs selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0102] In another aspect, a non-naturally occurring protein is provided that comprises or consists of an amino acid sequence having at least 80% sequence identity with SEQ ID NO:1. The non-naturally occurring protein further comprises one or more mutations (such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, or 79 mutations) selected from the group consisting of A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V, E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P), Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, 5135(E or P), V144A, 5147(P or A), L148(D or V), Q152(L or P), T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M), A193(I or S), A194(L, S or T), N205(D or K), 5216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R, A330T, D357L, D378N, D380E, I383A, Q387R, L390M, 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R); and optionally a sequence motif at a specified position in SEQ ID NO:1 selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0103] In another aspect, a variant or synthetic protein as described herein may additionally comprise a peptide fused to the N-terminal end or the C-terminal end of the protein directly or via a linker.
[0104] In another aspect of the embodiments, an enzyme preparation is provided which contains a variant protein or a synthetic protein as described above and a buffer. The enzyme preparation may additionally contain a plurality of proteins described herein and/or a reversible inhibitor of polymerase activity and/or dNTPs.
[0105] In another aspect of the embodiments, a polynucleotide is provided that encodes a variant protein or synthetic protein as described above. The polynucleotide may be expressed in a transformed host organism.
[0106] In general, methods are provided for synthesizing a variant or synthetic protein of the type described above having polymerase activity which in one aspect includes synthesizing a protein of the sort described above; and optionally determining whether the protein has a desired property associated with polymerase activity, the polymerase activity being selected from the group consisting of increased thermostability; stability in storage; improved tolerance to salt; increased performance in isothermal amplification; does not alter the pH of a solution during sequencing; improved strand displacement; improved kinetics; altered processivity; altered ribonucleotide incorporation, altered non-standard deoxyribonucleotide incorporation; altered dUTP incorporation; higher fidelity; and increased Rtx activity as compared with the protein of any of SEQ ID NOs:1-23.
[0107] In another aspect, the method includes (a) synthesizing a protein wherein the protein has an amino acid sequence which is capable of being generated from single selected protein fragments obtainable from 8 different segments described in FIG. 2 ; and (b) assaying the synthetic protein for polymerase activity and properties associated therewith. The protein may be synthesized by cloning a DNA sequence encoding the protein.
[0108] In another aspect, a method is provided that includes selecting a protein variant or synthetic DNA polymerase protein from those described above; and expressing the protein as a fusion protein with an additional peptide at one or both ends of the DNA polymerase amino acid sequence.
[0109] In another aspect, a method is provided for isothermal amplification that includes: (a) providing a preparation comprising of a variant protein or synthetic protein selected from those described above; (b) combining a target DNA with the preparation; and (c) amplifying the target DNA at a temperature less than 90° C. to obtain an amplified target and optionally obtaining a quantitative measure of the amount of amplified DNA in the preparation.
[0110] In another aspect there is provided a DNA polymerase having one or more improved properties for isothermal amplification compared with SEQ ID NO:1, wherein the improved properties are selected from the group consisting of:
(a) an increased reaction speed in the range where the increase is at least 10% and as much as 20%; 500% or 1000%; (b) an increased temperature stability in the range of 50° C. to 100° C., 50° C. to 90° C. or 60° C. to 90° C.; (c) an increased salt tolerance in the range of 10 mM-1 M, or 20 mM-200 mM or 500 mM monovalent salt; (d) an increased storage stability at 25° C., retaining at least 50% activity over 45 weeks, over 1 year or over 2 years; (e) an enhanced dUTP tolerance of the range of an increase of 50% to 100% dUTP; and (f) an increased reverse transcriptase activity by at least 2 fold.
[0117] In the aforementioned aspect the DNA polymerase: (a) may have at least two or three or four or five or six of the improved properties; (b) may have at least 80% amino acid sequence identity but less than 100% amino acid sequence identity with any of SEQ ID NOs:1-23 and containing at least 12 artificially introduced single amino acid mutations that occur in a three amino acid motif that differs from an amino acid in the corresponding site of a naturally occurring Bst polymerase; or (c) may be such that at least one of the three amino acid motifs is selected from the group consisting of 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
BRIEF DESCRIPTION OF THE FIGURES
[0118] FIG. 1A shows an alignment of 23 wild type Bst DNA polymerase (LF) sequences. Not shown is a methionine optionally added at the N-terminal end of each of SEQ ID NOs:1-23 to facilitate expression of the polymerase in a host cell.
[0119] FIG. 1B shows sequence pair distances of the sequences in FIG. 1A using the software program Lasergene MegAlign™ (DNASTAR, Madison, Wis.).
[0120] FIG. 2 shows a 115 fragments arrayed in 8 segments where a fragment selected from each segment joined in order to the neighboring fragment forms an intact synthetic protein having DNA reagent properties.
[0121] FIGS. 3A and 3B show melt peaks for a parent Bst DNA polymerase FL or LF and variant DNA polymerases.
[0122] FIG. 3A shows the melt peaks for the variant DNA polymerase (FL) which has a melting temperature (Tm)=73.5° C. (Δ) and the parent Bst DNA polymerase (FL) has a Tm=68° C. (◯).
[0123] FIG. 3B shows the melt peaks for a parent Bst DNA polymerase LF (◯) which has a Tm=65° C. while the variant DNA polymerase (Δ) has a Tm=70° C.
[0124] The reactions were performed in 1× Detergent-free ThermoPol™ Buffer (New England Biolabs, Ipswich, Mass.) and 1× SYPRO Orange (Life Technologies, Carlsbad, Calif.).
[0125] FIGS. 4A-E show how the properties of a variant DNA polymerase can be screened for significant beneficial properties using an isothermal amplification protocol (Notomi, et al., Nucleic Acids Research, 28:E63 (2000)) and lambda DNA.
[0126] FIG. 4A shows an analysis of reaction speed. The variant DNA polymerase shows faster DNA amplification than the parent Bst DNA polymerase.
[0127] FIG. 4B shows the results of an assay to determine salt tolerance. The time in which the amplification reaction took to reach a threshold level of product was graphed against increasing KCl concentration in the reaction. The variant DNA polymerase was more tolerant to changes in salt concentration than the parent Bst DNA polymerase.
[0128] FIG. 4C shows the results of an assay to determine an increase in thermostability of a variant DNA polymerase by at least 3° C. compared with the parent Bst DNA polymerase. The time in which the amplification reaction took to reach a threshold level of product was graphed against increasing reaction temperature. The variant DNA polymerase was able to amplify DNA at a higher temperature than the parent Bst DNA polymerase.
[0129] FIG. 4D shows the results of an assay for storage stability in which a variant polymerase remains stable for at least 28 weeks at room temperature (22° C.) versus about 13 weeks for the parent Bst DNA polymerase (8000 U/ml for each enzyme was used).
[0130] FIG. 4E shows the results of an assay for dUTP tolerance in which a parent Bst DNA polymerase is significantly inhibited by increasing amounts of dUTP while the variant DNA polymerase activity is relatively stable as dUTP levels increase (1.4 mM dUTP corresponds to complete substitution of dTTP with dUTP). The ability to incorporate dUTP without inhibition of the polymerase is a useful feature of a DNA polymerase for various applications including strand modification and differentiation. Thermophilic archaeal DNA polymerases do not amplify DNA effectively in the presence of dUTP. Taq DNA polymerase can incorporate dUTP into substrate but Taq DNA polymerase is not suitable for isothermal amplification because it is not capable of the requisite amount of strand displacement.
[0131] FIGS. 5A and 5B shows that the DNA polymerase mutants described herein with improved polymerase activity also have improved reverse transcriptase activity.
[0132] FIG. 5A shows the results of determining Rtx activity using RT-qPCR. The lower the value of cycles (Cq) the greater the activity of the Rtx. From left to right, the bar chart shows Primer alone, RNA alone, Bst polymerase large fragment (BstLF), 2 mutants of the DNA polymerase described herein, Rtx, Avian Myeloblastosis Virus Reverse Transcriptase (AMV) and Moloney Murine Leukemia Virus Reverse Transcriptase (MMLV).
[0133] FIG. 5B shows gel electrophoresis of amplified DNA resulting from an RNA template and BstLF DNA polymerase or mutants. The lanes are labeled left to right as follows: primer alone, RNA alone, BstLF, Mutant 1 and 2, Rtx, AMV and MMLV.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0134] As used herein, the term “synthetic” with respect to proteins or peptides refers to a non-naturally occurring amino acid sequence that is generated either by expression of a gene encoding the non-naturally occurring amino acid sequence or is generated by chemical synthesis. The gene encoding the non-naturally occurring amino acid sequence may be generated, for example, by mutagenesis of a naturally occurring gene sequence or by total chemical synthesis.
[0135] A “variant” protein refers to a protein that differs from a parent protein by at least one amino acid that is the product of a mutation. A variant polymerase is intended to include a “synthetic” protein and vice versa as the context permits. The examples utilize a variant DNA polymerase but it will be understood to a person of ordinary skill in the art that the assays described in the examples are applicable to analyzing synthetic proteins also.
[0136] “Non-naturally occurring” refers to a sequence or protein that at the date in which the embodiments of the invention are presented herein, no naturally occurring amino acid sequence corresponding to the alleged non-naturally occurring amino acid has been described in the publically available databases.
[0137] “Isothermal amplification” refers to a DNA amplification protocol that is conducted at a temperature below 90° C. after an initial denaturation step, where an initial denaturation step is required.
[0138] The term “stability” as used in the claims includes thermostability and storage stability as illustrated in FIG. 4 and in the examples.
[0139] We have developed a set of variant proteins that are mutants of a highly conserved family of DNA polymerases belonging to Family A DNA polymerases. One or more of the amino acid mutations and/or amino acid motifs described herein are capable of enhancing the properties of these polymerases such as those properties determined by the assays described in the examples.
[0140] The Family A DNA polymerases are highly conserved so that it will be readily appreciated that with the teaching of the present embodiments, a person of ordinary skill in the art could select a naturally occurring DNA polymerase sequence (such as from GenBank) having at least 80% sequence identity with SEQ ID NOs:1-23 and introduce one or more of the specified mutations and/or motifs described herein to obtain polymerases with improved properties such as the type described in the examples.
[0141] In one embodiment, the DNA polymerase mutant proteins comprise or consist of an amino acid sequence that has at least 75% amino acid sequence identity, at least 80% amino acid sequence identity, or at least 85% amino acid sequence identify and as much as 90% amino acid sequence identity or 95% amino acid sequence identity to the parent DNA polymerase provided in the sequences described in SEQ ID NOs:1-23 wherein the amino acid sequence is less than 100% identical to the amino acid sequence of any of SEQ ID NOs:1-23.
[0142] Percentage sequence identity may be calculated by any method known in the art such as for example, using the BLOSUM62 matrix and the methods described in Henikoff, et al., PNAS, 89 (22):10915-10919 (1992)).
[0143] The at least one amino acid mutation in the variants is identified using the numbering scheme described in FIG. 1 with a reference amino acid as it occurs in SEQ ID NO:1 replaced by a desired amino at the specified position.
[0144] Accordingly, a parent polymerases having amino acid sequences with at least 75%, 80%, 85%, 90%, or 95% sequence identity to any of SEQ ID NOs:1-23 may be altered by at least one mutation selected from the group consisting of: A1E, G3(K, E or D), K5(L, A or V), E8(M or A), E9D, M10I, A13(D, E, T or V), I14D, V15A, V17(T, E or G), I18V, E20(M or D) M34(Q or L), E36D, I46F, L48(N or I), M57(L or I), P59(T or A), T61L, D65S, S66(F, E or P), Q67A, L69(V or K), A73E, M81V, A84R, V88(A or I), R99V, A102D, N113A, D117(T, S or A), A118D, G119(D or E), I121(A or V), V124K, E131H, S135(E or P), V144A, S147(P or A), L148(D or V), Q152(L or P), T153(A or V), Q170(R or E), M173(L or I), D175E, N178(E, K or R), Q183(L, E or R), L185F, T186(L or I), K187(E or D), Q190(L or M), A193(I or S), A194(L, S or T), N205(D or K), S216(L or E), R223(V, K or G), A224E, I225(Q or V), V247L, R307H, M316R, A330T, D357L, D378N, D380E, I383A, Q387R, L390M, 1400V, E406D, A410S, N411R, A433S, N437G, T439K, A452E, Q459(R or E), N463(V, E or D), L484D, D486E, V494L, T501M, Q530R, I552M, E557(K, Q or R) and T568(E or R).
[0145] The variant may optionally include one or more motifs selected from the group consisting of: 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0146] The DNA polymerase protein variants described above may be screened using at least one method described in Examples 1-6 so as to identify those variants having at least one of the functional properties that are at least typical of a Family A DNA polymerase, such as, Bst DNA Polymerase with an amino acid sequence corresponding to SEQ ID NO:1. The DNA polymerase may additionally have improved properties as compared with the wild type Family A DNA polymerases such as those including one of specific activity, reaction speed, thermostability, storage stability, dUTP tolerance, salt tolerance and reverse transcriptase activity.
[0147] In another embodiment, a synthetic protein is described that contains sequences from single fragments selected from each of 8 segments assembled in order of the 8 numbered segments (see FIG. 2 ). The synthetic protein may be synthesized either as a single DNA or protein sequence or as a set of polynucleotides or peptides that are ligated together using techniques known in the art (see for example Gibson Assembly™ Master Mix (New England Biolabs, Ipswich, Mass.), U.S. Pat. No. 7,435,572 or U.S. Pat. No. 6,849,428):
[0148] a Fragment 1 selected from Segment 1 having an amino acid sequence selected from the group consisting of SEQ ID NOs:24-39;
[0149] a Fragment 2 selected from Segment 2 having an amino acid sequence selected from the group consisting of SEQ ID NOs:40-56;
[0150] a Fragment 3 selected from Segment 3 having an amino acid sequence selected from the group consisting of SEQ ID NOs:57-72;
[0151] a Fragment 4 selected from Segment 4 having an amino acid sequence selected from the group consisting of SEQ ID NOs:73-87;
[0152] a Fragment 5 selected from Segment 5 having an amino acid sequence selected from the group consisting of SEQ ID NOs:88-99;
[0153] a Fragment 6 selected from Segment 6 having an amino acid sequence selected from the group consisting of SEQ ID NOs:100-111;
[0154] a Fragment 7 selected from Segment 7 having an amino acid sequence selected from the group consisting of SEQ ID NOs:112-125;
[0155] a Fragment 8 selected from Segment 8 having an amino acid sequence selected from the group consisting of SEQ ID NOs:126-138.
[0156] A proviso for creating a synthetic protein is that the synthetic protein has a sequence that differs from any SEQ ID NOs:1-23.
[0157] Preferably, a synthetic protein comprising segments 1-8 has at least one, two, three, four, five, six, seven, eight, nine or 10 sequence motifs selected from 3 . . . EEK . . . 5, 15 . . . ADE . . . 17, 65 . . . SPQ . . . 67, 86 . . . RAI . . . 88, 185 . . . LTE . . . 187, 186 . . . TEL . . . 188, 222 . . . LKE . . . 224, 306 . . . VHP . . . 308, 314 . . . HTR . . . 316, 555 . . . LCK . . . 557, 556 . . . CKL . . . 558 and 567 . . . VEL . . . 569.
[0158] The synthetic proteins described herein and characterized by a non-natural amino acid sequence generally retain DNA binding properties making these synthetic proteins useful for example as DNA detection reagents. The variants may be screened using at least one method described in Examples 1-6, or by other screening methods common used in the art, so as to identify those variants having at least one of the functional properties that are at least typical of a Family A DNA polymerase and/or have one or more improved properties selected from at least one of specific activity; reaction speed; thermostability; storage stability; dUTP tolerance and salt tolerance; increased performance in isothermal amplification; non-interference of pH during sequencing; improved strand displacement; altered processivity; altered ribonucleotide incorporation; altered modified nucleotide incorporation; and altered fidelity when compared to the corresponding parent polymerase. The improved properties of these mutant enzymes have been demonstrated to enhance the performance of sequencing platforms (for example, the Ion Torrent™ sequencer (Life Technologies, Carlsbad, Calif.)). The improved properties of these mutant enzymes enhance their use in isothermal amplification for diagnostic applications.
[0159] The DNA polymerase variants and synthetic proteins described herein may be expressed in suitable non-native host cells such as E. coli according to standard methods known in the art. To facilitate expression, the variant DNA polymerase may additionally have a methionine in front of the first amino acid at the N-terminal end. Host cells may be transformed with DNA encoding the variant optionally contained in a suitable expression vector (see New England Biolabs catalog 2019-10 or 2011-12 for expression vectors known in the art for this purpose). Transformation is achieved using methods well known in the art.
[0160] The DNA polymerase variants and synthetic proteins characterized herein may further be modified by additions and/or deletions of peptides at their N-terminal and/or C-terminal ends. For example, fusion of a peptide to a synthetic protein may include fusion of one or more of a DNA binding domain (such as Sso7d from archaea), an exonuclease domain (such as amino acids 1-289 of Bst DNA polymerase), a peptide lacking exonuclease activity (for example, a mutated exonuclease domain similar to amino acids 1-289 of Bst DNA polymerase), an affinity binding domain such as a Histidine tag, chitin binding domain, or intein, and a solubility tag such as maltose binding domain (MBP). The addition of a peptide fused to an end of the amino acid sequence of the DNA polymerase may be used to enhance one or more of the functional features described in Examples 1-6. Aptamers may be fused to one end of the mutant DNA polymerase.
[0161] The variants may be stored in a storage or reaction buffer that includes a detergent such as a non-ionic detergent, a zwitterionic detergent, an anionic detergent or a cationic detergent. The storage or reaction buffer may further include one or more of: a polynucleotide, for example, an aptamer for facilitating a hot start; polynucleotide primers, dNTPs, target polynucleotides; additional polymerases including additional DNA polymerases; RNA polymerases and/or reverse transcriptases; crowding agents such as polyethylene glycol; and/or other molecules known in the art for enhancing the activity of the DNA polymerase variants.
[0162] The DNA polymerase variant and synthetic proteins may be used for DNA synthesis, DNA repair, cloning and sequencing (see for example U.S. Pat. No. 7,700,283 and US Application Publication No. US 2011/0201056) and such as illustrated in the examples and also for temperature dependent amplification methods. Examples of isothermal amplification methods in addition to loop-mediated isothermal amplification (LAMP) used in the present examples include helicase dependent amplification (HDA) (see for example U.S. Pat. No. 7,829,284, U.S. Pat. No. 7,662,594, and U.S. Pat. No. 7,282,328); strand displacement amplification (SDA); nicking enzyme amplification reaction; recombinase polymerase amplification; padlock amplification; rolling circle amplification; and multiple displacement amplification (see for example Gill, et al., Nucleosides, Nucleotides and Nucleic Acids, 27:224-243 (2008)). The variant and synthetic DNA polymerases described herein may also be used in sample preparation for sequencing by synthesis techniques known in the art. The variant and/or synthetic polymerases may also be used in quantitative amplification techniques known in the art that may be performed at a temperature at which the variant or synthetic protein effectively polymerizes nucleotides.
EXAMPLES
[0163] The examples below illustrate assays and properties of Bst DNA polymerase variants described above.
Example 1
Assay for Determining the Properties of a Variant DNA Polymerase
[0164] (a) Loop-Mediated Isothermal Amplification (LAMP)
[0165] The properties of a variant polymerase can be determined using an isothermal amplification procedure such as a LAMP protocol (Nagamine, et al., Mol. Cell. Probes, 16:223-229(2002); Notomi, et al., Nucleic Acids Research, 28:E63 (2000)).
[0166] The LAMP reaction used bacteriophage A genomic DNA (New England Biolabs, Ipswich, Mass.) as the template. The LAMP primers used here were:
[0000]
(SEQ ID NO: 139)
FIP (5′-CAGCCAGCCGCAGCACGTTCGCTCATAGGAGATATGGTAGA
GCCGC-3′),
(SEQ ID NO: 140)
BIP (5′GAGAGAATTTGTACCACCTCCCACCGGGCACATAGCAGTCCT
AGGGACAGT-3′),
(SEQ ID NO: 141)
F3 (5′-GGCTTGGCTCTGCTAACACGTT-3′),
(SEQ ID NO: 142)
B3 (5′-GGACGTTTGTAATGTCCGCTCC-3′),
(SEQ ID NO: 143)
LoopF (5′-CTGCATACGACGTGTCT-3′),
(SEQ ID NO: 144)
LoopB (5′-ACCATCTATGACTGTACGCC-3′).
[0167] The LAMP reaction used 0.4 U-0.2 U variant Polymerase/μL, 1.6 μM FIP/BIP, 0.2 μM F3/B3, 0.4 μM LoopF/LoopB, and 5 ng lambda DNA in a buffer containing 1× ThermoPol Detergent-free, 0.1% Tween 20, 6-8 mM MgSO 4 and 1.4 μMdNTP. The reaction was followed by monitoring turbidity in real time using the Loopamp® Realtime Turbidimeter LA-320c (SA Scientific, San Antonio, Tex.) or with a CFX96™ Real-Time fluorimeter (Bio-Rad, Hercules, Calif.). The reaction conditions were varied to determine the optimum range that the variant DNA polymerase could perform LAMP. This was compared with the parent Bst DNA polymerase. The parent Bst DNA polymerase was typically used at 65° C. in these LAMP reaction conditions. However, the temperature was varied to determine the optimum temperature for a particular variant. Different salt conditions and rates of reaction were tested and variants identified which were 10%-50% faster than the parent polymerase and had an increased salt tolerance to as much as 200 mM KCl.
[0000] The results are shown in FIG. 4 .
[0168] (b) DNA Polymerase Activity Assay Using Modified Nucleotides in a Comparison of the Activity of a Fusion Variant Protein with Exonuclease Activity, with Full Length Parent Bst Polymerase.
[0169] This assay was used to determine the activity of the variant polymerase having exonuclease activity as a result of an additional 289 amino acid sequence at the N-terminal end that has been described in detail for parent DNA Bst polymerase. The activity was measured by incorporation of a radioactive 3 H-dTTP in a DNA substrate using various concentrations of a variant polymerase. A DNA polymerase reaction cocktail (40 μl) was prepared by mixing 30 nM single-stranded M13 mp18, 82 nM primer #1224 (5′-CGCCAGGGTTTTCCCAGTCACGAC-3′) (SEQ ID NO:145), 200 μM dATP, 200 μM dCTP, 200 μM dGTP, and 100 or 200 μM dTTP including 0.6 to 0.8 μCi [3H]-dTTP. The DNA polymerase reaction cocktail was mixed with DNA polymerase (2.2 to 8.7 ng for the parent Bst DNA polymerase (FL), 0.27 to 1 ng for the fusion variant, or 2.5 to 20 ng for the parent BstLF), or water for the no enzyme control, and incubated at 65° C. for 5 minutes. Reactions were halted and precipitated by acid precipitation as follows. A 30 μl aliquot of each reaction was spotted onto 3 mm Whatman discs and immediately submerged into cold 10% Trichloroacetic acid (TCA) in 1 L beaker in an ice bucket. A total counts control was spotted as described but not washed. Filters were washed three times with cold 10% TCA for 10 minutes with vigorous shaking and twice with room temperature 95% isopropanol for 5 minutes. Filters were dried under a heat lamp for 10 minutes and counted using a scintillation counter. The pmoles of dNTPs incorporated were calculated for each sample from the fraction of radioactive counts incorporated, multiplied by the total amount of dNTPs and the volume of the reaction.
[0170] A tenfold increase in specific activity of the fusion variant polymerase was found compared with the parent FL Bst polymerase where the fusion variant DNA polymerase was present in the mixture at 506,000 U/mg while the parent Bst DNA polymerase was present at 48,000 U/mg. (1 unit=incorporation of 10 nmol dNTP in 30 minutes at 65° C.).
[0171] A 15% increase in activity of the variant polymerase compared with the parent Bst large fragment DNA polymerases was observed in which the variant DNA polymerase was present in the mixture at 370,000 U/mg and the parent BstLF was present at 260,000 U/mg.
Example 2
Variant DNA Polymerase Thermostability
[0172] The thermostability of the variant DNA polymerase was assessed by incubating the polymerase at differing temperatures followed by performing either one or both of the DNA polymerase assay described in Example 1. The results are shown in FIG. 4C .
Example 3
Inhibitor Resistance of the Variant DNA Polymerase
[0173] The resistance of a variant DNA polymerase to inhibitors such as blood is determined by adding increasing concentrations of the inhibitor into the DNA polymerase assay and determining the change, if any, in the apparent specific activity of the protein. The DNA polymerase assay was performed as described in Example 1 at 65° C.
[0174] Another inhibitor of DNA polymerase is dUTP which is used to prevent carryover contamination in isothermal amplification by replacing dTTP. In this case it is desirable for the polymerase to be insensitive to dUTP inhibition so as to utilize dUTP as a substrate for LAMP. FIG. 4E shows that the mutant polymerase can efficiently utilize dUTP while the wild type Bst polymerase is inhibited by substituting dTTP with dUTP in the amplification reaction.
Example 4
Increased Resistance to High Salt Concentration
[0175] The resistance of a variant DNA polymerase to increased salt concentration was determined by adding increasing concentrations of salt (for example, KCl or NaCl) to the DNA polymerase assay described in Example 1 and determining the activity of the protein at 65° C. and comparing its activity to parent Bst DNA polymerase (see FIG. 4B ).
Example 5
Increased Stability in Storage
[0176] The stability of a variant DNA polymerase during storage was determined by incubating the enzyme in storage buffer (10 mMTris-HCl pH 7.5, 50 mM KCl, 1 mM Dithiothreitol, 0.1 mM EDTA, 50% Glycerol, 0.1% Triton X-100) at a temperature ranging from 4° C. to 65° C. for a time period ranging from 1 day to 28 weeks, and assaying DNA polymerase activity remaining after storage using the LAMP method described in Example 1. The remaining activity was compared to a sample stored at −20° C. for the same amount of time. The stability of the variant was then compared to the stability of parent Bst DNA polymerase (See FIG. 4D ). When this period was extended to 60 weeks, no detectable loss of activity of the mutants was observed even in the absence of glycerol.
Example 6
Assay for Determining the Melting Temperature of a Variant Polymerase for Comparison with a Parent DNA Polymerase Using a SYPRO Orange Assay
[0177] The assay was performed as follows: Each 50 μl reaction contains 1× ThermoPol Buffer, detergent-free (20 mM Tris-HCl pH 8.8, 10 mM (NH 4 ) 2 SO 4 , 10 mM KCl, 2 mM MgSO4, 1× SYPRO Orange protein gel stain, and DNA polymerase concentrations ranging from 2.2 to 17.5 μg (parent BstLF mutant) or 0.6 to 4.8 μg (parent Bst FL mutant). The reactions were placed in a CFX96 Real-Time System. The temperature was raised 1° C. per second from 20 to 100° C., and the fluorescence (in the FRET channel) was read at each temperature. Here, the Tm is the inflection point of the sigmodial curve of fluorescence plotted against temperature. The inverted first derivative of the fluorescence emission in FIGS. 3A and 3B is shown in relation to temperature, where the location of the minima corresponded to the value of the Tm (see FIG. 3 ).
Example 7
Whole Genome Amplification Using a Variant Bst DNA Polymerase
[0178] The variant DNA polymerase can be tested for suitability in whole genome amplification using the methods termed hyperbranched strand displacement amplification (Lage, et al., Genome Research, 13 (2):294-307 (2003)) or multiple-strand displacement amplification (Aviel-Ronen, et al., BMC Genomics, 7:312 (2006)).
Example 8
DNA Sequencing on a Semiconductor Device Using a Variant DNA Polymerase
[0179] The variant DNA polymerase can be tested for its suitability in DNA sequencing, for example, as described in Rothberg, et al., Nature, 475(7356):348-352(2011), an integrated semiconductor device enabling non-optical genome sequencing.
Example 9
Solid-Phase DNA Amplification Using a Variant Polymerase
[0180] Variant DNA polymerase can be tested for its suitability in solid-phase DNA amplification, for example as described in (Adessi, et al., Nucleic Acids Research, 28:E87 (2000), which describes a method for the amplification of target sequences with surface bound oligonucleotides.
Example 10
Enhanced Reverse Transcriptase Activity
[0181] The reverse activity of the mutant Bst DNA polymerase was determined using a two-step RT-qPCR assay (Sambrook, et al., Molecular Cloning—A Laboratory Manual, 3 rd ed., Cold Harbor Laboratory Press (2001)). The first step was for cDNA synthesis using the mutant enzymes and various traditional reverse transcriptases. The second measures the amount of synthesized cDNA by qPCR. The RT step was performed using 6 uM Hexamer (Random Primer Mix, New England Biolabs, Ipswich, Mass.) as primers in Isothermal Amplification Buffer (New England Biolabs, Ipswich, Mass.) supplemented with 6 mM Mg and 200 uM dNTP with 0.1 ug Jurkat Total RNA (Life Technologies, Carlsbad, Calif.) and incubated at 65° C. for 20 minutes. 1 ul of the RT product was added to qPCR reaction for GAPDH gene with 200 nM of forward (5′-AGAACGGGAAGCTTGTCATC) (SEQ ID NO:146) and reverse primer (5′-CGAACATGGGGGCATCAG) (SEQ ID NO:147), 200 uM dNTP, 1.25 unit of Taq DNA polymerase in 25 ul of 1× Standard Taq Buffer (New England Biolabs, Ipswich, Mass.) containing 2 uM of dsDNA-binding fluorescent dye SYTO® 9 (Life Technologies, Carlsbad, Calif.). The PCR cycles were: 95° C. for 1 minute, then 50 cycles at 95° C. for 10 seconds, 61° C. for 15 seconds and 68° C. for 30 seconds, and a final step of 68° C. for 5 minutes. The PCR was performed on a CFX96 Real-Time PCR machine and the Cq value was obtained as an indication of the amount of specific cDNA being synthesized ( FIG. 5A ). Mutant 1 and mutant 2 (4 th and 5 th bar from left in bar chart) make abundant cDNA as indicated by having Cq values similar to that of traditional RTs (6 TH , 7 th , and 8 th bar from left) in qPCR. Wild type BstLF (3rd bar from the left) is the same as controls (1st and 2 nd bar from left) without RT. After completion of the PCR reaction, 10 ul of PCR product was analyzed by electrophoresis in a 1.5% agarose gel ( FIG. 5B ) to verify the size of the PCR product. The lanes from left to right are primer alone, RNA alone, BstLF, mutant 1, mutant 2, Rtx, AMV and MMLV. Mutant 1, mutant 2 and all RTs (Rtx, AMV and MMLV) lanes gave a band of expected size (207 base pairs) but no specific band with wild type BstLF or controls. These results demonstrate that mutant 1 and mutant 2 has much improved Rtx activity compared to wild type BstLF.
[0182] All references cited herein, as well as U.S. provisional application Ser. No. 61/530,273 filed Sep. 1, 2011 and U.S. provisional application Ser. No. 61/605,484 filed Mar. 1, 2012, are herein incorporated by reference. | Compositions of novel polymerase variants and methods of identifying, making and using these novel polymerases are described. The variants have been shown to have advantageous properties such as increased thermostability, deoxyuridine nucleoside triphosphate tolerance, salt tolerance, reaction speed and/or increased reverse transcriptase properties. Uses for these improved enzymes have been demonstrated in isothermal amplification such as LAMP. Enhanced performance resulting from the use of these variants in amplification has been demonstrated both in reaction vessels and in dedicated automated amplification platforms. | 2 |
This application claims benefit of provisional patent application Ser. No. 61/357,252, filed Jun. 22, 2010.
TECHNICAL FIELD
The present invention relates to means for raising and lowering coverings for windows and other openings, in particular, to means for rotating a roller to which is fastened shade or the like.
BACKGROUND
Shades used for covering window openings and the like are commonly raised and lowered, to change the extent of blockage of an opening, by winding and unwinding—or reeling and unreeling, the shade on a roller. In the past, a roller has been driven in various ways, including by having a manually driven shaft, called a wand here, which is connected to the roller by a universal joint, a flexible shaft, a gear box and so forth. A universal joint (also called a U-joint) is a familiar mechanical fitting which allows the axis of a rotatable driving member to be offset from the axis of the driven member. U.S. Pat. No. 1,744,686 of Pease shows a relatively crude universal joint comprising two interlaced loops, for driving a gear system of a roller. U.S. Pat. No. 7,204,292 of Nien shows a universal joint in combination with a worm gear which drives a roller.
Particularly when the fabric of a shade is heavy, the weight of the hanging-down portion of the shade can cause the roller to turn, thus allowing the shade to unwind from its desired set position. Such kind of motion is sometimes referred to here as counter-rotation. Counter rotation can be resisted when there is a universal joint connected to the roller. If a wand or other driver which is connected to the joint is put at a sharp offset angle to the axis of the roller then the weight of the wand or slight holding force applied to it will resist rotation at the joint.
Another option is to interpose a gear box, for instance a worm gear box, between the wand and roller, because such a system by its nature resists counter rotation. Another way is to lock a wand against counter-rotation when there is only a flexible shaft connecting the wand and the roller. For example, the wand can be fastened to a window frame. Still another way is to make the handle-end of the wand hinged, so it can form a crank end that extends at an angle to the length of the rest of the wand; and the crank end may contact a window frame or a fitting or the shade itself.
However, there are situations in which it may be undesirable to have an element on the window frame to which the handle of a wand attaches, or to have a wand which has a crank end. Gear boxes may be expensive or slow down the speed at which the roller may be driven. When a universal joint is not well-aligned, i.e., when the driver is at a substantial angle to the driven parts, it may require a lot of force to turn the roller, and the motion can be unsmooth and difficult to the user.
Improved ways are still being sought, to simplify and improve the operation of a window treatment which is raised and lowered.
SUMMARY
An object of the invention is to provide a means for lifting a window treatment which prevents reverse rotation or unrolling of a shade or other window treatment part. A further object of the invention is to have a drive system for a lift-type window treatment which is easy to use and economic to construct.
In accord with an embodiment of the invention, a window treatment shade assembly comprises a shade which is alternately raised and lowered by reeling and unreeling the shade from a roller. The roller is rotated by a drive assembly which is connected to an end of the roller. The drive assembly is comprised of a flexible shaft connected to the roller; a universal joint connected to the flexible shaft; and, a means for rotating the universal joint, such as a wand, connected to the universal joint. Preferably, the universal joint is specially configured, and it is comprised of mating knuckles, each of which has a link with a slot; each link is engaged within the slot of the mating link. In a variation of the foregoing, a lifting member connected to a shade, such as a Roman shade, winds around the roller.
In exemplary use of the invention, the flexible shaft is spring-like and tends to bias the driven end of the universal joint toward the horizontal rotational axis of the roller. When the driven end of the universal joint is in such a location, the drive assembly is said to be in its home position. To raise or lower the shade, the wand which is connected to the driven end of the universal joint is pulled downwardly. That bends the flexible shaft downwardly, moving the drive assembly to its drive position; and it causes the links and thus the knuckles of the universal joint to align. The user then rotates the wand and turns the universal joint and thus rotates the roller, to raise and lower the shade to the desired elevation. When the desired setting is reached, the user lightly raises the wand upwardly, and then releases the wand. The universal joint will then be in the home position again, with knuckles at nominally right angles. Thus, the weight of the wand (and handle) hinders counter-rotation and unwinding of the shade from the roller. Unwinding is also prevented by contact of the wand with the wall or frame of the opening, or by contact with the fabric of the shade, according to the direction of the unrolling moment and the particular application.
In an embodiment of the invention the universal joint is comprised of specially configured mating knuckles. Preferably at least the driven knuckle has a U shape link with a slot which closely fits the head of the link of the mating knuckle; and, there is a wider portion of the slot near the inner end of the link, sufficient to enable rotation of one link within the slot of the other. The unique knuckles have particularly smooth driving action compared to a common universal joint and are particularly positive with respect to locking the roller in the desired position.
The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description of preferred embodiments and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a shade on a roller with a driver mechanism comprised of a wand and joint in the drive position. The components are also shown in their home or lock position, in phantom.
FIG. 1A is a partial perspective view of the lower end of a wand having both a collar and an articulating crank end.
FIG. 2 is a perspective is a perspective view of the portions of the apparatus shown in FIG. 1 , when in the home or lock position.
FIG. 3 is a side view of a U shape link of a knuckle, with the knuckle body in phantom.
FIG. 4 is a side view of an alternative U shape link.
FIG. 5 is a side view showing how a drive knuckle moves from the rest or lock position to the drive position, relative to a driven knuckle, in a knuckle joint.
FIG. 6A shows two joint knuckles assembled in their drive position, with the driven knuckle 36 in side view.
FIG. 6B shows the assembly of joint knuckles from FIG. 6A , with the driven knuckle 36 in top view.
FIG. 7 is similar to FIG. 6B , and shows a knuckle joint in its drive position, corresponding in pictured orientation with FIG. 1 .
FIGS. 8A , 8 B, and 8 C are respectively side, edge, and end views of a U shape link of a knuckle.
FIG. 9 is a quasi-isometric view of the body of a knuckle attached to the end of a wand, with the top part of the U shape link cut away. FIG. 9 is particularly related to FIG. 3 .
FIG. 10 is a vertical cross section through the link of knuckle 36 as shown in the assembly of FIG. 6B .
DESCRIPTION
The disclosure of provisional U.S. patent application Ser. No. 61/357,252, filed Jun. 22, 2010, entitled “Cordless Roman Shade with Self-Locking Handle” and the disclosure of commonly owned U.S. patent application Ser. No. 12/829,834 of M. Hanley et al., filed Jul. 2, 2010, and entitled “Handle with Anti-Rotation Mechanism for a Window Treatment,” are hereby incorporated by reference.
Embodiments of the present invention relate to so-called cordless Roman shade window treatments, and means for raising and lowering such shades, which are described in the Ser. No. 12/829,834 application. The shades described in the application, and further below, may be used for other purposes than covering window openings, such as for other openings and spaces where it is desirable to adjustably control passage of light or matter.
FIG. 1 shows a window treatment assembly embodiment comprising a shade 26 and associated driver 29 , namely a wand 28 with handle 30 , for actuating and raising and lowering the shade. For simplicity in the following description, reference is often made to the wand as representative of the actuator which may comprise several parts, e.g., the handle, and articulated end, and a collar as described below. Shade 26 is shown partially rolled around roller 23 , the longitudinal axis of which is indicated by the line 24 . The ends of the roller 23 are rotatably supported in brackets 58 which attach to a window frame or the like, not shown, but suggested by frame phantom 59 at one bracket. In the generality of the invention, the shade assembly is attached to some supporting structure during use.
A driver assembly 20 for raising and lowering the shade comprises a driver 29 , a portion of which is wand 28 , universal joint 32 to the lower end of which is attached a wand 28 , and a flexible drive shaft 34 connecting roller 23 to the upper or near end of the universal joint, also referred to in particular as the knuckle joint. Flexible drive shaft 34 is preferably a tightly wound metal coil spring, an example of which is detailed below. Alternately, shaft 34 may be a piece of steel flexible shaft, well known in commerce. Shaft 34 may be connected to the end of the roller by various means, including that it may be force-fit or press-fit, pinned, or otherwise fastened within a cavity 25 at the end of the roller 23 . See FIG. 2 . The other end of the shaft 34 is connected to universal joint 32 , in particular to the driven knuckle part 36 . Similar alternative means of attachment may be used to connect the shaft to the knuckle body.
FIG. 1 shows the elements in their operating or drive position, and indicates how counter-clockwise rotary motion (arrow A) imparted to the handle end 30 of wand 28 by a user results in the shade 26 being raised up and wound (arrow B) as a reel of fabric 22 about the roller 23 . FIG. 1 shows that the wand has a handle 30 at its lower end, to make easier gripping of the wand by the user, and to add mass to the driver/wand for resisting counter-rotation as explained below. A wand may have no handle and may be a simple polygonal cross section plastic shaft. Alternately, the wand may have a crank end as described below and as shown in FIG. 1A .
In FIG. 1 the driver assembly 20 is shown in its operating or drive position, wherein the joint 32 is more or less straight, due to the user having pulled downwardly on the driver 29 and having overcome the resilient, or bias, force of the preferred flexible shaft 34 . FIG. 1 also shows, in phantom, the drive assembly and elements when they are in their rest or home position. The items designated 20 P (assembly), 32 P joint), 34 P (shaft), 28 P (wand), etc., are the same items as those having the number with no suffix P. The assembly 20 moves from its operating position to its rest position (indicated by arrow C) when the user lightly thrusts the wand 28 upwardly, as described in more detail further below. When shaft 34 has the aforementioned coil spring construction, or a structural analog, the bias created by the resilience of the flexible shaft aids the upward motion.
FIG. 2 shows driver assembly 20 in more detail, in its rest position, where the parts of knuckle joint 32 are at a more or less right angle. Preferred joint 32 is comprised of two mating identical knuckle parts 36 , 38 . FIGS. 3 , 8 and 9 detail the construction of typical knuckle part, or knuckle half, 38 ; and FIG. 5-7 detail the construction and function of the knuckle joint. These aspects are discussed further below.
When, as shown in FIG. 2 , wand 28 and knuckle joint 32 are in their home positions (also called the lock position), and counter rotation of the roller 23 is resisted. This can be understood as follows: If the roller 23 starts to rotate, that motion is transmitted through driven knuckle 36 . But knuckle 36 cannot rotate without also rotating with knuckle 38 , the centerline of which is at an about right angle to the centerline of knuckle 36 when the drive assembly is in its home position. The counter-rotation force transmitted to knuckle 38 is such as to tend to lift the wand 28 , to urge it to rotate toward a plane which is more of less perpendicular to the plane in which the shade and wand hang. (Alternately, when the shade winds around the roller in the opposite direction, counter-rotation will tend to push the wand into the plane of the window frame. Of course, the drive system may be moved to the opposite end of the roller from that shown in FIG. 1 and the wand rotational directions will be reversed.) The term “counter rotation” is used here mostly in the sense of referring to unwanted motion which unwinds the sheet from the roller.
The weight of the wand, and the distance of its center of mass from the axis of rotation of the knuckle joint, create a moment which opposes the counter-rotation moment generated by the weight of the shade as it seeks to unroll off the roller. In the embodiment of FIG. 1 , the center of gravity of the wand will depend on the weight of the wand and handle 30 . The distance between the center of gravity of the wand and the center of joint 32 will preferably be at least half the distance to the free end of the wand, i.e., half the distance to the outer end of handle 30 , in the embodiment of FIG. 1 and FIG. 2 .
When the system is in its rest position, and a user is not applying downward force to the wand, a preferred flexible shaft 34 has a stiffness and strength sufficient, to counter the weight of the wand and to cause the shaft 34 to approach a horizontal position, more or less in-line with, but still curving somewhat downward with respect to, the line of axis 24 of the roller. Another useful shaft 34 may have less stiffness or strength.
To raise or lower the shade, a user pulls downwardly on the wand 28 , overcoming any resilient resistance to deflection of shaft 34 . That causes the knuckle joint to move from the rest or lock position, shown in FIG. 2 and in phantom in FIG. 1 , to the drive position, shown in FIG. 1 .
FIGS. 3 to 7 detail a preferred knuckle construction. FIG. 5 shows how the wand-driven knuckle 38 rotates relative to the other knuckle 36 with which it is engaged. (For simplicity and consistency with the other related Figures, FIG. 5 pictures the wand being rotated upwardly in the vertical plane, compared to the wand pulling the knuckle parts downwardly. The relative motion in Fig. is of course is the same relative motion which results when the wand and knuckle 38 are pulled downwardly.)
Both preferred embodiment knuckles have similar construction, which promotes economic production and assembly. (As indicated below they do not need to be identical in detail configuration.) With reference to FIG. 3 to FIG. 7 , typical knuckle 38 comprises a U shape link 40 which has a slot 48 . The slot has a wider portion 50 near the base or body 44 of the knuckle. When the wand is pulled downwardly, to bend the flexible shaft downward and thus to bring the links toward alignment, the wider portion of the slot enables the head 56 of drive knuckle 38 to rotate within the slot of the driven knuckle 36 , as illustrated by FIG. 5 .
The U shape link 40 has a cross piece or head 56 that connects the opposing legs which define the slot 48 . Knuckle 36 is similarly configured, having a link 42 , slot 148 with wider portion 150 , and head 156 . As the knuckles move into lengthwise alignment due to the user pulling on the wand, the head 56 of the link 40 of knuckle 38 slides lengthwise within the slot 48 of link 42 of knuckle 36 . The resultant configuration is shown in FIG. 6A and FIG. 6B (which are respectively side and top views, and collectively referred to as FIG. 6 ). When the knuckles are aligned lengthwise, rotating of the wand and attached drive knuckle 38 will rotate driven knuckle 36 and shaft 34 . FIG. 7 is like FIG. 6B ; it is another view of the knuckle joint 32 in its drive position, but pictured to correspond with FIG. 1 .
When the user stops turning the wand upon reaching the desired extension of the shade, the user raises the wand upwardly in the lengthwise direction of the wand, which is the reverse of the motions just described and illustrated by FIG. 5-6 .
Note that the rectangular, preferably square, cross section of head 56 of knuckle 38 fits closely in the slot 148 of the mating knuckle 36 . Thus, when moving from the drive to head position, the head 56 (and link 40 ) slides lengthwise in slot 148 of link 42 until it reaches the wider portion 150 at the base of the U shape link 42 . At that location, the knuckle 40 is able to rotate relative to knuckle 42 because the space 150 allows rotation of the head within the slot. See FIG. 5 . The resilient force of the preferred flexible shaft 34 , and the continued light upward motion of the wand by the user, cause the knuckle 36 to resume its nominal horizontal position. The assembly will then reach the rest position (alternately called the home or lock position) shown in FIG. 2 . The length dimensions of the different portions of the slot enable the aforementioned rotational motions.
The construction of a typical preferred knuckle is now described. Referring to FIG. 3 and FIG. 9 , the wand 28 is received in a hole 52 in the body 44 of the knuckle 38 . Link 40 is detailed in the three mutually orthogonal views of FIGS. 8A , 8 B and 8 C. Link 40 has legs with bulbous ends 52 which are gripped as they slide into the undercut of a transverse slot 54 of the body 44 when the assembly 20 is manufactured. Wand 28 is inserted into the cavity 52 next, so that the wand sticks upwardly in the space between the opposing side leg ends 52 of the link. That prevents the legs from moving laterally within the slot. Set screw 58 retains the wand in place. The other knuckle 36 is similarly constructed, except that it is the end of the flexible shaft 34 which keeps the bulbous leg ends of the link within the slot, instead of a wand.
In another embodiment of the invention, a link 42 A, shown in FIG. 4 , has a slot 48 A which has a width W which is wider than the cross section of the head 56 A and a uniformly wide slot portion—i.e., portion 50 which characterizes link 42 , is absent and rotation of the head within the slot is possible along its whole length. Thus, the head 56 , 56 A of one knuckle can rotate relative to the other knuckle at any point along the length of the slot, because the slot 48 A of a first knuckle is wide enough to enable rotation of the head 56 A of a second identical knuckle to turn within the slot 48 A. This embodiment has a less positive action since there is more “play” in the joint.
As will be appreciated, in the invention, both knuckles do not have to have identical construction, although making them so is an aid to economic mass production. In particular, the bases can have different configurations. And, a driven knuckle which has link defining a close head-fitting slot with wider portion (as shown in FIG. 3 ) may be used with a drive knuckle which has a plain, wide slot (as shown in FIG. 4 ).
The knuckle and universal joint construction described above is a special (and unique) case of a universal joint. A common universal joint, known in commerce, or a knuckle joint without the special fit of the preferred embodiment described above, may be used in carrying out the invention. As will be appreciated from the foregoing, a knuckle joint is one in which the mating parts which are engaged are loop shaped, preferably U-shape. Common universal joints and flexible shafts are commercially available from McMaster Carr, Inc., Robinsville, N.J.; although for common commercial window treatments lower cost and thus more primitive items may be preferred. The ease of operation and range of functionality may be less good when the embodiment comprises a commercial universal joint of a common knuckle joint. Even so, there will not be significant counter-rotation, by which is meant that the sheet will not unwind from the roller in a degree which is substantial compared to the mean useful extension of the sheet from the roller.
The reason for preference of the special configuration knuckle joint which is described in connection with FIG. 3-7 is as follows. Reference should be made to FIG. 10 , which is a cross section through the knuckle assembly of FIG. 6B . When the parts of the knuckle joint are in a working or drive position, where the parts of the joint lie in some approximation of straight line (which could be nominally along the z-axis), the knuckle joint of the present invention has one degree of substantial freedom of movement, e.g., in the x plane looking along said z-axis straight line. In comparison, a common universal joint under the same situation will have two degrees of freedom, i.e., in the x-plane and in the orthogonal y-plane. Given that the flexible shaft 34 is “wiggly” and resiliently “wants” to go to its home position, there is a tendency for a common low cost universal-type joint, especially, for example, one having mating links or loops, to “kick” out of alignment when being driven. That makes the use of the driver (wand) more erratic and uncertain from the standpoint of operator perception. The unique construction of the invention knuckles overcomes those problems in a surprisingly straightforward and economic fashion.
The wand is preferably a hexagonal or round rod of semi-rigid extruded acrylic plastic or polyvinylchloride plastic. The wand may have other cross sections, such as square. The wand may be a solid or hollow rod, and may be made of another plastic or metal. Other components of the drive system are preferably made of POM (polyoxymethylene) plastic.
From the foregoing it will be appreciated that there is a desirable interrelationship between the flexible shaft and the joint, whether it be a preferred knuckle joint or some other universal joint.
In another embodiment of the invention, the handle portion 30 of the wand 28 may be hinged relative to the rest of the wand length at one, preferably two, places, to thereby form a crank handle. FIG. 1A shows alternate embodiment wand 28 A which has a lower end 62 which is hinged at pivot pin 64 , so it can move as illustrated by the arrow to a position nominally perpendicular to the length axis 66 of the wand. Such an articulate wand is said to have a crank end. FIG. 1A also shows collar 60 , which may be a loosely-fit piece of semi-rigid or rigid plastic tubing within which wand 28 A freely rotates, is positioned around the lower end of wand 28 A. Thus, a user may grasp the collar and thereby steady the wand while applying the rotary force to the wand—in the instance of the crank end, by twirling the crank, often with a single finger. The collar may also be used on the wand in the embodiment of FIG. 1 . In still another embodiment, the wand has a second hinged portion, so that the distal end of the wand may be made parallel to, but offset from, the wand portion which connects to the joint. See the related application Ser. No. 12/829,834.
While a simple wand, in its variations, is economic and effective, in the generality of the claimed invention the term wand and driver shall include other rotary drive means which are equivalent in function and result to a manually turned wand, for instance, an electric motor actuator connected to the universal joint directly, or by means of a wand or analogous structure.
The flexible shaft 34 is preferably a 2+ inch long tightly wound coil of 0.06 inch diameter music wire, i.e., hardened steel. It has an about one-quarter inch outside diameter. By “tightly wound” is meant that the adjacent turns of the coil are touching or nearly touching each other, i.e., the pitch of the turns of the coil is between 100 and 120 percent of the wire diameter. For reasons which are evident from the foregoing description, the shaft 34 is desirably resilient and sufficiently strong to help lift itself and the driven knuckle upwardly, when the user desires that to happen and pushes the wand upwardly.
In the generality of the invention, a flexible shaft need not have the resilience and “toward-horizontal” bias which has been described. In another embodiment of the invention, shaft 34 has insufficient resilience and or strength to overcome the weight of the wand, or none. When the shaft 34 has such character, the user may, after having changed the position of the shade by rotating the wand, raise the wand upwardly to thereby push the knuckle joint 32 upwardly, which will push the shaft 34 upwardly. That will cause the upper knuckle 36 to move to the horizontal home position, thereby enabling locking of the driver assembly. To the extent the shaft has such low strength that, upon release by the user, the weight of the wand will pull the shaft down to the point the knuckles become aligned, and the locking feature is defeated, the wand may be clipped to the frame of the window or a wall, as by a clip, magnetic means, etc. Alternately, when the handle is hinged to the rest of the wand length, as shown in FIG. 1A , the handle may be bent nominally perpendicular to the wand length, to thereby form a crank end which can be placed in contact with a window frame or a fitting or the shade itself, to thereby resist counter-rotation of the wand.
The co-pending patent application Ser. No. 12/829,834, referred to above, describes a Roman shade with which the invention is particularly useful. Roman shades often are made of relatively heavy fabric. In the invention of the application Ser. No. 12/829,834 the Roman shade is raised by rolling up a lifting element, that is, a fabric piece which is attached to the lower end of the shade. The lifting element and not the shade itself is wound around the roller when it is rotated. See for example FIG. 6 and FIG. 9 of the related application. Thus, in the generality of the invention, rotation of the roller by the drive assembly can directly or indirectly lift the shade of a window treatment.
The invention, with explicit and implicit variations and advantages, has been described and illustrated with respect to one or more embodiments. Those embodiments should be considered illustrative and not restrictive. Any use of words such as “preferred” and variations suggest a feature or combination which is desirable but which is not necessarily mandatory. Thus embodiments lacking any such preferred feature or combination may be within the scope of the claims which follow. Persons skilled in the art may make various changes in form and detail without departing from the spirit and scope of the claimed invention. | A window treatment, in which a shade is raised and lowered, is comprised of a roller upon which shade material is reeled and unreeled. A wand drives a universal joint, preferably a uniquely configured knuckle joint, and the universal joint drives a flexible shaft which is connected to the roller. Special shaping of the parts and slots of the U shape links of mating knuckles enables smooth and positive universal joint operation. A user may pull down on the wand, to bend the flexible shaft and bring the knuckles into alignment, whereupon turning of the wand rotates the roller. When the wand is released the resilience of the flexible shaft helps lift the driven knuckle so it is parallel to the horizontal roller, and the drive roller moves to a home position which inhibits counter-rotation of the roller due to the weight of the shade. | 4 |
RELATED APPLICATIONS
This application claims the priority of Provisional Application Ser. No. 60/029,483 filed Oct. 4, 1996.
FIELD OF THE INVENTION
This invention relates to semiconductor devices, and more specifically relates to a novel device in which a plurality of die, which may be of diverse size and of diverse junction pattern, are fixed to a common lead frame and within a common package or housing.
BACKGROUND OF THE INVENTION
Numerous electrical circuits, for example, DC to DC converters, synchronous converters, and the like require a number of semiconductor components such as MOSFETs and Schottky diodes. These components are frequently used in portable electronics apparatus and are commonly separately housed and must be individually mounted on a support board. The separately housed parts take up board space. Further, each part generates heat and, if near other components, such as microprocessors, can interfere with the operation of the microprocessor.
It would be desirable to reduce the board space required by plural semiconductor devices and to reduce part count and assembly costs in power converters and other power subsystems for high-density applications.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the invention, two or more diverse semiconductor die are laterally spaced and mounted on a common lead frame with a first one of each of their power terminals electrically connected to the lead frame. The main lead frame body then has a first set of externally available pins which are used to make connection to the first one of the power terminals of each of the diverse die. The die are also provided with second power terminals at the tops of the die, and these are connected to respective external pins of the lead frame which are isolated from one another and from the first set of external pins. One or more of the die may also contain a control terminal, such as the gate electrode of a MOSFET die, and a further and isolated pin of the lead frame is connected to this gate terminal.
The lead frame and die are then over-molded with a suitable insulation compound housing, with the various pins extending in-line and beyond the edge surfaces of the housing and available for external connection.
The housing may take the form of a surface-mounted housing with a very small "footprint". By way of example, a MOSFET die and a Schottky diode die may be contained within and may have their drain electrodes and cathode electrodes respectively soldered to a common conduction lead frame pad to be interconnected within the housing. The FET source and gate terminals on top of the die are wire bonded to insulated lead frame pins and the top Schottky diode anode is also connected to an isolated pin so that any desired external connection can be made to the package.
While any package style can be used, the novel invention has been carried out with an SO-8 style small outline package.
The novel package of the invention can improve efficiency of a DC to DC converter by reducing power drain on batteries, leading to a longer life. For desk top systems, the device reduces power dissipation and heat generation near temperature-sensitive parts such as microprocessors. The device also provides substantial savings in board space while reducing component count and assembly costs.
For example, the use of a copackaged FET Type IRF7422D2 (a (-20) volt 90 mohm P channel FET) and a Schottky diode (30 volt, 1 ampere) in a buck converter circuit provided a 60% saving in board space and assembly cost.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a known buck converter circuit using a P channel MOSFET.
FIG. 2 is a circuit diagram of a buck converter circuit employing an N channel MOSFET and a parallel Schottky diode.
FIG. 3 is a perspective diagram of an SO-8 style package which can be used to house both the MOSFET die and Schottky die of FIGS. 1 and 2 in accordance with an embodiment of the invention.
FIG. 4 is a schematic top view of the package of FIG. 3 with the die of the circuit of FIG. 1 copackaged on a common lead frame.
FIG. 5 shows a top view of the lead frame of the package of FIGS. 3 and 4 with the MOSFET die and Schottky diode die fastened to the lead frame.
FIG. 6 is an enlarged view of the portion of FIG. 5 which is within the dashed line in FIG. 5.
FIG. 7 is a schematic top view of an alternative embodiment of the package of FIG. 3 with the die of the circuit of FIG. 1 copackaged on a common lead frame.
FIG. 8 shows a top view of the lead frame of the package of FIG. 7 with the MOSFET die and the Schottky diode die fastened to the lead frame.
FIG. 9 is an enlarged view of the portion of FIG. 8 which is within the dashed line in FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, there is shown a conventional buck converter circuit, sometimes known as a step down converter, which is commonly used to reduce the voltage to integrated circuits and processors on the circuit board of a portable electronic device or the like. For example, the circuit might be used to reduce an input voltage of 12 volts DC to 5 volts DC (or 3.3 volts DC in some cases) to drive an integrated circuit or other load (not shown).
The circuit of FIG. 1 is well known and uses a P channel MOSFET 10 for the switching function under the control of a suitable control circuit 11 connected to the FET gate G. FET 10 may be a 20 v, 90 m-ohm die available from the International Rectifier Corporation. A Schottky diode 12 which may be a 30 volt, 1 ampere die has its cathode connected to the drain D of FET 10 and is used to perform output current recirculation into inductor 13 and capacitor 14. As will be later shown, and in accordance with the invention, FET 10 and Schottky diode 12 are provided in die form and are mounted on a common lead frame of a single package shown by dotted line block 15. This novel combination produces a 60% space saving on the support board of the device and reduces assembly cost.
It will be apparent that the invention can be employed in many other circuit configurations. For example, FIG. 2 shows a synchronous buck converter circuit using an N channel MOSFET 20 as the switching device, an N channel MOSFET 21, and a Schottky diode 22 in parallel for synchronous rectification.
In accordance with the invention, FET 21 and Schottky diode 22 may be die which are copackaged within a common housing, as shown by dotted block 23. This circuit is useful to avoid losses found in the "lossyl" forward voltage drop of the Schottky diode 12 of FIG. 1. It also eliminates the effects of the inherent body diode of the vertical conduction FET 21 from the circuit since the Schottky diode 22 handles the reverse current flow seen by the synchronous rectifier during the "wait" state of controller 24.
FET 21 of FIG. 2 may be a 30 v, 35 m-ohm die available from the International Rectifier Corporation.
Housings 15 and 23 may take the form of a known housing Type SO-8, shown in FIGS. 3 and 4. Thus, FIG. 3 shows an SO-8 surface mount housing with eight in-line pins 1 to 8 (FIG. 4) which extend from a plastic insulation housing 30. As seen in FIG. 4, the FET die 10 and Schottky diode 12 are internally mounted on a common lead frame, as will be later described and are interconnected to enable their external connection as in FIG. 1 or 2 (with an appropriate FET die 10 or 21) or in other circuit configurations.
In FIG. 4, the drain of FET 10 and cathode of Schottky diode 12 are connected to one another and to pins 5 to 8 of a common lead frame section as will be later described. The source and gate of FET 10 are connected by wire bonds to isolated pins 3 and 4, respectively, and the anode of Schottky diode 12 is connected by wire bonds to isolated pins 1 and 2.
FIGS. 5 and 6 show the lead frame and FET 10 and Schottky 12 die in more detail. Thus, a lead frame 40 is provided which contains a main pad body 41 from which pins 5 to 8 integrally extend. The main pad body 41 is larger than the main pad body of a conventional lead frame so that both the FET die 60 and the Schottky diode 12 may be mounted to it. According to a novel aspect of the invention, the walls of plastic insulation housing 30 are thinner than a conventional housing to accommodate the larger main pad body without significantly reducing resistance to moisture.
The lead frame also contains pins 1 to 4 and respective bond pad extensions which are within molded housing 30. These are originally integral with the lead frame body 40 (during molding), but are shown in their severed condition which isolates pins 1 to 4 from one another and from main pad 41. Typically, pins 1 to 4 are coplanar with each other and with the main bond pad 41.
Lead frame 40 is a conductive frame and may have a conventional lead frame solder finish. The bottom cathode surface of diode 12 and the bottom drain surface of FET 10 are connected to pad 41 as by a conductive epoxy die attach compound and are thus connected to pins 5 to 8. Alternatively, the cathode surface of diode 12 and the drain surface of FET 10 are soldered to pad 41 or are connected to the pad using a conductive glass containing silver particles.
The top anode electrode of Schottky diode 12 is wire bonded by gold bonding wires 50 and 51 to pins 1 and 2, respectively (before molding), while the source electrode and gate electrode of die 10 are bonded by gold wires 52 and 53 to the internal bonding extensions of pins 3 and 4, respectively, also before molding the housing 30. Alternatively, aluminum bonding wires are used. The internal bonding extension of the pins are typically silver or gold plated. The bonding wires are generally bonded to the die surface and to the internal bonding extensions using thermosonic ball bonding, as is known in the art, though other processes may be used.
Thereafter, the molded housing, which may be a mold compound such as NITTO MP7400. It is formed in a conventional molding operation. However, other types of housings, such as a ceramic housing, a hermetic housing or an injection molded metal housing, may be used.
It should be noted that other package styles could be used, but the copackaging in a surface-mount package conserves considerable board space. The resulting device can be soldered down to a printed circuit board using conventional mass production soldering techniques.
FIGS. 7 and 8 shows an alternative embodiment of the invention in which the source of FET 10 is connected by wire bonds 151 and 152 to isolated pins 2 and 3, the gate of FET 10 is connected by wire bonds 153 to isolated pin 4, and the anode of Schottky diode 12 is connected by wire bonds 150 to isolated pin 1. The drain of FET 10 and the cathode of Schottky diode 12 are connected to one another and to pins 5 to 8 of a common lead frame section in the manner described above.
FIGS. 8 and 9 show the lead frame of this embodiment and the FET 10 and the Schottky diode 12 in greater detail. The lead frame 140 is similar to the lead frame 40 described above and includes a similar main pad body 141. The bottom cathode surface of Schottky diode 12 and the bottom drain surface of FET 10 are connected to pad 141 in a similar manner to that described above, and the top anode electrode of Schottky diode 12 and the source and gate electrodes of FET die 10 are similarly bonded to the internal bonding extensions of the pins as described above. Similarly, the housing 130 is formed in the manner described above.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not only by the specific disclosure herein, by only by the appended claims. | A MOSFET die and a Schottky diode die are mounted on a common lead frame pad and their drain and cathode, respectively, are connected together at the pad. The pad has a plurality of pins extending from one side thereof. The lead frame has insulated pins on its opposite side which are connected to the FET source, the FET gate and the Schottky diode anode respectively by wire bonds. The lead frame and die are molded in an insulated housing and the lead frame pins are bent downwardly to define a surface-mount package. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the fabrication of semiconductor-based devices. More particularly, the present invention relates to improved techniques for fabricating semiconductor-based devices with low dielectric constant materials.
[0002] In semiconductor-based device (e.g., integrated circuits or flat panel displays) manufacturing, dual damascene structures may be used in conjunction with copper conductor material to reduce the RC delays associated with signal propagation in aluminum based materials used in previous generation technologies. In dual damascene, instead of etching the conductor material, vias, and trenches may be etched into the dielectric material and filled with copper. The excess copper may be removed by chemical mechanical polishing (CMP) leaving copper lines connected by vias for signal transmission. To reduce the RC delays even further, low dielectric constant materials may be used. Low dielectric constant materials are here defined as materials with a dielectric constant of less than about 3.7. These low dielectric constant materials may include organo-silicate-glass (OSG) materials, such as Coral™ and Black Diamond™, or may be purely organic materials, such as SILK™ or Flare™. OSG materials may be silicon dioxide doped with organic components such as methyl groups. Etching these materials and stripping the photoresist on these materials may be significantly different and much more challenging than when conventional oxide materials are used. Oxygen containing plasmas may not be suitable for stripping resist on OSG materials, since oxygen plasmas may oxidize the organic content of low k OSG materials or may cause bowing during the etch of purely organic low k materials.
[0003] To facilitate discussion, FIG. 1A is a cross-sectional view of a stack 100 on a wafer 110 used in the damascene process of the prior art. A contact 104 may be placed in a dielectric layer 108 over the wafer 110 . A barrier layer 112 , which may be of silicon nitride or silicon carbide, may be placed over the contact 104 to prevent the copper diffusion. A via level low k material layer 116 may be placed over the barrier layer 112 and dielectric layer 108 . A trench stop layer 120 may be placed over the via level low k layer 116 . A trench level low k material layer 124 may be placed over the trench stop layer 120 . A hard mask and/or an antireflective coating (ARC) layer 128 may be placed over the trench level low k material layer 124 . A patterned resist layer 132 may be placed over the hard mask and/or an antireflective coating (ARC) layer 128 . The via level low k material layer 116 and the trench level low k material layer 124 may be formed from a low dielectric constant OSG material or organic material. The trench etch stop layer 120 may be formed from silicon carbide or silicon nitride. SiON or organic anti reflective coating (BARC) may be used to form the ARC layer 128 .
[0004] [0004]FIG. 1B is a cross-sectional view of the stack 100 after a via 136 and a trench 140 have been etched. To etch through the hard mask and/or an antireflective coating (ARC) layer 128 , the etch stop layer 120 and the barrier layer 112 it may be desirable to use a fluorine containing gas as a gas source for an etching plasma. To etch through the via level organic low k material layer 116 and the trench level organic low k material layer 124 , it may be desirable to use an ammonia (NH 3 ) containing gas as a gas source for an etching plasma. In addition, for organic low k materials, a fluorine source may be added to NH 3 to remove any unwanted polymeric residue from the open areas of the wafer. To etch through the via level OSG low k material layer 116 and the trench level OSG low k material layer 124 , it may be desirable to use a fluorine containing gas similar to the gas used to etch the ARC layer 128 , the etch stop layer 120 and barrier layer 112 . To strip the photo resist after via, trench, or barrier etch, it may be desirable to use NH3 gas. After the trench and via etches of OSG materials a polymer crust 144 may be deposited over the patterned resist layer 132 and side walls of the trench 140 and via 140 . To remove a silicon containing polymer crust 144 it may be desirable to use a fluorine containing etchant gas in combination with NH3. Although it is desirable to use an etchant gas with a fluorine containing gas and an ammonia containing gas either together or in alternating steps, such attempts in the prior art resulted in the formation of particles, which may contaminate the plasma processing chamber and may increase defects in the resulting semiconductor structure. Thus such processes, which used ammonia and fluorine in the same chamber were avoided.
[0005] It is desirable to provide an efficient etching with minimal particle contamination.
SUMMARY OF THE INVENTION
[0006] To achieve the foregoing and other objectives and in accordance with the purpose of the present invention for etching a stack, generally, the stack is placed in a plasma processing chamber. A fluorine containing gas is flowed into the plasma processing chamber. An ammonia containing gas is flowed into the plasma processing chamber. A plasma is generated. The stack is then etched.
[0007] In addition, the present invention provides a device for etching stacks on a substrate. The device comprises: a plasma chamber with chamber walls; a plasma confinement device for reducing plasma contact with the chamber walls; a gas source; plasma generation and energizing device; and an exhaust system for pumping plasma away. The gas source comprises a fluorine containing gas source and an ammonia containing gas source.
[0008] These and other features of the present invention will be described in more detail below in the detailed description of the invention and in conjunction with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0010] FIGS. 1 A-B are cross-sectional views of a stack on a wafer used in the damascene process of the prior art.
[0011] [0011]FIG. 2 is a schematic view of a plasma processing chamber that may be used in a preferred embodiment of the invention.
[0012] [0012]FIG. 3 is a flow chart of a process that uses the plasma processing chamber.
[0013] FIGS. 4 A-B are cross-sectional views of a stack on a wafer used in the damascene process in a preferred embodiment of the invention.
[0014] [0014]FIG. 5 is a more detailed flow chart for the step of etching the via.
[0015] FIGS. 6 A-C are cross-sectional views of a stack on a wafer used in the damascene process in a preferred embodiment of the invention after a via has been etched.
[0016] [0016]FIG. 7 is a more detailed flow chart for the step of etching the trench.
[0017] [0017]FIG. 8 is a graph of the number of particles over 0.16 microns versus the number of wafers processed found during a test.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention will now be described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention.
[0019] To facilitate discussion, FIG. 2 is a schematic view of a plasma processing chamber 200 that may be used in a preferred embodiment of the invention. The plasma processing chamber 200 comprising confinement rings 202 , an upper electrode 204 , a lower electrode 208 , a gas source 210 , and an exhaust pump 220 . The gas source 210 comprises a fluorine containing gas source 212 and an ammonia containing gas source 216 . The gas source 210 may comprise additional gas sources. Within plasma processing chamber 200 , a substrate 224 is positioned upon the lower electrode 208 . The lower electrode 208 incorporates a suitable substrate chucking mechanism (e.g., electrostatic, mechanical clamping, or the like) for holding the substrate 224 . The reactor top 228 incorporates the upper electrode 204 disposed immediately opposite the lower electrode 208 . The upper electrode 204 , lower electrode 208 , and confinement rings 202 define the confined plasma volume 240 . Gas is supplied to the confined plasma volume 240 by gas source 210 and is exhausted from the confined plasma volume 240 through the confinement rings 202 and an exhaust port by the exhaust pump 220 . A first RF source 244 is electrically connected to the upper electrode 204 . A second RF source 248 is electrically connected to the lower electrode 208 . Different combinations of connecting RF power to the electrode are possible. In case of Exelan HP both the RF sources are connected to the lower electrode and the upper electrode is grounded. Chamber walls 252 surround the confinement rings 202 , the upper electrode 204 , and the lower electrode 208 . Both the first RF source 244 and the second RF source 248 may comprise a 27 MHz power source and a 2 MHz power source. The upper electrode 204 and the lower electrode are spaced are preferably spaced apart by a distance of about 1.35 cm but may have a spacing up to 2.0 cm.
[0020] [0020]FIG. 3 is a flow chart of a process that uses the plasma processing chamber 200 . A stack 400 is formed on a wafer 224 (step 304 ), as shown in FIG. 4A. A contact 404 may be placed in a dielectric layer 408 over a wafer 224 . A barrier layer 412 , which may be of silicon nitride or silicon carbide, may be placed over the contact 404 to prevent a copper or metal diffusion. A via level low k material layer 416 may be placed over the barrier layer 412 . A trench stop layer 420 may be placed over the via level low k layer 416 . In a preferred embodiment, the trench stop layer 420 may be made of silicon nitride (SiN). A trench level low k material layer 424 may be placed over the trench stop layer 420 . A hard mask and/or an antireflective coating (ARC) layer 428 may be placed over the trench level low k material layer 424 . A patterned resist layer 432 patterned for etching a via may be placed over the hard mask and/or an antireflective coating (ARC) layer 428 . The via level low k material layer 416 and the trench level low k material layer 424 may be formed from a low dielectric constant OSG material or organic material. The trench etch stop layer 420 may be formed from silicon carbide, instead of silicon nitride, and the hard mask layer may be formed from SiN. The ARC layer 428 may be formed from SiON or organic anti reflective coating. The patterned resist layer 432 may be made of a photo resist layer with the ARC layer 428 acting as an antireflective coating. The stack 400 may be placed over other layers over the wafer 224 .
[0021] The wafer 224 may then be placed in the plasma processing chamber 200 (step 308 ). A via is then etched (step 312 ). Generally, to provide etching in the plasma processing chamber 200 a gas is flowed from the gas source 210 . Energy is provided by the first RF source 244 and the second RF source 248 , which energizes and ionizes the gas generating a plasma. The plasma is partially confined to the confined plasma volume 240 , where the plasma is able to etch the stack 400 on the wafer 224 . The plasma is then vented past the confinement rings 202 to the exhaust pump 220 . The confinement rings 202 reduce plasma interaction with the chamber walls 252 . FIG. 4B is a schematic view of the stack 400 with an etched via 440 . To etch the via 440 the hard mask and or ARC layer 428 , the trench level low k material layer 424 , the trench stop layer 420 , and the via level low k material layer 416 are etched.
[0022] [0022]FIG. 5 is a more detailed flow chart for the step of etching the via (step 312 ) where the trench level low k material 424 and the via level low k material 416 are organic. First the via is etched through the hard mask/ARC layer 428 (step 504 ). One recipe set of parameters for etching the hard mask/ARC layer 428 is provided in Table I where sccm stands for Standard Cubic Centimeters per minute.
TABLE I MORE PREFERRED PREFERRED PARAMETERS BROAD RANGE RANGE RANGE PRESSURE 0-140 35-105 60-80 (mTorr) Flow rate of Ar 80-320 120-200 150-170 (sccm) Flow rate of C 4 F 8 1-9 3-7 5 (sccm) Flow rate of CF 4 10-80 30-50 35-45 (sccm) Flowrate of O 2 4-26 10-20 13-17 (sccm) Power at 27 MHz 250-750 300-700 450-550 (Watts) Power at 2 MHz 500-1500 750-1250 900-1100 (Watts)
[0023] In a preferred embodiment for etching the hard mask/ARC layer 428 : the flow rate of pressure was approximately 70 mTorr; approximately 500 Watts was provided at 27 MHz; approximately 1,000 Watts was provided at 2 MHz; the flow rate of Argon (Ar) was approximately 160 sccm; the flow rate of oxygen (O 2 ) was approximately 15 sccm; the flow rate of CF 4 was approximately 40 sccm; the flow rate of C 4 F 8 was approximately 5 sccm.
[0024] Next the via level organic low k material layer 424 is etched (step 508 ). One recipe set of parameters for etching the trench level low k material layer 424 is provided in Table II.
TABLE II MORE PREFERRED PREFERRED PARAMETERS BROAD RANGE RANGE RANGE PRESSURE 0-300 100-200 140-160 (mTorr) Flow rate of NH 3 500-1500 750-1250 900-1100 (sccm) Power at 27 MHz 250-750 300-700 450-550 (Watts) Power at 2 MHz 0-500 0-250 0 (Watts)
[0025] In the preferred embodiment for etching the trench level low k material layer 424 : the flow rate of pressure was approximately 150 mTorr; approximately 500 Watts was provided at 27 MHz; approximately 0 Watts was provided at 2 MHz; the flow rate of NH 3 was approximately 1,000 sccm. During the via etch of the organic low k material using NH 3 plasma, all the resist material to form the via pattern is removed. After via etch the stack is repatterned with photo resist trench pattern to form trench pattern on the wafers.
[0026] Next the trench stop layer 420 is etched (step 512 ). One recipe set of parameters for etching an SiN trench stop layer 420 is provided in Table III.
TABLE III MORE PREFERRED PREFERRED PARAMETERS BROAD RANGE RANGE RANGE PRESSURE 0-180 60-120 80-100 (mTorr) Flow rate of Ar 75-300 100-200 130-170 (sccm) Flow rate of CHF 3 6-18 9-15 11-13 (sccm) Flow rate of CF 4 10-40 15-35 20-30 (sccm) Flow rate of O 2 5-15 7-13 9-11 (sccm) Flow rate of N 2 15-45 20-40 25-35 (sccm) Power at 27 MHz 300-1200 450-750 550-650 (Watts) Power at 2 MHz 50-200 75-125 90-110 (Watts)
[0027] In the preferred embodiment for etching the trench stop layer 420 : the flow rate of pressure was approximately 90 mTorr; approximately 600 Watts was provided at 27 MHz; approximately 100 Watts was provided at 2 MHz; the flow rate of Argon (Ar) was approximately 150 sccm; the flow rate of oxygen (O 2 ) was approximately 10 sccm; the flow rate of CF 4 was approximately 25 sccm; the flow rate of CHF 3 was approximately 12 sccm; the flow rate of N 2 was approximately 30 sccm.
[0028] Next the trench level low k material layer 424 is etched (step 516 ). One recipe set of parameters for etching the trench level low k material layer 424 is provided in Table IV.
TABLE IV MORE PREFERRED PREFERRED PARAMETERS BROAD RANGE RANGE RANGE PRESSURE 0-300 100-200 140-160 (mTorr) Flow rate of NH 3 500-1500 750-1250 900-1100 (sccm) Power at 27 MHz 250-750 300-700 450-550 (Watts) Power at 2 MHz 0-500 0-250 0 (Watts)
[0029] In the preferred embodiment for etching the via level low k material layer 416 : the flow rate of pressure was approximately 150 mTorr; approximately 500 Watts was provided at 27 MHz; approximately 0 Watts was provided at 2 MHz; the flow rate of NH 3 was approximately 1,000 sccm;.
[0030] While etching via 440 in the OSG low k materials to the barrier layer 412 the via etching may be stopped. A silicon containing polymer crust 444 may be deposited over the patterned resist layer 432 and the sidewalls of the via 440 as a result of the via etching. The plasma chamber 200 may be used to strip the polymer crust 444 , when etching OSG low k materials, and the patterned resist layer 432 , when etching either OSG low k materials or organic low k materials, (step 316 ). A recipe for stripping the polymer crust 444 and patterned resist layer 432 may use NH 3 as a plasma source gas for stripping the photoresist. Once the polymer crust 444 and patterned resist layer 432 have been stripped, the wafer 224 may be removed from the plasma chamber 200 to allow the depositing of a new patterned resist layer 504 (step 320 ), as shown in FIG. 6A.
[0031] The wafer 224 may be placed back in the plasma chamber 200 (step 324 ). A trench 604 is etched (step 328 ), as shown in FIG. 6B. FIG. 7 is a more detailed flow chart for the step of etching the trench (step 328 ) when the trench level layer 424 is an organic low k material. First, the trench is etched through the hard mask/ARC layer 428 (step 704 ). One recipe set of parameters for etching the hard mask/ARC layer 428 is provided in Table I above. In a preferred embodiment for etching the hard mask/ARC layer 428 : the flow rate of pressure was approximately 70 mTorr; approximately 500 Watts was provided at 27 MHz; approximately 1,000 Watts was provided at 2 MHz; the flow rate of Argon (Ar) was approximately 160 sccm; the flow rate of oxygen (O 2 ) was approximately 15 sccm; the flow rate of CF 4 was approximately 40 sccm; the flow rate of C 4 F 8 was approximately 5 sccm.
[0032] Next the trench level organic low k material layer 424 is etched (step 708 ). One recipe set of parameters for etching the trench level organic low k material layer 424 is provided in Table II. In the preferred embodiment for etching the trench level low k material layer 424 : the flow rate of pressure was approximately 150 mTorr; approximately 500 Watts was provided at 27 MHz; approximately 0 Watts was provided at 2 MHz; the flow rate of NH 3 was approximately 1,000 sccm.
[0033] Once the trench 604 has been etched to the trench stop layer 420 the trench etching may be stopped. The barrier layer 412 may then be etched (step 332 ). One recipe set of parameters for etching the barrier layer 412 is provided in Table V.
TABLE V MORE PREFERRED PREFERRED PARAMETERS BROAD RANGE RANGE RANGE PRESSURE 100-220 130-190 150-170 (mTorr) Flow rate of Ar 100-500 200-400 250-350 (sccm) Flow rate of CHF 3 5-40 10-30 15-25 (sccm) Flow rate of N 2 40-200 60-140 80-120 (sccm) Power at 27 MHz 300-800 500-600 400 (Watts) Power at 2 MHz 50-400 100-300 200 (Watts)
[0034] In the preferred embodiment for etching the barrier layer 412 : the flow rate of pressure was approximately 158 mTorr; approximately 400 Watts was provided at 27 MHz; approximately 200 Watts was provided at 2 MHz; the flow rate of Argon (Ar) was approximately 300 sccm; the flow rate of CHF 3 was approximately 20 sccm; the flow rate of N 2 was approximately 100 sccm.
[0035] A silicon containing polymer crust 608 may be deposited over the patterned resist layer 432 and the sidewalls of the via 440 and trench 604 as a result of the trench etching, as shown in FIG. 6B. The plasma chamber 200 may be used to strip the polymer crust 608 and patterned resist layer 504 (step 336 ). A recipe for stripping the polymer crust 608 and patterned resist layer 504 may use NH 3 as a plasma source gas for stripping the photoresist.
[0036] Once the polymer crust 608 and patterned resist layer 504 have been stripped, the wafer 224 , as shown in FIG. 6C, may be removed from the plasma chamber 200 (step 340 ).
[0037] In an Exelan HP, made by LAM Research Corporation™ of Fremont, Calif., a test was performed using the above recipes for 500 wafers. An O 2 clean was done every 60 seconds. Particles were collected periodically in 25 or 50 wafer intervals. A particle count was taken using an NH 3 recipe as described above for 10 seconds, where the particle size monitored was 0.16 to 9,000 microns with 6 mm edge exclusion. The test temperature was about 0° C. FIG. 8 is a graph of the number of particles over 0.16 microns (Particle count) versus the number of wafers processed (0-500) found during the test. It can be seen that the level of particle generation is below 30 , which is normal for the chamber, indicating that the confinement rings 202 , small plasma volume 240 , and exhaust pump 220 speed help to minimize plasma contact with the walls of the chamber so that formed ammonium fluoride does not have a chance to condense onto the walls of the chamber to form a higher number of particles.
[0038] In another embodiment of the invention, where the trench level low k material layer 424 and the via level low k material 416 are made of an OSG material the trench level low k material 424 , the via level low k material 416 , the ARC layer 428 , barrier layer 412 , and the trench stop layer 420 may be all etched with fluorine containing etchant gases. For stripping the patterned resist layer 432 an NH 3 stripping gas may be used. More preferably an NH 3 gas combined with a CF 4 gas may be used to strip the patterned resist layer. In such an embodiment an ammonia containing gas and a fluorine containing gas are used at the same time within the same plasma chamber and at alternating times.
[0039] In other embodiments other types of plasma confinement devices, which keep plasma from the chamber walls may be used in place of the confinement rings. Other types of plasma generation and energizing systems may be used in place of the upper and lower electrodes 204 , 208 and the first and second RF sources 244 , 248 , which may generate and energize a plasma in a small plasma volume.
[0040] Another embodiment of the invention may use a combined resist strip and barrier etch step to reduced etching damage as described in U.S. patent application Ser. No. ______ (Attorney Docket Number LAM1P158) entitled “A Combined Resist Strip And Barrier Etch Process For Dual Damascene Structures” by Rao Annapragada and Reza Sadjadi, with the same filing date, and which is incorporated by reference.
[0041] Sidewalls formed by the crust may be removed during the stripping of the resist or may be removed using a separate wet stripping as described in U.S. patent application Ser. No. ______ (Attorney Docket Number LAM1P156) entitled “Method of Preventing Damage To Organo-Silicate-Glass Materials During Resist Stripping” by Rao Anapragada, with the same filing date, and which is incorporated by reference.
[0042] While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and substitute equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and substitute equivalents as fall within the true spirit and scope of the present invention. | A method of etching a stack using a fluorine containing gas and an ammonia containing gas is provided. Generally, the stack is placed in a plasma processing chamber. A fluorine containing gas is flowed into the plasma processing chamber. An ammonia containing gas is flowed into the plasma processing chamber. A plasma is generated. The stack is then etched.
In addition, a device for etching stacks on a substrate is provided. The device comprises: a plasma chamber with chamber walls; a plasma confinement device for reducing plasma contact with the chamber walls; a gas source; plasma generation and energizing device; and an exhaust system for pumping plasma away. The gas source comprises a fluorine containing gas source and an ammonia containing gas source. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for reinforcing a slope, and more particularly to such a method, which is capable of recovering and restoring the slope as the status quo so as to maintain its stability without additional reduction of its gradient using a reverse analysis technique.
[0003] 2. Description of the Prior Art
[0004] In the case of artificially constructing a slope by excavating or cutting a natural sloping land, the slope gradually loses its stability as time goes by and is finally degraded or deformed to do damage to a person's life or property. Additional cutting or reinforcement, thus, is needed when there is a problem in the stability of the excavated or cut slope, but it is impossible in some cases to additionally cut the slope in view of its topographical features. The present invention provides a method for reinforcing the already-constructed slope so as to make it possible to stabilize it and restore it to its own natural state by means of an environmentally favorable method of construction.
[0005] A reinforcing method by a soil nailing method has been conventionally used as the method of reinforcing the slope. The conventional slope reinforcing method by the soil nailing method is based on a limit equilibrium analysis in which a static limit equilibrium theory is introduced to examine an overall failure surface over the entire soil. Such a soil nailing method includes Davis method proposed by Shen et al. in 1981, a method proposed by Gassler and Gudenhus and considering only tensile capacity of a reinforcement member (soil nail), and a French method, proposed in 1983, considering an effect of shear capacity on the overall stability and bending stiffness in accordance with the tensile capacity of the reinforcement member, the last one having been practically used up to the present. The soil nailing method is a method in which soil parameters of the ground are determined in advance on the basis of results from a laboratory test and a field test in situ, an internal stability condition is studied to be adapted to characteristics of the reinforcement member, and then an external stability condition is studied. Herein, the internal stability condition is a stability condition for the reinforcement member capable of resisting a slope failure force under a condition for limit equilibrium state, and the external stability condition is a stability condition for such a case that a slope failure line is located at an outer periphery of the reinforcement member. In the soil nailing method, the surface of the slope is subjected to a surface treatment by a stiff structure using concrete or shotcrete. At present, this structure constructed by the soil nailing method is practically used as a vertical excavation-type bracing structure.
[0006] [0006]FIG. 1 is a schematic diagram showing the slope reinforcing method in accordance with the soil nailing method. The soil nailing method comprises the steps of studying a underground water level and special conditions in connection with an applicable limit; determining soil parameters by a field in situ test, a borehole pressure meter test, a laboratory soil test, etc.; calculating a skin friction resistance by a pull-out test to determine an adhesion force of a nail; determining construction spacing, drilling angles and lengths of the nails on the basis of the determined soil parameters and adhesion force to study an internal stability condition; calculating a post-reinforcement stability by iterative calculations on assumed slope failure line of the ground; planning design of a construction section in accordance with the determined results and constructing the nails; and treating the constructed surface with a stiff structure of concrete or shotcrete.
[0007] The slope reinforcing method by the soil nailing method, however, has no backup measures to counter a case that the values of the soil parameters (a cohesion (C), an internal friction angle (Φ), a construction density (γ), an elastic modulus (E s ), a limiting pressure (p l ) or the like) applied to the design do not correspond with field deformation behavior, and thus cannot overcome problems arising due to deciding the soil parameters determined by the field test in situ, the laboratory test and so forth as representative values. Also, the method cannot predict maximum tensile and shear forces formed within the given reinforcement member in a certain position, but provides only an overall factor of safety. That is, the following expression is established:
V f = R c [ 1 + 4 tan 2 ( π 2 - α ) ] 1 2 ≅ T f = 4 V f tan ( π 2 - α ) [ Exp . 1 ]
[0008] wherein V f is a shear force, T f is a tensile force, R c is a shear strength, and α is an angle of a potential failure plane. As seen from Expression 1, only the tensile force acts if α=0 and only the shear force is effective if
α = π 2
[0009] because there is a relationship of
R c = R n 2 .
[0010] The Davis method and French method are typically cited as basic analysis techniques of slope reinforcement by the soil nailing method. The Davis method considers only a tensile resistance and the French method considers a tensile resistance together with the shear resistance (cf. Technical Teaching Report 78, Earth Reinforcement, 1989. 12, The Korean Highway Corporation).
[0011] According to the analysis by the French method, the tensile force within the upper reinforcement member must be 0 when an estimated potential failure line actually has a longitudinal extension direction
( α = π 2 )
[0012] in an upper portion of the slope, but the tensile force is practically strengthened in the reinforcement member, thereby causing a problem in analysis.
[0013] As stated above, the conventional reinforcing method by the soil nailing method is a method in which an overall surface treatment of a nail head with concrete or shotcrete is performed as the final process after the soil nail reinforcement, thus having many problems, for example, spoilage of a fine view, difficulty in maintenance, lack of environmental intimacy due to spoiling of a natural scene and the like. Besides, since the analytic technique is one in which a field investigation, sampling, a laboratory test, a field location test (PMT), etc. are performed in advance to analyze ground strength characteristics and then the analyses of the slope stability and the reinforcing method are conducted on the basis of results of the ground strength characteristics, it not only requires a heavy cost and a long time, but often causes a problem in that the theoretical strength characteristics do not correspond with the actual field conditions. That is, there is a problem in that a failure model about a theoretical analysis does not correspond with a field failure model.
SUMMARY OF THE INVENTION
[0014] A countermeasure to reinforce a slope requires a rapid, accurate and safe reinforcing method capable of minimizing damage to a person's life and property.
[0015] The present invention relates to such a method, in which a slope stability analysis is performed while ground strength characteristics suitable to a field failure model are most rapidly and easily analyzed by applying a reverse analysis technique based on field ground deformation characteristics so as to be make it possible to rapidly judge the-above mentioned problems at a low cost, and then a reinforcement construction is rapidly and safely carried out.
[0016] For the purpose of this, the present invention provides an environmentally favorable method of slope earth reinforcement without spoilage of a natural environment, which comprises a process of reversely analyzing the field ground deformation characteristics of the unstable slope to make it possible to judge the ground strength characteristics and a process of recovering and restoring the unstable slope by introducing and applying an earth reinforcement theory, i.e., a theory that an apparent cohesion is increased by reinforcement members so as to make it possible to secure stability.
[0017] That is, the present invention has been made to solve the above-mentioned problems and to prevent a slope from gradually losing its stability as time goes by and being finally degraded or deformed to do damage to a person's life or property, it is an object of the present invention to provide a reinforcing method for environmentally favorably, economically and rapidly reinforcing such an unstable slope without removal thereof, which comprises a process of accurately and rapidly determining ground strength characteristics of the deformed slope by applying a reverse analysis technique so as to make it possible to most economically and rapidly reinforce the unstable slope, a process of providing slope drain holes (subterranean horizontal drain holes) in the slope in order to suppress action of pore water pressure, using a reinforcing steel bar as a reinforcement member, filling grout composed of cement, water and high fluidizing agent around the reinforcing steel bars to integrate the reinforcement members with ambient earth and rock and so to form reinforced earth with permeation and cementation of the grout in micro-cracks existing within the unstable slope, thereby making it possible to most rapidly and safely reinforce the slope applying an earth reinforcement theory, i.e., a theory that an apparent cohesion is increased by the reinforcement members, and a process of treating a surface portion of the slope by covering artificial greening soil covering containing natural monofilaments so as to make vegetation growth on the slope possible, thereby environmentally favorably reinforcing the slope without spoilage of natural environment.
[0018] To accomplish this object, there is provided a method for reinforcing a slope in accordance with the present invention, the method comprising the steps:
[0019] studying a underground water level, slope configuration, a soil condition status and rock joint orientation in connection with an applicable limit of the slope, on the basis of which soil parameters, including a cohesion and an internal friction angle, are determined using the Janbu method so as to be adapted to characteristics of the deformed ground;
[0020] analyzing stability of the slope using the soil parameters determined by the Janbu method to estimate a driving force and a resistance force of the slope;
[0021] planning a construction section of a reinforcement zone to be constructed with reinforcement members in order to increase the resistance force of the slope;
[0022] determining a position and a quantity of subterranean horizontal drain holes in consideration of the underground water level condition to study an external stability;
[0023] checking an internal stability within the reinforcement zone against a critical failure section in consideration of a pull-out force and a shear capacity of the reinforcement member; and
[0024] preparing design drawings so as to satisfy the external and internal stabilities and carrying out a reinforcement construction work.
[0025] An apparent cohesion increasing with construction spacing between the reinforcement members is preferably
C ′ = 3.6 γ _ ~ 4.2 γ _
[0026] when a SD40:φ25M/M reinforcing steel bar is used,
C ′ = 4.9 γ _ ~ 5.6 γ _
[0027] when a SD40:φ29M/M reinforcing steel bar is used,
C ′ = 5.9 γ _ ~ 7.0 γ _
[0028] (t/m 2 ) when a SD40:φ32M/M reinforcing steel bar is used as a nail bar.
[0029] Preferably, the step of carrying out the reinforcement construction work comprises the steps of: insert-laying the reinforcement members in the slope in accordance with the design drawings; mixing cement, water and high fluidizing agent with each other to produce grout and gravitationally injecting the grout around the reinforcement members; laying slope drain holes in the slope in such a manner that they extend beyond the reinforcement zone in accordance with the design drawings; installing main earth-pressing steel plates, PVC-coated wire mesh and sub earth-pressing steel plates to fix the reinforcement members; and treating surfaces of the slope with general artificial greening soil covering or artificial greening soil covering mixed with natural monofilaments by a spray attaching vegetation method.
[0030] It is preferred that a safety factor of the slope is 1.4 or more in the construction section of the reinforcement zone.
[0031] As for a weathered residual soil layer slope or a rock mass slope having remarkable joint orientation, the step of determining the soil parameters may be performed by determining a dip angle (a bedding plane angle or a plunge angle) (θ) of the slope joint as the internal friction angle (φ) and inversely calculating a cohesion (C) at the determined internal friction angle under a condition for limit equilibrium state F s ≦1.0.
[0032] As for an unsaturated earth cut slope ground, the step of determining the soil parameters may be performed by determining the internal friction angle (φ) through a direct shear test and inversely calculating the cohesion (C) at the constant internal friction angle ( φ=const. ) under a condition for limit equilibrium state F s =1.0.
[0033] In the case of degradation or deformation of the slope, the step of determining the soil parameters may be performed by determining the internal friction angle (φ) through the direct shear test and inversely calculating the cohesion ( C ), considering an estimated failure line under a condition for limit equilibrium state of 0.85≦F s ≦1.03.
[0034] In the case that the slope is unstable and forms an irregular stratified profile corresponding to a limit equilibrium state, the step of determining the soil parameters may be performed preliminarily by assuming that a critical failure line passes through the lowest portion of an upper stratum of the slope, determining the internal friction angle (φ r ) through the direct shear test for a specimen of the upper stratum of the slope and inversely calculating the cohesion (C) under a condition for limit equilibrium state 0.9≦F s ≦1.05, and secondarily by assuming that the critical failure line passes through the lowest portion of a lower stratum of the slope, determining the internal friction angle (φ r ′) through the direct shear test for a specimen of the lower stratum of the slope and inversely calculating the cohesion (C′) under a condition for limit equilibrium state 0.9≦F s ≦1.05.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The above and other objects, features and other advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0036] [0036]FIG. 1 is a schematic diagram showing a conventional slope reinforcing method in accordance with a soil nailing method;
[0037] [0037]FIG. 2 is a schematic diagram showing a slope reinforcing method in accordance with the present invention;
[0038] [0038]FIG. 3 is a graph showing an apparent cohesion increased by reinforcement members;
[0039] [0039]FIG. 4 is a graph showing the apparent cohesion whose restraint stress is increased by the reinforcement members;
[0040] [0040]FIGS. 5 a and 5 b are views showing forces acting on a failure plane by the reinforcement member and a triangle of force for those forces, respectively;
[0041] [0041]FIG. 6 is a sectional layout view of the reinforcement members to be grouted in the unstable slope;
[0042] [0042]FIG. 7 is a view showing sectional conditions from which strength characteristics of a weathered residual soil layer slope or a rock mass slope having a discontinuity can be analyzed by a reverse analysis technique;
[0043] [0043]FIGS. 8 a and 8 b are views showing sectional conditions from which strength characteristics of an unsaturated earth cut slope ground can be analyzed by the reverse analysis technique;
[0044] [0044]FIGS. 9 a to 9 c are views showing sectional conditions from which strength characteristics in accordance with occurrence of degradation or deformation of the slope can be analyzed by the reverse analysis technique;
[0045] [0045]FIG. 10 is a view showing sectional conditions from which strength characteristics can be analyzed by the reverse analysis technique in the case that the slope is unstable and forms an irregular stratified profile;
[0046] [0046]FIG. 11 is a view showing critical failure lines of the respective stratums of the slope;
[0047] [0047]FIG. 12 is a view showing sectional conditions from which positions of the critical failure lines of the respective stratums and strength characteristics can be analyzed by the reverse analysis in the case that the slope is unstable and forms the irregular stratified profile;
[0048] [0048]FIG. 13 is a plan layout view in accordance with a rhombus type method of construction in which each construction spacing of a square type method of construction is rotated by 45°;
[0049] [0049]FIGS. 14 a and 14 b are a typical sectional layout view of slope drain holes, i.e., subterranean horizontal drain holes in accordance with a position of a underground water level and a plan layout view of the subterranean horizontal drain holes, respectively;
[0050] [0050]FIGS. 15 a and 15 b are a sectional layout view and a plan layout view of the subterranean horizontal drain holes in the case of water eruption;
[0051] [0051]FIG. 16 a view showing boundary conditions for a plastic deformation section of a surface portion of the slope reinforced with reinforcing steel bars;
[0052] [0052]FIG. 17 is a view showing a finished product in a state that nail head portions are joined with a main earth-pressing metal plate, a PVC-coated wire mesh and a sub earth-pressing metal plate by double nuts, and artificial greening soil covering is covered;
[0053] [0053]FIG. 18 is a view showing the nail head portions combined with the double nut.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] Hereinafter, a preferred embodiment of the present invention will be described with reference to the accompanying drawings. In the following description and all drawings, the same reference numerals are used to designate the same or similar components, and so repetition of the description of the same or similar components will be omitted.
[0055] [0055]FIG. 2 is a schematic diagram view showing a method for reinforcing a slope using a reverse analysis technique in accordance with the present invention.
[0056] A basic principle of the slope reinforcing method using the reverse analysis in accordance with the present invention is as follows:
[0057] Henry Vidal, a Frenchman, discovered that seashore sand can be heaped up higher and endure a greater external force when pine needles are put into the sand than when only the sand is heaped up. This is due to a principle that the sand in contact with reinforcement members is linked with the reinforcement members by fiction forces therebetween, and the sand out of contact with the reinforcement members is linked with the reinforcement members owing to a property of stress transition to the reinforcement members according to a phenomenon of an internal stress transmission by friction between sand particles, that is, an arching phenomenon when the reinforcement members are disposed at a constant spacing within the sand, which results in forming a lump structural body in which the whole sand is contacted or linked with the reinforcement members, i.e., a reinforced earth having a far greater strength than the pure sand.
[0058] The increase in strength of the sand by the reinforcement members is achieved in such a manner described below.
[0059] [0059]FIG. 3 is a graph showing an apparent cohesion increased by the reinforcement members, in which the apparent cohesion (anisotropic cohesion) is increased due to increase of a vertical stress caused by the reinforcement members.
[0060] Δσ 1 is an incremental value of the vertical stress caused by the reinforcement members, which leads to an increase of compressive strength of the reinforced sand with the result that the apparent cohesion is increased by the reinforcement members horizontally reinforcing the sand.
[0061] [0061]FIG. 4 shows that a restraint stress is increased by the reinforcement members. With respect to the restraint stress increased by the reinforcement members, whereas the pure sand horizontally expands when the vertical stress (σ v ) is increased, the reinforced sand suppresses a horizontal displacement by friction forces between the sand and the reinforcement members when the vertical stress (σ v ) is increased. That is, as shown in FIG. 4, the restraint stress (Δσ 3 ) in addition to a lateral pressure (σ 3 ) is applied to the reinforced sand by the friction forces generated between the sand and the reinforcement members to increase the compressive strength of the reinforced sand.
[0062] In the reinforced sand whose apparent cohesion is increased by the reinforcement members, the apparent cohesion to which Coulomb's theory is applied is as follows:
[0063] [0063]FIGS. 5 a and 5 b show forces acting on a failure plane by the reinforcement members and a triangle of force for those forces, respectively, with reference to which the following expression is established:
tan ( α - φ ) = F + σ 3 · A · tan α σ 1 · A [ Exp . 2 ]
[0064] wherein A is a cross sectional area of the reinforced sand, α is a horizontal angle of a failure plane, F is a sum of tensile forces of the respective reinforcement members cut by the failure plane, and φ is an internal friction angle of the sand.
[0065] On the other hand, the sum of tensile forces acted by the respective reinforcement members is given by the following expression:
F = A · tan α Δ H · T s [ Exp . 3 ]
[0066] wherein ΔH is vertical spacing between the reinforcement members per unit width and T S is a tensile force of the respective reinforcement members per unit width.
[0067] The following relational expressions can be derived from Exps. 2 and 3:
A · tan θ Δ H · T s + σ 3 · A · tan α = σ 1 · A · tan ( α - φ ) [ Exp . 4 ] σ 1 = tan α ( T s Δ H + σ 3 ) cot ( α - φ ) [ Exp . 5 ]
[0068] wherein σ 1 is a vertical stress, α is a failure angle, K p is a passive earth pressure factor, and φ is an internal friction angle of earth. In Exp.1,
α = 45 ° + φ 2 and K p = tan 2 ( 45 ° + φ 2 )
[0069] if σ 1 is maximal, and thus the vertical stress is given by the following expression:
σ 1 = K p · σ 3 + K p · T s Δ H [ Exp . 6 ]
[0070] Since the vertical stress is σ 1 =K p σ 3 +Δσ 1 when the reinforced sand experiences failure, the following expression is established:
K p σ 3 + σ 1 = K p · σ 3 + K p · T s Δ H [ Exp . 7 ]
[0071] wherein σ 3 is a horizontal stress and Δσ 1 is an increment of the vertical stress.
[0072] Consequently, the following expression can be derived from Exps. 6 and 7:
Δσ 3 = K p · T s Δ H [ Exp . 8 ]
[0073] Δσ 1 is the increment of the vertical stress caused by the reinforcement members, which is expressed using the apparent cohesion (C′) as follows:
σ 1 =K p ·σ 3 +2 {square root}{square root over (K p )}· C′ [Exp. 9]
[0074] From Exps. 6 and 9, the apparent cohesion (C′) can be expressed by the following expression (Gunkiyeon 84-W-1 Research Report, “The Study of Gao-textile and Earth Reinforcement”, March 1985, Korea Institute of Construction Technology):
C ′ = K p · T s Δ H 2 K p = T s Δ H · K p 2 [ Exp . 10 ]
[0075] According to the result from Juran's model test in 1981, the apparent cohesion of Exp. 10 can be converted to the following expression:
C o = ∑ V o A [ Exp . 11 ]
[0076] wherein V o is a shear force of the reinforcement members and A is a reinforcement cross sectional area.
[0077] When the tensile force, that is, a skin friction resistance force around the reinforcement members acts to the same or greater extent than the shear force of the reinforcement members, the following relationship is obtained from Exps. 10 and 11:
∑ V o A = T s Δ H · K p 2 [ Exp . 12 ] ∑ V o = T s Δ H · K p 2 · A . [ Exp . 13 ]
[0078] Herein, the reinforcement members are grouted in the unstable slope as planned in FIG. 6.
[0079] In FIG. 6, L o is length of the reinforced slope per unit linear meter, ΔH is construction spacing between the reinforcement members per unit linear meter, D f is a driving force of slope failure per unit linear meter, and R f is a resistance force against a slip failure plane per unit linear meter.
[0080] Since
Δ H = L o n = γ _
[0081] ( {overscore (γ)} is a construction density of the reinforcement members, i.e., the number of the reinforcement members per unit area) if A=L o , V o of Exp. 13 is as follows:
∑ V o = T s L o n · K p 2 · L o = T s · K p 2 · n [ Exp . 14 ]
[0082] Because of ΣV o =nV o ( n is the number of the reinforcement members), the following expression is established:
V o ≈ T s · K p 2 [ Exp . 15 ]
[0083] A stability study based on the friction resistance (tensile force) of the grout around the reinforcement members is required in the case of earth, and a stability study based on the shear force or the friction force of the reinforcement members is required in the case of a rock mass.
[0084] With regard to a stability condition of the slope, a suppression force required for reinforcement is necessary in order to secure a sufficient stability condition against the slip failure driving force in the following case:
F s = R f D f = ResistanceForce DrivingForce ≤ 1.0 [ Exp . 16 ]
[0085] That is, under the following condition,
F s = R f + P n D f [ Exp . 17 ]
P n =F S ·D f −R f [Exp. 18]
[0086] the suppression force required for reinforcement (P n ) is expressed as P n =ΣV o ≈nV o when the stability condition is planned by means of the shear force of the reinforcement members.
[0087] Thus, the construction density of the reinforcement members ({overscore (γ)}) is as follows:
γ _ = L o n = L o P n T s · K p 2 [ Exp . 19 ]
[0088] Since the stability condition for the pull-out resistance is given as below,
P n = F s · P ′ = π DL · τ ( F s ) ′ [ Exp . 20 ]
[0089] the designed tensile force (V o ) is as follows:
P ′ = P n F s ≈ T s [ Exp . 21 ]
[0090] wherein P u is an ultimate pull-out resistance force, τ is a friction resistance force of the grout and the ambient ground, D is a borehole drilling diameter, and L is a length of the reinforcement members.
[0091] A stress limiting condition for the reinforcement members is as follows:
[0092] A deformed bar (SD35 or SD40) is used as the reinforcement member A long-term allowable stress of the deformed bar is 2000 kg/cm 2 for shear reinforcement and is 2200 kg/cm 2 (or 2000 kg/cm 2 ) for tensile reinforcements. An allowable tensile stress (T s ) of the reinforcement members is substantially equal to the pull-out resistance force (P u ), an allowable shear stress (V o ) of the reinforcement members is also substantially equal to the pull-out resistance force (P u ), and the resistance force (P n ) required for suppressing the slope failure driving force is smaller than an allowable shear reinforcement stress (ΣV o ) of the reinforcement members.
[0093] The increased apparent cohesion and the construction spacing between the reinforcement members, therefore, have he following relation:
C ′ = T s Δ H · K p 2 = P n γ · K p 2 · 1 F s [ Eq . 22 ] C ′ = ∑ V o L o = nV o L 0 = nV o n γ _ = V o γ _ [ Eq . 23 ]
[0094] When the reinforcing steel bar is used as a nail bar, the apparent cohesion to be increased in consideration of corrosion margin of about 3 to 5 mm is as follows:
C ′ ≈ 3.9 γ _ ( t / m 2 ) ( C ′ = 3.6 γ _ ~ 4.2 γ _ )
[0095] in the case of using a SD40:φ25M/M reinforcing steel bar,
C ′ ≈ 5.2 γ _ ( t / m 2 ) ( C ′ = 4.9 γ _ ~ 5.6 γ _ )
[0096] in the case of using a SD40:φ29M/M reinforcing steel bar,
C ′ ≈ 6.4 γ _ ( t / m 2 ) ( C ′ = 5.9 γ _ ~ 7.5 γ _ )
[0097] in the case of using a SD40:φ32M/M reinforcing steel bar.
[0098] The construction density ({overscore (γ)}) is 1 piece per 0.64 m 2 to 1 piece per 3.0 m 2 .
[0099] Of Eqs. 22 and 23, the one with the smallest value is used for analyzing increase of the apparent cohesion in accordance with the construction density ({overscore (γ)}) of the reinforcement members.
[0100] The passive side nails cause a shear force and a bending moment on both sides of the potential failure plane within the reinforcement members, but ground displacement in a direction in which the nails and the failure plane form a right angle, that is, displacement necessary for forming the shear resistance and the bending resistance by the nails is larger than that necessary for causing the tensile force within the reinforcement members. In other words, bending stiffness of the reinforcement members substantially has no effect on structure behaviors in a state that the ground displacement is slight. Thus, this means that the shear force built up in the reinforcement members is far smaller than the maximum tensile force, and the bending stiffness substantially has no effect on either the displacement of the failure plane body or the tensile force of the reinforcement members. Because of the balanced distribution of passive earth pressure, the bending moment to the potential failure plane is 0 at a site where the maximum tensile force and the shear force are produced and thus the failure plane within the reinforcement members is displaced in a position behind the reinforcement members by the restraint effect of the ambient friction force.
[0101] Reverse analysis is a term used in the present invention, and is defined as a method of designing the construction section by examining deformation of the field ground and studying the external stability condition, followed by studying the internal stability condition; in contrast with the conventional method of designing the construction section by studying the internal stability condition, followed by studying the external stability condition and calculating the stability.
[0102] The reason why the reverse analysis technique is used for determining the soil parameters is that clay within the deformed discontinuity or slip plane is difficult to sample, there are many problems caused by using results from soil test of the representative specimen as the representative values for the whole slope, and it is impossible to catch a deformed portion in advance because geological structural characteristics in a highly-weathered slope are not uniform and deformation occurs in a weak portion of the discontinuity. Since the slope has a disadvantageous property that it suffers significant deterioration of strength characteristics together with acceleration of slackness with the passage of time due to relaxation and looseness of all kinds of joints and discontinuities and expansion of viscous earth material filled inside of the slope under the influence of water, it is also impossible to discover this deterioration of the strength characteristics by means of a field survey, a laboratory test and a field in situ test. Besides, as for strength characteristics of a rock, it is unreasonable to regard the results of the laboratory test as the field strength characteristics because of the influence of anisotropy in accordance with a joint property, and the analysis based on the various field in situ tests in a place where deformation in accordance with the anisotropy property occurs and the dynamic laboratory test via sampling does not correspond well with field deformation and degradation behaviors.
[0103] That is, a cut slope is a discontinuous body exhibiting complex geological structural characteristics due to having being subjected to a variety of external forces for a long time, and thus the conventional slope reinforcing method by the soil nailing method has a problem in that the assumed conditions do not correspond with reality, because of the phenomena of slackness of the slope and deterioration of joint strength characteristics in accordance with the progress of weathering as time goes by.
[0104] The determination of the soil parameters by means of the reverse analysis technique is conducted by use of the Janbu method according to the ground characteristics as follows:
EXAMPLE 1
[0105] Reverse Analysis Technique for Strength Characteristics of Weathered Residual Soil Layer Slope or Rock Mass Slope having Remarkable Joint Orientation (Discontinuity)
[0106] [0106]FIG. 7 is a view showing sectional conditions from which strength characteristics of a weathered residual soil layer slope or a rock mass slope having a discontinuity can be analyzed by the reverse analysis technique.
[0107] This method is a method considering a dip angle (a bedding plane angle or a plunge angle) capable of causing a slip obtained from result of a stereo net projection for searching orientation of the discontinuity and the joint.
[0108] A condition for limit equilibrium state of the slope is F s ≦1.0 , that is, a condition that the unstable slope (overburden) above the slope dip angle ( θ ) (in a stable condition) is finally deformed or degraded with the passage of time is θ≈φ, and the value of apparent cohesion ( C ) is determined by inverse calculation thereof under the condition of F s ≦1.0.
[0109] Although a residual strength ( φ r ) is generally smaller than φ by 5 to 10° when the slope in which the failure actually has occurred is reversely analyzed, it is ignored because it was analyzed as very stable in consideration of the cohesion, and only φ is considered, or a median value between φ and φ r is used to inversely calculate the value of cohesion and to apply a failure model corresponding to the field conditions through feedbacks of the calculated values of cohesion.
EXAMPLE 2
[0110] Reverse Analysis Technique for Strength Characteristics of Unsaturated Earth Cut Slope Ground
[0111] [0111]FIGS. 8 a and 8 b are views showing sectional conditions from which strength characteristics of an unsaturated earth cut slope ground can be analyzed by the reverse analysis technique.
[0112] In general, sand has a shear strength characteristic that the strength is increased by a cohesion enhancement effect due to an apparent cohesion generated in a compacted state, but the apparent cohesion is lost in a disturbed or deranged state and only a friction resistance of ultimate earth, i.e., an internal friction angle exists to change a residual internal friction angle to an angle of repose. Thus, the deformation of earth slope causes a problem of a falling-off in strength in accordance with the loss of cohesion (C), rather than providing an effect of a lowering of internal friction angle ( φ ). A basic concept of this example is as follows:
[0113] A value of φ a peak strength or an average value of the peak strength and a residual strength) is determined by a direct shear test or a ring direct shear test for a ring sampling specimen, the so determined value is taken as φ=const. under a condition for limit equilibrium state F s ≈1.0, and C is inversely calculated at the constant φ. That is, the value of cohesion is inversely calculated by the Janbu method under the conditions of φ=const.and F s ≈1.0.
[0114] According to a shear strength characteristic based on the present experiential theory, Terzaghi proposed that ultimate strength parameters C′ and φ′ in the case of partial shear is applied while being reduced in comparison with those ( C o and φ o ) in the case of normal shear, that is,
C ′ = 2 3 C o
[0115] and
φ ′ = tan - 1 ( 2 3 tan φ o ) ,
[0116] but this is only a condition when a horizontal stress is in a restrained state by a vertical stress acting under the ground. The slope cannot secure this restrained state of the horizontal stress. That is, the internal friction angle, one of fundamental properties of earth, changes slightly with the change in acting stress, but the cohesion, another fundamental property of earth, changes very significantly according to the change in conditions such as the compacted state, the slackness with the passage of weathering, etc. Consequently, the cohesion in the final stage is inversely calculated by the Janbu method on the assumption that the angle of repose and the internal friction angle of earth are in equilibrium to each other and in accordance with the field conditions of the slope (considering whether the slope is in a fixedly changed state, a quasi-fixedly changed state or a potentially changed state) while the value of φ being maintained within a range of residual strength from the peak strength and determined through feedbacks of the calculated
EXAMPLE 3
[0117] Reverse Analysis Technique for Strength Characteristics in Accordance with Degradation or Deformation of Slope
[0118] [0118]FIGS. 9 a to 9 c are views showing sectional conditions from which strength characteristics in accordance with occurrence of degradation or deformation of a slope can be analyzed by the reverse analysis technique.
[0119] Taking into account an estimated failure line connecting an upper deformed point with a lower deformed point on the basis of the field deformation model, as shown in FIG. 9 c, the value of cohesion inversely calculated and determined from φ r by the Janbu method by considering a standard safety factor of F s =0.85˜0.9 is used in the case of the fixedly changed state in which slip activity is still going on, a standard safety factor of F s =0.9˜0.95 is used in the case of the quasi-fixedly changed state in which the slope was deformed by the slip activity, but the slip activity has stopped (provided that additional deformation may occur by an additional external force and a rainfall), and a standard safety factor of F s =1.0˜1.05 is used in the case of the potentially changed state in which only initial deformation occur.
[0120] Such a safety factor according to a kind of slope is listed in Table 1 (Experiential theory).
[0121] In the case of the rock mass slope, its strength is deteriorated mainly by a decrease of cohesion due to the slackness phenomenon in accordance with infiltration water pressure, progression of weathering and stress release rather than by a lowering of internal friction angle when directions of joint and discontinuity is similar to that of slope, which is the cause of degradation or deformation of the slope.
TABLE 1 F in slip F in slip activity-stopped activity- state progressing state rock mass slope 1.1 0.99 weathered rock 1.05˜1.1 0.95˜0.99 slope colluvial soil 1.03˜1.05 0.93˜0.95 slope clayish soil 1.0˜1.03 0.9˜0.93 slope Note potentially quasi-fixedly changed F changed F
[0122] In the case of the earth slope, its strength is also deteriorated mainly by the decrease of cohesion due to the slackness phenomenon in accordance with infiltration water pressure (usually, a frozen damage in the winter season), progression of weathering and stress release rather than by a lowering of internal friction angle.
[0123] In the case of the rock mass slope, therefore, the strength characteristic of the estimated failure line connecting the deformed sections is obtained by the reverse analysis technique described in Example 1, and in the case of the earth slope, the strength characteristic, that is, the value of cohesion is inversely calculated and obtained by the reverse analysis of the Janbu method so as to make it possible to correspond with the field deformed section model according to the technique described in Example 2 or the method of test as shown in FIGS. 9 a and 9 c if sampling at the deformed sections is possible and in consideration of only the internal friction angle except the cohesion.
EXAMPLE 4
[0124] Reverse Analysis Technique for Strength Characteristics in Case a Slope is Unstable and Forms Irregular Stratified Profile Corresponding to Limit Equilibrium State
[0125] [0125]FIG. 10 is a view showing sectional conditions from which strength characteristics in the case that a slope is unstable and forms an irregular stratified profile can be analyzed by the reverse analysis technique.
[0126] (1) Reverse Analysis for Strength Characteristics of Slope Stratum I Assuming that Slope is in Limit Equilibrium State
[0127] The techniques according to Examples 2 and 3 are used as the reverse analysis techniques for strength characteristics under a condition given as 0.9<F s <1.05.
[0128] That is, a critical failure line is assumed to pass through the lowest portion of a slope stratum I 7 and as for an upper portion of the slope stratum I , a value of φ, one of the strength characteristics, is determined and then a value of C, another strength characteristic, is inversely calculated and determined using the techniques according to Examples 2 and 3 by the Janbu method under the condition given as 0.9<F s <1.05.
[0129] (2) Reverse Analysis for Strength Characteristics of Slope Stratum II Assuming that Slope is in Limit Equilibrium State
[0130] The strength characteristics are reversely analyzed by the technique according to Example 1 under a condition given as 0.9<F s <1.05. Herein, the strength characteristics obtained from the above (1) are used as the strength characteristics to be applied to the slope stratum I.
[0131] That is, the critical failure line is assumed to pass through the lowest portion of a slope stratum II, and a value of φ, one of the strength characteristics, is determined and then a value of C , a strength characteristic of the slope stratum II, is inversely calculated and determined using the technique according to Example 1 and the strength characteristics of the slope stratum I obtained from the above (1) by the Janbu method under the condition given as 0.9<F s <1.05.
[0132] After the soil parameters are determined in such a way, the results of the stability analysis for the slope in the present state are analyzed. The techniques for studying stability of slope can be divided into the Bishop method, the Spencer method and the Janbu method, but the Janbu method is preferred to the others because magnitudes of driving force and resistance force calculated for the same critical slip surface (condition for limit equilibrium state) under the condition of the same safety factor are relatively lager in the Janbu method than in the other methods when a countermeasure is taken to reinforce the cut slope and so the suppression force required for reinforcement is also calculated at a larger value by the Janbu method, the Janbu method analyzes the failure plane assumed considering the ground conditions in place of analyzing a position of a failure source, and the Janbu method capable of being applied to the slope having many rocks solves a problem that a force system acting on a rock is assumed only for unit rock and thus cannot be considered as a force acting between rocks when the analysis is performed in accordance with the experiential relationship or the earth pressure theory. The Janbu method is reasonable in view of securing the slope stability. Thus, the technique for studying the slope stability is conducted using the Janbu method of STABL 5M computer aided analysis programs.
[0133] If the soil parameters are determined as a result of the reverse analysis for the field slope conditions, then the external stability of the slope is studied.
[0134] In order to judge a construction plan of the reinforcement zone for the critical failure line, the slope stability condition is checked prior to initial reinforcement construction. With regard to this, FIG. 11 shows a view which can be used for positional judgment of the critical failure line according to the respective slope stratums.
[0135] The reinforcement zone is arbitrarily planned and then a section of the reinforcement zone is planned so as to be adapted to a safety factor condition of 1.4<F s <1.5 by use of the trial and error technique.
[0136] [0136]FIG. 12 is a view showing sectional conditions from which, in the case that the slope is unstable and forms an irregular stratified profile, positions of the critical failure lines of the respective stratums and the slope stability conditions against the critical failure line can be analyzed by the reverse analysis, and the safety factor condition against the critical failure line is F s (III)>1.5, F s (II)>1.4, 1.4<F s (I)<1.5 in FIG. 12.
[0137] If the external stability condition for the reinforcement zone is checked, then the internal stability condition is studied.
[0138] First, the construction density ({overscore (γ)}) is calculated. Since there is a relation of
Δ C = V o γ _ = C ′ - C ,
[0139] wherein C is the cohesion of the original ground and C′ is the increased cohesion of the reinforcement zone, the construction density is expressed as follows:
γ _ = V o C ′ - C [ Exp . 24 ]
[0140] wherein V o ≈3.9t in the case of the φ25M/M reinforcing steel bar, V o ≈5.2t in the case of the φ29M/M reinforcing steel bar, and V 0 ≈6.4t in the case of the φ32M/M reinforcing steel bar.
[0141] Next, the construction spacing between the reinforcement members is calculated.
[0142] Since there is a relationship of horizontal spacing ( S H )·vertical spacing( S V )={overscore (γ)}, horizontal spacing ( S H )=vertical spacing (S V )={square root}{square root over (γ)}.
[0143] The construction pattern is planned as a rhombus type construction pattern in which each construction spacing of a square type construction pattern is rotated by 45° as shown in FIG. 13.
[0144] After the external stability is studied, a study of the internal stability is performed.
[0145] The stability condition against the estimated critical failure line in the respective slope stratums is calculated by the expression of
F s = R f + P n D f ,
[0146] the stability condition by the shear force of the nail satisfies
F s = R f + n V o D f > 1.5 ~ 2.0
[0147] from the relationship that the suppression force required for reinforcement is P n =nV o , and if the soil is loose (disturbed) soil, the stability based on the skin friction resistance force (tensile force) between a cylindrical body grouted around the nail and the original ground is studied considering the sum total of the skin friction force of a fixation portion with respect to the estimated critical failure line as the suppression force required for reinforcement on the condition of
F s = R f + n V o D f > 1.5 ~ 2.0 :
[0148] suppression force required for reinforcement of subterranean nail
P n = n · π DL ( τ F s ) ,
[0149] allowance shear force of a reinforcing steel bar ( V o )<skin friction force
( π DL ( τ F s ) ) ,
[0150] allowance tensile force of a reinforcing steel bar (T s )≦skin friction force
( π DL ( τ F s ) ) .
[0151] Next, the water level is studied. The condition of fully saturated state of the slope is practically accompanied with many analytical problems because of rainfall, by the reason of which the underground water level line is determined by the slope horizontal drain holes for suppressing rise of the underground water level or lowering the underground water level. The slope horizontal drain holes are provided beyond the reinforcement zone, and the stability analysis of the slope is performed while the seepage line of the underground water level is determined by connecting 2/3 points of the slope horizontal drain holes. At this time, the stability is studied on the condition of F s ≧1.2. The subterranean horizontal drain holes, the slope drain holes, are laid in a manner as shown in FIGS. 14 a and 14 b.
[0152] The construction density of the slope horizontal drain holes is determined in a range between a maximum of 1 piece per 30 m 2 and a minimum of 1 piece of 10 m 2 , and the slope horizontal drain holes are arranged in a triangular construction pattern. It is preferred that a borehole drilling diameter is about 3 inches, the drainpipe is a PE or PVC tube of about 2-inch caliber, the drain aperture is formed in a type of strainer, the drainpipe has a circular cross section so as to be cleanable, and the construction direction inclines upwardly to the horizontal plane by about 5 to 10°. In the case of the loose soil layer, the drainpipe is covered with a filter mat. In a section of the slope in which water is erupted by infiltration water, the slope horizontal drain hole is further provided as shown in FIG. 15. When a shallow failure is produced due to minute cavities on the slope surface, the slope surface weathered into a loose state by the lasting rainfall is infiltrated by rainwater so that the slope is maintained in the saturated state from its surface to a certain depth, thereby deteriorating the shear strength characteristic of the earth so considerably as to cause a failure. Accordingly, the analysis for this is carried out as follows;
[0153] Primarily considering the lower stratum below the critical failure line as a very stable stratum under the condition of no underground water level and secondarily considering the groundwater level to be positioned in a surface portion of the upper stratum above the critical failure line, the stability analysis is performed by use of the reverse analysis technique described in Example 3. The assumed condition of the reverse analysis is that the lower stratum below the critical failure line does not suffer failure. As the reinforcement countermeasure is used the aforementioned methods for enhancing the strength characteristics of earth and excluding the influence of water (increase of pore water pressure due to the ground water level) in which the suppression force required for reinforcement are provided by the apparent cohesion enhancement effect due to the shear strength or the tensile strength (skin friction force) of the reinforcing steel bar, and the groundwater level is lowered by the slope horizontal drain holes.
[0154] A designed construction section is determined so as to satisfy the above stability conditions. After the construction work in accordance with the designed construction section is done, the surface of the slope is treated by joining earth-pressing steel plates and PVC-coated wire mesh with the reinforcement member and attaching artificial greening soil covering containing natural monofilaments to the surface.
[0155] With regard to this surface treatment, the PVC-coated wire mesh to be used for the surface treatment is provided against the maximal deformation of the surface earth between the nail reinforcement members due to plastic deformation, and the stability condition thereof will be described below with reference to FIG. 16.
[0156] A deformed section of the surface per unit linear meter between the nails is expressed by
A = l 2 tan θ 2 ,
[0157] weight of the deformed section per unit linear meter between the nails is expressed by
W = r t A ≈ 1.9 2 l 2 tan θ
[0158] (t/m) (when considering unit weight of the surface of γ 1 =1.9t/m 3 ), a section of the soil covering per unit linear meter between the nails is expressed by A′=0.1l (when considering a thickness of 10 cm), weight of the soil covering per unit linear meter between the nails is expressed by W′=r 1 ′A′=0.16l (t/m) (when considering unit weight of the soil covering), an allowance tensile strength of a core wire of the PVC-coated wire mesh per strand is expressed by P=σ s A s , and the allowance tensile strength of the core wire of the PVC-coated wire mesh per unit extension meter is expressed
P = n σ s A s × 1 γ
[0159] is a horizontal construction spacing) when the number of core wire of the PVC-coated wire mesh to be joined with each nail spot is n strands. Thus, the stability condition of the PVC-coated wire mesh is as follows:
[0160] Since there is a relationship of
F s = R f + P D f > 1.5 ,
[0161] cross sectional area of the core wire of-the wire mesh to be used is expressed as below:
A s = ( 1.5 D f - R f ) γ n σ s [ Exp . 25 ]
[0162] wherein A s is cross sectional area of the core wire per unit strand, n is the number of strands of the joined core wire, σ s is an allowance tensile strength of the core wire, γ is horizontal spacing between the nails, l is vertical spacing between the nails, R f is a resistance force of the surface deformed section and the artificial soil covering against the slip activity, and D f is a slip driving force of the surface deformed section and the artificial soil covering, which values are expressed by the following expression
D f = W sin ( 45 ° + φ 2 ) + W ′ sin ( 45 ° + φ 2 + θ ) [ Exp . 26 ] R f = cl cos ( 45 ° + φ 2 ) + W cos ( 45 ° + φ 2 ) tan φ + c ′ l cos ( 45 ° + φ 2 + θ ) + W ′ cos ( 45 ° + φ 2 + θ ) tan φ ′ [ Exp . 27 ]
[0163] c′ is the cohesion acting between the soil covering and the surface portion of the slope, and if c′=0 , this corresponds to the condition for limit equilibrium state, thus establishing a relational expression of
φ ′ = 45 ° + φ 2 + θ .
[0164] In this case, Exp. 27 is converted to the following expression:
R f = cl cos ( 45 ° + φ 2 ) + W cos ( 45 ° + φ 2 ) tan φ + W ′ cos ( 45 ° + φ 2 + θ ) tan ( 45 ° + φ 2 + θ ) [ Exp . 28 ]
[0165] wherein c and φ are the cohesion and the internal friction angle of earth in the plastic deformation section of the slope surface, and c′ and φ′ are the cohesion and the internal friction angle acting on the boundary surface between the soil covering and the slope surface.
[0166] If the PVC-coated wire mesh is joined, then the slope surface is treated with general artificial soil covering or artificial soil covering mixed with natural fibers (monofilaments) by a spray attaching vegetation method in order to prevent erosion and outflow of earth in accordance with the plastic deformation of the slope surface and the progression of weathering.
[0167] That is, the reinforcement construction work of the slope is carried out in such a manner that a position of drilling point is marked according to the designed construction section as shown in FIG. 17, the marked point is drilled and the reinforcing steel bar is insert-laid in the slope, cement, water and high fluidizing agent are mixed with each other to produce grout and the grout is gravitationally injected around the reinforcing steel bar, the slope drain holes are laid in the slope, metal earth-pressing plates and PVC-coated wire mesh are installed, and the slope surfaces are treated with the general artificial soil covering or the artificial soil covering mixed with natural monofilaments by the spray vegetation attaching method.
[0168] As described above, the present invention provides a method for reinforcing a slope, in which an already-constructed slope can reinforced to secure stability and an unstable slope can be restored to its own natural state by means of an environmentally favorable method of construction, strength characteristics are examined by a reverse analysis technique so as to be adapted to given field conditions in accordance with a deformed or degraded state of the ground, and an internal stability condition is studied after an external stability condition is studied using a reinforced theory and then a construction work is carried out, thereby making it possible to rapidly carry out the construction work suitable to the actual field at a low cost.
[0169] Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed is a method for reinforcing a slope, in which field ground deformation characteristics of an unstable slope can be rapidly and reliably judged, and the unstable slope is recovered and restored to its own natural state so as to make it possible to secure stability by introduction and application of an earth reinforcement theory, i.e., a theory that an apparent cohesion is increased by reinforcement members. This slope reinforcing method comprises the steps of: studying application conditions in connection with an applicable limit, in consideration of which determining soil parameters using the reverse analysis technique of the Janbu method; analyzing stability of the slope using the soil parameters by the Janbu method to estimate an slip failure force and a resistance force of the slope; planning a construction section of a reinforcement zone in order to increase the resistance force of the slope; disposing slope horizontal drain holes in consideration of the underground water level condition to study an external stability; checking an internal stability within the reinforcement zone against a critical failure; section in consideration of a pull-out force and a shear capacity of the reinforcement member; preparing design drawings; carrying out a reinforcement construction work; and treating surfaces of the greening soil. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to an image processing method and apparatus and, more particularly, to an image processing method and apparatus for performing a level conversion of image data, by way of example.
When two images having different color tones are combined in an image processing apparatus according to the prior art, the result of the combination will be unnatural owing to the different tones if the combination is performed as is. When such images are combined, therefore, the user manually subjects the R, G, B level values or other levels of one image to a conversion and adjustment and then executes synthesis processing, whereby a more natural composite image can be obtained.
Further, when it is desired to make a photographic image lacking vividness more vivid and sharp in the conventional image processing apparatus, the user manually subjects the R, G, B level values or other levels of the photographic image to a conversion and adjustment, thereby making it possible to convert the image to one having a desired contrast.
Thus, by subjecting image data to be operated upon to a conversion of the pixel level at will, the user can obtain the desired image data.
However, since the pixel level conversion is carried out manually in the conventional image processing apparatus described above, it is required that the user have thorough knowledge of the constitution and features of the image data to undergo the level conversion and of image processing techniques in general. This means that the level conversion operation for obtaining a desired image cannot be performed by anyone in simple fashion.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an image forming method and apparatus through which the color tone of image data can easily be made to approach that of any image data.
According to the present invention, the foregoing object is attained by providing an image processing method comprising: an analysis step of analyzing a pixel level distribution in first image data; a conversion condition generating step of generating conversion conditions for second image data based upon results of analysis performed at the analysis step; and a conversion step of converting the second image data based upon the conversion conditions.
As a result, the color tone of the second image data can be made to approach that of the first image data with facility.
It is another object of the present invention to provide an image forming method and apparatus through which natural synthesis of images is possible.
According to the present invention, the foregoing object is attained by providing an image processing apparatus further comprising a synthesis step of combining the second image data, which has been obtained by the conversion, with the first image data.
As a result, it is possible to achieve natural synthesis of the second image data and first image data.
It is another object of the present invention to provide an image forming method and apparatus that make it easy to perform appropriate conversion of image data contrast.
According to the present invention, the foregoing object is attained by providing an image processing method comprising a sensing step of sensing a highlight area and a dark area of image data; a conversion condition generating step of generating conversion conditions for the image data based upon the highlight area, dark area and a predetermined value; and a conversion step of converting the image data based upon the conversion conditions.
As a result, it is possible to easily convert the contrast of image data appropriately.
The invention is particularly advantageous since image data can be subjected to an appropriate level conversion automatically.
Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing the general construction of an image processing apparatus according to an embodiment of the present invention;
FIGS. 2A-2C are diagrams showing examples of histograms of a reference image in this embodiment;
FIG. 3 is a diagram showing an example of conversion tables in this embodiment;
FIG. 4 is a flowchart showing color tone conversion processing in this embodiment;
FIG. 5 is a diagram showing an example of conversion tables in this embodiment;
FIG. 6 is a block diagram showing the general construction of an image processing apparatus according to a second embodiment of the present invention;
FIGS. 7A-7C are diagrams showing examples of histograms of a reference image in the second embodiment;
FIG. 8 is a diagram showing an example of a basic conversion table in the second embodiment;
FIG. 9 is a diagram showing an example of a conversion table in the second embodiment;
FIG. 10 is a flowchart showing level conversion processing in the second embodiment;
FIG. 11 is a diagram showing an example of a conversion table in the second embodiment; and
FIG. 12 is a diagram showing an example of a conversion table in the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail in accordance with the accompanying drawings.
<First Embodiment>
This embodiment is characterized in that after an appropriate level conversion is performed automatically in regard to two color images displayed on a display unit, for example, in such a manner that the color tone of the image data of one image (which shall be referred to as a “target image”) is made to conform to the color tone of the other image (which shall be referred to as a “reference image”) in response to a designation made by the user via a pointing device, the two images are combined.
FIG. 1 is a block diagram showing the general construction of an image processing apparatus according to a first embodiment of the present invention. The image processing apparatus according to this embodiment includes a CPU (central processing unit) 1 , a ROM (read-only memory) 2 , a RAM (random access memory) 3 , a keyboard 4 , a mouse 5 , a display unit 6 and an external storage device 7 . These components are interconnected by a bus line 8 .
The CPU 1 , which is in the form of a microprocessor, for example, controls the operation of the foregoing components. The ROM 2 stores a system program 210 and an image application program 220 , which is for executing various image processing. The image application program 220 includes a color tone conversion program 221 , which is a characterizing feature of the present invention, and an image synthesis program 222 . The RAM 3 includes a reference image data area 301 for storing an image serving as a reference for color tone, a target image data area 302 for storing a target image whose color tone is to be converted, a histogram area 303 for storing a histogram of the reference image, a conversion table area 304 which stores a conversion table for converting the color tone of the target image, and an area 305 used for other processing and as a work area.
In this embodiment, it is assumed that the image data stored in the reference image data area 301 and target image data area 302 is read in from the external storage device 7 . Further, variables such as distributions SUM_R, SUM_G, SUM_B and a maximum distribution MAX, which are described later, are provided in the area 305 . In this embodiment, both the reference image data and target image data will be described as being RGB image data of eight bits for each of R, G, and B, as a result of which there are 24 bits of information for one pixel.
The keyboard 4 allows the user to input data such as characters, numerals and symbols and to issue various instructions to the CPU 1 . The mouse 5 is used to click on (designate) various items of information displayed on the display unit 6 , thereby issuing various instructions to the CPU 1 . A device such as a trackball, pen or touch-sensitive panel may be substituted for the mouse 5 as long as the substituted device is a so-called pointing device. The display unit 6 , which is constituted by an LCD or the like, displays various data in response to control performed by the CPU 1 . The external storage device 7 comprises a medium such as a floppy disk, CD-ROM or hard disk. Various data that has been read out of the external storage device 7 under the control of the CPU 1 is developed in the RAM 3 via the bus line 8 .
It should be noted that the system program 210 , color tone conversion program 221 and image synthesis program 222 in the ROM 2 may be stored in the external storage device 7 , such as a hard disk. In this case these programs would be read out and then expanded in the RAM 3 and executed by the CPU 1 .
Image synthesis processing in the image processing apparatus constructed as set forth above will now be described in detail.
First, the principles of color tone conversion according to this embodiment will be described with reference to FIGS. 2 and 3.
FIGS. 2A-2C illustrate examples of histograms of a reference image created in this embodiment. These histograms are obtained by the CPU 1 in dependence upon reference image data and are stored in the histogram area 303 of RAM 3 . Since the image data in this embodiment is composed of eight bits for each of R, G and B, the data has values of 256 levels, namely 0 to 255, for each color. However, in order to simplify the description of the histogram examples shown in FIGS. 2A-2C, the 256 levels are divided into 16 stages and the number of pixels per stage is indicated. In FIGS. 2A-2C, (a) is a histogram of the R (red) component. This histogram indicates that among all R-component pixels that make up the reference image, pixels having pixel values (levels 0 to 15) in the 0th stage are zero in number and pixels having pixel values (levels 16 to 31) in the 1st stage are one in number. FIGS. 2 ( b ) and ( c ) similarly illustrate histograms of the G (green) and B (blue) components, respectively.
FIG. 3 shows an example of conversion tables according to this embodiment. These conversion tables are obtained by the CPU 1 in dependence upon reference image data and are stored in the conversion table area 304 of RAM 3 . In this embodiment, an input pixel value of a target image is converted for every color component in accordance with the conversion tables shown in FIG. 3 . The conversion tables are created in the following manner: First, on the basis of the histograms of the reference image shown in FIGS. 2A-2C, the sum totals of the products of the pixel values and numbers of pixels [i.e., (pixel value)×(number of pixels)] for each of the components R, G, B are obtained as the distributions SUM_R, SUM_G, SUM_B, respectively. Then, letting the maximum value, i.e., the maximum distribution, among these three distributions be represented by SUM_R, for example, a conversion table for the B component of the target image data is created in such a manner that a pixel value V′ resulting from conversion of a pixel whose pixel value is V will be represented by
V′=V×SUM
—
B/SUM
—
R
Similarly, in regard to the G component, a conversion table for the G component is so as to obtain
V′=V×SUM — G/SUM — R
More specifically, on the basis of the histograms of the reference image, the inclination of each color in the reference image data, for example the fact that there are few B components and many R components, is recognized, and the conversion tables are created so as to reflect this inclination. Accordingly, as a result of subjecting the target image data to a color tone conversion using these conversion tables, it is possible to make the conversion in such a manner that the B components are reduced to a quantity similar to that of the reference image data. This color tone of the target image thus can be made to approach that of the reference image.
Image synthesis processing according to this embodiment will now be described in detail with reference to the flowchart of FIG. 4 . It should be noted that various initialization processing executed when the image application program 220 , etc., is started up is omitted from this flowchart.
When the image application program 220 is started up by the CPU 1 in this embodiment, the image application program 220 , the color tone conversion program 221 for converting color tone and the image synthesis program 222 for combining images are read out of the ROM 2 . However, in order not to make wasteful use of memory, it is preferred that the color tone conversion program 221 and image synthesis program 222 be read out at such time that color conversion processing and image synthesis processing has been started from the image application program 220 . Further, though various information and storage areas necessary when the color conversion processing of this embodiment is executed are acquired in the RAM 3 , the reference image data area 301 , target image data area 302 , histogram area 303 and conversion table area 304 may be acquired when the apparatus is started up. However, it is preferred that these areas be acquired when each is required. By adopting this expedient, memory areas are not used wastefully. This is useful in a case where other processing using memory areas is executed concurrently. Likewise, the area 305 used for other processing and as a work area in the RAM 3 may be acquired in advance when the image application program 220 is started up or when this storage area becomes necessary.
In the flowchart of FIG. 4, image data (target image data) whose color tone is desired to be converted is called to the target image data area 302 at step S 101 . When the start of color tone conversion processing based upon the color tone conversion program 221 is commanded in accordance with execution of the image application program 220 , image data (reference image data) whose color tone is the reference is called to the reference image data area 301 at step S 102 . It is of course permissible to reverse the order of steps S 101 and S 102 , i.e., to start the color tone conversion processing after the reference image data is called. In either case, when color tone conversion processing is executed in this embodiment, the image data that has been called to the reference image data area 301 and target image data area 302 is stored to establish the necessary information.
Executing steps S 101 and S 102 described above specifies the two images that are to be combined.
It should be noted that the calling of the target image data and reference image data in this embodiment may be performed by displaying a plurality of images represented by image data stored on the external storage device 7 , for example, on the display unit 6 and having the user select the desired images from these displayed images by the keyboard 4 or mouse 5 . Naturally, file names may be entered directly using the keyboard.
When color tone conversion processing has thus started, histograms of the reference image data are created at step S 103 . These histograms are obtained by evaluating the values (0 to 255) of all pixels of each of R, G and B and finally counting the numbers of pixels of each and every pixel value, as shown in FIGS. 2A-2C.
This is followed by step S 104 , at which the values of (pixel value)×(number of pixels) are obtained for all pixel values and the sum totals of these products are found as the distributions SUM_R, SUM_G, SUM_B for R, G, B, respectively. For example, in the example of R shown at (a) of FIGS. 2A-2C (where the pixel values are assumed to be 0 to 16 for the sake of convenience), the number of pixels of pixel value 0 is zero, the number of pixels of pixel value 1 is one, . . . and the number of pixels of pixel value 15 is three. Therefore, SUM_R is
SUM — R =0×0+1×1+ . . . +14×10+15×3=983
Similarly, we have SUM_G= 707 and SUM_B= 328 in (b) and (c), respectively, of FIGS. 2A-2C.
Next, at step S 105 , the distribution among the distributions SUM_R, SUM_G, SUM_B obtained at step S 104 having the largest value is decided upon as the maximum distribution MAX.
Conversion tables for the color components other than the color component for which MAX is indicated (the component having the largest distribution) are created at step S 106 . In the example of FIGS. 2A-2C, SUM_R is the maximum distribution and, hence, is adopted as MAX. Accordingly, conversion tables for the color components G, B are created. The conversion tables in this embodiment are obtained in accordance with the equation
V′=V×SUM
—
X/MAX
where V represents a pixel value before conversion, V′ a pixel value after conversion and SUM_X the distribution of a color component other than that having the maximum distribution. In the example of FIGS. 2A-2C, SUM_X corresponds to SUM_G and SUM_B regarding the G and B components, respectively. Examples of the conversion tables thus obtained are illustrated as graphs in FIG. 3 . In FIG. 3, the conversion table of the G component has a slope SUM_G/SUM_R and that of the B component has a slope SUM_B/SUM_R.
In this embodiment, a conversion table is not created in regard to the R component, which is the component having the maximum distribution, because the pixel values of this component are not converted. That is, the slope of the graph of the R component in FIGS. 2A-2C is 1. Naturally, in a case where some conversion is performed even in regard to a color component for which the distribution is maximum, a suitable conversion table need only be created.
Conversion of pixel values is actually performed at step S 107 in accordance with the conversion tables created at step S 106 . Here the pixel values of all pixels of the color components of the target image data for which conversion tables have been created (i.e., the G and B components in the example of FIG. 2) are rewritten while reference is made to the conversion tables. In other words, in a case where the values of R, G and B of a pixel of interest are, e.g., 6, 10 and 13, respectively, the pixel value of R is not rewritten because a conversion table has not been created for this component. If the value V′ after the conversion in regard to V=10 in the conversion table for G is V′=7, the value of G of the pixel of interest is rewritten to 7. Similarly, if the value V′ after the conversion in regard to V=13 in the conversion table for B is V′=4, the value of B of the pixel of interest is rewritten to 4.
When all pixel values have thus been converted in accordance with the conversion tables, an image whose color tone is close to that of the reference image is obtained. In other words, the color tone of the target image can be made to approach that of the reference image.
The target image obtained by the color tone conversion and the reference image are combined at step S 108 by starting up the image synthesis program by the image application program 220 . Since the color tones of the target image and reference image are near to each other in this case, a more natural composite image is obtained.
It should be noted that the image synthesis processing at step S 108 need be performed only as needed. For example, it is possible as a matter of course for the target image obtained by the color tone conversion to be saved in the area 305 beforehand and combined with another image specified by the user or combined with two or more images which include a reference image, by way of example.
<Modification of First Embodiment>
In the first embodiment, an example is described in which a conversion based upon a linear function, namely V′=V×SUM_X/MAX, is performed using conversion tables. However, this does not impose a limitation upon the present invention for it is also possible to create conversion tables using a non-linear function, such as by employing a gamma function. FIG. 5 illustrates examples of conversion tables based upon a gamma function. In accordance with the conversion tables shown in FIG. 5, no conversion is performed in regard to 0 and 255, which are the lowest and highest levels of a pixel value; only pixel values intermediate 0 and 255 are converted. Applying this technique makes it possible to obtain an effect in which the greater the components of R, G or B in terms of the input pixel values, the more the color tone thereof remains, so that color tone approaches that of the reference image more where the R, G or B components are fewer. In a case where the gamma function is used, the necessary parameter γ should be found from the distribution SUM_X of each color or the value of the maximum distribution MAX.
In this embodiment, color image data, which is similar to the target image data, composed of pixel levels of each and every color component is described as the reference image data, namely the data referred to in order to convert the color tone of the target image data. However, vector data of a color or a color table in which values representing colors have been written may serve as the data referred to in order to perform the color tone conversion. Similarly, the target data that is to undergo the color tone conversion is not limited to image data but may be data other than image data, such as vector data.
It is described that the reference image data and target image data in this embodiment are both read in from the external storage device 7 . However, the reference image data may be incorporated in the color tone conversion program 221 or image synthesis program 222 or in an area of the ROM 2 in advance. If histograms of this reference image data and conversion tables are obtained beforehand and described in the color tone conversion program 221 in such case, then processing for generating the histograms and conversion tables need no longer be executed on each occasion. This makes processing at high speed possible.
Thus, in accordance with the first embodiment as described above, the color tone of a color image can be automatically converted to conform the color tone of any other color image. In addition, by combining these color images, it is possible to obtain a synthesized result having a more natural color tone.
<Second Embodiment>
A second embodiment according to the present invention will now be described.
The second embodiment is characterized in that a pixel level conversion is performed automatically so as to obtain an appropriate image data contrast.
FIG. 6 is a block diagram showing the general construction of an image processing apparatus according to the second embodiment of the present invention. Components in FIG. 6 identical with those of the first embodiment shown in FIG. 1 are designated by like reference characters and need not be described again.
In the second embodiment, the ROM 2 stores the system program 210 and the image application program 220 for executing various image processing. The image application program 220 includes a pixel level conversion program 223 , which is a characterizing feature of this embodiment. The RAM 3 includes the image data area 302 for storing a target image whose color tone is to be converted, the histogram area 303 for storing a histogram of image data, the conversion table area 304 which stores a conversion table for converting the levels of the image data, and the area 305 used for other processing and as a work area.
In the second embodiment, it is assumed that the image data that is stored in the image data area 302 is read in from the external storage device 7 . Further, variables such as α, β are acquired in the area 305 . Further, in the second embodiment, the image data will be described as being RGB image data of eight bits for each of R, G, and B, as a result of which there are 24 bits of information for one pixel.
It should be noted that the system program 210 and pixel level conversion program 223 in the ROM 2 may be stored in the external storage device 7 , such as a hard disk. In this case these programs would be read out and then expanded in the RAM 3 and executed by the CPU 1 .
Pixel level conversion processing in the image processing apparatus construction as set forth above will now be described in detail.
First, the principles of pixel level conversion according to the second embodiment will be described with reference to FIGS. 7 and 8.
In order to adjust the contrast level of image data in the second embodiment, histograms are obtained for respective ones of the colors R, G, B, and a conversion is performed based upon these histograms in such a manner that the pixel levels of this image data will be spread widely over the full range 0-255 (divided into 0th to 15th stages in the second embodiment for the sake of convenience) of possible output. Examples of these histograms are shown in FIGS. 7A-7C. These histograms are obtained by the CPU 1 in dependence upon image data and are stored in the histogram area 303 of RAM 3 . Since the image data in the second embodiment is composed of eight bits for each of R, G and B, the data has values of 256 levels, namely 0 to 255, for each color. However, in order to simplify the description of the histogram examples shown in FIGS. 7A-7C, the 256 levels are divided into 16 stages and the number of pixels per stage is indicated. In FIGS. 7A-7C, (a) is a histogram of the R (red) component and indicates the number of pixels per level. For example, this histogram indicates that among all R-component pixels that make up the reference image, pixels having pixel values (levels 0 to 15) in the 0th stage are zero in number and pixels having pixel values (levels 16 to 31) in the 1st stage are one in number. FIGS. 7 ( b ) and ( c ) similarly illustrate histograms of the G (green) and B (blue) components, respectively.
In regard to the histogram of each color shown in FIGS. 7A-7C, a prescribed value (number of pixels) is predetermined as a threshold value and serves as information for creating a conversion table. The conversion table is created in such a manner that a range of pixel values which possess numbers of pixels that exceed this threshold value is broadened to the full range of levels 0-255 (divided into the 0th to 15th stages in the second embodiment) capable of being output or to a range close to this range. In the examples of the histograms shown in FIGS. 7A-7C, the threshold value is “3”.
FIG. 8 illustrates an example of a conversion table created in the second embodiment. This conversion table is created separately for each of the colors R, G and B. FIG. 8 shows an example for the G component, the top of FIG. 8 depicting the histogram for G and the bottom showing an example of a conversion table obtained from this histogram. This conversion table is found by the CPU 1 in dependence upon the image data on a per-color basis and is stored in the conversion table area 304 of RAM 3 . The pixel values of the image data are converted for each color component in accordance with this conversion table.
In the histogram for G shown at the top of FIG. 8, the range of pixel values having numbers of pixels that exceed the threshold value extends from the 4th to the 11th stages. Accordingly, the conversion table in the second embodiment is created in such a manner that the range of pixel values of the 4th to 11th stages is widened to the range of 0th to 15th stages. That is, in the image data prior to conversion, pixels having the pixel values of the 0th to 4th stages are converted to the 0th stage (level 0), which is the lowest stage, and pixels having the pixel values of the 11th to 15th stages are converted to the 15th stage (level 255), which is the highest stage. In regard to the pixels having pixel values from the 5th to the 10th stages, these are converted to values in the 1st to 14th stages by proportional calculation. In other words, the conversion table for the G component is obtained in the form of the graph shown at the bottom of FIG. 8 .
Depending upon the image, there are instances where the overall color tone is offset or inclined toward a certain, specific color. For example, if the image is of a scene such as a sunset, the overall image has an orange-colored gradation. If reference is made to the histogram of this image of the sunset, often a certain pixel value will be the peak value and pixels will have an inclination toward the vicinity of this pixel value. More specifically, pixel values are inclined to be larger in the histograms for R and G and smaller in the histogram for B. If level conversion processing based upon a conversion table of the kind described above is applied to such an image, the histograms of the image after conversion will widen overall for all of R, G and B. As a consequence, the orange color that prevailed in the sunset image before conversion will take on a more bluish tinge after the conversion and, hence, the color tone after conversion will be much different.
In order to avoid this phenomenon in which the color tone of an image is changed by a pixel level conversion, the second embodiment imposes limits upon the range of pixel values in which a conversion is made to the fixed values of level 0 (the 0th stage) and level 255 (the 15th stage) shown in FIG. 8 . Such an example is shown in FIG. 9 . Here M and N represent lower and upper limits, respectively, of a histogram that exceeds a threshold value. It should be noted that constants may be given beforehand as values of α and β, or α and β may be calculated in accordance with given functions based upon values of M and N indicating the lower and upper limits of the histogram that exceeds the threshold value. Also conceivable is a method of creating a conversion table to conform to whichever of the R, G, B histograms has the broadest range of pixel values that exceed the threshold value.
The processing for pixel level conversion in the second embodiment will now be described in detail with reference to the flowchart of FIG. 10 . It should be noted that various initialization processing executed when the image application program 220 , etc., is started up is omitted from this flowchart.
When the image application program 220 is started up by the CPU 1 in the second embodiment, the image application program 220 and color tone conversion program 223 for converting pixel level are read out of the ROM 2 . However, in order not to make wasteful use of memory, it is preferred that the pixel level conversion program 223 be read out at such time that level conversion processing has been started from the image application program 220 . Further, though various information and storage areas necessary when the level conversion processing of the second embodiment is executed are acquired in the RAM 3 , the target image data area 302 , histogram area 303 and conversion table area 304 may be acquired when the apparatus is started up. However, it is preferred that these areas be acquired when each is required. By adopting this expedient, memory areas are not used wastefully. This is useful in a case where other processing using memory areas is executed concurrently. Likewise, the area 305 used for other processing and as a work area in the RAM 3 may be acquired in advance when the image application program 220 is started up or when this storage area becomes necessary.
In the flowchart of FIG. 10, image data to undergo a pixel level conversion is called to the image data area 302 at step S 201 . It should be noted that the calling of the image data in the second embodiment may be performed by displaying image data of a plurality of images stored on the external storage device 7 , for example, on the display unit 6 and having the user select the desired images from these displayed images by the keyboard 4 or mouse 5 . Naturally, file names may be entered directly using the keyboard.
When the start of pixel level conversion processing based upon the image application program 220 is commanded in accordance with execution of the image application program 220 , histograms of the image data are created at step S 202 . These histograms are obtained by evaluating the values (0 to 255) of all pixels of each of R, G and B and finally counting the numbers of pixels of each and every pixel value, as shown in FIGS. 7A-7C.
This is followed by step S 203 , at which a range of pixel values (levels) having numbers of pixels greater than a threshold value is obtained in the histogram created at step S 202 for each of the colors R, G, B. More specifically, the number of pixels of level 0 (the 0th stage in the second embodiment), which is the lowest level, is obtained. If this number of pixels exceeds the threshold value, then the lower limit of the sought pixel value range becomes level 0. If the number of pixels of level 0 is equal to or less than the threshold value, on the other hand, the number of pixels of level is obtained and this is compared with the threshold value in similar fashion. This comparison operation is repeated until a level having a number of pixels that exceeds the threshold value appears, and the level for which the number of pixels exceeds the threshold value is adopted as the lower limit of the sought pixel value range. The lower limit corresponds to a dark point. In FIG. 9, the lower limit (dark point) of this pixel value range is represented by M. Similarly, a comparison of the threshold value and numbers of pixels is performed successively from level 255 (the 15th stage in the second embodiment), which is the highest level. If a level having a number of pixels that exceeds the threshold value appears, this level is adopted as the upper limit of the sought pixel value range. The upper limit corresponds to a highlight point. In FIG. 9, the upper limit (highlight point) of this pixel value range is represented by N. Though it is so arranged here that the threshold value is not included in the sought pixel value range, it is of course permissible to obtain a range that includes the threshold value.
Next, at step S 204 , a conversion table is created based upon the pixel value range found at step S 203 . The conversion table in the second embodiment is created in such a manner that pixel value range obtained at step S 203 will be spread over the range of levels 0-255 (divided into 0th to 15th stages in the second embodiment for the sake of convenience) of possible output. However, as described above in conjunction with FIG. 9, limits indicated by range α and range β are imposed on the conversion to levels 0 and 255.
The ranges of α and β can be obtained as follows, by way of example: If the ranges of 0 to M and N to 255 are greater than a predetermined value, e.g., (total number of levels)/(8), the width of α is set to (total number of levels)/(8). If the range M to N is less than (total number of levels)×¾, the width of β is set to (total number of levels)/(8). By thus setting a pixel value range in which a conversion is made to levels other than the fixed values of levels 0 and 255, it is possible to avoid a situation in which color tone after level conversion will not change greatly from color tone prior to the level conversion. The conversion table is then created in accordance with the conversion equation given by the graph at the bottom of FIG. 9 .
Conversion of all pixel values of the image data is performed at step S 205 in accordance with the conversion tables created at step S 204 . More specifically, while referring to the conversion tables, the pixels values of all pixels constituting the image data are rewritten for all color components. In the example of the G component shown in FIG. 9, an original pixel value is converted to level 0 if it falls within any of levels 0 to M and to level 255 if it falls within any of levels N to 255. All other original pixel values are converted to values that are in accordance with the conversion tables.
By thus converting all pixel values making up image data in accordance with the conversion tables created at step S 204 , the range of pixel values in the image data resulting from the conversion will have a spread larger than that of the original image data. This makes it possible to obtain an image, such as an image having better contrast, that has been subjected to an appropriate level adjustment automatically.
Though the second embodiment has been described in regard to an example in which low- and high-luminance portions of an image are converted to the fixed values of level 0 and level 255, the fixed values are not limited to those of this example. Any fixed values may be used so long as they are suitable values of low- and high-luminance levels, such as lower- and upper-limit values of a range of levels over which output is possible.
In the second embodiment, the same range α is used for determining limits within fixed levels (0 and 255, for instance), both in the high-luminance (highlight) area and in the low-luminance (dark) area as shown in FIG. 9; however, the present invention is not limited to this, and different ranges α 1 and α 2 may be used in the low- and high-luminance areas, respectively, depending upon characteristics of a target image.
<Modification of Second Embodiment>
The second embodiment has been described in regard to an example in which pixel values resulting from a conversion are made level 0 or level 255 unconditionally in a region of levels having numbers of pixels equal to or less than a threshold value in a histogram. In such case, however, the color tone of a region of levels (a portion where luminance is low or high) having numbers of pixels equal to or less than the threshold value in the original image is lost. As a consequence, when a range of levels having numbers of pixels equal to or less than the threshold value is wide, pixel values are lost over multiple stages and the inevitable result is that the features of the original image are lost.
An effective way to avoid this is to create a conversion table of the kind shown in FIG. 11 in accordance with the second embodiment. As shown in FIG. 11, converted pixel values in a region of levels having numbers of pixels equal to or less than the threshold value are not fixed to level 0 or 255 but are instead converted by a function provided with a certain degree of slope a. By way of example, the slope a in FIG. 11 is given by a=M/2. The slope may thus be given by a simple equation. It should be noted that the value of slope a can be changed for the high- and low-luminance areas.
This makes it possible to avoid complete loss of information (color tone) in a range of levels having numbers of pixels equal to or less than the threshold value.
The technique described in conjunction with FIG. 11 can be applied also to the conversion table shown in FIG. 9 . Such an example is illustrated in FIG. 12 . Specifically, as shown in FIG. 12, limits indicated by α and β are imposed with respect to conversion to the fixed values of level 0 and 255, and a conversion table having a certain degree of slope is created in regard to a region of levels having numbers of pixels equal to or less than the threshold value. By creating a conversion table in this manner, information possessed by pixels having pixel values near levels 0 and 255 is prevented from being lost and it is possible also to prevent a large change in color tone.
In the second embodiment, it is stated that histograms and conversion tables are created for respective ones of the colors R, G, B. However, another conceivable method is to obtain a histogram regarding the luminance of image data and create a conversion table for luminance levels. In accordance with such method, there will be little change in color tone due to level conversion and it is possible to perform a conversion that improves only contrast.
Further, the second embodiment has been described in regard to an example in which color image data is subjected to a level conversion. However, it goes without saying that the present invention is applicable to monochromatic image data as well. That is, it is possible to make a conversion to more suitable contrast by creating a histogram and conversion table for the luminance components of the image data.
The second embodiment has been described in regard to an example in which a conversion table is obtained by a linear function (a proportional calculation). However, a non-linear function such as a gamma function may also be used.
Thus, in accordance with the second embodiment as described above, a conversion can be performed automatically in such a manner that a level such as the contrast of image data is rendered more appropriate. At such time it is possible to suppress a change in the color tone of the original image as well as loss of information in low- or high-luminance areas.
<Other Embodiments>
The present invention can be applied to a system constituted by a plurality of devices (e.g., a host computer, interface, reader, printer, etc.) or to an apparatus comprising a single device (e.g., a copier or facsimile machine, etc.).
Furthermore, it goes without saying that the invention is applicable also to a case where the object of the invention is attained by supplying a storage medium storing the program codes of the software for performing the functions of the foregoing foregoing embodiments to a system or an apparatus, reading the program codes with a computer (e.g., a CPU or MPU) of the system or apparatus from the storage medium, and then executing the program codes.
In this case, the program codes read from the storage medium implement the novel functions of the invention, and the storage medium storing the program codes constitutes the invention.
Further, the storage medium, such as a floppy disk, hard disk, optical disk, magneto-optical disk, CD-ROM, CD-R, magnetic tape, non-volatile type memory card or ROM can be used to provide the program codes.
Furthermore, besides the case where the aforesaid functions according to the embodiments are implemented by executing the program codes read by a computer, it goes without saying that the present invention covers a case where an operating system or the like running on the computer performs a part of or the entire process in accordance with the designation of program codes and implements the functions according to the embodiments.
It goes without saying that the present invention further covers a case where, after the program codes read from the storage medium are written in a function extension board inserted into the computer or in a memory provided in a function extension unit connected to the computer, a CPU or the like contained in the function extension board or function extension unit performs a part of or the entire process in accordance with the designation of program codes and implements the function of the above embodiment.
Thus, in accordance with the present invention as described above, image data can be subjected to an appropriate level conversion automatically.
As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims.
In a case where the present invention is applied to the aforesaid storage medium, the storage medium stores program codes corresponding to the flowcharts (FIG. 4, FIG. 10) described in the embodiments. | When performing image synthesis, in which a plurality of images having different color tones are combined, or when converting the contrast of an image, the prior art is such that a user must convert pixel levels manually. Consequently, it is required that the user have thorough knowledge of the constitution of the image data to undergo the level conversion and of image processing techniques in general. This means that the conversion cannot be performed by anyone in simple fashion. In accordance with the present invention, a conversion table is created automatically based upon the color distribution of first image data in such a manner that the color tone of second image data is made to approach that of the first image data, and the second image data resulting from a pixel level conversion by this conversion table is combined with the first image data, whereby there is obtained a natural composite image. In another aspect, an appropriate contrast conversion can be performed with ease by performing a pixel level conversion in accordance with a conversion table created based upon a pixel level distribution of image data. | 6 |
RELATED PATENT DATA
This patent is a divisional application of U.S. patent application Ser. No. 09/281,735, now U.S. Pat. No. 5,990,559 which was filed on Mar. 30, 1999; and which is a divisional application of U.S. patent application Ser. No. 09/141,840, which was filed on Aug. 27, 1998.
TECHNICAL FIELD
The invention pertains to methods of forming and using platinum-containing materials, and to circuitry incorporating roughened layers of platinum.
BACKGROUND OF THE INVENTION
Platinum is a candidate for utilization as a conductive material in advanced semiconductor processing. Platinum can be utilized in an elemental form, or as an alloy (such as, for example, rhodium/platinum), and can be deposited onto a substrate by, for example, sputter deposition or chemical vapor deposition (CVD) methods. Platinum is typically formed to have a relatively smooth upper surface. Such smooth upper surface can be advantageous in, for example, applications in which circuitry is formed over the platinum layer. Specifically, the relatively smooth surface can provide a substantially planar platform upon which other circuitry is formed. However, there can be advantages to incorporating roughened conductive layers into integrated circuitry in applications where high surface area is desired, as with capacitor electrodes. Accordingly, it would be desirable to develop methods of forming platinum layers having roughened outer surfaces.
In another aspect of the prior art, platinum-comprising materials are frequently utilized as catalysts in, for example, the petroleum industry, as well as in, for example, automobile exhaust systems. Frequently, an efficiency of a catalyst can be improved by enhancing a surface area of the catalyst. Accordingly, it would be desirable to develop methods of enhancing surface area of platinum-comprising materials.
SUMMARY OF THE INVENTION
In one aspect, the invention encompasses a method of forming a roughened layer of platinum. A substrate is provided within a reaction chamber. An oxidizing gas is flowed into the reaction chamber, and a platinum precursor is flowed into the chamber. Platinum is deposited from the platinum precursor over the substrate in the presence of the oxidizing gas. A temperature within the chamber is maintained at from about 0° C. to less than 300° C. during the depositing.
In another aspect, the invention encompasses a circuit comprising a roughened platinum layer over a substrate. The roughened platinum layer has a continuous surface characterized by columnar pedestals.
In yet another aspect, the invention encompasses a platinum catalyst characterized by a continuous outer surface portion of the platinum having a plurality of columnar pedestals that are at least about 400 Å tall. The surface portion covers an area that is at least about 4×10 6 square Angstroms.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a diagrammatic, fragmentary, cross-sectional view of a semiconductive wafer fragment processed according to a method of the present invention.
FIG. 2 is a fragmentary top view of the semiconductor wafer fragment of FIG. 1 .
FIG. 3 is a view of the FIG. 1 wafer fragment at a processing step subsequent to that of FIG. 1 .
FIG. 4 is a scanning electron microscope (SEM) micrograph of a platinum film produced by CVD of MeCpPt(Me) 3 .
FIG. 5 is a SEM micrograph of a platinum film produced by CVD of MeCpPt(Me) 3 under different conditions than those utilized for forming the film of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
The invention encompasses methods of forming platinum layers having roughened outer surfaces, and methods of incorporating such layers into capacitor constructions. FIG. 1 shows a semiconductor wafer fragment 10 at a preliminary processing step of the present invention. Wafer fragment 10 comprises a substrate 12 . Substrate 12 can comprise, for example, a monocrystalline silicon wafer lightly doped with a background p-type dopant. To aid in interpretation of the claims that follow, the term “semiconductive substrate” is defined to mean any construction comprising semiconductive material, including, but not limited to, bulk semiconductive materials such as a semiconductive wafer (either alone or in assemblies comprising other materials thereon), and semiconductive material layers (either alone or in assemblies comprising other materials). The term “substrate” refers to any supporting structure, including, but not limited to, the semiconductive substrates described above.
A diffusion region 14 is formed within substrate 12 and defines a node location to which electrical connection with a storage node of a capacitor is to be made. Diffusion region 14 can be formed by, for example, implanting a conductivity enhancing dopant into substrate 12 .
An adhesion layer 16 is formed over substrate 12 and in electrical contact with diffusion region 14 , and a platinum-comprising layer 18 is formed over adhesion layer 16 . Adhesion layer 16 is provided to enhance adhesion of platinum-comprising layer 18 to substrate 12 . In other embodiments (not shown) a platinum-comprising layer can be provided directly onto a silicon surface (either the monocrystalline silicon surface of substrate 12 , or an intervening amorphous or polycrystalline surface). Such embodiments are less preferred than the shown embodiment due to difficulties of adequately adhering platinum directly to silicon.
Adhesion layer 16 can comprise, for example, at least one of titanium nitride, iridium, rhodium, ruthenium, platinum, palladium, osmium, silver, rhodium/platinum alloy, IrO 2 , RuO 2 , RhO 2 , or OsO 2 . Adhesion layer 16 can be formed by, for example, chemical vapor deposition, and can be formed to a thickness of, for example, less than 100 Å.
Platinum-comprising layer 18 can comprise, for example, elemental platinum, or a platinum alloy, such as rhodium/platinum alloy. Platinum-comprising layer 18 is provided to have a roughened outer surface 20 . Such can be accomplished by chemical vapor deposition of platinum-comprising layer 18 under relatively low temperature conditions, and in the presence of an oxidizing atmosphere. For instance, a platinum-comprising layer 18 formed as follows will comprise a roughened outer surface 20 .
First, substrate 12 is inserted within a CVD reaction chamber. An oxidizing gas and a platinum precursor are flowed into the reaction chamber. Platinum is deposited from the platinum precursor over substrate 12 in the presence of the oxidizing gas. A temperature within the reaction chamber is maintained at from about 0° C. to less than 300° C. during the depositing, and a pressure within the reactor is preferably maintained at from about 0.5 Torr to about 20 Torr. Suitable control of the temperature and of a relative flow rate of the oxidizing gas to the platinum precursor causes deposited platinum layer 18 to have a roughened outer surface 20 . The platinum precursor is flowed into the reaction chamber in a carrier gas, such as, for example, a gas known to be generally inert to reaction with platinum precursor materials, such as, for example, helium or argon. The platinum precursor can comprise, for example, at least one of MeCpPtMe 3 , CpPtMe 3 , Pt(acetylacetonate) 2 , Pt(PF 3 ) 4 , Pt(CO) 2 Cl 2 , cis-[PtMe 2 (MeNC) 2 ], or platinum hexafluoroacetylacetonate; wherein Cp is a cyclopentadienyl group and Me is a methyl group. The oxidizing gas can comprise, for example, at least one of O 2 , N 2 O, SO 3 , O 3 , H 2 O 2 , or NO x , wherein x has a value of from 1 to 3. In embodiments wherein platinum layer 18 comprises a platinum/metal alloy, at least one other metal precursor can be flowed into the reaction chamber to deposit the platinum as an alloy of the platinum and the at least one other metal. The at least one other metal precursor can comprise, for example, a precursor of rhodium, iridium, ruthenium, palladium, osmium, and/or silver.
The oxidizing gas can assist in deposition of platinum from the platinum-comprising precursor by oxidizing carbon from the precursor during deposition of the platinum. Also, the oxidizing gas can influence a deposition rate of a platinum-comprising layer. Specifically, a greater rate of flow of the oxidizing gas relative to the flow of the platinum precursor can lead to faster deposition of the platinum-comprising layer. The rate of flow of platinum precursor is influenced by a rate of flow of carrier gas through a liquid organic precursor solution, and by a temperature of the precursor solution. In preferred embodiments of the invention, a carrier gas will be flowed through a liquid organic precursor solution at a rate of from about 2 sccm to about 1000 sccm and more preferably at less than or equal to about 30 sccm. In such preferred embodiments, the oxidizing gas will be flowed at a flow rate of at least about 50 sccm. The organic precursor will preferably be at a temperature of from about 0° C. to about 100° C., and more preferably from about 30° C. to about 50° C.
A rate of growth of platinum-comprising layer within the reaction chamber is also influenced by a temperature of the substrate. Specifically, if platinum is deposited under conditions wherein the temperature of the substrate is maintained at from about 220° C. to less than 300° C., the platinum will deposit at a rate of about 600 Å in about 30 seconds. If a temperature of the substrate is reduced to below about 210° C., a rate of deposition of platinum will decrease considerably. It is preferred that a deposition time for a 600 Å thick platinum-comprising layer be less than or equal to about 40 seconds to maintain efficiency of a production process. Accordingly, it is preferred that the temperature of the substrate be maintained at above about 210° C., and preferably at from greater than or equal to about 220° C. during deposition of the platinum-comprising layer within the reaction chamber.
It is also found that if a temperature is greater than 300° C. and less than about 350° C., a deposited platinum layer will have a smooth outer surface, rather than a desired roughened outer surface. Further, if the temperature of the substrate exceeds about 400° C., a deposited platinum surface will have holes extending to a surface underlying the platinum surface, rather than being a continuous surface overlying a substrate. Accordingly, it is preferred that the temperature of the substrate be well below 400° C., more preferred that the temperature be below 300° C., and even more preferred that the temperature be less than or equal to about 280° C. In preferred embodiments of the present invention, the temperature of the substrate will be maintained at from about 220° C. to about 280° C., whereupon it is found that a platinum layer having a roughened outer surface can be deposited to a thickness of about 600 Å in about 30 seconds.
Platinum layer 18 is preferably deposited to a thickness of at least about 400 Å to avoid having surface anomalies (such as crevices or holes) that extend entirely through layer 18 to an underlying layer, and is preferably deposited to a thickness of at least about 600 Å. However, in some embodiments holes extending entirely through layer 18 will be of little or no consequence in semiconductor circuitry ultimately formed from layer 18 . Such embodiments can include, for example, embodiments wherein adhesion layer 16 is provided beneath platinum-comprising layer 18 . Accordingly, in embodiments wherein platinum layer 18 is provided over an adhesion layer 16 , it can be preferred to provide platinum layer 18 to a thickness of less than 400 Å because of space limitations due to the close packing of capacitors. Also, in embodiments in which platinum layer 18 is utilized in forming circuitry having tight spacing requirements it can be preferred to form layer 18 to be relatively thin. For instance, in some capacitor constructions it can be desired to form layer 18 to be less than or equal to about 1000 Å, and more preferred to form layer 18 to be from about 300 Å to about 400 Å to avoid electrical contact between adjacent capacitor structures.
A fragmentary top view of wafer fragment 10 is shown in FIG. 2 . Layer 18 is preferably a continuous layer (defined as a layer without cavities extending therethrough to an underlying layer—such as the underlying layer 16 of FIG. 2) across its entirety. Alternatively, some portion of layer 18 is continuous. For example, consider an application where layer 18 overlies and contacts a conductive layer to form a circuit device comprising both layer 18 and the underlying conductive layer. In such applications, it is generally still desired that a substantial portion of layer 18 be continuous to, for example, maintain a uniform electrical contact between layer 18 and the underlying conductive layer. Such substantial portion will preferably cover a surface area of at least about 4×10 6 square Angstroms. A surface area of about 4×10 6 square Angstroms is illustrated in FIG. 3 as a square 50 having sides of about 2000 Angstroms.
FIG. 3 illustrates an embodiment wherein platinum-comprising layer 18 is incorporated into a capacitor construction 30 as a storage node. Specifically, a dielectric layer 22 and a capacitor electrode 24 are provided over platinum-comprising layer 18 to form capacitor construction 30 . Dielectric layer 22 can comprise one or more of silicon oxide or silicon nitride, or it can comprise other dielectric materials, such as, for example, tantalum pentoxide, or BaSrTiO 3 . Capacitor electrode 24 can comprise, for example, TiN, conductively doped silicon (such as polysilicon), or a metal, such as, for example, platinum. In embodiments wherein capacitor electrode 24 comprises platinum, capacitor electrode 24 can be formed by chemical vapor deposition over dielectric layer 22 . The chemical vapor deposition can be conducted either to form upper electrode 24 with a relatively smooth upper surface, or to form upper electrode 24 with a relatively rough upper surface. If capacitor electrode 24 is to be formed of platinum with a relatively smooth upper surface, it can be chemical vapor deposited in a reaction chamber with a temperature maintained at above about 300° C. and/or with an oxidizing gas flow rate of less than 50 sccm and a carrier gas flow rate of greater than 30 sccm. Also, any platinum comprised by capacitor electrode 24 can be in the form of elemental platinum, or an alloy, such as, for example, rhodium/platinum alloy.
As shown, layer 18 has a rough outer surface and layers 22 and 24 are conformal to the rough outer surface of layer 18 .
FIGS. 4 and 5 illustrate scanning electron microscope (SEM) micrographs of platinum films produced by CVD of MeCpPt(Me) 3 . FIG. 4 illustrates a surface produced within a reaction chamber in a time of about 6 minutes, wherein a temperature in the chamber was about 215° C., a pressure was about 5 Torr, a flow rate of carrier gas (He, with a pressure at the carrier gas bubbler of about 6 Torr) was about 5 sccm, and a flow rate of oxidizing gas (O 2 ) was about 50 sccm. The platinum surface formed comprises pedestals characteristic of columnar growth. The columnar pedestals terminate in dome-shaped (substantially hemispherical) tops. It can be advantageous to have substantially hemispherical tops, rather than tops having sharp edges, in forming capacitor constructions or other electronic circuitry from a deposited platinum layer. Specifically, the relatively rounded hemispherical surfaces can create relatively uniform electric fields at the surface of a deposited platinum layer. In contrast, if sharp edges were present, the sharp edges could form loci for high electric fields, and lead to leakage of electric current across the capacitor. The platinum layer illustrated in FIG. 4 can be referred to as “hemispherical grain” platinum to indicate a structure largely analogous to a material known in the art as hemispherical grain polysilicon.
The platinum layer of FIG. 4 is characterized by columnar pedestals generally having heights greater than or equal to about one-third of a total thickness of the platinum layer. Many of the pedestals shown in FIG. 4 have a height approximately equal to a thickness of the deposited platinum layer. Accordingly, if the deposited platinum layer has a thickness of about 600 Å, the individual pedestals can have a thickness approaching 600 Å. Such is only an approximation to the size of the pedestals as it is found that some of the pedestals will grow from surfaces of other pedestals, and some of the pedestals will grow less vertically than other pedestals. An average diameter of the pedestals is about 200 Å, and the pedestals are generally closely packed (i.e., the pedestals generally touch other pedestals and many pedestals fuse with other pedestals), but the distribution of the pedestals is typically not a close-packed structure (i.e., a structure wherein all the pedestals are tightly packed in, for example, an hexagonal type arrangement to form a maximum number of pedestals on a given surface). The columnar growth illustrated in FIG. 4 is found not to occur if a temperature within a CVD reaction chamber is above 300° C.
FIG. 5 illustrates a surface produced on a platinum film within a reaction chamber in a time of about 150 seconds, wherein a temperature in the chamber was 300° C., a pressure was about 0.5 Torr, a flow rate of carrier gas (He, with a pressure at the carrier gas bubbler of about 6 Torr) was about 30 sccm, and a flow rate of oxidizing gas (O 2 ) was about 10 sccm. The platinum layer deposited under the FIG. 5 conditions has a much smoother surface than that deposited under the FIG. 4 conditions. FIGS. 4 and 5 together evidence that it is possible to control a grain structure of a surface of a chemical vapor deposited platinum layer by controlling process parameters of a chemical vapor deposition reaction chamber.
Although the invention has been described with application to formation of a capacitor structure, it is to be understood that the invention can be utilized in a number of other applications as well. For instance, a platinum layer having a roughened surface can be utilized for formation of catalysts.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | In one aspect, the invention includes a method of forming a roughened layer of platinum, comprising: a) providing a substrate within a reaction chamber; b) flowing an oxidizing gas into the reaction chamber; c) flowing a platinum precursor into the reaction chamber and depositing platinum from the platinum precursor over the substrate in the presence of the oxidizing gas; and d) maintaining a temperature within the reaction chamber at from about 0° C. to less than 300° C. during the depositing. In another aspect, the invention includes a platinum-containing material, comprising: a) a substrate; and b) a roughened platinum layer over the substrate, the roughened platinum layer having a continuous surface characterized by columnar pedestals having heights greater than or equal to about one-third of a total thickness of the platinum layer. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a process for monitoring and for controlling a nitrating process, in particular for the nitration of toluene, with the aid of a computer-assisted, matrix-specific calibration model and a process model.
[0002] Various nitration processes are known in the prior art. For example, toluene is nitrated with nitric acid to yield nitrotoluidines by way of intermediate dye products. It is also known to nitrate toluene with mixed acids to yield nitrotoluene and dinitrotoluene. Dinitrotoluene is, for example, processed further to yield diamines, diisocyanates, trinitrotoluene or phloroglucinol.
[0003] For economic reasons, the aim in the course of nitration is to conduct the nitration with as small an excess of acid as possible. To this end, it is known from the state of the art to take samples from the process manually and to examine them analytically in the laboratory. The process is then readjusted manually when required.
[0004] One disadvantage of such manual sampling and adjustment is the high cost of labor for the sampling and for the laboratory analysis. Another disadvantage is that the effort increases linearly with the number of measuring-points. Furthermore, manual sampling is problematic from the point of view of industrial safety, since, particularly in the case of 2-nitrotoluene, it is a question of working with a substance that is detrimental to health. Therefore in the course of handling 2-nitrotoluene, the wearing of respiratory protection at all times as a precaution is prescribed.
[0005] Another disadvantage of manual sampling with subsequent laboratory analysis is the fact that readjustment of the process can only be effected irregularly and after relatively long time-intervals. This may result in use of a relatively large excess of acid; the plant cannot then be operated in optimal manner, either technically or economically.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is therefore to create an improved process for monitoring and controlling nitrating processes that enables a diminution of the excess of acid. Further objects underlying the invention are to create an online method of measurement with a computer-assisted process model and to create an appropriate production process for the nitration.
[0007] The objects of the present invention are achieved by online spectrometric measurement of the acid phase from the reaction mixture and transmission of that data to a process control system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a flow chart for the process of the present invention for improved monitoring and control of nitrating processes by virtue of the online measurement of the acid phase and the improved metering of nitric acid.
[0009] [0009]FIG. 2 is a block diagram of a two-stage nitration process according to the invention.
[0010] [0010]FIG. 3 shows various NIR spectra for various concentrations of nitric acid.
[0011] [0011]FIG. 4 is a flow chart for the process of creating the matrix-specific calibration model, the validation and enhancement thereof.
[0012] [0012]FIG. 5 is a schematic representation of a bypass with a measuring cell.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In accordance with the present invention, the acid phase recovered from the nitration reaction mixture is spectrometrically examined online. This is preferably done by infrared spectrometry. Such measurements are also designated as infrared spectroscopy. Appropriate IR spectrometers, in particular for the near-infrared range (NIR) are commercially available, for example from Polytec GmbH and other manufacturers.
[0014] In a preferred embodiment of the invention, the content of nitric acid in the acid phase is determined online after nitration by means of an NIR spectrometer and a suitable computer-assisted calibration model. Data for quantifying the content of nitric acid are then transmitted from the NIR spectrometer to the process control system, for example via a field bus. On the basis of the nitric-acid content in the acid phase that is determined after nitration, regulation by the process control system for the supply of nitric acid is possible. The online control of a production plant for the purpose of regulating various polymerization parameters is disclosed in U.S. Pat. No. 5,121,337 and EP-0 948 761 B1 [sic]. In these disclosed processes, a predictive model created on the basis of measured spectra is used.
[0015] In a particularly preferred embodiment of the invention, the measured NIR spectrum is evaluated with the aid of a matrix-specific calibration model. The physical matrix is predetermined by the nitrating process and is dependent on the parameters of the process. With the aid of chemometric methods, the measured spectra are referenced against results obtained from laboratory examinations.
[0016] This is effected in such a way that the same sample for which an NIR spectrum was determined online is also analyzed in the laboratory with the aid of titration measurements. By virtue of the examination and the comparison of a suitable number of varying samples, it is possible to create a matrix-specific calibration model with the aid of chemometry. This matrix-specific calibration model is stored on a computer that is programmed to control the recording of the spectrum and to evaluate the measured spectrum online with the aid of the calibration model, so that the nitric acid content is available to the process control system online.
[0017] The nitration of toluene to yield dinitrotoluene (DNT) is generally conducted in two stages. The spectrometric examination of the acid phase is undertaken at least after the second nitrating stage, in order to readjust the supply of nitric acid to the first and/or the second nitrating stage.
[0018] In another preferred embodiment of the invention, the NIR spectrometer is connected to several measuring-points. The NIR spectrometer is multiplexed, in order to carry out spectrometric measurements in succession at the various measuring-points. By reason of this multiplex operation of the NIR spectrometer, the measurement effort increases degressively with the number of measuring-points.
[0019] The invention is particularly advantageous because it enables distinctly improved process control. In particular, the invention enables the production plant to be operated continuously, close to the technical and economic optimum. Another advantage is the improvement in industrial safety.
[0020] Preferred embodiments of the invention will be elucidated in greater detail below with reference to the drawings.
[0021] [0021]FIG. 1 is a flow chart for a process according to the invention for monitoring and controlling nitrating processes. In step 100 , nitric acid (HNO 3 ) is supplied continuously to a nitrating stage. The product of the nitrating stage is a two-phase system composed of nitrated organic phase and acid phase. An NIR spectrum of the acid phase is recorded by means of a suitable measuring cell and an NIR spectrometer. This is undertaken in step 102 . In step 104 , the HNO 3 content in the acid phase is determined by evaluation of the NIR spectrum by means of a matrix-specific calibration model. This measurement is preferably undertaken inline or online, i.e. in the current product stream.
[0022] In step 106 , the HNO 3 content that has been ascertained is transmitted to a process control system. In step 108 , the quantity of continuously supplied HNO 3 is readjusted manually or by the process control system, in order to reduce the HNO 3 content in the acid phase if necessary.
[0023] [0023]FIG. 2 is a block diagram of an embodiment of an appropriate plant. The plant has a reactor 200 for the purpose of realizing a first nitrating stage (mononitration MNT). The feed materials are toluene 201 , sulfuric acid 202 and nitric acid 203 . The product of the first nitrating stage is a two-phase system which is separated, in the separator 208 connected downstream, into the organic phase 211 and the acid phase 209 .
[0024] A measuring-point 205 for recording an NIR spectrum of the acid phase may be provided downstream of the reactor 200 . To this end, an NIR spectrometer 220 may be connected to the measuring-point 205 via an optical waveguide 206 .
[0025] The separator 208 is followed by a further reactor 210 for the purpose of realizing the second nitrating stage (dinitration DNT). The feed materials are MNT 211 , sulfuric acid 212 and nitric acid 213 . The product of the second nitrating stage is a two-phase system which is separated, in the separator 218 connected downstream, into the organic phase 230 and the acid phase 219 .
[0026] A measuring-point 215 is preferably arranged downstream of the output of the reactor 210 . The NIR spectrometer 220 is connected to the measuring-point 215 via an optical waveguide 216 . As a result, NIR spectra for the acid phase can be recorded.
[0027] The measuring-points 205 and 215 may each be operated with their own spectrometer; however, they are preferably operated with a single spectrometer 220 which switches between the measuring-points 205 and 215 .
[0028] The NIR spectrometer 220 passes on the measured NR spectra for evaluation by means of the matrix-specific computer-assisted calibration model 222 . The computer with the matrix-specific calibration model 222 passes on its results for the content of nitric acid to the process control system 224 . The subsequent regulation (manual or automated) of the metering 207 or 217 of the first 200 and/or the second 210 nitrating stage, respectively, permits improved monitoring of the process and improved process control for the content of HNO 3 in the acid phase within the range 0-5%, in particular close to 0%, preferably within the range from 0% to 0.3%.
[0029] In a preferred embodiment of the invention, the HNO 3 content is determined only at measuring-point 215 and not at measuring-point 205 . The measurement of the HNO 3 content at measuring-point 215 after the second nitrating stage is generally sufficient for regulation of the production of dinitrotoluene.
[0030] In the case where production of dinitrotoluene is undertaken in multiple lines, several parallel measuring-points 215 may be provided. All the measuring-points 215 are then preferably connected to the same NIR spectrometer 220 , which operates in multiplex mode. The NIR spectrometer 220 accordingly measures the spectra at the measuring-points 215 in succession, in cyclic sequence. By virtue of the multiplexing of the NIR spectrometer 220 , it is possible for the instrumentation effort for implementation of the HNO 3 measurements to be optimized.
[0031] [0031]FIG. 3 shows the spectra 300 , 302 and 304 . Spectrum 300 has been recorded for 75% sulfuric acid without nitric-acid content. Spectrum 302 has been recorded for 75% sulfuric acid with 1% nitric-acid content. Spectrum 304 has been recorded for 75% sulfuric acid with 5% nitric-acid content.
[0032] The measured NIR spectra 300 , 302 and 304 accordingly differ distinctly, depending on the percentage content of nitric acid in the acid phase. In corresponding manner it is possible for the nitric-acid content in the acid phase to be determined by measurement of the NIR spectrum. To this end, a matrix-specific calibration model based on comparative titration measurements is preferably used.
[0033] [0033]FIG. 4 illustrates the procedure for obtaining a database for the generation of a matrix-specific calibration model. Step 400 illustrates the creation of such a calibration model; step 420 illustrates the validation of this model.
[0034] Step 402 represents the physical matrix, which is process-specific and dependent on the process parameters with regard to its special composition.
[0035] The nitric-acid content, which is ascertained by means of manual sampling 406 with subsequent titration 408 , is used for creation of the calibration model. Sampling and titration may also be undertaken in automated manner and online, or manually and offline. In parallel, a measuring cell, with which the NIR spectra pertaining to the samples can be recorded, is installed in the process flow. This is undertaken in step 404 .
[0036] In step 410 , the results from the titration determinations are compared and are correlated with the respective NIR spectra with the aid of chemometric methods.
[0037] In step 412 , all of the comparisons between all of the NIR spectra and all of the titration results are combined and are correlated in a model. The parameters of the model are adapted and adjusted in such a way that the content of nitric acid for the existing substance system and the existing process parameters are reproduced optimally. Once the model has been adapted and optimized, the matrix-specific calibration model is available at the end of step 412 .
[0038] Subsequently, in step 420 , validation of the model is undertaken in respect of the current process. Whenever titration results are available in a manner temporally appropriate to the spectra arising from the process, said results can be integrated in accordance with step 400 for the purpose of successive enhancement of the model (step 422 ).
[0039] [0039]FIG. 5 shows an embodiment of the invention with a measuring-point (for example, measuring-point 215 of FIG. 2). The product stream of the current production flows through the line 500 . A bypass 502 is located on the line 500 . The bypass 502 has a measuring cell 504 . Located upstream and downstream of the measuring cell 504 in the direction of flow is a shut-off device 506 and 508 , respectively. The shut-off devices enable access to the measuring cell while the product stream is running.
[0040] List of Reference Symbols
[0041] reactor 200
[0042] toluene 201
[0043] sulfuric acid 202
[0044] nitric acid 203
[0045] measuring-point 205
[0046] optical waveguide 206
[0047] regulation of metering 207
[0048] separator 208
[0049] acid phase 209
[0050] reactor 210
[0051] mononitrotoluene (MNT) 211
[0052] sulfuric acid 212
[0053] nitric acid 213
[0054] measuring-point 215
[0055] optical waveguide 216
[0056] regulation of metering 217
[0057] separator 218
[0058] acid phase 219
[0059] NIR spectrometer 220
[0060] calibration model 222
[0061] process control system 224
[0062] organic phase 230
[0063] spectrum 300
[0064] spectrum 302
[0065] spectrum 304
[0066] line 500
[0067] bypass 502
[0068] measuring cell 504
[0069] shut-off device 506
[0070] shut-off device 508
[0071] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | A process for monitoring and/or controlling a nitrating process, having the following steps:
measuring inline infrared spectra of nitric acid content in a reaction mixture stream downstream of the nitration reaction, preferably near-infrared spectra,
evaluating the measured spectra by means of a computer-assisted, matrix-specific calibration model for the purpose of determining the content of nitric acid,
transmitting the results of spectrometric examination to a process control system,
inputting the results of spectrometric examination for the purpose of specifying the content of nitric acid in the acid phase into a regulator ( 224 ) for control of the metering ( 207, 217 ) of nitric acid into a nitrating reactor. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to photographic systems and more particularly, it concerns apparatus for accommodating modified format sizes of photographic sheet film in existing camera systems.
In the camera system marketed by Polaroid Corporation under the trademarks "Polaroid SX-70 Land Camera" and "Polaroid SX-70 Land Film", camera structure and operation are integrated with a container or pack of film in the sense that electric power for camera operation is supplied by a battery packaged with each film pack, a main power switch is closed upon full insertion of the film pack to connect the battery with camera carried electric circuitry, and the film container defines the location of each film unit during exposure relative to the focal plane of the camera. Each film unit in the system carries a supply of processing fluid in an amount calibrated to cover the image format area thereof after exposure and as a result of passage of the film unit between a motor driven processing roller pair supported in the camera. In particular, the processing fluid is spread across the interface between a pair of plastic sheets in each unit, at least one of which plastic sheets is transparent for exposure of a light sensitive layer carried between the sheets and so that the resulting positive photographic image may be viewed.
Because of the construction of each film unit, its exterior appearance is that of a framed photograph in which four marginal edges are defined by paper or other similar material folded about these edges to secure the two plastic sheets in overlying coextensive relationship. The bottom marginal edge of the framed photograph is wide relative to the marginal side and top edges principally because it encloses the pod or supply of processing fluid carried by each film unit. Also, because of the construction of the units, the top wall of the container in which the film sheets are contained is provided with marginal lips dimensioned to substantially cover the framing margins of the photographic film unit including the bottom marginal edge in which the processing fluid pod is located.
In the operation of the system, the uppermost film unit in the container is exposed and then engaged at its rear edge (the top edge of the photograph) by a linearly driven pick and advanced through a slot in the front wall of the container for a distance calibrated to place the leading edge of the exposed film unit (the bottom edge of the photograph) within the nip of the processing roller pair. The rollers then feed the exposed unit forwardly to first rupture the processing fluid pod, spread the processing fluid across the interface between the plastic sheets and finally discharge the exposed and processed unit from the camera.
The outside dimensions of each unit of the presently available "Polaroid SX-70 Land Film" are approximately 89×108 mm to provide a substantially square image area approximately 79 mm on the side. The width of the framing margin at the bottom of the photograph is approximately 19 mm whereas the framing margins at the side and top edges of the photograph are approximately 5 mm. While the dimensions of the photograph are well suited for storage in albums or the like, versatility of such systems would be enhanced significantly by a capacity for exposing and processing smaller format photographs, particularly positive transparencies on the order of a 35 mm format for use in a projector designed to handle 2" by 2" slides.
Because of system design, the adaptation of such small format photographs, due to reduced size alone, gives rise to such problems as positioning smaller format film units properly within the existing film well of the camera and accommodation of the smaller format film units by camera carried components such as the camera viewing system, the pick by which each film unit is advanced from the film pack container, the positioning of processing rollers carried by the camera and the like.
Additional problems are associated with adapting the existing system to the formation of positive transparencies. As above-mentioned, the light sensitive materials in which the photographic image is formed in the existing system are carried between two plastic sheets of each film unit. In the standard film unit, the top one of the two plastic sheets is transparent for exposure of the light sensitive layer and for viewing but the back sheet of the standard film unit is opaque. The photochemical materials contained in each standard film unit includes an opacifying agent to protect light sensitve chamicals from ambient light during an imbibition period of several minutes in order to allow complete processing of photographic materials contained in the film unit after the unit is ejected from the camera. Where both plastic sheets of the unit are transparent, as would be required to provide a positive transparency, it is not possible, given the current state of the art, to duplicate the opacifying agent function with chemicals. thus, some provision must be made for protecting the exposed film unit for the imbibition time after it is ejected from the camera.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, small format film units are adapted for exposure and processing in a camera designed to handle larger, standard format film units by releasably mounting each small format unit on a carrier having outside peripheral dimensions corresponding to those of the standard format film units. The individual assemblies of mounted film units and carriers are stacked in a standard film pack container and thus insertable directly into the existing camera of the system. As each assembly is presented at the focal place of the camera, the film unit is exposed and the carrier advanced to the processing rollers of the camera. Passage of the assembled unit and carrier through the processing rollers will spread the processing fluid of the unit in conventional fashion and discharge the carrier and unit from the camera. The unit is then separated from the carrier and the carrier discarded.
To enable processing of the small format film units as positive transparencies, the carrier is constructed to provide a dark chamber into which the film unit moves after exposure so that when the assembly of the carrier and film unit is ejected by the camera into ambient light, the film unit will be enclosed in the dark chamber. The dark chamber is established by forming the carrier of two relatively movable parts; namely, a carrier slide and an envelope. The carrier slide and envelope are moved relative to one another upon initial translation of the assembly from the film pack container to the processing rolls. Specifically, this initial movement results first in a relative movement of the carrier slide and film unit mounted thereon into the dark chamber established by the envelope portion of the carrier.
Among the objects of the present invention are, therefore: the provision of a photographic system in which an existing camera designed for relatively large format film units is adapted for exposure of relatively small format film units; the provision of such a system which is capable of exposing and processing film units carrying a supply of processing fluid; the provision of such a system which requires a minimal modification of existing camera structure; the provision of such a system which facilitates processing of film units to provide positive transparencies; the provision of a unique film pack for use in such camera systems and by which film units of reduced format sizes are readily accommodated; the provision of a film unit assembly by which a film unit is protected from ambient light upon discharge of the assembly from the camera of such systems; and the provision of a unique viewfinder masking arrangement by which the viewfinder of an existing collapsible camera may be adapted to small format film units.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description to follow taken in conjunction with the accompanying drawings in which like parts are designated by like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-section depicting operating components of a foldable single lens reflex camera in which the present invention may be used;
FIG. 2 is an exploded perspective view illustrating a viewfinder mask in accordance with the present invention;
FIG. 3 is a modified embodiment of the viewfinder mask illustrated in FIG. 2;
FIG. 4 is a plan view of a film pack incorporating the present invention;
FIG. 5 and 6 are respectively plan views corresponding to FIG. 4 but showing components in different relative positions;
FIG. 7 is a perspective view illustrating a film unit and film unit mount used in the embodiment illustrated in FIGS. 4-6;
FIG. 8 is an enlarged fragmentary cross-section on line 8--8 of FIG. 5;
FIG. 9 is a plan view similar to FIG. 4 but illustrating an alternative embodiment of the present invention;
FIG. 10 is a plan view of the embodiment illustrated in FIG. 9 but with parts thereof in different physical relationship;
FIG. 11 is a plan view of a film unit and carrier assembly of the embodiment illustrated in FIGS. 9 and 10;
FIG. 12 is an exploded perspective view of the carrier assembly illustrated in FIG. 11; and
FIG. 13 is an enlarged fragmentary cross-section on line 13--13 of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 of the drawings, a foldable, single lens reflex camera 10 is shown to include a body 12 defining a film pack well 14, a shutter housing 16 supporting an objective lens 18, a foldable cover member 20 and a viewfinder 22. A reflex mirror 24 (only partially shown in FIG. 1) is pivotally supported by the body 12 for movement between a viewing position in which it overlies the well 14, and an exposure position in which it lies against the underside of the cover member 20. The camera 10, as thus constituted, is now well-known and available commercially under the trade designation "The Polaroid SX-70 Land Camera".
In addition to the components identified in the preceding paragraph, the camera includes as existing components, a processing roller pair 26 defining a pressure nip 28 and a linearly driven pick 30. In FIG. 1, the camera 10 is shown loaded with a conventional or standard film pack 32 defined by a container 34 which houses a plurality of overlying film units 36 biased upwardly by a leaf spring follower 38. As shown in FIG. 1 and also in FIGS. 4-6 of the drawings, the container 34 includes a bottom wall 40, side walls 42, a front wall 44, a rear wall 46 and an upper marginal wall 48 defining a rectangular opening or window 50 through which the uppermost of the film units 36 may be exposed. The front wall 44 of the container is provided at its upper end with a slot 52 through which the uppermost film unit 36 may be advanced forwardly to the pressure nip 28 of the processing roller pair 26. As is well-known, this operation ruptures a processing fluid pod 54 contained in each film unit and spreads the processing fluid uniformly over the image format area of each sheet assembly 36. Also, the left rear corner of the back wall 46 is cut away, as is the upper marginal wall 48 in this region so that the pick 30 may engage the rear edge of the uppermost film unit 32 to advance this unit through the slot 52 until the leading edge of the unit is engaged by the pressure nip 28. This cut out portion of the container 34 is designated by the reference numeral 55 in FIGS. 4-6 of the drawings.
The viewfinder 22 of the camera 10 is an articulated assembly of components designed to be self-erecting to an operative condition illustrated in FIG. 1 when the cover 20 and the shutter housing 16 are erected to the condition shown from a collapsed storage condition. To facilitate this operation, the viewfinder includes a plate-like cover 56 from which a skirt-like collapsible bellows 58 depends about the front and side portions of the cover. An eye piece 60 is pivotally supported from the rear edge of the cover 56 is movable from the position shown in FIG. 1 to a collapsed condition against the cover 56 under the control of a slotted lever pair 62. The eye piece 60 is aligned optically with a foldable concave mirror 64 pivoted from a front part 66 of the camera cover assembly for movement from the erected position shown downwardly under the cover 56 under the control of a slotted lug pair 68 fixed to the underside of the cover 56.
In the operation of the viewfinder 22, the optical path of light from a subject to be photographed proceeds from the lens 18 to a mirror 70 fixed to the underside of the cover member 20, downwardly to the top of the reflex mirror 24, upwardly to the mirror 70, to the concave mirror 64 and to the eye piece 60, all as represented by the dashed lines illustrated in FIG. 1. In the standard camera, the optical components are calibrated so that a real image of the viewed subject is formed in space at a point intermediate the eye piece or lens 60 and the concave mirror 64. The eye piece 60 is, therefore, a lens arranged to focus on that real image which is related, in terms of format area, to the opening 50 in the top wall of the film pack container 34. As an incident to correlating the optics of the viewfinder 22 to a film unit having a reduced image format area, viewfinder masking arrangements shown in FIGS. 2 and 3 of the drawings are provided. In the embodiment of FIG. 2, a removable viewfinder mask 72 is shown to include a thin sheet of metal or other similar form sustaining opaque material to define a generally trapezoidal mounting portion 74 from which a mask portion 76 extends. A window 78, corresponding in size to a reduced image format and taking into account the optical parameters of the viewfinder 22, is provided in the mask portion 76.
The trapezoidal configuration of the mounting portion 74 complements the shape of a viewfinder recess 80 provided in the cover member 20 of the existing camera 10. A mount 82 for the mask 72 is secured by pressure-sensitive adhesive, for example, to the upper edge of the cover. The mount 82 has a pair of projecting lugs 84 positioned so as not to interfere in any way with collapsibility of the viewfinder 22 and the camera 10. The lugs are further positioned to extend through slots 86 in the trapezoidal body portion 74. The mask 72 is removably secured in place by a detent spring 88 engaging the lugs 84.
An alternative embodiment of the viewfinder mask is shown in FIG. 3 and designated by the reference numeral 90. In this instance, the mask is a simple sheet of opaque material provided with an area of pressure-sensitive adhesive 92 to facilitate its being removably secured against the base of the viewfinder recess 80. By use of appropriate indicia (not shown) the mask may be positioned properly in the path of the viewfinder as shown in FIG. 1 of the drawings and left remaining in place even though the camera 10 and the viewfinder 22 is collapsed to a storage condition.
In both the embodiments of FIGS. 2 and 3, the mask window is located approximately at the point between the eye piece 60 and the mirror 64 where the real image of the viewed subject is formed. Because of this, the eye piece 60 will focus on the mask window 78 and thus facilitate a correlation of the window dimensions with those of reduced format area.
In FIGS. 4-8 of the drawings, one embodiment of a small format film pack for use in the standard camera 10 is illustrated. In FIGS. 7 and 8, a small format film unit, designated generally by the reference numeral 94 is shown to be of a construction similar to the standard film unit. As such, the unit 94 includes a pair of plastic sheets 96 retained in a superimposed relationship by a marginal frame 98 of paper or other suitable material secured about the edges of the sheets 96 by appropriate adhesives or the like. A processing fluid pod 100 is located in the lower framing margin, in the context of the photograph to be produced, or in the leading margin of the unit 94 in the context of orientation of the film unit in the camera 10 and passage through the processing rollers 26. The film unit 94 is intended to provide, when exposed and processed, a photographic positive transparency in which an image is provided over the area of the exposed plastic sheets 96. The size of the marginal framing 98 may vary slightly but preferably is selected to correspond with the dimensions of a 2" by 2" slide transparency. Consistent with such slides, the image format area established by the exposed plastic sheets 96 could in practice approximate a 35 mm film format.
The small format film pack shown in FIGS. 4-8 of the drawings includes the standard container 34 together with such other components as the spring follower 38 and the storage battery (not shown) as are conventionally provided in the standard film pack. In accordance with the present invention however, the film units 36 of the standard film pack are replaced by sheet-like assemblies of the small format film units 94 and a carrier 102, such assemblies being stacked in the container 34 over the spring follower 38 (See FIG. 1). The construction of the carrier 102, as well as the assembly therewith of the film unit 94 is shown most clearly in FIGS. 4 and 6-8 of the drawings. Each carrier 102 includes as separate parts an envelope 104, having a rectangular peripheral configuration to fit within the container 34 in the same manner as the standard film unit 36, and a carrier slide 106.
The carrier slide 106 is preferably formed of thin synthetic resinous material or resin impregnated paper which is resilient and capable of yieldably retaining a folded conformation. As shown in FIG. 7, the carrier slide 106 is shaped to establish a base panel 108 formed at its leading edge 110 with a rearwardly folded panel 112 of a size adapted to overlie the marginal edge of the base panel 108 and at opposite edges thereof, a pair of forwardly struck tabs 114 are formed. A rearwardly struck tab 116 extends between the tabs 114. Also a rear tab 118 is formed on the trailing or rear edge of the base panel 108. The base panel 108 is of a size to complement the exterior dimensions of the film unit 94 and such that when the unit 94 is placed on the base panel 108, it will be retained with the carrier slide as a result of the panel 112 and the rear tab 118.
The envelope 104 is formed of opaque material such as black paper and as shown most clearly in FIGS. 6 and 8, includes a full back panel 120 closed on the side and rear edges with a front panel 122. The edges of the panels 120 and 122 at the leading edge 124 of the carrier 102 are opened and spaced by a filler 126 which may be of cardboard or similar material. As may be seen in FIGS. 5 and 6, the front panel 122 of the envelope 104 is provided with a trapezoidal cutout 128 extending from the leading edge 124 to a linear transverse edge 130. The edge 130 is positioned so that the distance from it to the rear edge 132 of the envelope 104 exceeds the combined fore and aft dimension of the marginal edge 98 of the unit 94 opposite the processing fluid pod 100 and the fore and aft dimension of the image format area defined by the exposed plastic sheets 96.
The film units 94 are each assembled with a carrier 102 by first placing the film units into the carrier slide 106 and then inserting the unit 94 and the slide 106 as a sub-assembly into the envelope 104. The assembly of the unit 94 and the carrier 102 are then conventionally stacked in the container 34 to be positioned initially as shown in FIG. 4 of the drawings. In this initial position, it will be noted that the complete image format area of the film unit 94 is presented through the opening 50 in the container 34. After the uppermost film unit 94 in the container 34 has been exposed in the camera 10, the camera pick 30 will move forward to engage the rear left-hand corner of the carrier 102 so that it and the film unit 94 assembled therewith will be advanced forwardly through the slot opening 52 in the front wall 44 of the container (FIGS. 5 and 8). Because of the forwardly struck tabs 114 on the carrier slide 106, however, continued forward movement of the slide 106, and thus also of the film unit 94, will be prevented by engagement of the tabs 114 with the forward marginal edge of the opening 50 in the container 34. Since at this time, the leading edge 124 will have passed between the processing roller pair 26 in the camera, the envelope 104 will be advanced and the film unit 94 with the carrier slide 106 retained. When the linear edge 130 of the cutout 128 in the front panel 122 in the envelope engages the rearwardly struck tab 116, continued forward movement of the carrier by the processing roller pair 26 will cause the tabs 114 to deflect rearwardly and pass the assembly of the carrier 102 and the film unit 94 forwardly to rupture the pod 100 and spread the processing fluid contained therein uniformly throughout the interface between the plastic sheets 96 of the small format film unit. As the assembly of the carrier 104 and the film unit 94 is discharged from the camera into ambient light, the photochemical materials between the plastic sheets 96 will be protected from light by the chamber established between the front and rear panels of the envelope 104 rearwardly of the linear edge 130. After a suitable imbibition time has passed to a point where the photochemical materials contained in the film unit 94 are no longer light-sensitive, the slide 106 and the unit 94 may be removed from the envelope 104 and the envelope and the carrier slide 106 discarded.
An alternative embodiment of the film unit and carrier assembly of the present invention is illustrated in FIGS. 9-13 of the drawings. In this instance and as shown most clearly in FIGS. 12 and 13 of the drawings, the small format film unit 94 is supported by a carrier slide 134 of cardboard or other suitable material having a thickness approximating the combined thickness of the plastic sheets 96. The carrier slide 134 is provided with a generally centrally located rectangular opening in which the film unit 94 is releasably secured such as by pressure-sensitive tape 136 or other similar type material. The slide 134 is of partial rectangular configuration to establish side edges 138 and a rear edge 140 complementing the interior dimensions of the container 34. The front portion of the slide 134 is formed as a forwardly projecting tongue 142 of a transverse dimension less than the distance between the edges 138 to establish a pair of forwardly facing abutment shoulders 144. The sub-assembly of the unit 94 and the carrier slide 134 are received in an envelope 146 having front and back panels 148 and 150 respectively. The panels 148 and 150 are joined at their side edges and at portions 152 of the front edge on opposite sides of an opening 154. The opening 154 is centrally disposed in the leading edge of the envelope and is of a length slightly in excess of the width of the tongue 142.
As in the previous embodiment, the front wall 148 is provided with a generally trapezoidal cutout 156 but in this instance terminates forwardly in a linear transverse edge 158. The back panel 150 extends to a rear edge 160 provided with tapered corner portions 162. The sub-assembly of the carrier slide 134 and the film unit 94 is assembled with the envelope 146 in a manner such that the rear edge 140 of the carrier slide 134 overlies the rear edge 160 of the envelope 146. In this condition, the tongue 142 will be contained in the envelope 146 and the film unit 94 presented through the trapezoidal opening 156 as shown in FIG. 9 of the drawings. After the film unit is exposed, the pick 30 will engage the left side of the rear edge 140 of the slide carrier to advance the tongue 142 through the opening 54 until the tongue is received in the nip 28 of the processing roller pair 26. Because of the tapered corner portions 162, the pick 30 will not engage or move in any way the envelope 146. The processing roller pair will continue to advance the carrier slide 134 until the shoulders 144 engage the closure portions 152 on the envelope. Thereafter, the complete assembly will be withdrawn from the container 34 and pass through the processing roller pair 26.
It will be noted that the distance between the front edge of the envelope 146 and the linear transverse edge 158 of the trapezoidal opening 156 is adequate so that the image format area of the film unit 94 will be enclosed between the front and rear panels 148 and 150 of the envelope 146 when the shoulders 144 engage the closed portions 152 of the front edge of the envelope. Accordingly, unit 94 will be concealed from ambient light upon discharge of the assembly from the camera. After a suitable imbibition time has passed, the assembly of the carrier slide 134 and the film unit 94 may be withdrawn from the envelope. Because of the manner in which the unit 94 is mounted in the aperture of the carrier slide 134, the carrier slide may serve as a convenient holder by which the image formed as a positive transparency on the unit 94 may be viewed. Alternatively, the slide may be removed from the holder 134 as desired.
Thus, it will be seen that as a result of the present invention, an improved small format film pack is provided by which the above-mentioned objectives are completely fulfilled. It is contemplated that modifications and/or changes may be made in the embodiments of the invention as disclosed herein without departure from the inventive concepts manifested by such embodiments. Accordingly, it is expressly intended that the foregoing description is illustrative of preferred embodiments only, not limiting, and that the true spirit and scope of the present invention be determined by reference to the appended claims. | A film pack by which an existing camera system is adapted to expose and process small format film units. The film pack includes a plurality of film unit and carrier assemblies stacked in a standard film pack container designed to fit the film well of the existing camera. The carrier of each assembly is dimensioned to fit the interior of the container and to support the film unit mounted thereon properly in relation to the optical system of the camera. Each carrier is preferably formed as a two-part assembly to include a film unit carrier slidably supported by an envelope. The carrier and the envelope cooperate with the camera carried processing components in a manner to enclose the film unit in a dark chamber as it is discharged from the camera. Also, a viewfinder mask is provided for the existing camera so that a viewed image will be correlated with the reduced image format of the film unit in the film pack. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Claiming Benefit Under 35 U.S.C. 120
This application is related to U.S. patent application Ser. Nos. 09/714,726 and 09/801,604 (to be amended when Serial Numbers are assigned), filed on Nov. 16, 2000 and Mar. 8, 2001, respectively by Leland James Wiesehuegel, et al.
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT STATEMENT
This invention was not developed in conjunction with any Federally sponsored contract.
MICROFICHE APPENDIX
Not applicable.
INCORPORATION BY REFERENCE
This application incorporated by reference U.S. patent application Ser. Nos. 09/714,726 and 09/801,604 (to be amended when Serial Numbers are assigned), filed on Nov. 16, 2000 and Mar. 8, 2001, respectively by Leland James Wiesehuegel, et al., in their entirety, including figures.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to electronic commerce, to conducting a business-to-business interactive offer and bid collection over a computer network, and more specifically to technologies for automatically placing bids in an online offer or auction.
2. Description of the Related Art
Prior to the advent of electronic auctioning over computer networks or electronic commerce, auctions were held in a group of gathered bidders with an auctioneer. As shown in FIG. 1 , an auction ( 1 ) is conducted on behalf of a seller ( 2 ) by an auctioneer ( 4 ). The auctioneer receives a list of items to be sold and possibly a minimum and/or reserve price for those items. During the auction, a plurality of bidders ( 6 ) place bids ( 5 ) under the guidance and control of the auctioneer ( 4 ). In some cases, multiple bidders ( 9 ) may pool ( 8 ) their bids, and the pooled bids ( 7 ) are submitted as a single bid with a combined quantity to the auctioneer ( 4 ).
The auctioneer enforces the rules of the auction, such as minimum bid price and quantities, minimum bid incrementing from the previous bid for a new bid, and time limits for placing bids. Auction bidders are typically qualified as to their ability to complete the purchase should their bid be the winning bid prior to entering the auction room.
Many online auctioning systems such as “priceline.com” have become very popular for individuals and businesses to use to take advantage of auctions at which they cannot be physically present. Such e-commerce auctions or online auctions are usually conducted over a specified period of time of opening and closing for bids, and are typically conducted under one of several well-known sets of rules or models. These common models include “Dutch” auctions, progressive auctions, “Yankee” auctions, single-bid auction, sealed bid auctions, reserve auctions, and hybrids of these types of auctions.
However, most sales offering and bid systems conducted by manufacturers of goods or service providers are conducted under a different set of procedures and processes. Turning to FIG. 2 , a typical trader and broker system for offering and accepting bids is shown ( 20 ). In such a business-to-business (“B2B”) offering and bidding process ( 20 ), a manufacturer or service provider ( 21 ) will notify one or more traders ( 24 ) of available products or services, quantities, and minimum acceptable bid values ( 22 ). The trader then provides offerings ( 23 ′) to one or more brokers ( 25 ), to which the brokers may respond with bids ( 23 ).
In some cases, bids may be accepted for either partial lots or whole lots of offered products. These offerings ( 23 ) and the corresponding bids ( 23 ) are collected by the trader, and the trader ( 24 ) makes a decision of which bids to accept. The traders ( 24 ) subsequently respond to the manufacturer or service provider ( 21 ) with actual orders or purchases ( 22 ).
Although the B2B offering and bid acceptance process may be conducted similarly to an auction, it is not an auction in the strict sense in that the order fulfillment, or bid acceptance, process is conducted usually by the trader at his discretion. For example, under a typical auction process, the highest qualified bidder may be defined as the bid winner. However, in a B2B offering and bid collection system, the trader may favor the second or third highest bid over the highest bid for the fact that the broker placing the second or third highest bid has preferred business arrangements, such as a longer history of purchasing from the trader or a history of larger volume purchases with the trader.
Brokers typically buy on speculation, and sell to end users. Brokers may sell to multiple retailers of products or services, or they may represent a single large retailer of a product or service.
Traders are typically commissioned sales professionals, and the structure of their commissions may vary depending on the quantities and the commodities or category of products being sold.
A particular broker may receive offers from multiple traders who represent a particular manufacturer or service provider. For example, a broker that represents a chain of computer stores may receive computer memory offers from a first trader, software upgrade offers from a second trader, and peripheral offers from yet a third trader, all of whom represent the same manufacturer. In response, this broker may bid or place “offers” for products or services in different categories, and must submit those bids to different traders based on the traders' commodities or categories of products that each trader handles.
The related patent application disclosed an on-line B2B offer system which is suitable for presenting information to bidders and brokers for products and services on which they are entitled to bid. The online offer system of the related applications allow brokers to act as “bidders”, and traders to act as “auctioneers” or “offerors”, to draw an analogy to online auctioning systems, while simultaneously meeting the specific needs of B2B commerce transactions.
“Proxies” are a bidding option for participants in auctions and offers. For example, in a “real” auction, a participant may send an agent to the auction to place bids on his or her behalf. The participant may instruct the agent to counter bid all bids up to a maximum, but if the proxy maximum is reached, not to counter bid above the maximum. During the actual auction, the agent may submit bids to beat the highest current bid until his proxy limit is reached, at which time the agent would not bid further.
The related applications disclosed an online, business-to-business offering system which also provided a proxy agent function that allowed a participant to specify a maximum proxy value for the system to automatically execute on behalf of the participant. In this case, the software agent polls the current status of the bid level in a particular offer or auction, and immediately places a bid higher than the highest competitive bid until the proxy maximum has been reached.
While this is efficacious in many respects, especially by allowing the participant to automatically “top” the current bid while not being personally involved in the bid placing, it has some potential shortcomings. The most notable of which is the possibility that two (or more) automatic proxy agents may bid against each other, submitting increasing bids as quickly as possible given the computing and communications resources allow. Thus, the bidding would rapidly escalate until all but one of the proxy agent's maximum limit has been reached.
This is analogous to a very wealthy participant sending a agent to an auction with a very high proxy limit, and when the bidding opens, the agent quickly escalates the bidding to his maximum limit. This experience may be seen negatively by the other participants of the auction, taking much of excitement and sense of adventure out of the process for the losers. This can lead to dissatisfaction and disillusionment in the process itself, and these unsatisfied participant's may choose not to be involved in future auctions.
A “real” or live proxy agent usually understands this problem, and will conduct himself in a less conspicuous manner. For example, he may wait to sense the “pace” of the bidding, only placing higher bids after some delay has occurred from the last placed bid. Or, he may wait until a time near the closing of the auction to place a higher bid, allowing other participants to bid against each other during the interim. However, to date, this problem has not been addressed by online auction and offering systems.
Therefore, there is a need in the art for a system and method which allows a participant in an online auction or offering process to create a proxy agent with instructions for the pace, timing, and limits of automatic proxy bidding.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description when taken in conjunction with the figures presented herein provide a complete disclosure of the invention.
FIG. 1 discloses the well-known arrangement of sellers, auctioneers, and bidders.
FIG. 2 shows the common business arrangement between manufacturers, service providers, traders, and brokers.
FIG. 3 shows and exemplary user interface dialog for configuring a bid parameter set for a proxy agent managed bid.
FIG. 4 illustrates the logical flow of the process of the proxy agent.
FIG. 5 shows a generalized system architecture of the invention.
FIG. 6 sets forth the preferred embodiment of the system of the invention.
SUMMARY OF THE INVENTION
In an on-line auction or offering system, such as an online Dutch, Yankee, or Traditional (interactive) type of auction, delay-paced automatic proxy bidding is provided to a user according to a user-supplied counter bid delay value by automatically checking by an application server a current bid level of the online auction having a plurality of bids from other participants separated in time to form a bidding pace, determining by an application server that any a proxy condition has been met, and placing by an application server computer a counter bid the auction responsive to the proxy conditions being met and a time following or upon the elapse of a counter bid delay from a time of placement of the current bid, wherein the automatic checking, determining and placing counter bids produce a delay paced online proxy bidding according to the counter bid delay value and wherein escalation of the pace of bidding within the auction system is avoided.
This allows the user to automatically participate in the bidding throughout the entire process, but avoids automatic and rapid counter bidding by opposing proxy users.
DETAILED DESCRIPTION OF THE INVENTION
It will be recognized by those skilled in the art that certain combinations and integration of the features presented herein may be made without departing from the spirit and scope of the invention. Further, it will be recognized that many of the architectural details disclosed herein are disclosed under the inventor's preferred embodiment in order to enhance the robustness and reliability of the invention, but these details may not be necessary to realize the fundamental functionality of the invention.
Throughout the disclosure given herein and the following claims, the term “broker” is used to describe a bidding party or bidder, and the term “trader” is used to describe a party who conducts the process of promoting offers to bidding parties. This is nearly analogous to bidder and auctioneer in the context of a traditional auction, respectively, although the offering and bidding process provided by the invention may be used to conduct business-to-business offers as well as traditional types of auctions.
Even though the following description of the preferred embodiment is given relative to implementation as a feature of function in a specific interactive offering system, it will be recognized by those skilled in the art that the invention may be equally well implemented as a feature or function in conjunction with any on-line auction or offering system.
General Description of the Interactive Offering System
The following general description of the Interactive Offering System (“IOS”) is summarized from the related application. Turning to FIG. 5 in which the general architecture of the system of the preferred embodiment of the invention is shown, the Interactive Offer Server (“IOS”) ( 51 ) is associated with an offering database ( 52 ). The offering system ( 50 ) is included in the larger architecture ( 59 ) which includes the brokers' consoles ( 58 ), the administrator console ( 56 ), and the traders' consoles ( 54 ). All consoles and the interactive offering server may communicate either as an integrated package within one computer system, or as separate computer systems integrated and communicating over a computer network such as the Internet.
In the general architecture of FIG. 5 , the manufacturer or service provider's goods availability list ( 55 ) is received by the trader consoles ( 54 ). The trader then creates proposed offerings for bidders or brokers. The proposed offerings are input into the offering database ( 52 ), which are then retrieved by the administrator using his administrator console ( 56 ).
The administrator authorizes the proposed offerings and makes a note or change in the offering database records to indicate such authorization.
During the open bidding process, the brokers or bidders may use their consoles, such as web browser personal computers ( 58 ), to retrieve their offerings, and to submit bids via the IOS ( 51 ). When a broker makes contact with the interactive offering server, his identity is first verified by an Authentication Server ( 57 ), according to the preferred embodiment.
In response to the broker's request for products or services offerings, the IOS queries the offering database ( 52 ) and presents the broker with offerings which contain items to which he or she is entitled to bid. An authentication server ( 57 ) is included in the preferred embodiment so as to allow the interactive offering server to authenticate the broker prior to presenting any offerings to the broker. As such, the general architecture ( 59 ) as shown in FIG. 5 provides each broker with one or more offerings which have been authorized.
Turning to FIG. 6 , the detailed organization of the system according to the preferred embodiment is shown. A sales preparation system ( 60 ) comprising an IBM Lotus Notes system provides available materials list to the traders via their trader consoles ( 61 ), which are networked personal computers also running Lotus Notes applications. These available materials lists could alternatively be simple text file lists or spreadsheets, as well as database records. Alternatively, the trader consoles ( 61 ) may be dedicated computer consoles, web browser computers, or other appropriate computer user interface devices such as wireless web browsers.
Using a trader console, a trader then filters the available materials list for each broker or bidder to prepare proposed broker offerings to be stored in the IOS production server ( 62 ).
An administrator may use an administrator's console ( 64 ) to query the database of the IOS production server ( 62 ) to retrieve and review a trader's proposed offerings. He may authorize all or some of the proposed offerings, and place those authorized offerings in the IOS database for replication to the IOS staging server ( 65 ).
Posting of the authorized offerings to the IOS staging server ( 65 ) is preferably done by a Lotus Notes replicator function. As both the IOS production server ( 62 ) and staging server ( 65 ) are based on IBM Lotus Notes systems in the preferred embodiment, the replicator is a natural function of Lotus Notes which is easily incorporated and maintained. An IBM Lotus Enterprise Integrator (“LEI”), formerly known as “Notes Pump”, then prepares a DB2 database file ( 66 ) from the IOS staging server ( 65 ).
Further according to the preferred embodiment, all of these previously described systems and components and processes are executed and placed behind a protective data “fire wall” ( 603 ) for system security. The posted available offerings for the brokers are replicated to another database outside the firewall, preferably in a DB2 format ( 67 ) again. This “outside” database is available for query by at least one application server ( 68 ).
Also according to the preferred embodiment, a clustered pair of application servers ( 68 ) are used to query the outside database ( 67 ) for available offerings for brokers. The application servers are provided requests from the brokers via network dispatchers ( 69 ). The network dispatchers ( 69 ) receive broker requests for offerings by a proxy server ( 600 ). Thus, the brokers may use their broker consoles ( 602 ), such as web browser personal computers or wireless web browsers, to query the outside database ( 67 ) via a computer network ( 601 ) such as the Internet.
The network dispatchers provide balanced loading to the application servers ( 68 ), and they provide for redirection of requests to one of the application servers should the other application server experience a failure. After the brokers receive their offerings of entitled materials or services on which they may bid via their broker consoles ( 602 ), they may post bids which are stored in the outside database ( 67 ).
The posted bids are then replicated from the outside database ( 67 ) to the inside database ( 66 ) behind the firewall. The LEI then moves those bids, converts them from DB2 format to Lotus Notes format, and stores them in the IOS staging server ( 65 ). These bids are further replicated from the Lotus Notes format in the IOS staging server ( 65 ) to the IOS production server ( 62 ), where they then may be retrieved and reviewed by the traders using the trader consoles ( 61 ). Thus, the entire offering-to-bid process is completed. The traders may then choose to accept or reject each posted bid.
According to the preferred embodiment, the application servers ( 68 ) are web server hardware platforms, such as IBM RS6000 computers running the IBM AIX operating system, accompanied by the IBM WebSphere product. Java servlets are used to interact with the broker console computers ( 602 ), which could be alternately realized in such technology as Microsoft's Active Server Pages or Java server pages.
Further according to the preferred embodiment, the application servers are provided with communications capability to an authentication server ( 57 ) which may include lists of brokers and passwords against which broker log-in attempts may be validated.
General Proxy Agent Implementation
The preferred embodiment of the invention is as a Java servlet class on the IOS server of the related applications. Alternatively, it can be implemented as an object-oriented class of functions on any suitable auction or offering server. It can be implemented as non-object oriented code, as well.
According to the preferred embodiment, the bids placed by the participants or bidders are enhanced to include additional parameters regarding proxy and timed firing of the proxy. These parameters are passed with the usual bid information to the IOS server, which then instantiates a proxy agent on behalf of that participant or bidder. The proxy agent instance then remains present in memory, and is activated or run periodically by the server, such as once per minute.
Turning to FIG. 4 , when the proxy agent instance ( 40 ) is instantiated ( 41 ), it receives the bid parameter set ( 42 ) for the bidder or participant. Then, the proxy agent checks ( 43 ) each auction's bid level for which it is configured to automatically bid by querying the bid or offer database ( 52 ), evaluates ( 44 ) the proxy firing parameters in the bid parameter set ( 42 ) comparing it with the system time ( 45 ), and automatically submits ( 46 ) a higher bid or bids, if necessary, to one or more auctions. Then, the proxy agent suspends ( 47 ) itself until it is resumed some time later by the auction or offering system, such as one minute later.
This general process allows the inclusion of several optional proxy controls and limits, as discussed in more detail in the following paragraphs.
Delay Paced Proxy Bidding
Table 1 shows the enhanced bid parameter format for placing a bid with delay paced proxy options:
TABLE 1
Bid Parameters with Delay Paced Proxy
auction_name=“10GB hard drives, SCSI”, initial_bid=“$10.00”,
maximum_bid=“$45.00”, delay_pace=“10 min”, increment=“$1.00”
<CR>
auction_name=“floppy drives, USB”, initial_bid=“$2.00”,
maximum_bid=“$6.50”, delay_pace=“20 min”, increment=“$0.25”
<CR>
According to this example bid, shown in comma separated variable (“CSV”) format, the proxy agent would initially place a bid into a specified auction, such as the “10 GB hard drives” auction, for an initial bid value, such as $10.00. It would then periodically monitor the highest bid placed in this auction, wait until no higher bids have been placed for at least a specified delay_pace period, such as 10 minutes, and then place a new bid equal to the current highest bid plus a specified increment, such as $1.00. If the proxy agent reaches its maximum authorized bid, such as $45.00 in this example, it would not place any further bids.
Table 1 shows a second example for an auction for another commodity, paced at 20 minute bid intervals. As such multiple bids for multiple offerings or auctions can be processed by a single proxy agent, given that the periodic resumption rate of the proxy agent instance is equal to or less than the shortest specified bid period. For example, if a bid delay is specified of 30 seconds, the proxy agent preferably is resumed and run at least every 30 seconds or more often.
Scheduled Proxy Bidding
Table 2 shows an example of a bid parameter set which specifies scheduled proxy bidding:
TABLE 2
Bid Parameters with Scheduled Proxy Bidding
auction_name=“10GB hard drives, SCSI”, initial_bid=“$10.00”,
max_bid=“$45.00”, until=“4:00 PM”, max_bid=“$55.00”, until=“6:00
PM”,
max_bid=“$70. 00”, until=“close” <CR>
Similar the bid example of Table 1, this bid is formatted in CSV but instead sets a three-period schedule, each period having a different maximum proxy limit. Each time the proxy agent is resumed or run, it will check an auction bid level, such as the “10 GB hard drives” auction, and if it needs to place a higher bid and has not exceeded the bid limit for the current time period, it will place a higher bid. Once it has placed its maximum authorized bid during a time period, the proxy agent will not place any further bids until a new time period with higher limits is entered, or until the close of the auction or offering, whichever occurs first.
Again, similar to the example of Table 1, multiple auctions may be handled by the proxy agent simply by configuring multiple sets of bid parameters into the bid data.
Near-Close (“Last Minute”) Proxy Firing
Table 3 shows a configuration of bid parameters which allows the proxy agent to wait until a certain time before closing of the auction to placing higher bids:
TABLE 3
Bid Parameters with Last Minute Proxy Firing
auction_name=“10GB hard drives, SCSI”, initial_bid=“$10.00”,
max_bid=“$45.00”, within_close=“15 min”<CR>
As in this example, the proxy agent will wait until a specified time before the scheduled close of the auction or offering, such as 15 minutes before closing, and then automatically place bids up to the maximum authorized bid limit, such as $45.00.
Compound Proxy Controls
The preferred embodiment allows for combinations of the three types of proxy controls previously discussed, simply by combining the parameters provided in the bid itself. For example, one bid proxy may be configured to have three schedule periods, each period having a different maximum bid limit and a different delay pace. Further, a bid may be placed with multiple bid periods with multiple limits up to a specified time before closing, at which time another limit is authorized. Table 4 shows examples of these two bid configurations.
TABLE 4
Bid Parameters with Compound Proxy Instructions
auction_name=“10GB hard drives, SCSI”, initial_bid=“$10.00”,
max_bid=“$45.00”, until=“4:00 PM”, delay_pace=“10 min”,
max_bid=“$55.00”, until=“6:00 PM”, delay_pace=“5 min”,
max_bid=“$70.00”, until=“close”, delay_pace=“1 min”<CR>
auction_name=“floppy drives, USB”, initial_bid=“$2.00”,
max_bid=“$4.50”, until=“4:00 PM”,
max_bid=“$5.00”, until=“6:00 PM”,
max_bid=“$7.00”, within_close=“15 min”<CR>
FIG. 3 shows an exemplary user interface dialog ( 30 ) to allow a bidder or auction participant to specify any or all of these parameters. The user interface dialog ( 30 ) allows the bidder or participant to submit basic bid information ( 31 ) such as item part numbers and quantities, for one or more items on which he or she wishes to bid. In the preferred embodiment, the user simply inputs a part number, and the description and quantity are automatically filled by the system as the bidding of the preferred embodiment is accepted in “full lots” only. However, in other systems and businesses, partial lot bidding may be allowed, so the user may be allowed to input or overwrite the suggested quantity.
The bidder also indicates an initial bid value ( 32 ) per item, which is then multiplied by the quantity to generate a total bid ( 33 ) for that item.
To realize the present invention, additional user interface parameters for the proxy controls ( 34 ) are provided to the user. In the example of FIG. 3 , this may be a language or text field, or alternatively it may be a set of check boxes, radio buttons, drop-down lists, or forms hyperlinked to the dialog ( 30 ).
A button or other icon is provided to finalize and submit ( 35 ) the bid by transmitting the bid parameter set to the IOS server.
It will be understood by those skilled in the art and from the foregoing description that various modifications and changes may be made in the preferred embodiment of the present invention without departing from its spirit and scope, such as use of or integration to other on-line offering and auction systems, use of alternate bidder consoles and document formats, and implementation using alternate programming languages and methodologies. It is intended that this description is for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be defined by the following claims. | Delay-paced online proxy bidding by providing a counter bid delay value parameter for automatic proxy bidding on behalf of a user in an online auction; automatically checking by an application server a current bid level of the online auction having a plurality of bids from other participants separated in time to form a bidding pace; determining by an application server that any a proxy condition has been met; and placing by an application server computer a counter bid the auction responsive to the proxy conditions being met and a time following or upon the elapse of a counter bid delay from a time of placement of the current bid; wherein the automatic checking, determining and placing counter bids produce a delay paced online proxy bidding according to the counter bid delay value and wherein escalation of the pace of bidding within the auction system is avoided. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to equipment for the automatic sewing of shoulder pads for clothing.
Shoulder pads for clothing are currently produced manually by operators equipped with conventional sewing machines. This results in long production cycles for the shoulder pads, high production costs, and inconsistent quality of the shoulder pads produced.
SUMMARY OF THE INVENTION
The object of the present invention is to provide equipment of the type specified at the beginning of the description, which does not have the above disadvantages and enables the shoulder pads to be produced automatically at a fast production rate and to a high standard of quality.
According to the invention, this object is achieved by virtue of the fact that the equipment includes a support structure, at least one sewing machine supported for sliding on the structure, an oscillator device adapted for connection to a tool which clamps together two, facing, shaped pieces of cloth with an interposed pad for forming the shoulder pads, the oscillator device being supported by the structure for rotation about an axis parallel to the line along which the sewing machine slides, means for driving the sewing machine in reciprocating rectilinear motion, and means associated with the oscillator device for causing the reciprocating rotation of the tool in synchronism with the movement of the sewing machine in order to provide for the sewing together of the pieces of cloth and the pad along a predetermined outline.
By virtue of these characteristics, the manual aspect of the production of the shoulder pads is reduced simply to the loading of the pieces of cloth and the pad into the appropriate tool, the loading of the tools into the equipment and their removal therefrom being achievable, to advantage, by automatic manipulators. Moreover, the loading and unloading of the tool are operations which can easily be automated, thus completely eliminating any manual operation.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become clear from the detailed description which follows with reference to the appended drawings, provided by way of non-limiting example, in which:
FIG. 1 is a schematic perspective view of equipment according to the invention,
FIG. 2 is a perspective view of a detail of FIG. 1 on an enlarged scale,
FIG. 3 is a detail of FIG. 2 which shows the connection between the two sewing machines,
FIG. 4 is a section taken on the line IV--IV of FIG. 3,
FIG. 5 is a perspective view of a portion of the equipment in an operative configuration,
FIG. 6 is a partially-sectioned side view of the equipment of FIG. 1,
FIG. 7 is a partially-sectioned view taken on the arrow VII of FIG. 6,
FIG. 8 is an exploded perspective view of a detail of FIG. 5, and
FIG. 9 is a section of a detail of FIG. 8 in an assembled configuration.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings equipment for the automatic production of shoulder pads for clothing is generally indicated 10. The equipment 10 has a support structure 12 carrying parallel horizontal guide bars 14. The bases 16 of two sewing machines 18 of known type are mounted for sliding on the bars 14 and have parallel vertical needles 18a which are operated by pulleys 18b driven by transmission belts 20.
The structure 12 of the equipment supports a transmission box 22 (FIGS. 3 and 4) to which power is supplied by means of a toothed belt 23, a pulley 24, a transmission shaft 25, a driving pulley 26, a further toothed belt 27, and a driven pulley 28. A first horizontal shaft 29 keyed to the latter pulley is rotatable relative to the box 2Z with the interposition of rolling bearings 30 and is in turn keyed to a gear 31 which is meshed with an identical gear 31a keyed to a second shaft 29a mounted for rotation relative to the box 22 with the interposition of rolling bearings 30a. Splined transmission shafts 33 are keyed to the first and second shafts 29 and 29a with the interposition of first universal joints 32 and are adapted to transmit the drive to auxiliary splined shafts 33a with the interposition of splined sleeves 34 which are adapted to enable the rotary motion also to be transmitted when the splined shafts 33a are in reciprocating motion towards and away from each other. With the interposition of second universal joints 35, the auxiliary splined shafts 33a rotate auxiliary shafts 36 which are mounted for rotation in holes 37 in the supports 16 of the sewing machines 18 and are adapted to drive, by means of pulleys 36a, the belts 20 which operate the sewing machines. A disc 40 is keyed to one end 29b of the first shaft 29 of the transmission box 22 and is provided with a radial prismatic guide 40b in which the end 41b of a crank pin 41 is slidably mounted for adjustment the crank pin 41 being connected, with the interposition of rolling bearings 42, to a connecting rod 43 whose function will become clear from the following description.
The reciprocating motion of the sewing machines 18 along the guide bars 14 is achieved by means of a disc 44 which is rotated by the main motor of the equipment (not shown) and carries an annular cam groove 44a for cooperating with a follower 45 connected to a control arm 46. The latter is articulated at 47 to a lever 48 which is pivoted at 49 on the structure of the equipment and is provided with a link-like end 48a for causing the sliding of one of the two sewing machines 18. The movement of the latter is transmitted to the other sewing machine 18, which moves along the same line as the first machine but in the opposite direction, by means of a rotary member 50 which is articulated to the transmission box 22 about a vertical axis and has its opposite end 50a articulated to adjustable rods 51. Between the two sewing machines lB, the structure 12 supports a pair of L-shaped brackets 53 which face each other and rotatably support the ends of a first splined shaft 54 to which a first slidable pulley 55 is keyed. The splined shaft 54 is rotated by means of a toothed belt 56 which is looped around pulleys 57 and is connected at 58 to the end 59a of a vertical operating rod 59. The latter is articulated to a horizontal lever 60 which is articulated centrally at 60a and is oscillated by means of the connecting rod 43. The movement of the latter causes, through the lever 60, a vertical reciprocating movement of the operating rod 59 which, in cooperation with a fixed guide 60b, causes the reciprocating motion of the belt 56 and this causes a reciprocating rotary motion of the splined shaft 54. By means of a belt 61, the first slidable pulley 55 drives a second pulley 62 which is keyed slidably to a second splined shaft 63 whose ends are supported for rotation by the brackets 53. A circular disc-shaped support 64 is also keyed to the second pulley 62 and has a radial notch 64a for the mounting of a tool 100, shown in detail in FIGS. 8 and 9.
The tool 100 comprises an upper element 112 and a lower element 114 formed by metal plates curved about a longitudinal axis X--X. The elements 112 and 114 have respective apertures 112a and 114a which substantially correspond in shape to, but are smaller than the semi-finished product S.
The latter is defined for example by two precut pieces T of unwoven cloth between which a pad I of wadding is interposed.
The lower positioning element 114 has a curved convex bridge 118 which connects the edges 116 of the aperture 114a and is arranged transverse the longitudinal axis X--X. A flat element 118a is also associated with the bridge 118 and is adapted to be interposed between a pair of slightly-spaced-apart discs 64b which constitute the disc-shaped support 64.
Around the edge 116 and in correspondence with the bridge 118, the lower element 114 has a surface portion 120 with a high coefficient of friction. Similarly, the upper element 112 has an annular surface portion 122 with a high coefficient of friction. To advantage, the surface portions 120 and 122 may, for example, be covered with suitable antislip paint.
Vertical coupling pins 124 are fixed to ends 114b of the lower elements 114 in correspondence with coupling bushes 126 fixed at ends 112b of the upper element 112. Each bush 126 has a longitudinal slot 126a for enabling cooperation between a cam element 128 articulated at 130 to the bush itself and the lateral surfaces of the coupling pins 124. The cam elements 128 are operated manually by means of levers 128a but may to advantage be operated automatically.
A pin 65 of a slider 66 which is slidable in holes in the brackets 53, parallel to the line along which the sewing machines 18 slide, is interposed betWeen the discs 64b. The slider 66 has an end 66a which is driven in reciprocating motion by a rocker arm 67 driven by a rod 68 which is slidable on a cam 69 keyed to a gear 70. The latter meshes with a complementary gear 71 keyed to the second shaft 29a of the transmission box 22. The rotation of the cam 69 therefore causes the slider 66 to move to and fro and, by means of the pin 65, cause the support 64, the belt 61 and the pulley 55 to slide to and fro along the splined shafts 63 and 54.
During the operation of the equipment, the operator or a suitable automatic manipulator places the tool 100, carrying two pieces of cloth T between which the pad I of wadding is interposed, on the disc-shaped support 64. The equipment then starts its operating cycle which provides for the reciprocating motion of the sewing machines 18, the synchronised reciprocating rotation of the disc-shaped support 64, and finally the sliding of the disc-shaped support to and fro along the splined shaft 63. The combination of these three movements enables the needles 18a of the sewing machines 18 to sew the pieces of cloth T and the pad with a zig-zag stitch along a predetermined outline which can be repeated exactly in successive cycles
When the cycle is complete, the operator or the manipulator removes the tool 100 with the sewn shoulder pads and transports them to a subsequent station for transverse cutting which produces two separate shoulder pads.
The equipment according to the invention lends itself to many adjustments Amongst these, there is mentioned the amplitude of oscillation of the connecting rod 43, which is adjustable by the radial positioning of the pin 41 relative to the disc 40.
Moreover, the equipment may include only one sewing machine. In this case, the sewing machine may conveniently be fixed to the structure and the tool carrying the shoulder pad may be driven in reciprocating rectilinear motion. | Equipment for the automatic sewing of shoulder pads for clothing includes a support structure, a pair of sewing machines (18) which are slidable along the same line on the structure and have parallel vertical needles (18a), and an oscillator device (64) adapted for connection to a tool for clamping the pieces of cloth and the pad of the shoulder pad and capable of reciprocating rotation about an axis parallel to the line along which the sewing machines (18) slide, so as to effect the automatic sewing of the shoulder pad along a predetermined outline. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method for removing unburned carbon from fly ash, in particular a method for removing unburned carbon contained in fly ash discharged from coal fired power plants.
[0003] 2. Description of the Related Art
[0004] Coal can be stably utilized as an energy source in the long term as the ratio of its proven reserves to annual production is more than 200 years. Therefore, the ratio of coal fired power generation to total power generation has been increasing year by year and the amount of coal ash generated (hereinafter referred to as “fly ash”) is expected to increase in the future.
[0005] In such circumstances, the large amount of fly ash needs to be efficiently utilized from the viewpoints of environmental conservation and the effective utilization of resources.
[0006] In order to expand the range of applications and amount of fly ash that is usable, it is necessary to improve the quality by removing the unburned carbon from fly ash, which will then lead to the expansion of applications such as a cement admixture, for example.
[0007] Therefore, the applicant has invented the method shown in FIG. 8 , where slurry is generated by adding water to fly ash 60 in a mixing tank 62 , a shearing force is applied to the slurry in a submerged stirrer 66 and then the unburned carbon in fly ash is efficiently removed in a floatation unit 72 (Refer to Patent document 1).
[0000] Patent document 1: Japan Patent No. 3613357
[0008] In the method described in the above referred to patent document 1, as shown in FIG. 9( a ), in order to enable for unburned carbon 91 , which is adherent to fly ash 90 or loose, to reach a capturing agent 92 as shown in FIG. 9( b ) by adding shearing force in a submerged stirrer 66 thereto after adding an oil-based capturing agent 92 to slurry that includes a large amount of water 93 that has no affinity to oil content, it has been necessary to either add more energy to the shearing force to eliminate the water 93 , or to add larger amount of capturing agent 92 than the amount of unburned carbon 91 content.
[0009] However, in either method, the issue exists that the cost of removing unburned carbon from the fly ash becomes too expensive, and this is because a driving power for the submerged stirrer 66 increases and longer time mixing is required.
BRIEF SUMMARY OF THE INVENTION
[0010] Taking these issues into consideration, the present invention was achieved with the purpose of providing a method for removing unburned carbon from fly ash at low cost and in a short time.
[0011] In order to achieve the above purpose, the present invention relates to a method for removing unburned carbon in fly ash wherein a mixture is generated by adding 0 to 40 wt % of water and a capturing agent to fly ash and mixing it, and a slurry is generated by adding more water to this mixture, then a shearing force is then applied to the slurry, and the unburned carbon in the fly ash is separated by floatation by supplying air while adding a foaming agent to the slurry to which the shearing force is applied and stirring.
[0012] According to the present invention, as the capturing agent is added to the fly ash that contains water content to the extent that it does not become slurry and is stirred and mixed, it is possible to reduce the driving energy required for stirring and mixing as it is not necessary to remove so much water from among fly ash and capturing agent.
[0013] It is desirable for the mixer to be a high speed flow type mixer or a ribbon blender.
[0014] Regarding as the high-speed flow type mixer, paddle-type mixer, an Eirich and a Henshel mixer are all available.
[0015] According to the method for removing unburned carbon in fly ash relating to the present invention, since it is possible to reduce the driving energy of the submerged stirrer and to lower the residual volume of unburned carbon by optimizing the amount of added capturing agent, it is possible to obtain a high quality fly ash at low cost and in a short time.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] FIG. 1 shows a schematic diagram of a plant system according to the embodiment of the present invention.
[0017] FIG. 2 shows a cross sectional view illustrating the structure of a mixer according to the first embodiment of the present invention.
[0018] FIG. 3 shows a cross sectional view illustrating the structure of a mixer according to the second embodiment of the present invention.
[0019] FIG. 4 shows a cross sectional view illustrating the structure of a mixer according to the third embodiment of the present invention.
[0020] FIG. 5 shows a cross sectional view illustrating the structure of a mixer according to the fourth embodiment of the present invention.
[0021] FIG. 6 shows a cross sectional view illustrating the structure of a modified example of a mixer according to the fourth embodiment of the present invention.
[0022] FIG. 7 shows a schematic diagram of a system in case that two mixers according to the first embodiment of the present invention are connected in series.
[0023] FIG. 8 shows a schematic diagram of a plant system according to the conventional embodiment prior to the present invention.
[0024] FIG. 9 shows a diagram that explains the state of the slurry before and after the shearing force is applied, wherein (a) shows the state before the shearing force is applied and (b) shows the state after the shearing force is applied.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Here the best form of the embodiment according to the present invention is described in reference to FIG. 1 . FIG. 1 is a schematic diagram of a plant system for implementing the present invention.
[0026] This system is mainly composed of mixer 5 that adds a capturing agent to fly ash to mix, mixing tank 7 that generates slurry by adding water to the mixed fly ash and capturing agent, submerged stirrer 9 that applies high shearing force to the slurry, adjusting tank 12 that generates air bubbles by adding a foaming agent to the slurry to which the high shearing force was applied, floatation unit 15 that separates unburned carbon by supplying air while stirring the slurry, and adhering the unburned carbon in the fly ash to the air bubble and floating, solid-liquid separator 17 that separates and recovers the fly ash from the sediment separated in floatation unit 15 , and hydro-extractor 23 that recovers the unburned carbon by dehydrating the floatating substances after being separated in the floatation unit 15 .
[0027] Next, the equipments composing the plant system are described in detail below.
[0028] Fly ash tank 1 is a tank that stores fly ash discharged from a coal fired power plant (not shown in the drawings). Unburned carbon that remains unburned upon combustion of coal in a boiler of a coal fired power plant adheres to or is contained in the fly ash.
[0029] Volumetric feeder 2 is a machine that feeds a certain volume of fly ash from the fly ash stored in the fly ash tank 1 to the mixer 5 , into which a rotary valve, for example, is utilized.
[0030] Capturing agent tank 3 is a tank that stores the capturing agent that is fed to the mixer 5 via pump 4 . As the capturing agent, any of kerosene, diesel oil or heavy oil can be used.
[0031] Mixer 5 is a high-speed flow type mixer used to add the capturing agent directly to the fly ash, to stir and mix them and also to apply shearing force to the mixture.
[0032] Here, since the amount of capturing agent is very small compared to the amount of fly ash, it is desirable to add water for atomizing the capturing agent by less than the 40 wt % that is the limit to the mixture not becoming slurry, or it is desirable to add water by 5 to 15 wt % to the fly ash with regard to suppressing the generation of dust from the fly ash and that the adhesive force among fly ashes should not be too large.
[0033] FIG. 2 shows the first embodiment of this mixer. FIG. 2 shows a cross sectional view illustrating the structure of the mixer according to the first embodiment.
[0034] Mixer 30 A according to this embodiment is that is so called “paddle-type” mixer and has the structure in which rotation shaft 33 that has multiple L-shape stirring paddles 32 is inserted down into vertically placed hollow cylindrical vessel 31 from above. At the top of the hollow cylindrical vessel 31 , volumetric feeder 2 that feeds a specified amount of fly ash F from the fly ash tank 1 and atomizer 34 that sprays capturing agent G containing water supplied via the pump 4 from capturing agent tank 3 are arranged.
[0035] Fly ash F fed to mixer 30 A is stirred and mixed with capturing agent G by stirring paddle 32 that is rotated by electric motor 35 , then it is applied a shearing force and discharged from the discharge port not shown in the diagram.
[0036] This mixer 30 A has the feature that the structure is simple and it is easy to handle.
[0037] FIG. 3 shows the second embodiment. FIG. 3 shows a cross sectional view illustrating the structure of mixer according to the second embodiment, and the same parts as those of FIG. 2 are designated by similar numbers.
[0038] Mixer 30 , according to this embodiment, is that is so called as “Eirich Mixer” (product of Japan Eirich Co.), that has the structure in which agitator 38 having small stirring paddle 37 is inserted at the eccentric position inside the hollow cylindrical vessel 36 placed obliquely from the above. Vessel 36 and agitator 38 rotate mutually in reverse direction. At the top in the vicinity of the bottom surface of vessel 36 placed obliquely, scraper 39 is arranged.
[0039] Fly ash F and capturing agent G fed to mixer 30 B rotate together with the vessel 36 and a high shearing force is applied by stirring paddle 37 of agitator 38 that rotates in reverse direction at the eccentric position. And, since fly ash F and capturing agent G that are carried up to the top of vessel 36 due to its rotation are reversed by the scraper 39 , the vertical mixing in the vessel 36 is accelerated.
[0040] In such a way, this mixer 30 B has the feature that it is possible to execute dense and uniform mixing and, at the same time, to apply high shearing force.
[0041] FIG. 4 shows the third embodiment of the mixer. FIG. 4 shows a cross sectional view of the mixer according to the third embodiment, and the same parts as those of FIG. 2 are designated by similar numbers.
[0042] Mixer 30 C according to this embodiment is that is so called as “Henshel Mixer” (product of Mitsui Miike Kakoki, Co.) that has the structure in which L-shape stirring paddle 44 installed to the top of rotary shaft 43 is arranged near the bottom surface of the vertically placed hollow cylindrical vessel 42 . Rotary shaft 43 is connected to driver 45 passing vertically through the bottom surface of the vessel 42 . At the lower side surface of the vessel 42 , discharge port 46 is attached obliquely downward.
[0043] Fly ash F and capturing agent G fed to this mixer 30 C are discharged through discharge port 46 after convection stirring and mixing are executed on them and a shearing force is applied to them with stirring paddle 44 that rotates at high speed.
[0044] This mixer 30 C has the feature that it is possible to execute mixing and applying a shearing force in a short time.
[0045] FIG. 5 shows the fourth embodiment of the mixer. FIG. 5 shows a pattern diagram illustrating the structure of the mixer of the fourth embodiment according to the present invention.
[0046] Mixer 50 according to the present invention is that is so called as “Ribbon Blender”. This mixer is composed of main body 51 that takes a rectangular solid of which bottom surface is shaped in convex and like a semicyclinder, and rotary shaft 52 installed in parallel to the direction of axis inside the main body 51 . At rotary shaft 52 , ribbon like paddles 53 a and 53 b that transfer the objective substance mutually in reverse direction are installed so as to spirally surround the rotary shaft 52 . The top surface of the main body 51 is connected to volumetric feeder 2 that feeds a given amount of fly ash, and to the inner-top part of the main body 51 , atomizing tube 54 for spraying capturing agent G is installed in parallel to the direction of axis.
[0047] Here, the atomizing tube 54 may be arranged inside the rotary shaft 52 as shown in FIG. 6 .
[0048] Fly ash F fed to this mixer 50 is moved like a shape of 8 looking at from the side view, and is stirred and mixed together with capturing agent G sprayed from the atomizing tube 54 installed at the upper-top part or inside of the rotary shaft, and finally is discharged from discharge port 56 .
[0049] This mixer 50 has the feature that the structure is simple and it is possible to process high volume of fly ash.
[0050] In any mixers according to the embodiments described above, it is desirable to compose mixers with multiple stages by connecting multiple mixers in series so as to enable to continuously and effectively mix of fly ash and capturing agent.
[0051] FIG. 7 shows a configuration example that serially connects mixer 5 with multiple stages. FIG. 7 corresponds to the case where two mixers 30 A according to the first embodiment are connected, in which similar numbers are given to the same parts as those of FIG. 2 .
[0052] Fly ash F and capturing agent G fed to the first stage mixer are mixed in the mixer 30 A and, after a shearing force is applied to, the mixture is fed to the second stage mixer through discharge port 57 . Mixture F fed to the second stage mixer is mixed again with capturing agent G fed through tube 58 and a shearing force is applied again.
[0053] Here, a method for connecting the mixers is not limited to the one shown in FIG. 7 , but it is of course good to connect three or more mixers depending on an objective performance, or to connect a plurality of the mixers according to other embodiments to the ones of the same embodiment or to the ones of the different embodiments.
[0054] Mixing tank 7 adjusts slurry by mixing fly ash and capturing agent that are mixed in mixer 5 by mixing with water fed from water feeder 6 .
[0055] Submerged stirrer 9 applies a high shearing force to the slurry that is adjusted in the mixing tank 7 by stirring with high speed to modify unburned carbon's surface.
[0056] Adjusting tank 12 is a tank in which foaming agent fed through pump 11 from foaming agent tank 10 is added and mixed to the slurry discharged from submerged stirrer 9 , by which the slurry becomes to a state that is possible to easily generate air bubbles.
[0057] Floatation unit 15 is a machine that separates unburned carbon by supplying air to the slurry fed through pump 13 while stirring to adhere the unburned carbon to air bubbles, and to float the air bubbles to the surface. As the method for supplying air used at this time, such methods that absorb air by rotation of stirrer in floatation unit 15 , or although it is not shown in diagrams, that forcibly inject air by air supplying equipment (such as blower) are desirable.
[0058] The unburned carbon separated as the floating substances in the floatation unit 15 is transferred through pipe 22 to hydro-extractor 23 . The slurry from which unburned carbon is separated and recovered as the sediment in the floatation unit 15 is transferred through pump 16 to solid-liquid separator 17 .
[0059] Solid-liquid separator 17 is a machine that separates the slurry to fly ash and water. Separated fly ash is transferred to dryer 18 as a cake, and separated water is returned through circulation tube 27 by pump 26 to mixing tank 7 to be recycled as water for generating slurry.
[0060] Dryer 18 is a machine to dry the fly ash as a cake with hot air generated by air heating furnace 21 . The fly ash after drying from which unburned carbon is separated becomes fly ash 20 as a commercial product and utilized as cement admixture, etc.
[0061] Bag filter 19 is a machine that recovers the fine powder of fly ash generated during the drying process in the dryer 18 by conducting the filtration dust collection, and the recovered fly ash also becomes fly ash 17 as a commercial product.
[0062] Hydro-extractor 23 is a machine that dehydrates the unburned carbon separated as the floating substances in the floatation unit 15 . Examples of hydro-extractor 23 include, filterpress and the like. In this case, the floating substances are dehydrated by pressurizing with a filter.
[0063] Since unburned carbon 25 after being dehydrated can be used as a fuel, a part of this is supplied to air heating furnace 21 to generate hot air used in the dryer 18 .
[0064] The water separated in the hydro-extractor 23 is transferred to the circulation tube 27 to be recycled in the mixing tank 7 similarly to the water separated from the solid-liquid separator 17 .
[0065] Next, a method for separating unburned carbon from fly ash that uses the above described system is described in reference to FIG. 1 .
[0066] Fly ash is cut out from fly ash tank 1 by the volumetric feeder 2 and input to the mixer 5 , and it is stirred and mixed with a capturing agent fed from capturing agent tank 3 . Then, a shearing force is applied to this mixture.
[0067] At this time, in the mixer 5 , since powdered fly ash is directly stirred and mixed, there exists no water differently from the case of slurry, driving energy to eliminate water from the mixture of fly ash and capturing agent is not required and, at the same time, added capturing agent can easily reach to the fly ash. Also, since a shearing force is applied to the unburned carbon contained in fly ash while stirring, and a part of shearing force that should be applied in the submerged stirrer 9 , which is a downstream process, can be borne on the unborned carbon, it is possible to reduce the driving energy of the submerged stirrer 9 to this extent.
[0068] The amount of capturing agent added in the mixer 5 is set to 0.05 to 10 wt % for fly ash when kerosene is used as a capturing agent.
[0069] Due to the very small amount of capturing agent for fly ash, water for atomizing capturing agent should be added by less than 40 wt % for fly ash, or more preferably, by 5 to 15 wt %.
[0070] Since a shearing force of 10 to 50 kWh/m 3 per unit weight is applied, or more preferably, 20 to 40 kWh/m 3 is applied to fly ash, it is possible to reduce the driving energy of the submerged stirrer 9 by about 50%.
[0071] In this way, the mixture of fly ash and capturing agent that is stirred and mixed and to which a shearing force is applied is transferred to the mixing tank 7 .
[0072] In the mixing tank 7 , slurry is generated by adding water to the mixture from water feeder 6 to mix. Concentration of generated slurry at this time is desirable to be in the range of 10 to 30 wt %.
[0073] Then, a high shearing force is applied to this slurry by mixing and stirring up in the submerged stirrer 9 . Owing to the high shearing force, the surface of the unburned carbon contained in the slurry is modified, an affinity to capturing agent 37 is increased and a floatability to separate by floatation of the unburned carbon is increased in floatation unit 15 in the later stage process.
[0074] Next, the slurry applied high shearing force is transferred to adjusting tank 12 to add a foaming agent and mix so as to make the slurry to easily generate air bubbles. The slurry is stirred and supplied air in the floatation unit 15 , then the unburned carbon contained in fly ash 36 is separated while adhering to air bubbles with capturing agent 37 and floating.
[0075] Since the unburned carbon separated as the floating substances by this means contains much water, it is dehydrated in the hydro-extractor 23 so that it may be utilized as a fuel.
[0076] Fly ash 20 as a commercial product can be also obtained by recovering the slurry from which the unburned carbon was separated as the sediment and by drying in dryer 18 after separating the water in the solid-liquid separator 17 . The yield of fly ash 20 as a commercial product can be increased by recovering the fine powder of fly ash in the dryer 18 by using the bag filter 19 .
[0077] As for the water separated in the solid-liquid separator 17 and the hydro-extractor 23 , it is transferred through the circulation tube 27 to the mixing tank 7 to recycle for generating slurry. | Disclosed is a method for removing unburned carbon from fly ash at low cost and within a short time. The method comprises the steps of adding a collecting agent to fly ash directly, agitating/mixing the mixture in a mixer ( 5 ), adding water to the resulting mixed material in a mixing vessel ( 7 ) to yield a slurry, applying a shearing force to the slurry in a submerged stirrer ( 9 ), and performing flotation separation of unburned carbon in a flotator ( 15 ). | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a reversible orthosis, of the type comprising a textile article which has opposite first and second faces and which is intended to be fitted around a part of the body of a user in order to support and/or immobilize this part of the body.
DESCRIPTION OF THE PRIOR ART
The reversibility of an orthosis can be made possible in particular by its not having a wrong side and thus being able to be worn either with its first face or second face in contact with a user's body. Thus, a reversible orthosis can be used equally well either for a left part or right part of the user's body.
The invention relates in particular to an orthopedic vest for supporting and immobilizing the shoulder, but can be used for other orthoses, for example for wrist orthoses.
Reversible orthopedic vests are already known which are placed around a user's thorax, shoulder and arm and are held in position by fastening systems with loops and hooks of the Velcro® type.
A vest of this kind is described, for example, in document U.S. Pat. No. 4,550,724. So that this vest can be effectively be reversible, it is necessary to provide each of the faces of the textile article with adhesive bands. This increases the cost of the vest, but it also poses another problem. Namely, when the vest is fitted on a user, one pair of bands with loops and hooks is not used, the unused pair depending on which shoulder, left or right, is fitted. This has the result that the first of the bands not used can be in contact with the user's skin, which detracts from the comfort experienced by the user, and, on the other hand, the second unused band is exposed on the outside of the vest and can for this reason catch on different objects or materials.
To overcome this disadvantage, it is possible to provide a flap that is equipped with a band complementing the unused band and intended to cooperate with it. This solution therefore requires an additional element, which poses a number of disadvantages. First, the increased quantity of textile and of textile bands of the Velcro® type used leads to an increase in the cost of the vest. Moreover, the flap stiffens the vest and, for this reason, the latter proves less effective and less comfortable because it is more difficult to adapt to the user's anatomy. Finally, the additional thickness created detracts from the esthetic quality of the vest.
SUMMARY OF THE INVENTION
The object of the present invention is to overcome the disadvantages mentioned above.
To this end, the invention relates to an orthopedic orthosis which can support and/or immobilize at least one limb of a patient, comprising a textile article with first and second faces, either of which first and second faces can equally well come into contact with the limb or limbs of the patient.
The orthosis is more particularly characterized in that it additionally has at least one fastening tab comprising an active face with fastening elements that are able to cooperate with first or second securing means arranged respectively on the first face and the second face of the textile article, and an inactive face opposite the active face, said fastening tab being fixed non-removably via its inactive face on a zone of the textile article contiguous to one of the edges of said textile article, so as to be able to pivot, about a pivot axis substantially parallel to this edge, between a first position, in which the active face catches by contact on the first securing means, and a second position, in which the active face catches by contact on the second securing means.
In this way, the active face of the tab can be oriented in the required manner, in order to be placed opposite the surface on which it is to be fastened. Thus, the orthosis is completely adaptable to the left or right half of the human body by virtue of its shape and the reversibility of the textile article, but also by virtue of the ability of the fastening means to pivot. The tab forms a kind of continuation of the first face or second face depending on the direction of use of the textile article.
The tab can comprise substantially identical first and second wings extending on either side of the pivot axis, the first wing being able to be folded back against the first face of the textile article, in the first position of the tab, and the second wing being able to be folded back against the second face of the textile article, in the second position of the tab.
The entire active surface of the tab is used irrespective of the direction in which the textile article is arranged, that is to say irrespective of the orientation of the tab.
According to a first embodiment, the tab is fixed on a band of the textile article delimited on one side by the edge of the textile article and on the other side by the pivot axis of the tab. This method of fixing is particularly robust.
According to a second embodiment, the tab is fixed substantially on the edge of the textile article, said edge forming the pivot axis of the tab. This results in a perfectly symmetrical structure, without excess thickness, and in easy pivoting of the tab.
The tab can be fixed on the textile article by sewing, welding or bonding.
According to one possible embodiment, the tab extends along substantially the entire length of the edge of the textile article. Alternatively, it would be possible to provide several bands spaced apart from one another along the edge.
For example, the fastening elements are formed by hooks, and the first and second securing means arranged respectively on the first face and second face of the textile article are formed by loops, establishing a self-adhering fixation system of the Velcro® type. This arrangement proves particularly comfortable for the patient since he then has a textile with loops arranged against his skin, which has a pleasant and gentle feel.
The first and/or second securing means comprise a band attached to the textile article or are formed by the actual textile of the textile article; this arrangement proves extremely practical because it does not result in additional thickness.
According to one possible embodiment, the textile article is intended to form an orthopedic vest for supporting and immobilizing the shoulder, and comprises:
a first panel intended to cover the rear area of the user's thorax;
a second panel forming a lateral continuation of the first panel and intended to cover the front area and rear area of the shoulder and of the arm;
a third panel forming a lateral continuation of the second panel, remote from the first panel, and intended to cover the front area of the thorax;
a fourth panel forming a continuation of a portion of the lower part of the third panel and intended to serve as a rest for the forearm.
At least one fastening tab can be fixed near the edge of the first panel remote from the second panel and/or the edge of the fourth panel remote from the third panel, said tab being intended to cooperate with securing means formed on the third panel.
The orthosis can additionally comprise a belt extending laterally from the lower part of the third panel in the same direction as the second panel, and a fastening tab fixed near the edge of the belt remote from the third panel, said tab being intended to cooperate with securing means formed on the first panel.
BRIEF DESCRIPTION OF THE FIGURES
To ensure that it is clearly understood, the invention is described in further detail below with reference to the attached figures which depict, by way of non-limiting examples, several possible embodiments of orthoses according to the invention.
FIG. 1 is a plan view of a textile article intended to form an orthopedic vest, a corner of the textile article having been curved back for clearer illustration;
FIG. 2 is a perspective view of a strap intended to be joined to the textile article from FIG. 1 ;
FIG. 3 is an enlarged view of the detail III from FIG. 1 , showing the fastening tab according to a first embodiment;
FIG. 4 is a view similar to FIG. 3 , the fastening tab having pivoted relative to its pivot axis;
FIGS. 5 and 6 are schematic representations of the join between the tab and the textile article, according to the first embodiment and second embodiment, respectively;
FIGS. 7 and 8 show the steps involved in fitting the vest from FIG. 1 in place; and
FIGS. 9 and 10 are schematic representations showing a user fitted with the vest from FIG. 1 , seen from the front and from the back, respectively.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a textile article 1 , in a plan view, which will form an orthopedic vest when fitted in place on a user.
The textile article 1 is generally flat and has a first face 2 and an opposite second face 3 , the latter being partially visible in the corner shown partially folded back for this purpose.
The textile article 1 in the first instance comprises a substantially rectangular first panel 4 intended to cover the rear area of a user's thorax and delimited in particular by an upper edge 5 , a lower edge 6 and a free edge 7 .
The textile article 1 also comprises a second panel 8 forming a lateral continuation of the first panel 4 remote from the free edge 7 and intended to cover the front area and rear area of the shoulder and of the arm. The second panel 8 forms an inwardly curved bend at its lower part and is delimited in particular by a curved upper edge 9 and a curved lower edge 10 . In addition, a curved line 11 extending between the upper edge 9 and lower edge 10 , substantially at the center of the second panel 8 , forms a hump 12 located in the upper part of the second panel 8 , substantially centered laterally. In FIG. 1 , the hump 12 protrudes upward relative to the general plane of the textile article 1 . The concavity of the hump 12 can be inverted such that the hump 12 can protrude downward relative to the general plane of the textile article 1 . It is particularly by virtue of this inversion of the concavity that the vest can be adapted to the left or right shoulder of a user.
A third and substantially rectangular panel 13 forms a lateral continuation of the second panel 8 remote from the first panel 4 and is intended to cover the front area of the user's thorax. The third panel 13 is delimited in particular by an upper edge 14 , a lower edge 15 and a free edge 16 . The distance between the upper edge 14 and the lower edge 15 of the third panel 13 is greater than the distance between the upper edge 9 and lower edge 10 of the second panel 8 . The third panel 13 thus comprises a lateral edge 17 , of small height, opposite the free edge 16 and not joined to the second panel 8 .
A fourth panel 18 continues a portion of the third panel 13 at the latter's lower part and is intended to serve as a rest for the user's forearm. The fourth panel 18 has the general shape of a trapezoid whose bases form the upper edge and lower (free) edge 19 of the fourth panel 18 , the upper edge being coincident with the lower edge 15 of the third panel 13 . The fourth panel 18 is additionally delimited by a lateral edge 20 situated substantially in a continuation of the lateral edge 17 of the third panel 13 , and a lateral edge 21 . The distance between the lateral edges 20 , 21 of the fourth panel 18 is less (for example of the order of two thirds) than the distance between the free edge 16 and lateral edge 17 of the third panel 13 .
Finally, the textile article 1 comprises a belt 22 extending laterally from the edge 17 of the third panel 13 toward and substantially as far as the first panel 4 , substantially parallel to the lower edge 15 of the third panel 13 . The belt has an upper edge 23 and a lower edge 24 and also a free edge 25 remote from the lateral edge 17 .
The first and second faces 2 , 3 are made of a material having loops, in the manner of the loops in a fastener of the Velcro® type. For example, the textile article 1 can be made of polyurethane foam covered with a “down” or duvetine of polyamide loops. Alternatively, the first and second faces 2 , 3 could be without loops and, instead, could be provided with affixed tapes which themselves would have loops.
FIG. 2 shows a strap 26 comprising a first rectangular panel 27 and a second substantially rectangular panel 28 tapered to a point, these panels being joined by a curved transverse line 29 which gives the strap an elbow shape. At its ends, and on the same side, the first panel 27 has two zones 30 provided with fastening elements in the manner of hooks of a Velcro® system.
In a manner specific to the invention, the free edge 7 of the first panel 4 , the free edge 19 of the fourth panel 18 , and the free edge 25 of the belt 22 of the textile article 1 each comprise a fastening tab 31 extending along the entire length of said edge. The fastening tab 31 joined to the belt 22 will now be described in more detail with reference to FIGS. 3 to 6 , it being understood that the other tabs and their method of fixing are similar.
The tab 31 is a flat rectangle and has an active face 32 comprising fastening elements of the hook type as in a Velcro® system. The opposite face, called the inactive face 33 , has no such fastening elements. The tab 31 is fixed via its inactive face 33 to the textile article 1 , in this case the belt 22 , near the edge in question, in this case the free edge 25 .
According to a first embodiment, shown in FIGS. 3 to 5 , the tab 31 is fixed to a band 34 of the belt 22 , of width d, limited on the one hand by the edge 25 and on the other hand by a line 35 parallel to the edge 25 . The fixation is in this case effected by a seam 36 of zigzag configuration. A straight seam could also be used.
The band 34 is not fixed to the tab 31 in a centered position, but instead in such a way that the line 35 is situated substantially at the center of the tab 31 and thus defines two wings 37 , 38 of equal length 1 . By virtue of the flexibility of the textile article 1 and of the arrangement of the seam 36 , the tab 31 is able to pivot about the line 35 , as is shown in FIGS. 3 and 4 . In a first extreme position, the tab 31 is arranged in such a way that the inactive face 33 of the first wing 37 is folded back against the first face 2 of the textile article 1 , and, in a second extreme position, the tab 31 is arranged in such a way that the inactive face 33 of its second wing 38 is folded back against the second face 3 of the textile article 1 .
Thus, all of this is arranged as if the fastening elements of the active face 32 could be displaced from the first face 2 to the second face 3 of the textile article 1 depending on requirements, that is to say depending on whether one wishes to secure the first face or second face of the textile article 1 , and this simply by pivoting the tab 31 . It is therefore not necessary to provide fastening means on each of the faces 2 , 3 of the textile article. In addition, when the tab 31 is in the first extreme position, the second face 3 of the textile article 1 is without any fastening means (and vice versa in the second extreme position), and this avoids the risks of accidental fastening.
According to a second embodiment shown in FIG. 6 , the tab 31 is fixed to the edge 25 of the belt 22 by button points. In this case, the edge 25 is situated at the center of the tab 31 , thereby defining two wings 37 , 38 of equal width 1 , and the tab 31 is able to pivot about the edge 25 .
The tab 31 can be fixed to a zone of the textile article 1 comprising loops, either in a flat position, the totality of the active surface 32 being in contact with the same face of the textile article 1 , or in an astride position, the active faces 32 of the two wings 37 , 38 being folded back toward one another and enclosing between them the textile article 1 .
The way in which the textile article is fitted in place on a user will now be described.
In a first step, the concavity of the hump 12 is oriented in the direction suitable for the injured shoulder that is to be immobilized. In the figures, the shoulder in question is the left shoulder, and the hump 12 has to be oriented as shown in FIG. 1 . The face of the textile article 1 which will be oriented toward the user (the inside of the vest) is then the second face 3 .
In a second step, the hump 12 is placed on the shoulder, the third panel 13 covering the front of the thorax, the fourth panel 18 descending over the thighs, and the first panel 4 covering the back ( FIG. 7 ). The first panel 4 is wound around the user and folded back against the third panel 13 on which it is fixed, by cooperation between the hooks of the tab 31 and the loops of the textile of the third panel 13 . For this purpose, the tab 31 is oriented such that its active face 32 is opposite the third panel 13 .
Similarly, the belt 22 is wound around the user's waist and fastened, at the back, to the first panel 4 .
The user then places the arm corresponding to the injured shoulder against his chest, then the fourth panel 18 is folded back toward the third panel 13 , surrounding the arm ( FIG. 8 ), and fastened via the tab 31 to the third panel 13 .
The user can then fix the strap 26 around his elbow, said strap 26 being fixed, via the zones 30 , under the fourth panel 18 , beneath the forearm, and also on the second panel 8 , on the shoulder.
To fit the same textile article 1 in place on the other shoulder, it suffices first to invert the concavity of the hump 12 , then to place the textile article symmetrically to what has been described above (the second face 3 then being oriented outward from the vest and partially exposed) and to modify the orientation of the fastening tabs 31 simply by pivoting them about their pivot axis.
Thus, the invention affords a decisive improvement to the prior art by providing a reversible orthosis whose fastening means are themselves reversible.
It goes without saying that the invention is not limited to the embodiment described above by way of example, and instead it encompasses all the alternative embodiments.
The invention could therefore be employed for orthoses other than shoulder orthoses (for the wrists in particular). | This orthopedic orthosis, includes a textile article with first and second faces; the orthosis can be fitted in place such that either the first and second faces can equally well contact a patient limb. The orthosis has at least one fastening tab including an active face with fastening elements that may cooperate with first or second securing means arranged respectively on the first the second faces of the textile article, and an inactive face opposite the active face, said fastening tab being fixed non-removably via its inactive face on a zone contiguous to an edge of the textile article, so as to be able to pivot about an axis substantially parallel to this edge, between a first position, in which the active face catches by contact on the first securing means, and a second position, in which the active face catches by contact on the second securing means. | 0 |
[0001] The present invention relates to the connection of a lithium or lithium alloy foil electrode or electrodes to a contact lead, so as to promote good electrical and mechanical contact therebetween.
BACKGROUND
[0002] Primary and rechargeable batteries using metallic lithium as the active material for the negative electrode are known to have the highest energy per unit weight. In such batteries, the negative electrode, or anode, may be a lithium or lithium alloy foil component having a negative potential. The negative electrode may also include a current collector and a contact tab.
[0003] A current collector is an electrically conductive metallic foil, sheet or mesh that is generally used to provide a path for electrons from the external electrical circuit to the electrochemically active portion of the battery. A current collector will typically include a contact tab.
[0004] A contact tab is typically a metal foil portion of the current collector, which does not take part in the electrochemical process. It may extend from an edge of the main body of the current collector and is used to form the mechanical base for a weld to a contact lead.
[0005] A contact lead is a piece of electrically conductive metallic material used to form an electrical contact from the contact tab through a hermetically sealed battery container to the external electrical circuit. It is typically welded (in cells where metallic lithium is not used) or mechanically connected to the contact tab.
[0006] The contact lead must be connected or joined to the lithium in such a manner that a low resistance electrical connection is formed. Further, the connection or join must be mechanically strong enough to last for the expected life of the battery.
[0007] The current collectors in lithium primary batteries are typically composed of a metallic conductor other than lithium. The contact lead may be exposed to the electrolyte in an electrochemically active zone of the battery. This is not generally a problem in primary batteries; however it may cause problems in rechargeable (or secondary) batteries. In secondary batteries, lithium must be electrochemically deposited when the battery is recharged. In order to provide good reproducibility of performance, when the battery is repeatedly recharged, an excess of lithium is used so that lithium is only ever deposited onto lithium. If the contact lead or current collector is left exposed, then lithium will be plated onto a non-lithium substrate. This greatly increases the probability of unpredictable lithium deposition and hence poor cycling performance. This typically takes the form of active dendrite formation resulting in the quick degradation of the rechargeable lithium system. Examples of such failure mechanisms are described in U.S. Pat. No. 5,368,958, the full disclosure of which is incorporated into the present application by reference.
[0008] In a secondary battery with a lithium-based anode, the lithium is typically connected to the external circuit by one of two methods. Either a contact lead similar in design to that described for primary lithium batteries is used; as in U.S. Pat. No. 7,335,440, the full disclosure of which is incorporated into the present application by reference. U.S. Pat. No. 7,335,440 discloses the provision of a current collector in the form of a flat, solid piece of titanium, nickel, copper or an alloy of nickel or copper. The current collector is provided with a contact tab. A relatively long strip of alkali metal foil, having a width similar to the height of the current collector, is placed under the current collector and the two are pressed together. It is to be noted that, following assembly of the battery, the current collector (which is not made of an alkali metal) is immersed in electrolyte. Moreover, U.S. Pat. No. 7,335,440 states that this arrangement has problems in coiled, anode-limited cells of the type disclosed therein since there is a potential for a short circuit to be formed between the cathode material and the anode current collector when the thin layer of lithium has substantially depleted into the cathode in the outermost winding.
[0009] A variation of this method uses the metallic cell casing for the dual purpose of collecting current from the lithium, as in U.S. Pat. No. 7,108,942, the full disclosure of which is incorporated into the present application by reference. Additionally, the reverse face of the lithium electrode may be pressed or rolled against a thin metal current collector, as in U.S. Pat. No. 5,368,958, the full disclosure of which is incorporated into the present application by reference. The current collector can then be welded to a metal contact lead. However, if the current collector becomes exposed to the electrolyte, there is a risk that lithium will be plated onto the non-lithium current collector with the possible formation of dendrites that may short-circuit the battery. The metal current collector also adds unnecessary mass to the battery and reduces its specific energy.
[0010] In all of the examples described above, the metallic lithium is merely placed or pressed into contact with the current collector; there is no physical or chemical bond. This may be acceptable for primary batteries. However, for lithium metal rechargeable batteries such contact is not reliable. Indeed due to the reactive character of metallic lithium, corrosion layers may readily form on the interface of the mechanical connection between the lithium and the current collector. This may result in lower battery reliability as well as faster degradation in the capacity and cycle life of rechargeable lithium metal batteries.
BRIEF SUMMARY OF THE DISCLOSURE
[0011] Viewed from one aspect, there is provided a method of connecting at least one electrode to a contact lead, wherein the electrode comprises a sheet or foil having a contact zone, and wherein the contact lead comprises an electrically conductive lead with an end portion, the method comprising the steps of:
[0012] positioning the end portion of the contact lead and the contact zone of the at least one electrode so that there is overlap between the end portion and the contact zone;
[0013] ultrasonically welding the contact zone to the end portion so as to join the at least one electrode to the contact lead,
[0014] wherein at least the contact zone of the sheet or foil is formed from an alkali metal or an alloy of an alkali metal.
[0015] Preferably, the entire sheet or foil is formed from an alkali metal or an alloy of an alkali metal. The alkali metal may be lithium. Lithium metal and lithium allows are preferred as these tend to be useful as anode materials in secondary batteries, and are also soft and malleable, which allows a good connection to be made with the end portion of the contact lead when the welding step is performed.
[0016] Preferably, the contact zone is provided on a tab that protrudes from the edge of the sheet or foil. In a preferred embodiment, the tab provides the only point of contact between the sheet or foil and the end portion of the contact lead. Accordingly, the sheet or foil of the electrode may include a region for contact with the electrolyte that is not in direct contact with the end portion of the contact lead. The ultrasonic weld is preferably provided in a region that is not in contact with any of the electrolyte in the electrochemical cell or battery.
[0017] Preferably, there is no current collector in direct contact with the region for contact with the electrolyte. In fact, the electrode may be devoid of a current collector altogether.
[0018] Preferably, the end portion is formed from a metal that does not form an alloy with the alkali metal or alloy of alkali metal used to form the tab. Examples include metals or metal alloys comprising at least one of copper and/or nickel.
[0019] Without wishing to be bound by any theory, the ultrasonic welding step is believed to cause metal of the tab and/or the end portion to melt or soften, allowing the tab and end portion to be welded together under the applied pressure. The ultrasonic acoustic vibrations may also remove or disperse at least part of the alkali metal oxide layer formed on the tab, facilitating the formation of the bond. An advantage of the present invention is that melting or softening can be confined to the area of the join or weld, allowing a strong bond to be formed over a relatively small area. The area of the weld may be less than 50%, preferably less than 30%, more preferably less than 20%, yet more preferably, less than 10% (e.g. 1-5%) of the area of the sheet or foil.
[0020] Preferably, the ultrasonic welding step is carried out at frequencies of 15 to 70 kHz, more preferably 20 to 60 kHz, even more preferably 20 to 40 kHz, for example, about 40 kHz. The ultrasonic welding step may be carried out at a maximum pressure of 0.4 MPa, preferably 0.1 to 0.4 MPa, for example, 0.2 MPa.
[0021] The ultrasonic welding step may be carried out at a power of 100 to 5000 Watts. Amplitudes of 2 to 30 urn may be used.
[0022] In one embodiment, the ultrasonic welding step is carried out using an apparatus comprising a first clamping portion and a second clamping portion. The first clamping portion and second clamping portion are movable relative to one another from a first spaced apart position to a second position in which the first and second clamping portions are closer to one another. Preferably, only the second clamping portion is movable; the position of the first clamping portion is fixed.
[0023] The first clamping portion acts as a support for the materials to be welded. The second clamping portion is configured to vibrate at an ultrasonic frequency. To perform the welding step, the end portion of the contact lead is placed in contact with the contact zone of the at least one electrode so that there is overlap between the end portion and the contact zone. The overlapping structure is then placed between the first and second clamping portions, preferably on top of the first clamping portion. Optionally, a positioning jig may be used to support the overlapping structure in position. The second clamping portion is then moved relative to the first clamping portion so as to apply a clamping pressure between the materials to be welded. The second clamping portion is then vibrated at ultrasonic frequency. This pre-shapes and rubs the electrode and end portion of the contact lead against one another to prepare the surfaces for the formation of a join. The amplitude of the ultrasonic vibrations plays an important part in pre-shaping and preparing the relevant parts for weld formation. The first clamping portion is typically held in a fixed position while the second clamping portion vibrates. The contact zone of the electrode and end portion of the contact zone are then welded together in the main welding phase.
[0024] The end portion of the contact lead may be substantially flat or planar, or may take other shapes or configurations depending, for example, on the shape or configuration of the welding equipment that is used.
[0025] In one embodiment, a method of connecting at least one electrode to a contact lead, wherein the electrode comprises a sheet or foil having a contact zone, and wherein the contact lead comprises an electrically conductive lead with an end portion, the method comprising the steps of:
[0026] positioning the end portion of the contact lead and the contact zone of the at least one electrode so that there is overlap between the end portion and the contact zone;
[0027] ultrasonically welding the contact zone to the end portion so as to join the at least one electrode to the contact lead,
[0028] wherein at least the contact zone of the sheet or foil is formed from an alkali metal or an alloy of an alkali metal.
[0029] In some embodiments, there may be provided a plurality of electrodes, each comprising a sheet or foil with a tab (defining a contact zone) protruding from each sheet in substantially the same location, so that the tabs of the stack of electrodes are substantially aligned when the electrodes are aligned with each other and arranged as an electrode stack. For the avoidance of doubt, the tab defining the contact zone is formed of an alkali metal or an alloy of an alkali metal, preferably lithium or lithium alloy.
[0030] In these embodiments, the end portion of the contact lead may be placed on top of the tabs of the electrode stack, underneath the tabs of the electrode stack, or at an intermediate position between the top and the bottom (i.e. with at least one tab above and at least one tab below). The tabs of the electrode stack may be pressed together before the end portion is placed on top of or underneath the compressed tabs and the ultrasonic welding is performed.
[0031] In embodiments where there is provided a stack of electrodes, the welding step causes the tabs to bond together physically. Preferably, the ultrasonic welding step causes the tabs (contact zones) of at least two sheets or foils formed from an alkali metal or an alloy of an alkali metal to be welded together. In a preferred embodiment, the ultrasonic welding step creates, for example, a lithium to lithium weld in addition to a weld between lithium and the end portion of the contact lead.
[0032] The end portion of the contact lead may be planar and devoid of through-holes. Alternatively, the end portion may optionally be perforated, punched or have a mesh-like or reticulated form. When such through-holes are present, it is important is that the metal of the tabs is sufficiently malleable to enable it to pass through the through holes so as to cause the end portion to become embedded in what is preferably a single phase of the first metal. This forms an intimate contact between the metals of the end portion of the contact lead and the contact zone of the electrode, and thus between the contact lead and the electrode.
[0033] Where the end portion has through-holes, the openness of the end portion may be defined as the ratio of open area to the full surface area of the end portion. The openness of the end portion of the contact lead may be in the range of 5% to 95%, preferably 20% to 90%, for example, 50% to 80%.
[0034] The electrically conductive lead of the contact lead may itself be generally planar, for example in the form of a ribbon, although other profiles may be useful. The electrically conductive lead may be made of the same metal as the end portion, or of a different metal.
[0035] In this way, it is possible for form a reliable connection with a contact lead made of a metal other than the metal of the electrode. It will be understood that the contact lead, which will generally be exposed outside the casing of the battery, must be made of a metal that has good electrical conductivity but is not highly reactive when exposed to air or moisture. Suitable metals include nickel, copper, stainless steel or various alloys.
[0036] Moreover, the metal of the contact lead, since it is connected only to the protruding tabs of the electrodes, is desirably not directly exposed to electrolyte when the battery is assembled.
[0037] A further advantage is that a good connection can be made to the at least one electrode without the electrode as a whole needing to be formed or disposed on a current collector made of a metal other than the metal used in the sheet or foil of the electrode. In other words, the main part of the electrode that is exposed to the electrolyte consists solely of the first metal (e.g. lithium or a lithium alloy), with no need for a copper or nickel or other current collector that would add unnecessary weight and act as a substrate for the formation of dendrites during cycling.
[0038] Moreover, it is important that the metal of the contact lead is selected so that it does not form an alloy with the metal of the electrode. This is in order to avoid reduction of the amount of the first metal that is available to the electrochemical system of the battery. For example, lithium will form an alloy with aluminium, but not with nickel or copper.
[0039] According to a further aspect of the invention, there is provided a device obtainable according to the method described above. The device comprises at least one electrode comprising a sheet or foil having a contact zone formed from an alkali metal or an alloy of an alkali metal, and a contact lead comprising an electrically conductive lead with an end portion, wherein the end portion of the contact lead overlaps and is ultrasonically welded to the contact zone of the at least one electrode.
[0040] Preferably, the device comprises at least two electrodes comprising a sheet or foil having a contact zone formed from an alkali metal or an alloy of an alkali metal, and wherein at least a portion of said contact zones are ultrasonically welded to one another. Thus, for example when the contact zone is formed from lithium or a lithium alloy, an ultrasonic weld between lithium/lithium alloy and lithium/lithium alloy is formed.
[0041] In one embodiment of the device, at least two electrodes are aligned with each other and arranged as an electrode stack. The end portion of the contact lead may be placed on top of or underneath the electrode stack, such that the end portion overlaps and is ultrasonically welded to the contact zone of the at least one electrode. Alternatively, the end portion of the contact lead may be placed at an intermediate position between the top and the bottom of the electrode stack. In the latter embodiment, the contact zones on either side of the end portion of may preferably also be ultrasonically welded to one another. Accordingly, an alkali metal/alkali metal alloy to alkali metal/alkali metal alloy ultrasonic weld may also be formed.
[0042] Viewed from another aspect, there is provided a method of connecting at least one electrode to a contact lead, wherein the electrode comprises a sheet or foil of a first metal with a tab protruding from an edge of the sheet or foil, and wherein the contact lead comprises an electrically conductive lead with an end portion made of a second metal that does not alloy with the first metal and having a plurality of through holes, the method comprising the steps of:
[0043] i) positioning the end portion of the contact lead and the tab of the at least one electrode so that there is substantial overlap between the end portion and the tab;
[0044] ii) causing the metal of the tab to penetrate through the through holes of the end portion so as to join the at least one electrode to the contact lead.
[0045] In step ii), the metal of the tab may be caused to penetrate through the through holes by pressing and welding, for example by way of ultrasonic welding, thermal contact welding, laser welding or induction welding. Advantageously, the welding is effected in such a way so as not to cause significant thermal deformation or changes in the main laminar sheet or foil of the at least one electrode, but to concentrate the applied energy in the locality of the tab.
[0046] The end portion of the contact lead may be substantially flat or planar, or may take other shapes or configurations depending, for example, on the shape or configuration of any welding equipment that is used.
[0047] In some embodiments, there may be provided a plurality of electrodes, each comprising a sheet or foil of metal with a tab protruding from each sheet in substantially the same location, so that the tabs of the stack of electrodes are substantially aligned when the electrodes are aligned with each other and arranged as an electrode stack.
[0048] In these embodiments, the end portion of the contact lead may be placed on top of the tabs of the electrode stack, underneath the tabs of the electrode stack, or at an intermediate position between the top and the bottom (i.e. with at least one tab above and at least one tab below). The tabs and the perforated end portion are then pressed together and the first metal (of the tabs) is caused to penetrate through the holes in the perforated planar end portion (made of the second metal) of the contact lead. Alternatively, the tabs of the electrode stack may be pressed together before the perforated end portion is placed on top of or underneath the compressed tabs and the penetration of step ii) is performed.
[0049] In embodiments where there is provided a stack of electrodes, the pressing and welding step causes the tabs to join together physically as well as to penetrate into the through holes of the contact lead. Preferably, the welding step is an ultrasonic welding step. This welding step preferably causes the tabs of at least two sheets or foils (preferably formed from an alkali metal or an alloy of an alkali metal) to be welded together. In a preferred embodiment, the ultrasonic welding step creates, for example, a lithium to lithium weld between at least two lithium tabs in addition to a weld between at least one lithium tab and the end portion of the contact lead.
[0050] Particularly preferred metals for the first metal are lithium and lithium alloys, since these tend to be useful as anode materials in secondary batteries, and are also soft and malleable, which allows a good connection to be made with the perforated end portion of the contact lead when the pressing and welding step is performed.
[0051] The end portion of the contact lead may be perforated, punched or have a mesh-like or reticulated form. What is important is that when the first metal of the tabs is sufficiently malleable that it can pass through the through holes so as to cause the second metal of the end portion to become embedded in what is preferably a single phase of the first metal. This forms an intimate contact between the first and second metals, and thus between the contact lead and the electrodes.
[0052] The greater the openness or surface area of the end portion of the contact lead, the better the electrical (and physical) connection between the contact lead and the electrodes. The openness of the end portion may be defined as the ratio of open area to the full surface area of the end portion. The openness of the end portion of the contact lead may be in the range of 5% to 95%.
[0053] The electrically conductive lead of the contact lead may itself be generally planar, for example in the form of a ribbon, although other profiles may be useful. The electrically conductive lead may be made of the same metal as the second metal forming the end portion, or of a different metal.
[0054] In this way, it is possible for form a reliable connection with a contact lead made of a metal other than the metal of the electrode. It will be understood that the contact lead, which will generally be exposed outside the casing of the battery, must be made of a metal that has good electrical conductivity but is not highly reactive when exposed to air or moisture. Suitable metals include nickel, copper, stainless steel or various alloys.
[0055] Moreover, the metal of the contact lead, since it is connected only to the protruding tabs of the electrodes, is not directly exposed to electrolyte when the battery is assembled.
[0056] A further advantage is that a good connection can be made to the at least one electrode without the electrode as a whole needing to be formed or disposed on a current collector made of a metal other than the first metal. In other words, the main part of the electrode that is exposed to the electrolyte consists solely of the first metal (e.g. lithium or a lithium alloy), with no need for a copper or nickel or other current collector that would add unnecessary weight and act as a substrate for the formation of dendrites during cycling.
[0057] Moreover, it is important that the second metal (of the contact lead) is selected so that it does not form an alloy with the first metal (of the electrode). This is in order to avoid reduction of the amount of the first metal that is available to the electrochemical system of the battery. For example, lithium will form an alloy with aluminium, but not with nickel or copper.
[0058] In certain embodiments, the electrode is configured as an anode, or negative electrode, for a battery. However, it will be appreciated that the method is applicable also to cathodes, or positive electrodes, where these are made of a metal that is suitable for pressing and welding to a perforated second metal as described.
[0059] Viewed from a third aspect, there is provided, in combination, at least one electrode for a battery and a contact lead, wherein the electrode comprises a sheet or foil of a first metal with a tab protruding from an edge of the sheet or foil, and wherein the contact lead comprises an electrically conductive lead with an end portion made of a second metal that does not alloy with the first metal and having a plurality of through holes, wherein the first metal of the tab has been pressed and welded so as to penetrate through the through holes of the second metal end portion.
[0060] Embodiments of the present invention seek to provide a negative electrode (anode) eliminating the need for the current collector, and a method of forming a reliable physical contact between different pieces of metallic lithium and the contact lead, thereby to promote good electrical contact between metallic lithium and the material of the contact lead.
[0061] In preferred embodiments, an excess of metallic lithium is used such that at the end of the battery life there is a substantial amount of lithium metal which serves as the current collector for the negative electrode. The use of lithium as the current collector eliminates mechanical contact between metal lithium and another current collector material.
[0062] In some embodiments, there may be provided a plurality of electrodes, each comprising a sheet or foil of the first metal with a tab protruding from each sheet in substantially the same location, so that the tabs of the stack of electrodes are substantially aligned when the electrodes are aligned with each other and arranged as an electrode stack.
[0063] The lithium metal of the negative electrode in the region of the tabs may form a single phase connection from lithium electrode to lithium electrode in the electrode stack. Such connection is achieved by using pressing and welding as hereinbefore described.
[0064] The contact lead, or at least the end portion thereof, may be thin (for example, with a thickness of 5 to 50 μm), or may be thick (for example, with a thickness of 50 to 10,000 μm).
[0065] The contact lead may be substantially linear, or may have a ‘T’-shaped or ‘L’-shaped configuration.
[0066] The sheet or foil of the electrode may have a thickness of 30 to 150 μm, for example, 50 to 100 μm prior to the welding or joining step.
[0067] The end portion of the contact lead may be an integral part of the contact lead (in other words, formed from the same material as the rest of the contact lead and integral therewith), or may be a separate metal component, not necessarily of the same material as the rest of the contact lead, and welded thereto (for example by ultrasonic welding, thermal contact welding, laser welding, induction welding or other types of welding).
[0068] The electrodes described above may be used in a battery or electrochemical cell, preferably a lithium cell, such as a lithium-sulphur cell. The electrodes may be used as the anode of such cells. In one embodiment, the cell comprises i) at least one electrode as described above as the anode(s), and ii) at least one cathode, such as a cathode comprising sulphur as an active material. The anode(s) and cathode(s) may be placed in contact with a liquid electrolyte comprising a lithium salt dissolved in an aprotic organic solvent. A separator may be positioned between the anode and cathode. The electrolyte may be sealed within a container to prevent it from escaping. Preferably, the seal also prevents the alkali metal of the sheet or foil from being exposed to the surrounding environment. Thus, the weld between the contact zone or tab and the end portion of the contact leas is preferably located within the container, while at least a portion of the conductive lead accessible from outside of the sealed container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0069] Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:
[0070] FIGS. 1 a to 1 c shows a battery stack with anodes, cathodes and tabs, and three alternative positionings for a contact lead;
[0071] FIGS. 2 a to 2 e show possible designs for the contact lead;
[0072] FIG. 3 shows the contact lead being ultrasonically welded to the tabs; and
[0073] FIGS. 4 a to 4 d show an apparatus suitable for use in forming an ultrasonic weld in use.
DETAILED DESCRIPTION
[0074] A battery can be formed by an alternating stack of numerous cathodes and anodes. Each of these layers is divided by a separator. An ionic pathway is maintained by the presence, between each electrode, of an electrolyte. Each electrode 1 features a tab 2 protruding from its electrochemically active area and beyond the edge of the separator. These tabs 2 provide the first surface through which the stack 3 of lithium anodes will be welded to each other and joined to a contact lead 4 . The tabs 2 are first folded and/or formed by pressing. A contact lead 4 is then positioned at the top ( FIG. 1 a ) or bottom ( FIG. 1 b ) of the stack 5 of tabs 2 , or it may be positioned between any two lithium tabs 2 ( FIG. 1 c ).
[0075] The contact leads 4 may take a number of forms ( FIGS. 2 a to 2 e ). The body 6 is composed of a conductive metal ribbon, typically nickel, copper, stainless steel or some composite conductor. The end portion 7 (the area to be welded) may be perforated, meshed or punched. Alternatively, the end portion 7 may be devoid of any through-holes (not shown). The end portion 7 may be an integral part of the metal ribbon 6 , or it may be a separate piece welded to the ribbon 6 . Where the end portion 7 is a separate piece welded to the ribbon 6 , it may be made of a different metal to that of the ribbon 6 . The contact may be linear, “T” or “L” shaped. The perforations, when present, may be rhombic, circular, square, rounded, polygonal or any other suitable shape.
[0076] The tabs 2 and the contact lead 4 are then positioned between the two weld fixtures 8 of an ultrasonic welder ( FIG. 3 ). The ultrasonic welder then simultaneously applies pressure and an ultrasonic wave to the weld area. This causes the numerous lithium layers 2 to fuse together to form a lithium-lithium weld. Further, where the contact lead 4 includes through holes, the softened lithium percolates through the perforated or meshed area 7 of the contact lead 4 . The contact lead 4 is hence joined to the lithium 2 as the mesh 7 is intimately surrounded by lithium. The high surface area contact between the mesh 7 of the contact lead 4 and the lithium electrode 1 produces a low resistance and a mechanically strong electrical contact. When the ultrasonic wave ceases and the pressure is released, the contact lead 4 will be joined to the lithium anodes 1 .
[0077] FIGS. 4 a to 4 e depict an apparatus that may be used for forming an ultrasonic weld. The apparatus comprises a first clamping portion 12 and a second clamping portion 14 that are movable from a first spaced apart position to a second position where the portions 12 , 14 are closer to one another. The apparatus also includes a positioning jig 16 for supporting the parts 18 to be welded in position. The second clamping portion 14 is configured to vibrate at ultrasonic frequencies.
[0078] As best seen in FIG. 4 a , the parts 18 to be welded are placed on top of the first clamping portion 12 while the clamping portions are in their first spaced apart position. The second clamping portion 14 is then moved relatively towards the first clamping portion 12 to apply a clamping pressure between the parts 18 to be welded. The second clamping portion 14 is then vibrated at ultrasonic frequency ( FIG. 4 b ). This pre-shapes and rubs the parts 18 together, so that their surfaces are prepared for weld formation. In the main welding phase, the parts 18 are joined together (see FIG. 4 c ). The first and second clamping portions 12 , 14 are then moved apart to allow the welded parts 18 to be removed from the apparatus (see FIG. 4 d ).
Example 1
[0079] A linear nickel contact lead, composed of 50 μm thick nickel ribbon, was used. The endmost 5 mm of the contact lead was expanded to form a mesh. A battery with 60 lithium anodes, each of 78 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The lithium contact tabs were formed and trimmed to produce a flat welding area and to ensure that each of the tabs, regardless of its position, in the stack used the minimum quantity of lithium. The formed stack of lithium tabs was then positioned between the welding fixtures of an ultrasonic welder. The contact lead was then positioned on top of the stack of lithium tabs, such that the meshed region overlapped with the flat lithium welding zone. The welding conditions listed in Table 1 were then entered into an AmTech 900B 40 kHz ultrasonic welder. A single weld was then performed. Each of the 60 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the contact lead. This join had been created by the softened lithium penetrating through the mesh of the contact lead.
[0000]
TABLE 1
The welder setting used in Example 1.
Energy/J
Amplitude/μm
Trigger Pressure/Psi
Pressure/Psi
180
5
20
20
Example 2
[0080] A “T” shaped contact lead was made by welding a piece of nickel ribbon (50 μm thick) to a piece of copper mesh. The mesh opening was approximately 200×700 μm, with a bar width of 100 μm. The mesh was thrice as long as the nickel ribbon was wide. The mesh was 5 mm wide; the same as the welding zone. The mesh was positioned centrally to form the cross of the “T” and welded into position by an ultrasonic welder using the conditions given in Table 2, weld A. The contact lead was positioned between the welding fixtures of an ultrasonic welder such that the meshed region fell into the welding zone.
[0081] A battery with 20 lithium anodes, each of 78 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The stack of lithium contact tabs was formed and trimmed to produce a flat welding area and to ensure that each of the contact tabs, regardless of its position, in the stack used the minimum quantity of lithium.
[0082] The stack of lithium contact tabs was then positioned on top of the contact lead, between the welding fixtures of an ultrasonic welder. The copper mesh “arms” of the “T” shaped contact lead were then folded around the stack of lithium contact tabs. The welding conditions listed in Table 2, weld B were then entered into an AmTech 900B 40 kHz ultrasonic welder. A single weld was then performed. Each of the 20 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the contact lead. This join had been created by the softened lithium penetrating through the mesh of the contact lead.
[0000]
TABLE 2
The welder settings used in Example 2
Weld
Energy/J
Amplitude/μm
Trigger Pressure/Psi
Pressure/Psi
A
70
80
80
5
B
10
5
20
20
Example 3
[0083] An “L” shaped contact lead was manufactured by photochemical etching from a sheet of 100 μm thick stainless steel. The upright section of the “L” is continuous steel foil. The base of the “L” was etched with a mesh pattern. The mesh opening was 500×500 μm and the bar width was 100 μm. The base of the “L” was twice the width of the upright section. The width of the base section was 5 mm, the same as the weld zone.
[0084] A battery with 20 lithium anodes, each of 78 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The contact lead was positioned between the top face to the lowermost lithium contact tab and the bottom face of the remainder of the stack. The remainder of the stack of lithium contact tabs was pushed down onto the meshed region of the contact lead. The protruding meshed section of the contact lead was folded over the stack of contact tabs. The contact assembly was positioned between the welding fixtures of an ultrasonic welder such that the meshed regions fell into the welding zone.
[0085] The welding conditions listed in Table 3 were then entered into an AmTech 900B 40 kHz ultrasonic welder. A single weld was then performed. Each of the 20 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the contact lead. This join had been created by the softened lithium penetrating through the mesh of the contact lead.
[0000]
TABLE 3
The welder settings used in Example 3
Energy/J
Amplitude/μm
Trigger Pressure/Psi
Pressure/Psi
40
5
20
20
Example 4
Nickel
[0086] A square shaped contact lead was made by cutting a piece of plane nickel foil (100 μm thick). The contact lead was positioned between the welding fixtures of an ultrasonic welder such that the welding zone was 1 mm from the tab edge. The welding zone was a rectangle (20×6 mm).
[0087] A battery with 9 lithium anodes, each of 100 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The stack of lithium contact tabs was formed and trimmed to produce a flat welding area and to ensure that each of the contact tabs, regardless of its position, in the stack used the minimum quantity of lithium. The trimmed edges of lithium tabs fully covered the welding zone at the nickel foil.
[0088] The stack of lithium contact tabs was then positioned on top of the contact lead, between the welding fixtures of an ultrasonic welder. The welding conditions are listed in Table 4. The welder is a NewPower Ultrasonic Electronic Equipment CO., LTD 40 kHz ultrasonic welder. A single weld was performed. Each of the 9 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the nickel contact lead. This join had been tested per peel test procedure.
[0000]
TABLE 4
Frequency
40 kHz
Welding Time sectors:
Delay
0.15 s
Welding
0.18 s
Take off
0.20 s
Amplitude
50% (of 10 μm)
Pressure
0.21 MPa
Power
350 W
Energy
350 J
Example 5
Copper
[0089] A square shaped contact lead was made by cutting a piece of plane copper foil (100 μm thick). The contact lead was positioned between the welding fixtures of an ultrasonic welder such that the welding zone was placed 1 mm from the tab edge. The welding zone was a rectangle (20×6 mm).
[0090] A battery with 9 lithium anodes, each of 100 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The stack of lithium contact tabs was formed and trimmed to produce a flat welding area and to ensure that each of the contact tabs, regardless of its position, in the stack used the minimum quantity of lithium. The trimmed edges of lithium tabs fully covered the welding zone at the copper foil.
[0091] The stack of lithium contact tabs was then positioned on top of the contact lead, between the welding fixtures of an ultrasonic welder. The welding conditions are listed in Table 5. The welder is a NewPower Ultrasonic Electronic Equipment CO., LTD 40 kHz ultrasonic welder. A single weld was then performed. Each of the 9 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the copper contact lead. This join had been tested per peel test procedure.
[0000]
TABLE 5
Frequency
40 kHz
Welding Time sectors:
Delay
0.15 s
Welding
0.16 s
Take off
0.20 s
Amplitude
50% (of 10 μm)
Pressure
0.20 MPa
Power
300 W
Energy
300 J
Example 6
Stainless Steel, 316
[0092] A square shaped contact lead was made by cutting a piece of plane stainless steel foil (58 μm thick). The contact lead was positioned between the welding fixtures of an ultrasonic welder such that the welding zone was placed 1 mm from the tab edge. The welding zone was a rectangle (20×6 mm).
[0093] A battery with 9 lithium anodes, each of 100 μm thickness, was assembled. A stack of lithium contact tabs protruded from the battery. The stack of lithium contact tabs was formed and trimmed to produce a flat welding area and to ensure that each of the contact tabs, regardless of its position, in the stack used the minimum quantity of lithium. The trimmed edges of lithium tabs fully covered the welding zone at the stainless steel foil.
[0094] The stack of lithium contact tabs was then positioned on top of the contact lead, between the welding fixtures of an ultrasonic welder. The welding conditions are listed in Table 6, were then entered into the NewPower Ultrasonic Electronic Equipment CO., LTD 40 kHz ultrasonic welder. A single weld was then performed. Each of the 9 lithium layers were welded firmly to each other. A strong join was produced between the lithium and the stainless steel contact lead. This join had been tested per peel test procedure.
[0000]
TABLE 6
Frequency
40 kHz
Welding Time sectors:
Delay
0.15 s
Welding
0.18 s
Take off
0.20 s
Amplitude
80% (of 10 μm)
Pressure
0.21 MPa
Power
350 W
Energy
350 J
[0095] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0096] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0097] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. | There is disclosed a method of connecting a lithium electrode to a contact lead in a rechargeable battery. The electrode comprises a sheet or foil of lithium or lithium alloy with a tab protruding from an edge of the sheet or foil. The contact lead comprises an electrically conductive lead with an end portion made of a second metal that does not alloy with lithium and has a plurality of through holes. The end portion of the contact lead and the tab of the electrode are positioned so that there is substantial overlap between the end portion and the tab. The metal of the tab is then caused, for example by pressing and welding, to penetrate through the through holes of the end portion so as to join the electrode to the contact lead. A combination electrode/contact lead assembly made by this method is also disclosed. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a printing element comprising at least one polymer layer which has photoimageable constituents and additions to make the polymer layer either more hydrophobic or hydrophilic. The printing element may have two polymer layers on a substrate in which one of the layers comprises fluorinated acrylates or methacrylates.
BACKGROUND
[0002] Verbanic et al (U.S. Pat. No. 3,055,932) discloses unsaturated esters of fluorinated glycols and acyl halides. It discloses preparation of compositions of matter which are useful in the formation of polymeric materials for high temperature applications.
[0003] The present invention is directed to an article comprising at least one layer of polymer deposited on a substrate wherein the layer contains fluorinated compounds or additives that adjust the relative hydrophobicity of the layers.
BRIEF DESCRIPTION OF THE DRAWINGS AND FIGURES
[0004] FIGS. 1A and 1B illustrate a bi-layer structure for differential inking.
[0005] FIGS. 2A and 2B illustrate a bi-layer structure for differential inking.
[0006] FIG. 3 illustrates drop diameters as a function of concentration of fluorinated surfactants in the polymer layer.
SUMMARY OF THE INVENTION
[0007] The invention is directed to an article comprising:
[0008] a) a substrate
[0009] b) a first polymer layer disposed on the substrate wherein the first polymer layer comprises:
i) an elastomeric polymer; and ii) a initiator; and
[0012] c) a second polymer layer disposed on the first polymer layer wherein the second polymer layer comprises
i) an elastomeric polymer; and ii) a photoinitiator; and
wherein the first polymer layer or the second polymer layer further comprises a polymer of monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof; and
wherein the polymer layer that does not contain the polymer of the monomers contains a polymer of non-fluorinated acrylate or methacrylate monomers.
[0015] The invention is further directed to an article comprising:
[0016] a) a substrate
[0017] b) a first polymer layer disposed on the substrate wherein the a first polymer layer comprises
i) an elastomeric polymer; ii) an initiator; and iii) a polymer selected from non-fluorinated acrylate or methacrylate monomers;
[0021] c) a second polymer layer disposed on the first polymer layer wherein the a second polymer layer comprises
i) an elastomeric polymer; ii) a photoinitiator; and iii) a polymer selected from a non-fluorinated acrylate or methacrylate monomers;
wherein the first or the second polymer layer comprises fluorinated additives.
[0025] The invention is still further directed to a process comprising:
[0026] a) providing a substrate
[0027] b) depositing a first polymer layer on the substrate, the first polymer layer comprising
i) an elastomeric polymer; ii) an initiator; and iii) non-fluorinated acrylate or methacrylate monomers
[0031] c) crosslinking the first polymer layer;
[0032] d) depositing a second polymer layer on the first polymer layer, the second polymer layer comprising;
i) an elastomeric polymer; ii) a photoinitiator; and iii) monomers selected from the group consisting of:
[0000]
[0036] and mixtures thereof;
[0037] e) imaging a pattern on the second polymer layer forming an imaged pattern; and
[0038] f) developing the imaged pattern.
[0039] The invention is also directed to a process comprising:
[0040] a) providing a substrate;
[0041] b) depositing a first polymer layer on the substrate wherein the first polymer layer comprises
i) an elastomeric polymer; ii) a initiator; iii) monomers selected from the group consisting of:
[0000]
[0045] and mixtures thereof;
[0046] c) crosslinking the first polymer layer;
[0047] d) depositing a second polymer layer on the first polymer layer wherein the second polymer layer comprises;
i) an elastomeric polymer; ii) a photoinitiator; and iii) monomers selected from non-fluorinated acrylate or methacrylate;
[0051] e) imaging a pattern on the second polymer layer forming an imaged pattern; and
[0052] f) developing the imaged pattern.
DETAILED DESCRIPTION
[0053] In a standard imaged and processed flexographic printing plate, the difference in height (Δh) between the uppermost relief features and the floor of the plate typically ranges from about 100-500 microns. This dimension depends upon the desired size of the relief features and other specifics unique to the printing plate. When plates are intended to be used for high resolution printing applications (i.e. printing in the micron range), the value of Δh must be reduced so as to be comparable to the plate's very small feature sizes. Typically, the Δh-to-feature size ratio falls near unity for most high resolution printing processes. Unfortunately, the reduction in Δh tends to compromise the plate's mechanical durability and its elastomeric behavior that is required for good conformal contact between the plate and the object to be printed. One solution to this limitation involves the fabrication of a bi-layer construct that has both a photo- or a thermo-crosslinkable elastomeric floor layer providing for good mechanical properties and a thin photo-imageable elastomeric layer that is sequentially deposited on top that contains the desired relief features arranged in a pattern. In this way, the properties of the two layers can each be optimized separately so that the bottom layer adjacent to the substrate controls the plate's elastic modulus for optimal printing while the thin upper layer (with Δh˜desired feature size) controls the plate's printing resolution.
[0054] Bi-layer plates that are fabricated in this manner can be designed for differential inking with hydrophilic inks. Here, the printing plate comprises a flexible support or substrate and two additional crosslinkable elastomeric layers of essentially the same composition that have very different surface energies. Both of these additional layers would comprise elastomeric photopolymer compositions and one of these layers would also contain fluorinated nanoparticles, fluorinated additives (e.g. Zonyl® fluorosurfactants, DuPont, Wilmington, Del.), fluorinated telomers or fluorinated acrylate or methacrylate crosslinking monomers. The fluorine containing layer could be chosen to be at the top or at the bottom of the bi-layer printing plate. If the fluorine containing layer is at the top, the bottom layer would selectively ink with hydrophilic inks. On the other hand, if the fluorine modified layer is at the bottom, the top layer would selectively ink when hydrophilic inks are used. In either of these cases, good printing resolution is achieved because the relatively more hydrophobic fluorinated portions of the plate are not wetted by the ink while the other more hydrophilic areas are wetted by the ink.
[0055] These concepts are illustrated in FIGS. 1 and 2 . FIG. 1A shows a bi-layer printing plate containing fluorinated additives or fluorinated particles ( 16 ) that operates in a Gravure mode with hydrophilic inks where ( 14 ) is a support layer, ( 12 ) is a photo- or a thermally crosslinked elastomeric layer and ( 10 ) is a photo-crosslinked elastomeric layer containing fluorinated additives or particles that was exposed to actinic radiation through a photo-mask (imaged) and then subsequently developed to remove non-crosslinked material to form a pattern. FIG. 1B shows a bi-layer printing plate containing fluorinated additives or fluorinated particles ( 16 ) that operates in a flexographic mode with hydrophilic inks where ( 14 ) is a support layer, ( 12 ) is a photo- or a thermally crosslinked elastomeric layer that contains fluorinated additives or particles and ( 10 ) is a photo-crosslinked elastomeric layer that was exposed to actinic radiation through a photo-mask (imaged) and then subsequently developed to remove non-crosslinked material to form a pattern. FIG. 2A shows a bi-layer printing plate containing fluorinated monomers that operates in a Gravure mode with hydrophilic inks where ( 14 ) is a support layer, ( 12 ) is a photo- or a thermally crosslinked elastomeric layer and ( 18 ) is a photo-crosslinked elastomeric layer containing fluorinated crosslinking monomers that was exposed to actinic radiation through a photo-mask (imaged) and then subsequently developed to remove non-crosslinked material to form a pattern. FIG. 2B shows a bi-layer printing plate containing fluorinated monomers that operates in a flexographic mode with hydrophilic inks where ( 14 ) is a support layer, ( 16 ) is a photo- or a thermally crosslinked elastomeric layer that contains fluorinated crosslinking monomers and ( 10 ) is a photo-crosslinked elastomeric layer that was exposed to actinic radiation through a photo-mask (imaged) and then subsequently developed to remove non-crosslinked material to form a pattern.
[0056] Gravure or flexographic bi-layer printing plates that can be selectively inked with hydrophobic inks can be fabricated in a similar manner. In this case, both layers of the bi-layer plate would also comprise crosslinked elastomeric photopolymer compositions and one of the layers would also contain hydrophilic additives like ionic surfactants or particles of silica, alumina or titanium dioxide, or acrylate or methacrylate crosslinking monomers fitted with hydrophilic (e.g. hydroxyl carboxylic acid) functional groups. If the upper layer contained the hydrophilic additives or functional groups, the bottom layer of the bi-layer plate would selectively ink when contacted by hydrophobic inks. Conversely, if the hydrophilic layer is at the bottom, the upper layer of the plate would selectively ink when hydrophobic inks are employed. Again, good printing resolution is achieved because the relatively more hydrophilic portions of the bi-layer plate are not wetted by the hydrophobic ink while the other more hydrophobic areas of the plate are wetted by the ink.
[0057] Depending upon the particular application desired, the target resolution for high resolution printing plates can be in the range of 1-15 microns. Printing electronic devices using a reel-to-reel process requires the ability to print high resolution lines and spaces. The source-drain level of a thin film transistor is particularly demanding because the channel lengths required for good transistor performances are on the order of only a few microns. Currently it is not possible to print at these micron resolutions using available materials and/or processes. Standard printing plates do not have nearly the required resolution. In contrast, molded polydimethylsiloxane (PDMS) plates can reach these resolutions but are typically limited to printing thiol layers.
[0058] Bi-layer plates are described which are fabricated from commercially available block copolymers like poly(styrene-butadiene-styrene) or poly(styrene-isoprene-styrene) elastomers that have been mixed with smaller crosslinkable acrylate or methacrylate monomers. These polymerizable mixtures furnish robust, semi-interpenetrating networks (SIPNs) when crosslinked thermally or photochemically. The SIPN layers that result are elastomeric in their mechanical behaviors and form the two working layers contained in the bi-layer plate where one of the layers also contains hydrophobic or hydrophilic additives and/or monomers to modify its surface energy relative to the other layer. The two SIPN layers formed in this manner are chemically resistant to many solvents and dispersants that are used in standard ink formulations, including ethanol, aqueous alcohol mixtures, toluene and ortho-dichlorobenzene. Moreover, because the two SIPN layers contain many of these same chemical components, inter-layer adhesion between the two adjacent layers can be maintained. In addition to poly(styrene-butadiene-styrene) or poly(styrene-isoprene-styrene) elastomers, other elastomeric polymers and rubbers can also be used to form the two polymeric SIPN layers in the bi-layer plate, including various copolymers of butadiene with acrylonitrile and neoprene rubbers.
[0059] One embodiment of the present invention is an article which may be used as a printing element. In this embodiment, the substrate is selected to be relatively hydrophilic. The substrate may be Mylar® (DuPont Teijin Films, Bristol, UK). A relatively hydrophobic polymer layer is deposited on the substrate. The polymer layer may be deposited by spin coating, bar coating, spraying, dipping or similar coating technologies known to one skilled in the art. The polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and photoimaging constituents. Appropriate photoimaging constituents may include photoinitiators and/or photosensitizers among others. The polymer layer also comprises a polymer of the monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof.
[0060] The polymer layer may optionally further comprise fluorinated additives such as Zonyl® fluorosurfactants (DuPont, Wilmington Del.) or fluorinated particles. In this embodiment, the substrate is relatively hydrophilic while the polymer layer is hydrophobic due to the incorporation of the fluorinated monomers and/or fluorinated additives.
[0061] A second embodiment of the present invention is an article which may be used as a printing element. In this embodiment, the substrate is selected to be relatively hydrophobic. The substrate may be plasma treated polytetrafluoroethylene or another plasma treated fluoropolymer. A polymer layer is deposited on the substrate. The polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and photoimaging constituents. Appropriate photoimaging constituents may include photoinitiators and/or photosensitizers among others. The polymer layer may optionally comprise hydrophilic additives such as ionic surfactants or hydrophilic particles of silica, alumina or titanium dioxide. The polymer layer further comprises a polymer of non-fluorinated (meth)acrylate monomers that contain hydrophilic substituents such as hydroxyl or carboxylic acid groups. In this embodiment, the substrate is hydrophobic while the polymer layer relatively hydrophilic.
[0062] A third embodiment of the present invention is an article which may be used as a printing element. In this embodiment, the substrate may be any material that may be coated. A first polymer layer is deposited on the substrate. The first polymer layer may be deposited by any known coating technique. The first polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and initiator. The initiator may be Irgacure® 907 (2-Methyl-1-[4-(methylthio)phenyl]-2-(4-morpholinyl)-1-propanone) (Ciba Specialty Chemicals, Basel, Switzerland). A second polymer layer is deposited onto the first polymer layer. The second polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and photoimaging constituents. Appropriate photoimaging constituents may include photoinitiators and/or photosensitizors among others. Either the first polymer layer or the second polymer layer, but not both, also comprises a polymer of the monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof.
[0063] The polymer layer which comprises the polymer formed from the monomers above may optionally further comprise fluorinated additives such as Zonyl® fluorosurfactants (DuPont, Wilmington Del.) or fluorinated particles. The polymer layer that does not contain the polymer of the monomers contains a polymer of non-fluorinated acrylate or methacrylate crosslinking monomers.
[0064] A fourth embodiment of the present invention is an article which may be used as a printing element. In this embodiment, the substrate may be any material which may be coated. A first polymer layer is deposited on the substrate. The first polymer layer may be deposited by any known coating technique. The first polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and initiator. The initiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). A second polymer layer is deposited onto the first polymer layer. The second polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and photoimaging constituents. Appropriate photoimaging constituents may include photoinitiators and/or photosensitizors among others. Both the first and the second polymer layer also comprise a polymer of non-fluorinated acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be trimethylolpropane triacrylate (TMPTA), ethoxylated trimethylolpropane triacrylate (TMPEOTA) and/or 1,12-dodecanediol dimethacrylate (Sartomer CD262). Furthermore, either the first polymer layer or the second polymer layer, but not both, also comprises fluorinated particles or fluorinated additives that include Zonyl® fluorosurfactants (DuPont, Wilmington Del.).
[0065] A fifth embodiment of the present invention is an article which may be used as a printing element. In this embodiment, the substrate may be any material which may be coated. A first polymer layer is deposited on the substrate. The first polymer layer may be deposited by any known coating technique. The first polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and initiator. The initiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). A second polymer layer is deposited onto the first polymer layer. The second polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene and photoimaging constituents. Appropriate photoimaging constituents may include photoinitiators and/or photosensitizors among others. Both the first polymer layer and the second polymer layer also comprise a polymer of non-fluorinated acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. Furthermore, either the first polymer layer or the second polymer layer, but not both, also comprises hydrophilic additives like ionic surfactants or particles of silica, alumina or titanium dioxide.
[0066] The present invention is also a process to make printing elements. In one embodiment, a substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a first layer on the substrate. The first layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, an initiator and non-fluorinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The first layer may be deposited by any known coating technique. The initiator may be di(4-tert-butylcyclohexyl) peroxydicarbonate, Perkadox® 16 (Akzo Nobel) or Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The next step in the process is crosslinking the first layer. The crosslinking step may be thermal or, if the initiator is a photoinitiator, the crosslinking step may be by flood irradiation. In the next step of the process, a second layer is deposited onto the first polymer layer. The second layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator and fluorinated monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof.
[0067] The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The subsequent step in the process is irradiating an image into the second layer. The next step is developing the irradiated image by exposing the second polymer layer to a developing solution which dissolves the non-irradiated portions from the exposed image.
[0068] In a second process embodiment, a substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a first layer on the substrate. The first layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, an initiator and fluorinated monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof.
[0069] The first layer may be deposited by any known coating technique. The initiator may be Perkadox® 16 (Akzo Nobel) or Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The next step in the process is crosslinking the first layer. The crosslinking step may be thermal or, if the initiator is a photoinitiator, the crosslinking step may be by flood irradiation. In the next step of the process, a second layer is deposited onto the first polymer layer. The second layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator and non-fluorinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The subsequent step in the process is irradiating an image into the second layer. The next step is developing the irradiated image by exposing the second polymer layer to a developing solution which dissolves the non-irradiated portions from the exposed image.
[0070] In a third process embodiment of the present invention, a substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a first layer on the substrate. The first layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, an initiator and non-flourinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The deposition of the first layer may be by any known coating technique The initiator may be Perkadox® 16 (Akzo Nobel) or Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The next step in the process is crosslinking the first polymer layer. The crosslinking may be thermal or, if the initiator is a photoinitiator, the crosslinking may be by flood irradiation. In the next step of the process, a second layer is deposited onto the first polymer layer. The second polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator and non-flourinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland. The subsequent step in the process is irradiating an image into the second polymer layer. The next step is developing the irradiated image by exposing the second polymer layer to a developing solution which dissolves the non-irradiated portions of the exposed image. Either the first polymer layer or the second polymer layer, but not both, further comprises fluorinated particles or fluorinated additives that may include Zonyl® fluorosurfactants (DuPont, Wilmington Del.).
[0071] In a fourth process embodiment of the present invention, a substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a first layer on the substrate. The first layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, an initiator and non-flourinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The deposition of the first layer may be by any known coating technique The initiator may be Perkadox® 16 (Akzo Nobel) or Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland) The next step in the process is crosslinking the first polymer layer. The crosslinking may be thermal or, if the initiator is a photoinitiator, the crosslinking may be by flood irradiation. In the next step of the process, a second layer is deposited onto the first polymer layer. The second polymer layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator and non-flourinated crosslinking acrylate or methacrylate monomers. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland. The subsequent step in the process is irradiating an image into the second polymer layer. The next step is developing the irradiated image by exposing the second polymer layer to a developing solution which dissolves the non-irradiated portions of the exposed image. Either the first polymer layer or the second polymer layer, but not both, further comprises hydrophilic additives like ionic surfactants or particles of silica, alumina or titanium dioxide.
[0072] In a fifth process embodiment of the present invention, a relatively hydrophilic substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a layer on the substrate. The layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator and fluorinated monomers selected from the group consisting of:
[0000]
[0000] and mixtures thereof.
[0073] The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The subsequent step in the process is irradiating an image into the layer. The next step is developing the irradiated image by exposing the polymer layer to a developing solution which dissolves the non-irradiated portions from the exposed image.
[0074] In a sixth process embodiment of the present invention, a relatively hydrophilic substrate is provided. The substrate may be Melinex® ST504 (DuPont Teijin Films, Bristol, UK). The next step in the process is depositing a layer on the substrate. The layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator, non-fluorinated acrylate or methacrylate crosslinking monomers and fluorinated particles or fluorinated surfactants such as Zonyl fluorosurfactants (DuPont, Wilmington Del.). The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The subsequent step in the process is irradiating an image into the layer. The next step is developing the irradiated image by exposing the polymer layer to a developing solution which dissolves the non-irradiated portions from the exposed image.
[0075] In another process embodiment of the present invention, a relatively hydrophobic substrate is provided. The substrate may be plasma treated polytetrafluoroethylene or another plasma treated fluoropolymer. The next step in the process is depositing a layer on the substrate. The layer comprises a block copolymer of styrene-butadiene-styrene or styrene-isoprene-styrene, a photoinitiator, non-fluorinated acrylate or methacrylate crosslinking monomers and hydrophilic surfactants or hydrophilic additives that may include silica, alumina or titanium dioxide particles. The non-fluorinated (meth)acrylate monomers may be TMPTA, TMPEOTA and/or Sartomer CD262. The photoinitiator may be Irgacure® 907 (Ciba Specialty Chemicals, Basel, Switzerland). The subsequent step in the process is irradiating an image into the layer. The next step is developing the irradiated image by exposing the polymer layer to a developing solution which dissolves the non-irradiated portions from the exposed image.
EXAMPLES
Examples 1-9
[0076] These examples illustrate the effect of fluorine containing additives on the hydrophilicity of the surface of a thermal sub-layer composition. The non-fluorinated thermally crosslinkable polymer composition with the amount listed below in Table 1 was mixed and stirred at ambient temperature for a minimum of four hours or until the solid components were fully dissolved. 7.2 grams (1 gram solids) of the mixture were weight into 10 ml vials for the addition of the fluorine containing additive. One of three Zonyl fluorosurfactant additives, Z225, FTS or FSN, (DuPont) was added to each vial at the concentration specified in Table 1 and stirred overnight.
[0077] A thin film of each of the compositions was coated onto a clean 2″×2″ silicon wafer. The wafer was cleaned as follows; an acetone rinse was followed by a methanol and a DI-water rinse. The wafer was dried with high pressure nitrogen and exposed to an oxygen plasma treatment for 5 minutes in plasma-preen unit prior to coating of the film. The film was spin-coated at 3000 RPM for 90 seconds and then dried in a nitrogen purge box for 5 minutes prior to UV exposure. The films were flood exposed using an i-liner OAI (345 nm) for 10 minutes. The various crosslinked films that resulted were tested for their Ag ink wetting. A 5 micro liter drop of DGP50 silver ink (Advanced NanoProducts, Soeul, Korea) was dispensed from a height of 1″ above the surface of the film onto each of the surfaces of the various compositions. The drop was allowed to dry and the radius of the dry drop was then measured. The drop radius (in mm) as a function of fluorinated additive concentration is shown in Table 2 and FIG. 3 for the cases where fluorinated additives were not added to the compositions, the ink drop were observed to spread easily on the hydrophilic photopolymer surfaces. As the amount of fluorinated additive was increased, the film surfaces became progressively more hydrophobic and the radii of the drops became considerably smaller. As shown in Table 2 and FIG. 3 , both the FTS and the Z225 fluorosurfactant additives were found to be particularly effective in rendering the polymer film surfaces more hydrophobic (diminished ink drop radii).
[0000]
TABLE 1
Weight %
grs
Kraton DKX
73.5
7.35
TMPEOTA
19.5
2.4
Perkodox 16
5
0.5
GMA
2
0.5
Kraton DKX, styrene butadiene styrene
TMPEOTA
Perkodox thermal initiator,
GMA glycidyl methacrylate
[0000]
TABLE 2
Drop radius (mm)
% Fluorination
Ex: 1-3 FTS
Ex 4-6 Z225
Ex 6-9 FSN
0.0100
23.00
22.00
24.00
0.1000
15.00
12.00
20.00
1.0000
6.000
5.000
17.00
Example 10-11
[0078] The following examples illustrate the ability to selectively ink only the desired areas of a bi-layer plate operating in a Gravure mode (top layer does not ink while the bottom layer inks). The ability to differentially ink was achieved as follows. Two photopolymer compositions with similar formulations, but one containing the fluorosurfactant additive Zonyl Z225 (Example 11) and the other devoid of the additive (Example 10), were prepared. The two compositions are defined in Table 3 below.
[0000]
TABLE 3
Ex-10 Top Layer
Bottom Layer
(control)
Ex 11 Top Layer
Vector 4111A
3.875 grs
(77.5%)
4.075 grs
(81.5%)
4.075 grs
(81.5%)
CD501
0.875 grs
(17.5%)
0.875 grs
(17.5%)
0.85 grs
(17.0%)
Irgacure 907
0.025 grs
(0.5%)
0.025 grs
(0.5%)
ITX
0.01 grs
(0.2%)
0.01 grs
(0.2%)
TAOBN
0.015 grs
(0.3%%
0.015 grs
(0.3%%
Perkodox 16
0.25 grs
(5%)
Zonyl Z225
0.05 grs
(1%)
Where,
Vector 4111A (Dexco Polymers LP, Houston, TX) is an styrene-isoprene-styrene block copolymer employed as a binder
Sartomer CD501 is a diacrylate monomer (Sartomer Co, Exton, PA)
Irgacure 907 is a photo-initiator
ITX is a photo-sensitizer (Ciba Specialty Chemicals, Basel, Switzerland)
TAOBN is an oxygen inhibitor (Stratford Research, Inc., Stratford, CT)
Zonyl Z225 is a fluorinated surfactant
[0079] The bi-layer plates of Example 10 and Example 11 were fabricated onto clean 4″ Si wafers. The wafers were first cleaned by an acetone rinse, followed by sequential methanol and DI-water rinses. The wafers were dried using a high pressure nitrogen gun. The wafers were then placed in an oxygen plasma using a Plasma Preen unit for 5 minutes. Bottom layers with compositions defined in column 2 of Table 3 were spin-coated at 3000 RPM for 90 seconds for both samples (Example 10 and Example 11). After completing the coating steps, the wafers were purged for 5 minutes in a nitrogen atmosphere and then flood-exposed for 10 minutes using an OAI 345 nm i-liner also under a nitrogen atmosphere. A second layer was then applied to each. For the control sample (Example 10) the composition of the top layer is defined in column 3 of Table 3. The composition of the top layer for Example 11 is defined by column 4 in Table 3 where 1% of the fluorosurfactant Zonyl Z225 has also been added. The top layers were spin-coated onto the crosslinked bottom layers at 3000 RPM for 90 seconds. The samples were allowed to dry in a nitrogen atmosphere for 2 minutes prior to exposure with an i-liner OAI at 345 nm. Exposures were made through a photomask for 5 minutes prior to the development of the upper layers to remove material from the non-exposed areas.
[0080] A soda lime glass-chrome patterned photomask was used to make ten 1 cm×2.5 cm test patterns. Each individual test pattern was ½ positive (clear features) and ½ negative (clear background). Within each negative and positive area were a series of rectangles and lines. 3 and 5 micron rectangles were alternated and were sized with 1:1, 1:3 and 1:5 aspect ratios. The lines were 0.25″ in long and varied in width and spacing from 3 to 100 um. A neutral density filter with ten 1 cm×2.5 cm optical densities was aligned over the test patterns on the photomask. Thus a single exposure time would produce an exposure series. For example, a five minute exposure through an optical density of 0.01 corresponds to a 3 second exposure. This process allowed us to rapidly determine correct exposure time for each formulation as well as exposure latitude. After exposure was completed the sample was developed in Cylosol® for 2 minutes and dried by blowing it with a nitrogen gun.
[0081] The resolution of the resulting plates was analyzed via optical microcospy prior to inking. Both the control plate (Example 10) and fluorosurfactant containing plate (Example 11) were inked with a Ag nanoink DGP40 diluted 1:5 in alcohol. The ink was spin-coated onto the plate at 3000 RPM. The inked plates were then observed with an optical microscope and the areas that were inked and non-inked were determined both for the control and the fluorinated plates. Microscopic analyses showed that while the control plate was coated by ink throughout the plate, the plate with the fluorine-containing top layer inked only in those regions were the top fluorinated layer was absent, thus exposing the relatively more hydrophilic bottom layer to the ink. Since the recess areas of this plate ink while its upper relief layer containing the fluorosurfactant additive does not ink, this bi-layer plate operates in a Gravure mode. Moreover, the recess lines ranging from 3 to 30 micrometers in size were inked while the relief lines that separated the recess lines were not inked. Inking of the image was very uniform and silver containing lines showed good electrical continuity as measured by a two-point probe. The large areas with rectangular relief and recess features were also inked. While the control (example 10) showed no inking differentiation, only the recessed regions of the plate were inked in Example 11.
Example 12-13
[0082] The following example illustrates the ability to selectively ink a bi-layer plate comprising a hydrophilic latex underlay and a fluorinated positive resist overlay. Two photopolymer compositions of essentially the same formulation but one with a fluorinated additive and the other without the additive were prepared. The compositions are shown in Table 4 below.
[0000]
TABLE 4
Ex-12 Top Layer A
Bottom Layer A
(control)
Ex 13 Top Layer B
Vector 4111A
3.75 grs
(75%)
3.75 grs
(75%)
3.75 grs
(75%)
CD501
1.175 grs
(23.5%)
1.175 grs
(23.5%)
1.175 grs
(23.5%)
Irgacure 907
0.05 grs
(1.0%)
0.05 grs
(1.0%)
0.05 grs
(1.0%)
ITX
0.01 grs
(0.2%)
0.01 grs
(0.2%)
0.01 grs
(0.2%)
TAOBN
0.015 grs
(0.3%%
0.015 grs
(0.3%%
0.015 grs
(0.3%%
Zonyl FTS
0.05 grs
(1%)
Where,
Vector 4111A an SIS block co-polymer is used as a binder
CD501 di-acrylate monomer
Irgacure 907 is a photo-initiator
ITX is a sensitizer
TAOBN is an oxygen inhibitor
Zonyl FTS is a fluorinated surfactant
[0083] The bi-layer plates were fabricated onto a clean 4″ Si wafer. The wafer was first clean with an acetone rinse, followed by sequential methanol and DI-water rinses. The wafer was then dried using high pressure nitrogen gun. The wafer was then placed in an oxygen plasma using a plasma preen unit for 5 minutes. The bottom layer with composition A was spun coated at 3000 RPM for 90 seconds for both samples; example 10 and example 11. After coating the wafers were purged for 5 minutes in a nitrogen atmosphere and flood exposed for 10 minutes using a OAI 345 nm i-liner also in a Nitrogen atmosphere. A second layer was then applied. On the control sample the composition of the top layer was identical to that in the bottom layer (columns 2 and 3 Table 3). On sample B the composition of composition of the top layer is that of column 4 in Table 3 above which only varies by the addition of 0.5% FTS relative to that of the bottom layer. The top layers were spun onto the crosslinked bottom layers at 3000 RPM for 90 seconds. The samples were let dry in a nitrogen atmosphere for 2 minutes prior to their exposure in an i-liner at 345 nm and exposed through a photomask for 5 minutes prior to its development.
[0084] The pattern in the photomasks (Chrome on glass) comprised 10 repeats of a basic pattern 1″ in height and 0.5″ in width; ½ positive (clear features) and ½ negative (clear background. This basic repeat unit comprised 3 and 5 micron patches as well as an assortment of lines and spaces. The features in the 5 microns patch all 5 microns in height vary in length from 5 to 50 microns. The features in the 3 micron patch all 3 microns in height vary in length from 3 to 30 microns. The line, 0.25″ in length ranged from 3 to 100 microns in width; with spaces also varying in that range. This basic pattern area was repeated 10 times on the photomask. By placing a neutral density filter on top with areas of constant density that match the area of the underlying basic pattern, 10 different exposures could be obtained from a single exposure. That is, an optical density corresponds to a specific light transmission; thus an reduction in overall exposure time. For example, a 5 minute exposure through an neutral density filter with an OD of 0.01 corresponds to a 3 second exposure. Therefore by exposing through a 10 step filter we were able to rapidly determine the correct exposure for each formulation as well as the exposure latitude. After exposure was completed the sample was developed in Cylosol® for 2 minutes and dried by blowing it with a nitrogen gun.
[0085] The resolution of the plates was analyzed via optical microcospy prior to inking. Both the control and sample plates were ink with a Ag nanoink (ANP) DGP40 1:5 in alcohol. The ink was spun onto the plate at 3000 RPM. The inked plates were then observed in an optical microscope and areas that ink and did not ink determined both for the control and fluorinated plates. Results show that while the control plate inks throughout the plate, the sample with the fluorinated top layer inks only in those regions were the fluorinated layer was not exposed and was removed by the solvent, then exposing the hydrophilic bottom layer. Since these sample inks in the recess areas of the plate and not in the relief areas of the plate, these examples illustrate selective inking in a gravure mode.
[0086] The optical micrograph images illustrate that while recess and relief features ink in example 12 only the acrylic latex inks in example 13. The micrograph shows that the 10 microns recess lines inked while surrounding relief lines essentially did not. The image illustrates selective inking of various recess features 5 micron wide.
Example 14-17
[0087] The following example illustrates the ability to selectively ink a single layer fluorinated plate coated on a hydrophilic substrate. The ability to differentially ink was achieved as follows. The photopolymer compositions comprise various monomers whose preparations are listed in Table 5 below.
[0000]
TABLE 5
Example 14
Ex-15
Ex-16
Ex-17
20% Kraton DKX
19.75 grs
(79%)
19.75 grs
79%
19.75 grs
(79%)
19.75 grs
(79%)
in toluene
Compound 1
0.97 grs
(19.4%)
Compound 2
0.97 grs
19.4%
Compound 3
0.40
(4%)
0.97 grs
19.4%
Compound 4
0.97 grs
19.4%
Irgacure 907
0.5
0.001 grs
(1%)
GMA
0.05 grs
(1%)
0.05 grs
(1%)
0.05 grs
(1%)
0.05 grs
(1%)
DPL
0.025 grs
(0.5%)
0.025 grs
(0.5%)
0.025 grs
(0.5%)
0.025 grs
(0.5%)
TAOBN
0.0375 grs
(0.075%)
0.0375 grs
(0.075%)
0.0375 gr
(0.075%)
0.0375 gr
0.075%
Differential inking
4
2
4
2
observed
1-5 (5 is highest)
Printing resolution
5
5
20
5
obtained (microns)
Where,
Kraton DKX222CS SBS block co-polymer is used as a binder
Compound 1 is a fluorinated linear dimethacrylate with a F/C ratio = 0.82
Compound 2 is a fluorinated branched dimethacrylate with a F/C ratio = 0.76
Compound 3 is a fluorinated linear dimethacrylate with a F/C ratio = 1.0
Compound 4 is a fluorinated linear dimethacrylate with a F/C ratio = 0.75
Irgacure 907 is a photo-initiator
DPL is lauryl 5-(N,N-diethylamino)-2-phenylsulfonyl-2,4-pentadienoate
TAOBN is an oxygen inhibitor
[0088] The chemical structures and preparation of the four fluorinated dimethacrylates (compounds 1-4) with differing fluorine-to-carbon (F/C) ratios are described below.
[0000]
[0000] Preparation of the above di-methacrylate, Compound 1: A solution of 1H,1H,9H,9H-perfluoro-1,9-nonanediol (19.1 g, 46.3 mmol) and methacrylic anhydride (57.1 g, 370 mmol) in tetrahydrofuran (150 mL) was treated with sodium acetate (0.20 g) and 4-methoxyphenol (100 ppm). The resulting mixture was heated to reflux under a dried-air atmosphere for 48 hours and then cooled to room temperature. The tetrahydrofuran solvent was carefully removed under reduced pressure. The concentrated reaction mixture that remained was next diluted with ethyl ether (200 mL) and the resulting solution was rapidly stirred with 2% aqueous sodium carbonate (200 mL) for several hours to hydrolyze excess methacrylic anhydride reagent. The organic phase was separated and then sequentially washed with 2% sodium carbonate (100 mL), water (3×100 mL) and brine (50 mL). The organic phase was dried over anhydrous sodium sulfate, treated with 4-methoxyphenol (100 ppm) and then concentrated in vacuo to afford a clear, semi-viscous oil in 91% yield. Analysis of the product by FTIR revealed the absence of OH stretching near 3400 cm−1 and the presence of new signals at 1742 cm−1 (ester carbonyl) and 1638 cm−1 (methacrylate double bond). Proton NMR (CDCl3) spectroscopy confirmed the presence of terminal methacrylate groups in the product with resonances appearing near 6.2 and 5.8 ppm (methacrylate double bond) and 1.9 ppm (methacrylate methyl group). Theoretical flourine-to-carbon ratio=0.82
[0000]
[0000] Preparation of the above di-methacrylate, Compound 2: A solution of 1H,2H,3H,3H-perfluorononane-1,2-diol (19.5 g, 49.5 mmol) and methacrylic anhydride (76.0 g, 493 mmol) in tetrahydrofuran (150 mL) was treated with sodium acetate (0.100 g) and 4-methoxyphenol (100 ppm). The resulting mixture was heated to reflux under a dried-air atmosphere for 48 hours and then cooled to room temperature. The tetrahydrofuran solvent was carefully removed under reduced pressure. The concentrated reaction mixture that remained was next diluted with ethyl ether (200 mL) and the resulting solution was rapidly stirred with 2% aqueous sodium carbonate (200 mL) for several hours to hydrolyze excess methacrylic anhydride reagent. The organic phase was separated and then sequentially washed with 2% sodium carbonate (100 mL), water (3×100 mL) and brine (50 mL). The organic phase was dried over anhydrous sodium sulfate, treated with 4-methoxyphenol (100 ppm) and then concentrated in vacuo to afford a clear, semi-viscous oil in 76% yield.
[0089] Analysis of the product by FTIR revealed the absence of OH stretching near 3400 cm−1 and the presence of new signals near 1750 cm−1 (ester carbonyl) and 1637 cm−1 (methacrylate double bond). Proton NMR (CDCl3) spectroscopy confirmed the presence of terminal methacrylate groups in the product with resonances appearing near 6.2 and 5.8 ppm (methacrylate double bond) and 1.9 ppm (methacrylate methyl group). Theoretical fluorine-to-carbon ratio=0.76.
[0000]
[0000] Preparation of the above di-methacrylate, Compound 3: A solution of 1H,1H,12H,12H-perfluoro-1,12-dodecanediol (25.3 g, 45.0 mmol) and methacrylic anhydride (57.1 g, 370 mmol) in tetrahydrofuran (150 mL) was treated with sodium acetate (0.20 g) and 4-methoxyphenol (100 ppm). The resulting mixture was heated to reflux under a dried-air atmosphere for 48 hours and then cooled to room temperature. The tetrahydrofuran solvent was carefully removed under reduced pressure. The concentrated reaction mixture that remained was next diluted with ethyl ether (200 mL) and the resulting solution was rapidly stirred with 2% aqueous sodium carbonate (200 mL) for several hours to hydrolyze excess methacrylic anhydride reagent. The organic phase was separated and then sequentially washed with 2% sodium carbonate (100 mL), water (3×100 mL) and brine (50 mL). The organic phase was dried over anhydrous sodium sulfate, treated with 4-methoxyphenol (100 ppm) and then concentrated in vacuo to afford a clear, semi-viscous oil in 89% yield. Analysis of the product by FTIR revealed the absence of OH stretching near 3400 cm−1 and the presence of new signals at 1743 cm−1 (ester carbonyl) and 1638 cm−1 (methacrylate double bond). Proton NMR (CDCl3) spectroscopy confirmed the presence of terminal methacrylate groups in the product with resonances appearing near 6.2 and 5.8 ppm (methacrylate double bond) and 1.9 ppm (methacrylate methyl group). Theoretical flourine-to-carbon ratio=1.0.
[0000]
[0000] Preparation of the above di-methacrylate, Compound 4: A solution of 1H,1H,11H,11H-perfluoro-3,6,9-trioxaundecane-1,1′-diol (24.0 g, 58.5 mmol) and methacrylic anhydride (45.0 g, 292 mmol) in tetrahydrofuran (150 mL) was treated with sodium acetate (0.20 g) and 4-methoxyphenol (100 ppm). The resulting mixture was heated to reflux under a dried-air atmosphere for 48 hours and then cooled to room temperature. The tetrahydrofuran solvent was carefully removed under reduced pressure. The concentrated reaction mixture that remained was next diluted with ethyl ether (200 mL) and the resulting solution was rapidly stirred with 2% aqueous sodium carbonate (200 mL) for several hours to hydrolyze excess methacrylic anhydride reagent. The organic phase was separated and then sequentially washed with 2% sodium carbonate (100 mL), water (3×100 mL) and brine (50 mL). The organic phase was dried over anhydrous sodium sulfate, treated with 4-methoxyphenol (100 ppm) and then concentrated in vacuo to afford a clear, semi-viscous oil in 86% yield. Analysis of the product by FTIR revealed the absence of OH stretching near 3400 cm−1 and the presence of new signals near 1742 cm−1 (ester carbonyl) and 1638 cm−1 (methacrylate double bond). Proton NMR (CDCl3) spectroscopy confirmed the presence of terminal methacrylate groups in the product with resonances appearing near 6.2 and 5.8 ppm (methacrylate double bond) and 1.9 ppm (methacrylate methyl group). Theoretical fluorine-to-carbon ratio=0.75.
[0090] The printing plates in Examples 14-17 were fabricated on the acrylic side of a clean ST504 Melinex base (DuPont Teijin Films, Bristol, UK), which is highly hydrophillic. The base was first clean with a methanol rinse, followed by sequential DI water and isopropyl alcohol rinses. After a final rinse in DI water, the base was dried using high pressure nitrogen gun. The formulations were mixed overnight at room temperature and filtered through 1.5 um GMF filters. Each layer was spun onto the acrylic side of ST504 (DuPont Teijin Films, Bristol, UK) at 1000 RPM for 90 seconds and then exposed through a photomask for 10 minutes prior to its development in an OAI i-liner at 345 nm
[0091] The pattern in the photomasks (Chrome on glass) comprised 10 repeats of a basic pattern 1″ in height and 0.5″ in width; ½ positive (clear features) and ½ negative (clear background. This basic repeat unit comprised 3 and 5 micron patches as well as an assortment of lines and spaces. The features in the 5 microns patch all 5 microns in height vary in length from 5 to 50 microns. The features in the 3 micron patch all 3 microns in height vary in length from 3 to 30 microns. The line and spaces, 0.25″ in length ranged from 3 to 100 microns in width. This basic pattern area was repeated 10 times on the photomask. By placing a neutral density filter on top with areas of constant density that match the area of the underlying basic pattern, 10 different exposures could be obtained in a single experiment. That is, an optical density corresponds to a specific light transmission; thus a reduction in overall exposure time. For example, a 5 minute exposure through a neutral density filter with an OD of 0.01 corresponds to a 3 second exposure. Therefore by exposing through a 10 step filter we were able to rapidly determine the correct exposure for each formulation as well as the exposure latitude. After exposure was completed the sample was developed in toluene for 2 minutes and dried by blowing it with a nitrogen gun. The resolution of the plates (below, top right) was analyzed via optical microcopy prior to inking.
[0092] The sample plates were inked with a Ag nanoink DGP40 1:5 in alcohol. Where was the ink purchased from Advanced NanoProducts, Soeul, Korea. The ink was spun onto the plate at 3000 RPM. The inked plates were then observed in an optical microscope and areas that ink and did not ink determined. The plates have 3-5 micron resolution and selective inking can be achieved in the flexo mode. In compound 3, the high degree of fluorination led to modeling of the film surface with the lowering of the feature resolution. Compound 1 led to excellent resolution and selectivity of inking. As the fluorination was decreased, the selectivity decreased as well. Although small feature sizes were maintained the ink selectivity was not fully achieved.
Example 18-22
[0093] The following example illustrates the contact angle of the ink on plate formulations comprising various fluorinated monomers. The compositions and contact angles in water, toluene and ethanol are listed in Table 7 below.
[0094] The compositions in table 7, were stirred overnight at room temperature and coated on Si wafers. The wafer was first clean with an acetone rinse, followed by sequential methanol and DI-water rinses. The wafer was then dried using high pressure nitrogen gun. The wafer was then placed in an oxygen plasma using a Plasma Preen unit for 5 minutes. The films with the compositions of table 7 were spun coated at 1000 RPM for 90 seconds for both samples. The samples were let dry in a nitrogen atmosphere for 2 minutes prior to their flood exposure in an i-liner at 345 nm for 5 minutes development.
[0095] The contact angles with water, toluene and ethanol were measured with a VCA2500xe instrument manufactured by ASTProducts (Advanced Surface Technologies) in Billerica, Mass.
[0000]
TABLE 7
Control
Ex. 18
Ex-19
Ex-20
Ex-21
Ex-22
20% Kraton
88%
70%
70%
70%
70%
DKX222 in toluene
22grs
17.5grs
17.5grs
17.5grs
17.5grs
Irgacure 907
1%
1%
1%
1%
1%
0.05grs
0.05grs
0.05grs
0.05grs
0.05grs
ITX
1%
1%
1%
1%
1%
0.05grs
0.05grs
0.05grs
0.05grs
0.05grs
GMA
10%
10%
10%
10%
10%
0.5grs
0.5grs
0.5grs
0.5grs
0.5grs
PFS
18%
0.9grs
PFOA
18%
0.9grs
PFHDA
18%
0.9grs
VE-OPPVE
18%
0.9grs
Adv. Contact
98
101
103
89
108
angle in H2O
Adv, Contact
18
54
21
18
56
angle in toluene
Adv. Contact
wets
33
wets
wets
25
angle in EtOH
Where,
Kraton DKX222CS is an SBS block is used as a binder
Irgacure 907 is a photo-initiator
GMA is glycidyl methacrylate
PFS is perfluorostyrene
PFOA is perfluorooctyl acrylate
PFHDA is perfluorohexyl di-acrylate
VE-OPPVE is 1,1,1,2,2,3,3-heptafluoro-3-(1,1,1,2,3,3-hexafluoro-3-(2-vinyloxy)ethoxy)propan-2-yloxy)propane
TX is a sensitizer.
[0096] In addition, the formulation of example 21 was also imaged through a photomask showing well defined lines, spaces and 3×3 μm, 3×9 μm and 3×15 μm features.
[0097] Scanning electron micrograph images showed the inking of the recess areas and not inking of the relief areas throughout the plate both for the rectangular features as well as for the 5 to 50 micron lines and spaces. The 3 micron height rectangles with length varying from 3 to 30 microns were inked throughout the 5 mm×5 mm pattern uniformly without any ink retention in the surrounding areas. | The present invention relates a printing element comprising at least one polymer layer which has photoimageable constituents and additions to make the polymer layer either hydrophobic or hydrophilic. The printing element may have two polymer layers on a substrate in which one of the layers comprises fluorinated acrylates or methacrylates. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a metallic covering for the roof of buildings, which is laid on an unventilated roof support, for example formed of rigid concrete forming a flat receiving surface. The covering is constructed of rigid plates, usually formed of metal preferably a corrosion-resistant metal such as zinc. The plates are designed to interlock in a mating fashion with each other forming troughs running in the direction of the slope of the roof. It also relates to right-angled supports for the covering in accordance with the invention.
Roof coverings in zinc are now employed for roofing or boarding or guttering in highly corrosive industrial environments and in very polluted urban environments. The roof frames for such roof coverings are in general no longer made of wood wood provided ventilation for high-priced or city roofs in previous centuries. The roof frames are now made of concrete which in theory constitutes a stronger, longer lasting material than wood. Numerous instances of corrosion in such roofs laid on supports in concrete have nevertheless been reported. Such corrosion is not only the result of the aggressive atmosphere to which such roofs are exposed but also results from the supports which are inserted between the metallic plates (zinc, copper, galvanized or stainless steel, aluminium, etc.) and which most commonly are not wood and comprise, rather, roofing felts and non-woven materials. These materials foater acid reactions when soaked with the aqueous medium resulting from condensation.
In order to overcome the difficulties currently encountered in coverings such as roofing, boarding or guttering constructed using rigid plates laid on unventilated and rigid supports, such as concrete sections, it appeared to be necessary to improve ventilation between the under part of the roof and the rigid plates in order to avoid condensation, and if the plates are formed of metal, to isolate them from the unventilated roofing support, particularly in the case where the support is is formed concrete, using a neutral material which is more resistant to acid and corrosive reactions in an aqueous medium.
SUMMARY OF THE INVENTION
To this purpose, in accordance with the invention, intermediate plates are fixed directly to an unventilated support forming a continuous vapor-tight, planar receiving surface. The intermediate plates are formed of a soft and elastic material which absorbs expansion, which maintain its strength for long periods of time and is electrically and chemically non-corrosive with regard to the rigid plates. The intermediate plates can be a plastics material. The plates are fixed directly onto the unventilated support using tubular fastening means or screws which pass through the plate in a sealing manner. The head of the screw bears against the plate. The rigid plates are attached to support members laid on the intermediate plates and fixed to the rigid support using tubular fastening means or screws passing in a sealed manner through said intermediate plates surface protuberances or spacing elements which are regularly distributed on said intermediate plates are interposed between the rigid plates and the intermediate plates so as to provide a ventilation space under the rigid plates. The assembly of intermediate plates can be used as an under-roof assembly adapted to recover leaks and possible condensation from the main roofing structure formed by the rigid plates.
In another embodiment of the invention, the support members for the rigid plate are fixed to the intermediate plates and bear on surface protuberances or spacing elements thereby forming a ventilation space under the support members. A members, for the rigid plate are fixed to the intermediate plates whilst bearing on surface irregularities or spacing elements with the interpositioning, at least in some places, of a sealing and/or support element such as a seal formed of an elastomer foam can be positioned between the support members, and the intermediate plate. The surface protuberances or spacing elements are preferably an integral part of the intermediate plate and may accomodate, at least in part, the expansion of said intermediate plate. The surface protuberances or spacing elements integral with the intermediate plate are advantageously formed of studs of hollow frustro-conical shape having a substantially planar head which are regularly distributed in a projecting manner on one side of the planar plate suitably, formed of a thin plastic material.
In yet a further embodiment of the invention, support members exhibit a right-angled cross section one arm of which is adapted to be laid flat on the planar heads of several adjacent studs of frustro-conical shape said arm is provided with frustroconical-shaped cavities the minor base of which is directed to the side opposite the other arm of the support member. The other arm is adapted to cooperate with the rigid plates. The cavities of frustro-conical shape project by an extent which is substantially equal to the height of projection of the frustro-conical shaped portions of the intermediate plate, so that said arm is able to bear simultaneously on the planar heads of the frustro-conical portions of the intermediate plate and, at the base of these frustro-conical shaped cavities, directly on the intermediate plate. The minor base of the frustro-conical shaped cavities of the arm of the support members generally includes a hole into which a tubular fastening means or screw is engaged in order to fix the support member onto the unventilated support. The tubular fastening means or screws passing through the intermediate plates are substantially sealed at the point of passage through the plates by virtue simply of the tight fit between the periphery of these tubular fastening means or screws and the wall of a circular hole provided in the plates, the material of which is much more yielding than the metal forming said tubular fastening means or screws.
The invention also provides a support for a rigid covering, having a generally right-angled cross-section and being adapted to be fixed by one of its arms onto a receiving surface, and in which the arm intended for said fixing is provided with cavities of frustro-conical shape the minor base of which is directed to the side opposite the other arm of the right-angled section and in which the substantially flat surface of the minor base constitutes an abutment and fixing surface onto this receiving surface. The minor base of the frustro-conical portions include a hole for the passage of a fixing means providing attachment to the receiving surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aims advantages and characteristics of the invention will become more clear from the description which follows of several embodiments of the invention which should be considered as having a non-limiting nature and with reference to the attached drawings in which:
FIG. 1 is a top view of a portion of intermediate plate used for a metallic covering in accordance with the invention,
FIG. 2 is a sectional view of the portion of intermediate plate shown in FIG. 1 on which a right-angled support piece has been layed, fixed by screws to a rigid roofing support in concrete;
FIG. 3 is a perspective view of the support piece seen in section in FIG. 2;
FIG. 4 is a perspective view, partially torn away and on a smaller scale of two metallic plates which are mutually interconnected, for a roofing in accordance with the invention layed on an intermediate plate carrying studs in the form of truncated cones;
FIG. 5 is a perspective view, partially torn away and on a smaller scale of a roof in accordance with the invention constructed using metallic plates in the form of trays assembled pairwise on a joining strip or batten which is raised and employed for conventional zinc roofs.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference first to FIG. 4, the main components of a zinc roofs are shown, the roof being laid an unventilated concrete support 1 which forms a rigid flat receiving surface. Adjacent zinc plates 2 and 3 form a central trough 4 which runs in the direction of slope of the roof in order to discharge rainwater to a drain. These zinc plates 2 and 3 which can overlap at the end portions, exhibit, on their lateral sides, differing folds which interfit. The right hand fold 5 (in the sense of the drawing) exhibits a right-angled wall with an edge 6 folded over on itself once. The left hand fold 7 (shown on plate 3) is folded back on itself twice on the edge 8, in order to surround the edge 6 of the plate 2 and to prevent any overrunning of water in the case of heavy rain.
The right and left hand folds 5 and 7 of the two adjacent zinc plates 2 and 3 engage a support piece 9 (see FIG. 3) which takes the general form of a right-angled piece one arm 10 of which is arranged vertically between the two vertical walls of the folds 5 and 7. The arm 10 is provided with a longitudinal slot 11 into which the tabs 12 of hook members (not shown) engage, the hook members being crimped onto the vertical walls of the edge folds 5 and 7.
In accordance with the invention, the metallic plates 2 and 3 are laid on intermediate plates 14 in the form of a a sheet laid flat on the rigid concrete support 1. The sheets have protrusions on their surface which are directed towards the metallic plates 2 and 3. The surface protuberances can be in the form of studs 15 having a generally frustro-conical shape with their flat minor base 16 uppermost. In FIGS. 1 and 2 it can be seen how each intermediate plate 14 comprises a continuous plate formed of a plastic material 14a. Surface protuberances 15 are suitably formed in the body of the sheet by thermoforming. The protuberances 15 in the form of truncated cones constitute, on the back surface of the plate 14, projecting studs of limited height h comprised between 5 and 10 mm. In an advantageous embodiment, a plate formed of plastic material can be used which takes the form of a sheet having a thickness comprised in the range 0.5 to 1 mm and the truncated conical studs have a major base diameter comprised between 15 and 20 mm and a minor base diameter between 8 and 12 mm, the spacing between the studs being comprised between 25 and 40 mm, the studs being preferably arranged in a square pattern.
In FIG. 2, the fixing arrangement of the support piece 9 onto the rigid concrete support 1 can be seen. The support piece 9 can be made of a material which is highly resistant to corrosion such as stainless steel and can take the the form of a right-angled part 1. The other arm 17 of the support piece 9 is provided with several frustro-conical cavities or recesses 18 formed by cold forming. The cavities 18 are adapted to be positioned in the a spaces 19b provided between series of four frustro-conical studs 15 (see FIG. 1) while the remainder of the arm 17 bears on two adjacent planar surfaces 16 of the frustro-conical studs 15. The base 19 of the cavity 18 (see FIG. 3) is supported on the planar base portion 16 at the intermediate plate 14 where it is fixed by means of a screw 20 passing through a hole 19a provided through the base 19 (see FIG. 3) and which is screwed, for example, into an expansion plug 21 formed of a plastic material, which is force mounted and is provided with anti-pullout hooks 21b inside a hole 22 drilled in the concrete of the rigid support 1.
In order to provide fixing of the intermediate plate 14 at other points onto the rigid concrete support 1, screws 20a are provided which are regularly spaced and screwed into expansion sleeves 21a, if necessary shorter than the sleeve 21. The sleeves are force fitted in holes 22a drilled in the concrete 1. The head 23a of the screws 20a bears on the planar surface of the plate 14a either directly or via a flexible but rigid washer and can if necessary be surrounded by a waterproofing layer suitably formed of an elastomer material 38. The shank of the screws 20 and 20a can pass through a hole in the plate 14 which is drilled to a diameter slightly less than the diameter of the screw shank so that the elasticity of the walls of the hole ensure that the material of the plate 14 provides a sealing clamping effect which is relatively soft nevertheless, on the shank of the screw 20 or 20a. The heads 23, 23a, of the screws 20 and 20a may, if necessary, be rendered water-tight on the base of the cavity 18 by the insertion of an elastomer material surrounding the head of the screw.
In FIG. 4, the various elements of the roof are shown in FIGS. 1 to 3 will be seen again on a smaller scale. Each screw that is placed can be rendered water-tight at its head by the use of a layer of an elastomer-based liquid 38 which spreads around the head of screw 23 or 23a (see FIG. 2).
The roof shown in FIG. 5, which corresponds more closely to a conventional way of laying zinc roof coverings, employs symmetrical zinc plates 24, 25 in the form of trays. Between two adjoining zinc plates in the form of trays, a joining strip or batten 26 generally made of wood, is fixed onto the intermediate plates 14 provided with studs 15. The joining strip 26 which is laid in the direction of slope of the roof, here has a trapezoidal cross-section with its minor base 27 uppermost and its major base 28 lowermost which is laid on the planar sides 16 of the frustro-conical studs 15. The joining strip 26 may also exhibit a rectangular or square cross-section or or the like, and is fixed onto the rigid concrete support 1 by means of screws 29 which are generally screwed into sleeves held rigidly in the concrete such as the sleeve 21 shown in FIG. 2. The screws 29 should pass through the intermediate plate 14 in a sealed manner and a sealing joint 30 formed of elastomer foam can be inserted under the joining strip 26 between the generally planar portion of the intermediate plate 14 and the major base 28 of the joining strip. This sealing joint formed of elastomer material simultaneously ensures better load bearing characteristics of the strip on the plate 14 than those provided by the studs 15 which can suffer spreading out at certain points. While fixing the joining strips 26 onto the intermediate plate 14, under the major base 28, the U-shaped arm 31, of double hooks 32 can be inserted, the upper folded-over portion 33 of which can come into engagement with the raised edge portions 24a and 24b of the trays 24 and 25 thus opposing their extraction in the upward direction. In order to maintain in place a trough-sectioned covering element 34 covering the joining strip 26 and oppose its extraction in the upward sense, hooks 34a which are nailed onto the joining strip 26 can be provided. Each trough-sectioned piece of roof 34 which is also formed of zinc may be provided at its extreme edges with folded-over portions 35a and 36a which engage with the folded-over edges 34b of the hooks 34a. The trough-sectioned portion 34 can also be held in place by hooks fixed onto the bottom of the joining strip 26 and folded over onto one end of the trough-sectioned portion 34.
When mounting the tray-shaped metallic plates 24 and 25, the raised edge portions 24a and 24b of these plates slide under the lateral strip portions 35 and 36 of the trough-sectioned portion 34, and are held in position by double hook members 32 which can obviously be replaced by single hook members which for example are nailed onto the inclined lateral sides 26a and 26b of the wooden joining strip 26. The tray-shaped zinc roofing elements 24 and 25 which are oriented in the direction of greatest slope of the roof are covered by the lateral strip portions 35 and 36 of the trough-sectioned portion 34, which ensures good protection against rising up of water under the action of the wind. Laying of the zinc tray-shaped elements 24 and 25 hence makes provision for free expansion of the metallic plates in all directions which is essential as the temperature of the zinc can vary between 80° C. in the full sun in summer and -20° C. in winter. The zinc tray-shaped members 24 and 25 are moreover laid on the planar heads 16 of the studs 15 which provide a ventilation space 37 of the same vertical height as the degree of projection h of the studs 15 (over the planar portion 14a of the intermediate plates 14) between these intermediate plates and the metallic covering plates (see also the ventilation space 37 in FIG. 4).
The assembly of intermediate plates constitutes a combined assembly which is sealed in regards to the flow of water in the direction of the slope of the roof and which can perform the function of an under-roof surface which recovers small leaks and possible condensation from the metallic plates, and lead such water off to the drain. The method of laying shown in FIG. 5 can be adapted, in certain countries which do not use wood, to the use of wholely metallic battens which are layed as intermediate pieces between the tray-shaped zinc elements having flanged vertical lateral sides. The metallic batten is made up by a U-shaped continuous element also made of zinc and laid using the joining arm of the U (the arms of the U being vertical) on the rigid concrete support 1 upon which it is fixed by any suitable means such as screws or nails.
After fitting the U-shaped member, the vertically-directed arms of which have upper folded over edges which are placed against a flange on the lateral sides of the tray-shaped zinc elements, the projecting arms of the U-shaped element are closed of by means of a covering plate formed of zinc which covers it and also possesses flanges. The successive super-positioning of the flanges of the covering plate, the U-shaped section and the vertical side of the adjacent tray-shaped zinc roofing element are then folded-over together in the vertical sense, in order to simultaneously, seal the tray-shaped element, the covering plate and the joining strip against projected water. When the invention is applied to metallic joining strips or battens having a U-shaped profile as described above, the U-shaped profile of the batten is fixed onto the intermediate plate 14 with local insertion of a simple sealing joint such as the seal 30, in order to also provide a ventilation space 37 under the metallic U-shaped battens.
Laying of a roof according to the invention onto a rigid support such as concrete or a metallic structure starts with the laying of the intermediate plates 14 which mutually overlap at their edges in all four directions and are held onto the metallic support generally by means of screws the passage of which is rendered sealing by direct contact with the plastic material of the intermediate plate 14 or, if needed, with the interpositioning of an elastomer seal 38 between the head of the screw and the intermediate plate. The intermediate plates having been laid, intermediate supports 9 can now be fixed in place, or battens 26 or trough-sectioned elements 34 depending on the type of metallic plate selected. Once the support parts 9 or 26 are in place, the metallic plates can now be laid which are slid laterally one inside the other in the direction of the slope of the roof. The metallic plates come to rest on the planar heads 16 of the studs 15 forming a ventilation space 37 which prevents condensation occurring below the zinc and the starting of corrosion in association with an acidic aqueous phase, the risk of which is reduced due to the fact that the intermediate plates 14 are made of plastic material that does not corrode.
It is well understood that the examples and alternatives given in the foregoing description are adaptable to numerous variants available to those skilled in the art without in any way departing from the scope and spirit of the invention. | A roof system is provided for buildings having an unventilated roofing support such as concrete forming a planar receiving surface. An intermediate plate formed of an environmental-tight sheet of plastic material is placed on the planar receiving surface. The sheet contains a uniform pattern of protuberances such as frusto-conical studs having planar tops. A rigid roof covering formed of corrosion-resistant metal plates such as zinc is laid on top of the planar surfaces of the studs. The plates have interfitting, bent edges forming troughs. The studs space the rigid roof covering from the intermediate sheet forming a ventilation space for collecting leaks or condensation. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to vibrator tool assemblies and, in one possible particular embodiment, to a vibration system for drill bit housing to produce vibrations for advancing bottom hole assemblies in oil and gas operations.
[0003] 2. Description of the Prior Related Art
[0004] Oil and gas operators have continually found new methods of incorporating coiled tubing into various rig applications. Coiled tubing often has advantages over a conventional rig and drillstring, in that coiled tubing units can be less expensive and quicker to set up than conventional drilling rigs.
[0005] One major problem to both conventional and coiled tubing rigs is the ability to push tubing further into a wellbore under certain drilling conditions. Generally, drillers rely on the weight of the drillstring to counteract the frictional forces generated between the wellbore and drillstring. Once a certain depth is reached, or certain formations are drilled into, or at certain angles of the wellbore, the weight of the drill string is not sufficient to overcome the friction of the drill string to move the drill string downwardly as drilling continues. This tends to be especially true in coiled tubing operations, because coiled tubing cannot be rotated at the surface to overcome or reduce the friction the drill string with respect to the wellbore. Another significant factor is that coiled tubing tends to be more flexible and lighter compared to traditional drill pipe. As a result, coiled tubing may experience increased drag problems in the wellbore as compared with traditional drill pipe and is more prone to become lodged in the wellbore. This effect can become exacerbated in deviated wells and those with horizontal sections, where movement of pipe by the injector rig at the surface does not result in additional movement of the coiled tubing string into the wellbore. Furthermore, coiled tubing is more likely to stick in the wellbore based on the coiled design and spooled storage, which can create a spiral effect that may increase the number of sticking points inside the wellbore.
[0006] Various tools and methods have been utilized to deal with this problem, including vibrating tools, jars, tractors, centralizers, and pulsators. Thus, many designs have been utilized. While such tools have been utilized successfully, the forces created thereby are not necessarily efficient in utilizing the energy created thereby. Accordingly, the present invention will be appreciated by those of skill in the art.
SUMMARY OF THE INVENTION
[0007] One possible object of the present invention is to provide an improved vibrational tool for use in a bottom hole assembly.
[0008] Another possible object of the present invention is to provide a tool to overcome drag between coiled tubing and the inside of a wellbore.
[0009] Another possible object of the present invention is to provide a vibrational tool within a bit housing.
[0010] Another possible object of the present invention is to provide a tool that produces vibrations that are directed substantially in line downwardly and/or upwardly axially in line with the drilling string
[0011] Another possible object of the present invention is provide a stabilizing gyroscopic effect due to rotation of a symmetrical mass around the axis of the tool.
[0012] These objects, as well as other objects, advantages, and features of the present invention will become clear from the description and figures to be discussed hereinafter. It is understood that the objects listed above are not all inclusive and are intended to aid in understanding the present invention, not to limit the scope of the present invention.
[0013] Accordingly, the present invention may comprise a vibration system for use with a drill bit attached to tubular string in a well bore through which drilling fluid is pumped, comprising a drill bit housing, drill bit cutters secured to said drill bit housing, a symmetrical rotatable member positioned within said drill bit housing to rotate in response to drilling fluid flow through said drill bit housing, and a mechanical interconnection to said rotatable member whereby said rotatable member and said mechanical interconnection operate to produce vibrations within said drill bit housing.
[0014] In one embodiment, the mechanical interconnection may further comprise a pair of engagement surfaces which rotate with respect to each other.
[0015] The present invention may further comprise a spring assembly to keep the pair of engagement surfaces together and a reciprocating member.
[0016] In another embodiment, a first of the pair of engagement surfaces may be mounted to the rotatable member and a second of the pair of engagement surfaces may be mounted to the reciprocating member. The reciprocating member may comprise one or more recesses and protrusions.
[0017] In another embodiment, the present invention may comprise a vibration system for use with a drill bit attached to tubular string in a well bore through which drilling fluid is pumped, comprising a drill bit housing, drill bit cutters secured to said drill bit housing, a reciprocating member mounted in the drill bit housing operable for reciprocating in response to fluid flow through the drill bit housing for producing vibrations.
[0018] In another embodiment, a rotating member may be mechanically interconnected to the reciprocating member. A spring assembly may urge the reciprocating member towards the rotating member.
[0019] In one embodiment, the rotating member may comprise a plurality of grooves through which it receives the fluid flow for producing forces that rotate the rotating member. The grooves may comprise a plurality of branches.
[0020] In one embodiment, the rotating member is mounted to rotate around an axis which is aligned to the tubular string to which the drill bit is attached.
[0021] In another embodiment, a method for a drill bit attached to tubular string in a well bore through which drilling fluid is pumped may comprise steps such as providing a drill bit housing, providing that drill bit cutters are secured to the drill bit housing, and mounting a rotatable member within the drill bit housing to rotate generally or approximately around an axis in line with the tubular string to which the drill bit is attached in response to drilling fluid flow through the drill bit housing for producing a gyroscopic effect in the drill bit housing. In one embodiment, vibrations may or may not be produced. In one embodiment, the gyroscopic effect may be used by itself for smoother drilling. A flexible sub may be utilized to interact with the gyroscopic effect to direct the drill bit for directional drilling.
[0022] In another embodiment, the method may comprise providing a mechanical interconnection to the rotatable member whereby the rotatable member and the mechanical interconnection operate together to produce vibrations within the drill bit housing.
[0023] The method may further comprise providing the mechanical interconnection comprises a pair of engagement surfaces which rotate with respect to each other.
[0024] Other steps may include providing a spring assembly to urge the pair of engagement surfaces together, interconnecting a reciprocating member to the rotatable member, and providing that the reciprocating member reciprocates in alignment with the axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A more complete understanding of the invention and many of the advantages thereto will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
[0026] FIG. 1 is a side elevational schematic view, partially in section, which discloses the use of the invention in the wellbore accord with one possible embodiment of the invention;
[0027] FIG. 2A is an elevational view, partially in section, showing spring loaded cam members mounted between a symmetrically rotating mass and a reciprocating member, with the camming surfaces in a first position in accord with one possible embodiment of the invention;
[0028] FIG. 2B is an elevational view, partially in section, showing the cam members, which comprise protrusions and recessions of various types in a more separated position, in accord with one possible embodiment of the invention;
[0029] FIG. 3 is a top view, taken along lines 3 - 3 of FIG. 2A , showing roller bearings that can be utilized as cam members accord with one possible embodiment of the present invention;
[0030] FIG. 4 is an elevational view, partially in hidden lines, showing a vibrator section built into the drill bit housing in accord with one possible embodiment of the present invention; and
[0031] FIG. 5 is a view of a one embodiment of the rotating mass with the grooves, fins, or the like peeled off to show the layout in two dimensions in accord with one possible embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring now to the drawings, and more particularly to FIG. 1 , there is shown coiled tubing unit 10 with coiled tubing 20 extending into earth 30 . In this example, turbine 40 is rotating bit 50 . Turbine 40 spins in response to drilling fluid pumped by pump 60 which pumps drilling fluid 80 down the tubing and drilling fluid 70 outside the tubing through the annulus back to pump 60 .
[0033] It will be noted that the drawings are intended to be conceptual embodiments of the invention, which may be shown greatly simplified or exaggerated to emphasize the various concepts of the invention. The drawings are not intended to be manufacturing level drawings. Moreover, to the extent terms such as “upper,” “lower,” “top,” “bottom,” and the like are utilized herein they refer to the drawings. The tool 100 may be oriented differently during operation or transport than shown.
[0034] One or more vibrator sections 100 in accord with the present invention may be utilized to assist downward movement of the coiled tubing 20 or other tubular strings. Vibrators 100 may be positioned above or below turbine 40 and, if desired, can be rotated with bit 50 . In one embodiment shown in FIG. 4 and discussed hereinafter, one or more vibrator sections may be built into the bit housing 50 itself, if desired, and used either with or without other vibrator sections.
[0035] Vibrators 100 can be especially desirable in high angle or horizontal wells where the weight of the string may not be adequate in itself or not at all to cause the tubing to move downwardly for drilling. Vibrator sections 100 utilize drilling fluid flow 80 to vibrate, activate, move, oscillate, or otherwise work the string in order to move the drill string further down the hole to, for example, drill deeper. In one possible embodiment of the present invention, pulsating resistance to drilling fluid flow creates vibrations that tend to push the string into the wellbore.
[0036] FIGS. 2A and 2B show one possible embodiment of internal components of vibrator 100 . Vibrator 100 may comprise sliding member 102 , sometimes referred to herein as reciprocating member 102 , which reciprocates upwardly and downwardly (as per drawing orientation) as indicated by arrow 130 . Reciprocating member 102 may be cylindrical but other shapes, e.g., triangular, square, hexagonal, and other shapes, could also be possible at least for portions of reciprocating member 102 .
[0037] In this embodiment, reciprocating member reciprocates in response to camming action, discussed hereinafter, and rotation of mass 104 , which rotates in response to flow of entering drilling fluid as indicated by flow arrow 106 into tubular vibrator housing 108 and exiting as indicated by flow arrow 107 .
[0038] It will be understood that the drawings are intended to show concepts and that many variations are possible, only some of which are discussed hereinafter. For example, in one possible embodiment, reciprocating member may not be utilized and/or may be oriented differently with respect to mass 104 . The camming action could move other components and might be utilized to cause reciprocation of rotating mass 104 , which could be spring loaded in some way.
[0039] In FIG. 2A , engagement surface 120 on upper portion 122 of rotating mass 104 meshes or cams or follows with engagement surface 114 of reciprocating member 102 . In FIG. 2A reciprocating member 102 is spring loaded and reciprocates with respect to rotating mass 104 due to camming or following action as mass 104 rotates while reciprocating member 102 is prevented from rotation. In other words, as the protrusions and recessions, or camming surfaces of surface 120 and 114 , rotate with respect to each other, reciprocating member 102 is pushed away from and then urged back towards mass 104 by spring 150 . However, as noted above, the present invention is not limited to this embodiment.
[0040] Accordingly, in one embodiment of vibrator 100 , a mechanical connection connects rotation of mass 104 and changes the rotating motion of rotating mass 104 to reciprocating motion of reciprocating member 102 . Many different types of mechanical connections could be utilized to interconnect rotating mass 104 to reciprocating member 102 including geared connections, fluid connections, insertions, strap or chain connections, hydraulic connections, and the like. Mechanical connections of various types could be utilized between rotating mass 104 and reciprocating member 102 to create vibrations, different types of jarring effects, and the like. However, in the embodiment of FIG. 2A , FIGS. 2B , and 3 , vibrator 100 utilizes sturdy camming, or following action and drilling fluid flow to create the vibrations thereof.
[0041] In this embodiment, frame 110 supports reciprocating member 102 therein for sliding or reciprocating motion of reciprocating member 102 . Frame 110 may be secured to vibrator housing 108 by various means such as but not limited to mounts 113 . As shown in FIG. 2A , guide members 111 , slots, or the like in the sides of frame 110 may be utilized to allow sliding axially directed motion of reciprocating member 102 but prevent rotation of reciprocating member 102 . Because in this embodiment reciprocating member 102 cannot rotate, reciprocating member is constrained to reciprocate in response to rotation of mass 104 . Reciprocating member 102 may comprise various shapes. In one embodiment, reciprocating member 102 comprises a tubular sliding section upward section, which reciprocates generally along the axis of tubular vibrator housing 108 . Reciprocating member 102 and/or frame 110 may also have a middle portion, upper portion or other portions one or more of which can be circular, elliptical, triangular, square, rectangular, star shaped or the like. If desired, reciprocating member 102 or portions thereof may be solid and weighted or may be of relatively light weight. In any case, reciprocating member 102 and frame 110 are sufficiently sturdy to undergo significant vibration over long periods of time. If desired, weights may be added or removed from reciprocating member 102 .
[0042] In one embodiment, reciprocating member or mass 102 may also engage stops, anvils, or the like 117 , which may be utilized on either or both ends of the sliding travel during each stroke, which may repeatedly make contact in jarring fashion if desired. Reciprocating member 102 could be designed to engage upper surfaces or lower surfaces or both in frame 110 with a jarring action as described in one embodiment here.
[0043] Accordingly, in one embodiment shown in FIG. 2A , FIG. 2B , and FIG. 3 , camming engagement surfaces 114 and 120 are utilized to provide reciprocating motion of member 102 . Reciprocating member 102 may be of different sizes and lengths as desired. The stroke of reciprocating member 102 is determined by the length of the protrusions and recessions of engagement surfaces, such as recessions 118 and protrusions 116 , which may vary in one embodiment, but are not limited to, between one-quarter inch and one inch.
[0044] While spring 150 is shown on the top side of reciprocating member 102 in the orientation of FIG. 2 , the spring could be on the bottom side to create a jarring against the upper surface of frame 110 whereby reciprocating member 102 could be, for example only, tightened, spring-loaded, and released for acceleration again a jarring surface such as the top of frame 110 by an engagement mechanism with rotating mass 104 . Thus, the embodiment shown in the figures with spring 150 above reciprocating member 102 is only one possible embodiment of construction and operation. In another embodiment, spring 150 could be utilized to spring load rotating mass 104 to provide axially directed vibrational forces produced by mass 104 instead of reciprocating member 102 , which may also include jarring action at one end or the other of travel.
[0045] Accordingly, in one possible non-limiting example, reciprocating member 102 has an engagement end or surface 114 at a bottom end, which may be more clearly shown in FIG. 2B . Engagement end or surface 114 may operate as a type of cam. At the opposite end of reciprocating member 102 , reciprocating member 102 may comprise spring loaded end 115 . Spring-loaded end 115 may be energized with spring 150 , which urges engagement surface 114 of reciprocating member 102 against engagement surface 120 on mass 104 . The engagement surfaces 114 and 120 on each end, when rotated with respect to each other, cause a cam following motion, which in this embodiment, constrains spring-loaded reciprocating member 102 to reciprocate because reciprocating member 102 does not rotate and rotating mass 104 is axially fixed in position and does not reciprocate.
[0046] Spring 150 may comprise a spring assembly, which may be of many constructions. Spring 150 may comprise a spring or spring assembly which is intended to refer any type of mechanism to urge the engagement surfaces together including coiled resilient metal springs, compressed gas, multiple coiled springs, leaf springs, compression springs, extension springs, torsion springs, tapered springs, multi-spring combinations, magazine springs, elastomeric members, foam springs, combinations thereof, or any desired types of springs and is intended generally to cover resilient members that are operative as described in this embodiment. Conceivably the flow of drilling fluid might be utilized as an urging mechanism if the components are reconfigured. If the system were reversed in position with respect to fluid flow, then fluid flow could be directed to provide the spring or urging mechanism that urges the camming surfaces together.
[0047] In this embodiment, the tension required to compress spring 150 and the mass of reciprocating member 102 relates to the intensity of vibrations produced during operation. However, various factors such as spring tension, mass of reciprocating member 102 , mass of rotating mass 104 , stops or anvils 117 at the end of the stroke of reciprocating member 102 , the length of the protrusions/recessions of the engagement surfaces, different types of turbine or rotor fins, blades, grooves or the like will affect the vibration frequency and intensity and pattern of the vibrations produced by vibration tool 110 .
[0048] In the embodiment of FIG. 2A and FIG. 2B , engagement surface 114 has variations such as protrusions 116 and/or recessions 118 . In one embodiment, the surfaces such as protrusions 116 may be much smoother than shown, and in one embodiment the engagement surfaces may preferably be smooth or undulating, and spaced at any desired intervals, of any desired number, as is related to frequency characteristics and motions of vibrations produced thereby.
[0049] Accordingly, in one embodiment, engagement ends or surfaces 114 and 120 may comprise camming surfaces whereby the protrusions 116 and/or recessions 118 may preferably be smooth and quite rounded to produce a cam following type of action. However, if desired, the protrusions may slope upwardly and come to a distinct sharp edge whereby only one or two significant vibrations or jars occur per rotation of mass 104 . Thus, the engagement surfaces may not be completely smooth.
[0050] A relatively larger number of protrusions may be utilized to produce higher frequency vibrations. Irregular vibrations may be produced by spacing the cams at irregular or non-symmetrical spacing. Accordingly, the arrangement of protrusions and recessions may allow the vibrations to occur at a continuous frequency or at irregular frequencies, e.g., several quick beats and/or pauses and one beat, or the like, depending on the spacing of the cams. For example, with only one camming element, then only one beat might be produced per revolution of mass 104 . In another example, multiple and/or irregular beats may be produced per revolution of mass 104 . Accordingly, the number of protrusions/recessions and the spacing therebetween may be selected to create a desired frequency of vibration and motion. In one embodiment, the camming surfaces, such as protrusions 116 and/or recessions 118 and/or camming surfaces 120 may be interchangeable to change the vibration frequencies.
[0051] In one embodiment, corresponding camming surfaces 120 are provided on engagement end 122 of mass 104 , which is the upper end as shown in FIG. 2 . Camming engagement surfaces 120 may be of various types, shapes, and the like.
[0052] In one embodiment, roller bearings may be, but are not required to be utilized as camming surfaces 120 . FIG. 3 , which is cross-section 3 - 3 of FIG. 2A , looks down on roller bearing assembly 126 , which may comprise roller bearings 124 , as part of bearing race 128 , which is fastened with respect to mass 104 , and is fixed in position. Roller bearings 124 may be free to rotate individually but the roller bearing assembly 126 is fixed in position with respect to mass 104 , so as to rotate with mass 104 .
[0053] The camming surfaces may be reversed in position. In other words, the roller bearings could be affixed to reciprocating member 102 and/or roller bearings or other bearings could be used on both reciprocating member 102 and rotating mass 104 . Other types of frictionless bearings such as roller bearings, cylindrical bearings, ball bearings, thrust bearings, tapered bearings, combinations of the above, and the like may be utilized. Due to the opening and closing action, the camming surfaces are highly lubricated with each vibration, oscillation, or the like. Lubrication fluid may comprise the drilling fluid directed onto the camming surfaces and/or the camming surfaces may be mounted within a lubrication chamber.
[0054] Accordingly, in this embodiment, in response to rotation of mass 104 , member 102 reciprocates as indicated at arrow 130 . In this embodiment, spring 150 is positioned at a top end (as shown in the orientation of FIGS. 2A and 2B ) of reciprocating member 102 to urge engagement of engagement surface 114 against engagement surface 120 of mass 104 .
[0055] In one possible embodiment, mass 104 may rotate at least substantially symmetrically around the axis of vibrator housing 108 . Mass 104 arrow 145 indicates rotation of mass 104 but is not intended to necessarily show the direction of rotation, which may be in either direction, depending on the rotary drive features such as blades, grooves, or the like in rotating mass 104 . Mass 104 may be mounted by various mounting such as rotary mountings 132 and shaft 134 on opposite axial ends of rotating mass 104 . Rotary mountings 132 and 134 may in one embodiment be secured to housing 108 by support members 136 and 138 (shown at top and bottom of FIG. 2B ). In one non-limiting embodiment, rotary mountings 132 and 134 are designed to prevent axial movement. Rotary mountings 132 and 134 , and/or different types or numbers of mountings, may be utilized. Accordingly, in one possible preferred embodiment rotating mass 104 rotates in the axis of housing 108 but does not move axially. However, in another embodiment, rotating mass 104 may move axially for jarring action. Camming surfaces could be provided along the sides of rotating mass 104 and/or ends thereof to facilitate axial and rotational movement of a spring-loaded mass. In yet another embodiment, the drilling fluid may act as the spring force because the drilling fluid acts to urge a member in the direction of fluid flow.
[0056] Rotating mass 104 may comprise various shapes and can be generally rounded with a relatively flattened top, as shown in FIG. 2A and FIG. 2B . However, rotating mass 104 could be conical and have a triangular cross-section with relatively straight or slightly curving sides. In one embodiment, rotating mass 104 increases in diameter in the direction of fluid flow or the top (as shown in FIG. 2A or 2 B) in order to more fully and efficiently pull power out of the drilling fluid flow. In this embodiment, mass 104 increases in diameter in the direction of drilling fluid flow until reaching the top or another position at which time the drilling fluid is directed as desired, such as into the camming surfaces for lubrication purposes. Thus, in one presently preferred embodiment, from end 170 where fluid enters to drive rotating mass 104 , at least a portion of rotating mass 104 increases in diameter.
[0057] In one embodiment, rotating mass 104 , which rotates around an axis of housing 104 , which is also in line with the axis of the tubing connected thereto, may be utilized to produce a gyroscopic effect to stabilize the position of the tubing within the wellbore. Mass 104 may comprise a diameter in the range of but not limited to from 60 to 90 percent of the diameter of the tubing or housing 108 , and a length in the range of but not limited to from 40 to 80 percent of the length of housing 108 . Accordingly, the size of rotating mass 104 can be significant with respect to vibration tool 100 . If mass 104 is substantially solid metal, and depending of the rotational speed of mass 104 , the gyroscopic lateral stabilizing effect produced around the axis of housing 108 can be significant.
[0058] Mass 104 may be built in longitudinal sections so as to be more easily constructed. The grooves or fins of mass 104 utilized to rotate mass 104 in response to fluid flow may then be more easily formed, machined, cast or the like. Fasteners can then be used to put the sections of mass 104 back symmetrically with the mass of mass 104 being symmetric about the axis of vibrator housing 108 .
[0059] In one embodiment, the amount of mass of mass 104 is much greater, in the range of 50 to 100 times or more than the mass of reciprocating member 102 . In this embodiment, mass 104 may be largely solid and may therefore comprise in the range of but not limited to 30 to 80 percent of the total mass of vibrator section 100 . In one possible embodiment, reciprocating member 102 may comprise less than 10 percent of the total mass of vibrator section 100 and therefore may be considered a relatively lightweight component. In yet another embodiment, reciprocating member 102 may be made much heavier and used for jarring purposes, such as jarring against anvil surfaces 117 in which case reciprocating member 102 may comprise 30 to 80 percent of the total mass of vibrator section 100 .
[0060] FIG. 2B and FIG. 5 illustrate some non-limiting examples of fluid flow grooves or vanes to provide that mass 104 is effectively a turbine or rotor. One feature of a presently preferred embodiment, where mass 104 is prevented from axial movement, is that the diameter of all flow paths does not change due to paddles or the like that may be inserted in the fluid flow path. In other words, in this embodiment, vibration tool 100 is not driven by paddles or the like that may momentarily block fluid flow when they are engaged by the flow stream. This feature is useful in that a more consistent flow of fluid through vibration tool 100 does not impede operation of the turbine to rotate the drill bit and/or MWD systems that transmit signals to the surface. However, the invention is not limited to this embodiment. For example, if mass 104 were axially moveable and reciprocal, a possibility discussed hereinbefore, then the flow path volume might increase and decrease corresponding to axial movement of mass 104 .
[0061] FIG. 5 shows a flattened view of conceptual fluid flow lines with bottom 170 of mass 104 shown and the fluid flow lines, grooves, or fins effectively stripped off of mass 104 and flattened to a two dimensional view. FIG. 2B shows one possible view with flow lines on the sides of mass 104 . In FIG. 5 , fluid flow may enter four openings, grooves, flow lines, fins or the like, such as opening 172 . The width and depth of opening 172 may be varied. As well, the flow line, fins, or the like could be formed internally to mass 104 instead of being formed on the external surface as indicated.
[0062] Opening 172 then feeds flow lines, grooves, fins, or the like which may split from each other as indicated by 162 , 164 , 166 , and 168 shown conceptually in FIG. 2B and FIG. 5 . Thus, in one embodiment, multiple branches are provided.
[0063] In one embodiment, in order to keep the fluid pressure in each branch relatively constant so as to maximize the energy derived from the drilling fluid flow, the depths of each subsequent branch may be made shallower so that the total flow pressure through each of the branches until exit of the fluid from each branch is relatively constant. This may be accomplished in different ways. For example, at the split of a branch, e.g., the branch from 162 to 164 , the subsequent depth of the groove 162 and initial depth of grove 164 may be halved, with respect to the initial depth of groove 162 as indicated at 172 . At the branch from groove 164 to 166 , the subsequent depth of groove 164 may be halved and the initial portion of groove 166 may be halved again. The multiple branches and increasing diameter of rotating mass 104 provides that a large amount of the available power in the drilling fluid flow is utilized for rotating mass 104 and producing the pulsating or vibrational power. In another embodiment, additional more elongated fluid flow grooves or fins could be utilized that are longer but do not branch and have a relatively constant depth.
[0064] As well fluid flow may also (or may not) be provided through grooves in housing 108 as indicated in dashed lines by grooves 174 and 176 shown in FIG. 2B and FIG. 5 . In the embodiment shown in the figures, while rotating mass 104 has at least a portion thereof with an increasing diameter in the direction of fluid flow, housing 108 has a corresponding increasing internal diameter to accommodate rotating mass 104 .
[0065] FIG. 4 shows another embodiment of invention wherein in one embodiment a vibration section 100 is built into housing 51 of the drill bit 50 (shown for example in FIG. 1 ). Normally, drill bit housing 51 is a very sturdy structure into which bits such as roller cones, PDC cutters, jets, diamond cutters, and the like are built into the housing. Drill bit housings are well known. Vibration section 100 may be as described hereinbefore but could be built using various ways to create vibrations, jarring, or the like. By having the vibration section into drill bit housing 51 , the rates of drilling can often be improved significantly. The rotation of mass 104 could be utilized to stabilize the position of the drill bit due to the gyroscopic effect discussed hereinbefore, and prevent or reduce bit whirl should gage inserts try to grab the sides of the wellbore. Moreover, should vibration section 100 cease functioning, as long as the drilling fluid flow continues, then the bit can continue operation so bit reliability is not affected by mounting vibration section 100 therein. Drill bit housing may include sensors 180 built therein as well, which can be sent by systems such as MWD systems or other transmission systems as desired or the data may be stored in a memory for retrieval without the need for a transmission system. Sensors 180 for the bit may comprise vibration sensors to monitor operation of vibration section 100 and/or other sensors such as fluid flow, weight on bit, and the like.
[0066] In yet another embodiment, mass 104 may be utilized as a gyro without necessarily utilizing vibrational members. The use of rotating mass 104 as a gyro can be utilized to drill a smoother and/or straighter hole. Moreover, in combination with a flexible housing 182 , the gyroscopic effect of mass 104 may be used reactively to aid in steering the drill string. Even a small mass 104 at high speeds can produce large gyroscopic forces, which react strongly to being pushed one way or the other by use of flexible housing 182 , which may be of various constructions. Flexible housing 182 may be constructed in different ways to flex in different directions thereby interacting with the gyroscopic effect to enhance and/or control the direction of drilling. Flexible housing 182 may comprise a different sub attached to the bit or may be built into the shank of the drill bit housing itself. The angle shown for flexible sub 182 is exaggerated for effect and will typically comprise much smaller angles as known for directional drilling purposes. Rotating mass 104 can be lengthened and/or used in a different sub for gyroscopic purposes with or without flexible sub 182 .
[0067] Accordingly, in operation, drilling fluid flow enters vibrator housing 100 as indicated by fluid flow arrow 106 and exits from the opposite end thereof as indicated by flow arrow 107 . The drilling fluid flowing through vanes or fins formed on rotating mass 104 , which can be of many variations, cause rotation thereof. The rotation of mass 104 causes camming surfaces or engagement surfaces 114 and 120 or other mechanical interconnections to interact and produce reciprocating movement of reciprocating member 102 . In this embodiment, spring 150 presses the engagement surfaces together to create varying resistance to rotation of rotating mass 104 , which results in vibrations.
[0068] However, as discussed in many places above, it will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
[0069] The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive or to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. | A vibration system for drill bit housing and method is disclosed, which may be utilized to assist in lowering a drill string into a wellbore through which drilling fluid is pumped. In one embodiment, a drill bit housing contains a symmetrical rotatable member positioned to rotate in response to drilling fluid pumped through the housing, whereby a mechanical interconnection connected to the rotatable member produces vibrations within the drill bit housing for advancing bottom hole assemblies. | 4 |
FIELD OF THE INVENTION
This invention relates generally to antennas and, more particularly, to compact, lightweight antennas for mobile communications devices.
BACKGROUND OF THE INVENTION
As mobile telephone technology has advanced, the phone developers have concentrated on making the phone smaller so that more volume and weight could be set aside for battery storage, while keeping the overall form-factor of the phone to be pocket-sized. With the advent of new long-life battery storage technologies and low power digital modulation, the phone has been reduced to a size and battery life that is more than adequate in both departments. Now that these problems are effectively solved, an interest to adding new features to the phone beyond ordinary telecommunications has developed. Among these features is the accurate locating technology afforded by GPS receivers.
Adding a GPS receiver to a mobile phone permits dual use of many of the phone's current parts: embedded CPU, DSP, battery, user interface. Unfortunately, cellular downlink signals are different enough from GPS downlink that an entirely different antenna and filtering arrangement may be needed. For example, GPS downlink signals are typically circularly polarized, whereas cellular signals are not. Moreover, since dual antennas are needed, each antenna must be oriented so that while the mobile phone is positioned for each specialized use, as few phone parts and external obstacles are interposed between the external radio source and the phone antenna.
Since a mobile station such as a mobile phone must be highly miniaturized in order to provide its current functionality, designers adding new features must use as little real estate on the main circuit board as possible. Current generation circular polarized patch antennas, as described, for example, in the paper, “Compact Microstrip Antenna Loaded with Very High Permittivity Superstrate”, Chih-Yu Huang and Jian-Yi Wu, IEEE Antennas and Propagation Society International Symposium 1998, Jun. 21-26 1998, Atlanta Ga., may occupy as little as a square 20 mm on a side. This type of antenna, and others that lack holes are continuous conductor type antennas. Because GPS depends on line-of-sight (LOS) operation between the satellite(s) and the receiver, the GPS receive antenna must be on the top of the mobile station while employed for its locating function—which means for purposes of human-readable output, the mobile station's display must be situated on the same side as the antenna. Furthermore, the GPS antenna must be on the distant end, as opposed to the end that is grasped. Moreover, on that same side, the antenna competes for space with display, keyboard, microphone and speaker as principal front-side mobile phone components.
Deploying the GPS antenna on a flip or a boom causes its own problems. A flip requires extra enclosing hardware, as well as a resilient path for conductors to carry signals between the flip and the main phone. More parts thus produce higher cost, greater weight, lower reliability among other problems. The same problems apply to any other component that is deployed on a flip or boom.
OBJECTS OF THE INVENTION
It is therefore an object of this invention to provide an improved antenna for a mobile communications device that overcomes the foregoing and other problems.
Another object and advantage of this invention is to provide an auxiliary antenna for a mobile communications device that may be configured and hidden within the device while not disturbing significantly the functions of a basic cellular antenna.
It is a further object and advantage of this invention to provide an antenna that is transparent to sound so that sound devices may operate near the ground-plane of the antenna.
It is a further object and advantage of this invention to provide an antenna that can be situated between a speaker and a user's ear without changing the typical speaker location on the upper longitudinal middle of the front side of the phone.
It is a further object to provide an elliptically polarized antenna operating close to a non-polarized antenna such that both may be housed in a common enclosure.
SUMMARY OF THE INVENTION
The present invention provides a antenna that is compatible with the form of portable mobile devices. The antenna configuration includes a conducting portion that is flat and generally rectangularly shaped. The antenna maybe configured so the conducting portion of the antenna configuration may be mounted within a mobile station between a speaker and an earpiece. Slots may be implemented in each side to permit the conducting portion to operate like a microstrip antenna having dimensions much larger, but still with high levels of gain with respect to the desired frequencies. At least one hole may be implemented in the conducting portion to aid in sound transmission from the speaker to the earpiece. The implementation of a hole in the approximate center of the conducting portion has virtually no effect in the gain of the antenna since the central region for a continuous antenna having a rectangular shape (or with slots) is a voltage minimum.
In an embodiment of the invention, a mobile phone is provided a flat GPS antenna which has a hole through the central region. The hole is located just above a speaker or other input/output device, wherein the speaker is mounted on a printed circuit board (PCB), and the GPS antenna is set-off from the PCB, yet still enclosed within a case or casing of the mobile phone. The case has an earpiece which has holes located near to the GPS antenna hole. A cellular antenna is mounted below the PCB to permit reception and transmission of cellular frequencies. The GPS antenna, speaker, and cellular antenna are located on the part of the mobile phone that is the distant end, i.e. the remaining part of the mobile phone is for grasping and other handling by a person. In alternative embodiments, the cellular antenna may be any other type of antenna usually for cellular communications such as extendable, stub antennas or antennas embedded in flip portions of a mobile station.
Similar performance with a two-feed circularly polarized microstrip antenna can be achieved, while making the size of the two-feed antenna as small as the size of the single-feed arrangement. It is also quite common to generate elliptical polarization by using two feed points to excite two orthogonal modes on the patch with a 90 degrees phase difference between their excitations.
In another embodiment of the invention, the antenna generates elliptical polarization by using two blunt opposite corners of the patch. The placement of the feedpoint at the end of a slot is needed to provide the elliptical polarization. Enhanced performance occurs by putting a high permittivity superstrate over the patch as well as between the patch and the ground plane. The longest dimension is about 20 mm, which appears electrically as a half wavelength (about 9.5 cm for 1575 MHz GPS signals).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a elevation side cut away view of mobile station including a dual antenna configuration, according to an embodiment of the invention.
FIG. 2 is a elevation side view of a dual antenna configuration, according to an alternate embodiment of the invention.
FIG. 3 a is a top view of a GPS antenna configuration, according to an embodiment of the invention.
FIG. 3 b is an elevation view of a the GPS antenna of FIG. 3 a.
FIG. 4 a is a perspective view of a GPS antenna configuration according to an alternate embodiment of the invention.
FIG. 4 b is an elevation side view of the antenna configuration of FIG. 4 a.
FIG. 5 a is a perspective view of GPS antenna configuration according to an alternate embodiment of the invention.
FIG. 5 b is an elevation side view of the antenna configuration of FIG. 5 a.
FIG. 6 a is a perspective view of a mobile phone including an antenna configuration according to an alternate embodiment of the invention.
FIG. 6 b is an elevation side view of the antenna configuration of FIG. 6 a.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a elevation view of a dual antenna configuration 100 according to an embodiment of the invention. The main supporting surface is the printed circuit board 101 , which provides a ground plane on at least one side of the board. A radio transmit and receive patch antenna 103 such as U.S. patent application filed Jan. 19, 1998, appl. Ser. No. 09/005,103, is located on the back of the board, which affords the antenna fewer obstructions when an ear is placed close to the front side of the board. The front of the PCB 101 includes a sound transducer 105 which, for example, may be a speaker, 105 which is to located under a elliptically polarized GPS antenna 107 . The GPS antenna 107 provides a conductor hole 109 through which sound passes. Conductor hole 109 may be square, rectangular round or any other shape. Either side of the PCB 101 can operate as a ground plane. Both antennas are mounted on the distant end 131 of the PCB 101 , while the grasping end 133 may be mounted within portions of a mobile device used for handling, for example, by a hand. Surrounding the entire unit is a mobile phone exterior case 141 or casing which includes an earpiece 143 having at least one sound hole 145 .
GPS ellipticaly polarized antenna 107 further includes a dielectric superstrate 121 having a superstrate hole 109 a positioned above conductor hole 109 b of the substantially flat conductor 110 . In addition, below the conductor is the high permittivity dielectric substrate 125 and a substrate hole 109 c as well as a feed hole 129 , which provides a conduit through which feed probe 151 passes. Holes 109 , 109 a , 109 b , 109 c , may be square, rectangular, round or any other shape.
Both the substrate 125 and the superstrate 121 overlap all parts of conductor 110 and extend beyond the outer edges of conductor 110 . The substrate 125 and the superstrate 121 may come in contact with each other.
FIG. 2 shows an alternative embodiment wherein the PCB 201 has a PCB hole 202 with a speaker 205 mounted facing the hole, but on the back side of the PCB 201 . Transmit and receive antenna 203 is below the PCB 201 .
FIG. 3 a shows the general configuration of a GPS antenna conductor 300 according to the invention. Antenna conductor 300 may be used in place of antenna conductor 100 of FIG. 1 and FIG. 2 . All angles may be approximately 90° unless otherwise specified. The antenna conductor is generally rectangular, having sides 301 , 302 , 303 , 304 . In each side are slots 311 , 312 , 313 , 314 , having a slot width 318 and a slot length 319 . Each slot may be centered on either a horizontal center line 321 or a vertical center line 322 . Opposing corners have edges 323 , 324 , each with a blunt length 325 . The edge may be at approximately 45° angle to the sides. Centered on both center lines is conductor hole 350 having a square shape. The sides of the conductor hole 350 are approximately parallel to the sides of the antenna patch. All corners may be rounded due to manufacturing tolerances by radiuses up to 5% of the shortest side next to a corner.
Above and below conductor 300 is a superstrate and a substrate, each having a minimal amount of overlap, which may be better seen referring to FIG. 3 b. Superstrate perimeter 370 overlaps conductor 300 . Superstrate has a hole 371 that has a area at the top of the superstrate. The hole 371 may conform to the dimensions of the conductor hole 350 , or the hole 371 may be smaller in width than the conductor hole 350 .
Substrate 390 has a hole 372 that has a area at the top of the substrate. The hole 372 may conform to the dimensions of the conductor hole 350 , or the hole 372 may be smaller in width than the conductor hole 350 . Multiple holes through the substrate 390 and superstrate 370 can substitute for a single hole, so long as all the holes line up and together allow significant sound to pass through. In addition, each of the substrate and superstrate holes must have at least one end at the main conductor hole 350 .
In addition, substrate has a feed hole 380 through which a conductor or feed probe may pass. Feed hole 380 ends at feedpoint 381 on the underside of the antenna. Feedpoint 381 is centered on horizontal centerline 321 , but may function just as well on the vertical centerline 322 . The choice of centerlines, and location on either side of the conductor hole is not important since a mirror image of the antenna operates just the same as the opposite orientation, except that the mirror image antenna receives left-hand circular polarized signals. However, in the case where the invention must handle GPS signals, which are right-hand circular polarized, only the orientation as appears in FIG. 3 will properly receive such signals. All holes, whether in the substrate or the superstrate pass in an orthogonal direction in relation to the PCB. A GPS signal carrying conductor attaches by means known in the art to couple the antenna conductor via the feedpoint 381 to filter or amplifier circuitry located on or below the ground plane.
FIG. 4 a shows the general configuration of a GPS antenna conductor 400 according to the invention. Antenna conductor 400 may be used in place of antenna conductor 100 of FIG. 1 and FIG. 2 . All angles may be approximately 90° unless otherwise specified. The antenna conductor is generally rectangular, having sides 401 , 402 , 403 , 404 . In each side are slots 411 , 412 , 413 , 414 , having a slot width 418 and a slot length 419 . Each slot may be centered on either a horizontal center line 421 or a vertical center line 422 . Centered on both center lines is conductor hole 450 having a square shape. The sides of the conductor hole 450 are approximately parallel to the sides of the antenna patch. All corners may be rounded due to manufacturing.
Above and below conductor 400 is a superstrate and a substrate, each having a minimal amount of overlap, which may be better seen referring to FIG. 4 b. Superstrate perimeter 470 overlaps conductor 400 . Superstrate has a hole 471 that has a area at the top of the superstrate. The hole 471 may conform to the dimensions of the conducto r hole 450 , or the hole 471 may be smaller in width than the conductor hole 450 .
Substrate 490 has a hole 472 that has a area at the top of the substrate. The hole 472 may conform to the dimensions of the conductor hole 450 , or the hole 472 may be smaller in width than the conductor hole 450 . Multiple holes through the substrate 490 and superstrate 470 can substitute for a single hole, so long as all the holes line up and together allow significant sound to pass through. In addition, each of the substrate and superstrate holes must have at least one end at the main conductor hole 450 .
In addition, substrate has a first feed hole 480 through which a first conductor or feed probe may pass. First feed hole 480 ends at feedpoint 481 on the underside of the antenna. Feedpoint 481 is centered on horizontal centerline 421 . All holes, whether in the substrate or the superstrate pass in an orthogonal direction in relation to the PCB. A GPS signal carrying conductor attaches by means known in the art to couple the antenna conductor via the feedpoint 481 to filter or amplifier circuitry located on or below the ground plane.
In addition, substrate has a second feed hole 485 through which a second conductor or feed probe may pass. Second feed hole 485 ends at feedpoint 486 on the underside of the antenna. Feedpoint 486 is centered on vertical centerline 422 . All holes, whether in the substrate or the superstrate pass in an orthogonal direction in relation to the PCB. A GPS signal carrying conductor attaches by means known in the art to couple the second antenna conductor via the feedpoint 486 to filter or amplifier circuitry located on or below the ground plane.
FIG. 5 a shows the general configuration of a GPS antenna conductor 500 according to the invention. Antenna conductor 500 may be used in place of antenna conductor 100 of FIG. 1 and FIG. 2 . All angles may be approximately 90° unless otherwise specified. The antenna conductor is generally rectangular, having sides 501 , 502 , 503 , 504 . In each side are slots 511 , 512 , 513 , 514 , having a slot width 518 and a slot length 519 . Each slot may be centered on either a horizontal center line 521 or a vertical center line 522 . Centered on both center lines is conductor hole 550 having a square shape. The sides of the conductor hole 550 are approximately parallel to the sides of the antenna patch. All corners may be rounded due to manufacturing.
Above and below conductor 500 is a superstrate and a substrate, each having a minimal amount of overlap, which may be better seen referring to FIG. 5 b. Superstrate perimeter 570 overlaps conductor 500 . Superstrate has a hole 571 that has a area at the top of the superstrate. The hole 571 may conform to the dimensions of the conductor hole 550 , or the hole 571 may be smaller in width than the conductor hole 550 .
Substrate 590 has a hole 572 that has a area at the top of the substrate. The hole 572 may conform to the dimensions of the conductor hole 550 , or the hole 572 may be smaller in width than the conductor hole 550 . Multiple holes through the substrate 590 and superstrate 570 can substitute for a single hole, so long as all the holes line up and together allow significant sound to pass through. In addition, each of the substrate and superstrate holes must have at least one end at the main conductor hole 550 .
In addition, substrate has a first feed hole 580 through which a first conductor or feed probe may pass. First feed hole 580 ends at feedpoint 581 on the underside of the antenna. Feedpoint 581 is centered on diagonal centerline 521 . All holes, whether in the substrate or the superstrate pass in an orthogonal direction in relation to the PCB. A GPS signal carrying conductor attaches by means known in the art to couple the antenna conductor via the feedpoint 581 to filter or amplifier circuitry located on or below the ground plane.
In addition, substrate has a second feed hole 585 through which a second conductor or feed probe may pass. Second feed hole 585 ends at feedpoint 586 on the underside of the antenna. Feedpoint 586 is centered on diagonal centerline 522 . All holes, whether in the substrate or the superstrate pass in an orthogonal direction in relation to the PCB. A GPS signal carrying conductor attaches by means known in the art to couple the second antenna conductor via the feedpoint 586 to filter or amplifier circuitry located on or below the ground plane.
FIG. 6 a is a perspective view of an alternate embodiment of the invention which includes a stub antenna 601 , case 600 , PCB 603 and GPS antenna 605 . A case hole 606 is disposed above the GPS antenna hole 607 . Below the GPS antenna hole 607 is a speaker 609 . Stub antenna 601 is situated below the PCB 603 . The stub antenna 601 is the cellular transmit and receive antenna.
FIG. 6 b is a perspective view of an alternate embodiment of the invention which includes a stub antenna 601 , case 600 , PCB 603 and GPS antenna 605 . A case hole 606 is disposed above the GPS antenna hole 607 . Below the GPS antenna hole 607 is a speaker 609 . Stub antenna 601 is situated below the PCB 603 . The stub antenna 601 is the cellular transmit and receive antenna.
Operation of the mobile according to the embodiment of the invention is accomplished in one of two modes. For ordinary voice functions of receiving or replaying voice through a speaker, the mobile is operated with the hole of the patch antenna close to the ear of a user. The use of an accessory such as a bud speaker on an extended wire is also an option, wherein the phone may operate in any orientation. Operation of the mobile for purposes of receiving a GPS signal involves holding the mobile in a horizontal, front-up position. In this position, a user may manipulate a keyboard on a mobile phone or any other input device necessary to control the GPS receiver by handling the grasping end of the mobile phone.
Although the invention has been described in the context of particular embodiments, it will be realized that a number of modifications to these teachings may occur to one skilled in the art. For example, all manner of fixed, extendable, patch or microstrip antennas could be used for the transmit and receive antenna. Similarly, many elliptically polarized antennas may be substituted for the rectangularly shaped antenna. Thus, while the invention has been particularly shown and described with respect to specific embodiments thereof, it will be understood by those skilled in the art that changes in form and configuration may be made therein without departing from the scope and spirit of the invention. | An antenna configuration for a mobile communication device. The antenna configuration includes at least a first antenna configured so that the first antenna may be mounted near or between a speaker and a earpiece of a mobile station. In an embodiment of the invention, the first antenna comprises a substantially flat conductor including at least one hole for passing sound from the speaker to the earpiece of the mobile station. The first antenna is configured to receive GPS signals. A second antenna is implemented on the mobile station to transmit and receive cellular transmissions. | 7 |
TECHNICAL FIELD
The present invention relates to an air-purifying device for a vehicle and to an air-purifying device for a vehicle capable of directly purifying ozone in atmospheric air.
BACKGROUND ART
Ozone, which causes photochemical smog, is produced by a photochemical reaction of HC and NOx contained in exhaust gases from automobiles and factories. Therefore, reducing the amount of emissions of HC and NOx from automobiles is an efficient way to suppress the production of ozone and the occurrence of photochemical smog. Also, purifying ozone in the atmospheric air directly can be one of the ways to prevent the occurrence of photochemical smog. By purifying ozone as a product as well as reducing the amount of emissions of HC and NOx as reactants, the occurrence of photochemical smog can be prevented more effectively. In this respect, an automobile including an air-purifying device for a vehicle capable of directly purifying ozone in the atmospheric air has been put into practical use in some places including California in the United States of America. This air-purifying device for a vehicle, particularly, is called a DOR (Direct Ozone Reduction) system.
Previously-used air-purifying device for a vehicle (a DOR system), in which National Publication of International Patent Application No. 2003-515442 represents, is the one that uses metal oxide such as manganese dioxide as a catalyst. By coating a catalyst made of metal oxide on a radiator into which air is delivered during travel of a vehicle, ozone in the atmospheric air is degraded and purified by the catalyst.
It has been known that not only metal oxide catalyst such as manganese dioxide but also activated carbon have a function for purifying ozone. By activated carbon, ozone is converted into carbon dioxide by reaction with activated carbon itself. Since this reaction occurs at ambient temperature, it can be said that activated carbon has an advantage in a purification condition over the metal oxide catalyst which purifies ozone at a higher temperature than the ambient temperature. Moreover, activated carbon has countless fine pores and its surface area per unit volume is quite large. Therefore, it has many chances to contact with ozone in the atmospheric air and thus has high ozone purification performance per unit volume. In addition, the fine pores of the activated carbon have an effect which lowers activation energy for the conversion of ozone to radical oxygen by electron donation from carbon (a capillary condensation effect). With the capillary condensation effect, the degradation of ozone in the fine pores of the activated carbon is accelerated.
However, at present, none of those air-purifying devices for a vehicle with an ozone purifier including the activated carbon have been put into practical use. For there becomes a problem where the activated carbon is used as an ozone purifier, its ozone purifying function is easily deteriorated. The reason for this is particulate matter (hereinafter called “PM” or “PMs”) contained in the atmospheric air. Invading PM into the fine pores of the activated carbon results in a clogging, which leads to a significant decrease in substantive surface area of the activated carbon, that is, surface area capable of contacting with ozone. PMs include the ones which are emitted from vehicles such as diesel vehicles and the ones from soil. The clogging of the activated carbon is caused by the former with small particle size. Under an environment with automobiles, naturally, the former level increases. Therefore, in case of applying the activated carbon to the atmospheric air-purifying device for a vehicle, it becomes an issue of how to reduce damage from PMs in the atmospheric air, especially PMs from the vehicle.
CITATION LIST
Patent Literature
Patent Literature 1: National Publication of International Patent Application No, 2003-515442
SUMMARY OF INVENTION
The present invention has been made in view of the above-described issue. The purpose of the invention is to provide an air-purifying device for a vehicle that uses an ozone purifier including activated carbon. An air-purifying device for a vehicle, provided by the present invention, comprises an ozone purifier which is prepared so that the mode pore size of the activated carbon is smaller than the mode particle size of PM from vehicles. This ozone purifier is disposed on the surface of an on-vehicle component arranged on a portion where an air flow passage is formed while a vehicle is traveling. If the mode pore size of the activated carbon is smaller than the mode particle size of PM from vehicles, many PMs are unable to invade into the fine pores of the activated carbon. Thus, the clogging of the activated carbon caused by PM will be suppressed and the activated carbon's purifying function toward ozone will be kept at a high level.
There is a credible data on the particle size of PM from vehicles. The data, which is published by National Institute for Environmental Studies, shows in a graphic representation a relationship between particle size of PM from vehicles and number concentration. According to this data, many of particle sizes of PM from vehicles are distributed within a range from about 0.01 to 0.1 μm and their mode is around 0.05 μm. From this data, it is found that if a pore size of activated carbon is 10 nm or less, most of PMs from vehicles can be prevented from invading into the pore. Therefore, the activated carbon included in the ozone purifier is preferably prepared 10 nm or less in its mode pore size.
A preferable embodiment of the ozone purifier for a vehicle may comprise a PM collector collecting PMs contained in the atmospheric air delivered into the ozone purifier. As the PM collector, activated carbon with larger pore size than the activated carbon included in the ozone purifier may be used. For example, if the mode pore size of the activated carbon included in the ozone purifier is prepared 10 nm or less, then the activated carbon included in the PM collector is prepared so that its mode pore size is 10 nm or more. Since many of particle size of PM from vehicles are distributed within a range from about 0.01 to 0.1 μm, the activated carbon included in the PM collector is preferably prepared so that a distribution range of its pore sizes includes a range from 0.01 to 0.1 μm. By comprising such PM collector with the ozone purifier, the amount of PM delivered into the ozone purifier will be decreased. And the clogging of the activated carbon of the ozone purifier, which is caused by PM, will be able to be suppressed more effectively.
There are two preferable embodiments where the PM collector is provided. In the first embodiment, when an additional on-vehicle component (a second on-vehicle component) is arranged, with respect to said flow passage, on the upstream of the on-vehicle component with the ozone purifier, the PM collector is disposed on the surface of the second on-vehicle component. In this case, it is preferable that the on-vehicle component with the ozone purifier is a radiator. It is preferable that the additional on-vehicle component with the PM collector is a capacitor, a sub-radiator or a bumper grille. On the other hand, in the second embodiment, the PM collector is disposed on the surface of the on-vehicle component by being stacked on the ozone purifier so as to cover the surface of the ozone purifier. In this case, it is preferable that the on-vehicle component is a radiator.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view showing a structure of an automobile on which an air-purifying device for a vehicle according to each embodiment of the present invention is applied.
FIG. 2 is a schematic view culled from the automobile 2 shown in FIG. 1 and showing a part especially associated with the air-purifying device for a vehicle in first embodiment of the present invention.
FIG. 3 is a graph showing each distribution in pore size of activated carbon for ozone purification and activated carbon for PM collection.
FIG. 4 is a graph showing a relationship between particle size of PM from vehicles and number concentration.
FIG. 5 is a schematic view showing a relationship between pore size of activated carbon and ease of invading PM into fine pores.
FIG. 6 is a schematic view culled from the automobile 2 shown in FIG. 1 and showing a part especially associated with the air-purifying device for a vehicle in second embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
First Embodiment
A first embodiment of the present invention will be explained below with reference to Figures.
FIG. 1 is a schematic view showing a structure of an automobile on which an air purifying device for a vehicle according to the embodiment is applied. The air-purifying device for a vehicle is applied on an automobile 2 comprising an internal combustion engine 4 as a power unit. The exhaust gas discharged from the internal combustion engine 4 contains HC and NOx. Ozone is produced by photochemical reaction between HC and NOx as reactants. Therefore, the air-purifying device for a vehicle is applied on the automobile 2 comprising the internal combustion engine 4 , the ozone is purified while the automobile 2 is traveling, and thus, the damage to the environment caused due to the automobile 10 can be reduced.
In the automobile 2 , a radiator 6 is arranged on the front side of the internal combustion engine 4 . A capacitor 10 of an air conditioner is arranged on the front side of the radiator 6 . A radiator fan 8 is mounted on the reverse side of the radiator 6 . While the automobile 2 is traveling, the atmospheric air is taken in from a bumper grill 12 on a front surface of the automobile 2 . The taken air passes through the capacitor 10 and the radiator 6 to be discharged to the rear side. Even while the automobile 2 is stopping, an air flow passage from the bumper grill 12 through the capacitor 10 to the radiator 6 is formed by the revolution of the radiator fan 8 .
FIG. 2 is a schematic view culled from the automobile 2 and showing a part especially associated with the air-purifying device for a vehicle in the embodiment. In the air-purifying device for a vehicle, with the structure shown in FIG. 2 , an ozone purifier 20 including activated carbon is coated on the radiator 6 and PM collectors 22 and 24 are coated on the capacitor 10 and the bumper grill 12 respectively. The ozone purifier 20 may consist of activated carbon only or may include some catalyst materials other than the activated carbon. The PM collectors 22 and 24 include activated carbon in common with the ozone purifier 20 . However, there is a clear distinction between the ozone purifier 20 and the PM collectors 22 and 24 in pore size of the activated carbon.
In the air-purifying device for a vehicle, the activated carbon of the ozone purifier 20 is prepared so that its pore size is 10 nm or less, more practically, so that its mode in number concentration distribution of pore size is 10 nm or less. On the other hand, the activated carbon of the PM collectors 22 and 24 are prepared so that most of their pore sizes are distributed within a range from 10 to 1000 nm. Practically, the activated carbon of the PM collector 24 located in the front with respect to the flow direction of the atmospheric air is prepared so that its pore sizes are distributed within a range from 100 to 1000 nm and the activated carbon of the PM collector 22 located in the rear is prepared so that its pore sizes are distributed within a range from 10 to 100 nm. FIG. 3 is a graph showing an example of each distribution in pore size of the activated carbon of the ozone purifier 20 (activated carbon for ozone purification) and the activated carbon of the PM collectors 22 and 24 (activated carbon for PM collection). The abscissa of the graph shows radius of fine pores and the ordinate shows number concentration of the pores with the radius. In a case shown in this graph, the activated carbon for ozone purification is prepared so that its mode radius of pore is around 1.0 (10 Å) and the activated carbon for PM collection is prepared so that its mode radius of pores are distributed within a wide range from 1.0 to 1000 μm (10 to 10000 Å).
The reason why the difference in pore size of each activated carbon is set in this manner relates to the particle size of the PM from vehicles. FIG. 4 is a graph showing a relationship between particle size of PM from vehicles and number concentration published by National Institute for Environmental Studies. As shown in this graph, many of particle sizes of PM from vehicles are distributed within a range from about 0.01 to 0.1 μm (about 10 to 100 nm) and their mode is around 0.05 μm (50 nm). Therefore, if the mode pore size of the activated carbon is prepared 10 nm or less, most of PMs from vehicles can be prevented from invading into the fine pores and the clogging of the activated carbon can be suppressed. On the other hand, if the distribution of size of the activated carbon is prepared so as to include a range from 10 to 100 nm, then PMs from vehicles in the atmospheric air can be collected effectively.
FIG. 5 is a schematic view showing a relationship between pore size of activated carbon and ease of invading PM into fine pores. In case of the activated carbon of the PM collector 22 or 24 , since the distribution of its pore size is prepared so as to include the distribution range of the particle size of PM, PM 30 is susceptible to invade into the fine pores shown in the left side of FIG. 5 . On the other hand, in case of the activated carbon of the ozone purifier 20 , since its pore size is prepared so as to be smaller than the particle size of PM, PM 30 is difficult to invade into the fine pores shown in the right side of FIG. 5 . That is, the pore size of the activated carbon of the PM collector 22 or 24 is prepared so as to let PMs invade into the fine pores and enable to collect PMs, while the pore size of the activated carbon of the ozone purifier 20 is prepared so as to prevent PMs into the fine pores and enable to suppress the clogging.
As described above, according to the air-purifying device for a vehicle, since the activated carbon of the ozone purifier 20 coated on the radiator 6 is prepared so that its mode pore size is 10 nm or less, the clogging of the activated carbon caused by PM can be suppressed and the activated carbon's purifying function toward ozone can be kept at a high level. Moreover, according to the air-purifying device for a vehicle, PM with 100 nm or more particle size can be collected by the PM collector 24 coated on the bumper grill 12 and PM with 10 nm or more particle size can be collected by the PM collector 22 coated on the capacitor 10 . As a result of this, it becomes possible to decrease the amount of PM delivered into the ozone purifier 20 located in the rear of the PM collector 22 and 24 and to suppress the clogging of the activated carbon caused by PM more effectively. There is no limit how to adjust the pore size of the activated carbon.
Second Embodiment
Subsequently, a second embodiment of the present invention will be explained below with reference to Figures.
FIG. 6 is a schematic view culled from the automobile 2 and showing a part especially associated with the air-purifying device for a vehicle in the embodiment. As shown in FIG. 6 , in the air-purifying device for a vehicle, the ozone purifier 20 is coated on the surface of fins 16 of the radiator 6 , on which the PM collector 22 and 24 are additionally coated by two layers. The pore size of the activated carbon included in the ozone purifier 20 is prepared as explained in the first embodiment. The pore size of the activated carbon included in the PM collector 22 and 24 are also prepared as explained in the first embodiment.
According to the air-purifying device for a vehicle, the atmospheric air delivered into the radiator 6 firstly passes through the PM collector 24 which is prepared so that pore size of the activated carbon are distributed within a range from 100 to 1000 nm and then flows into the underlying PM collector 22 . In this process, PM with 100 nm or more particle size are collected by the PM collector 24 and removed from the atmospheric air. Since the underlying PM collector 22 is prepared so that pore size of the activated carbon are distributed within a range from 10 to 100 nm, PM with 10 nm or more particle size contained in the atmospheric air are collected while passing through the PM collector 22 . In this way, PM with 10 nm or more particle size contained in the atmospheric air, that is, most of PMs are removed from the atmospheric air before flowing into the ozone purifier 20 . Since the bottom ozone purifier 20 is prepared so that its pore size of the activated carbon is 10 nm or less, if PMs are remained in the atmospheric air, the clogging of the activated carbon by the remained PMs will be suppressed. Therefore, according to the air-purifying device for a vehicle, as in the first embodiment, the activated carbon's purifying function toward ozone can be kept at a high level.
Other
While the present invention has been described in terms of the embodiments, it is not limited to the embodiments, but extends to various modifications that nevertheless fall within the scope of the appended claims. For example, only the ozone purifier 20 may be applied on the vehicle without the PM collector 22 or 24 .
Moreover, the PM collector is coated on the capacitor in the first embodiment. However if the vehicle comprises a sub-radiator, the PM collector may be coated on the sub-radiator. The PM collector may be coated on at least the bumper grill, the capacitor and the sub-radiator rather than the first embodiment where the PM collectors with differential pore size are arranged back and forth.
Moreover, the PM collectors with differential pore size are coated by two layers in the second embodiment. However, the PM collectors may be formed by one layer. Moreover, it is not limited to the radiator over which the ozone purifier and the PM collectors are recoated. The ozone purifier and the PM collectors may be additionally coated on the bumper grill, the capacitor and the sub-radiator.
DESCRIPTION OF REFERENCE NUMERALS
2 automobile
4 internal combustion engine
6 radiator
8 radiator fan
10 capacitor
12 bumper grill
16 radiator fin
20 ozone purifier
22 , 24 PM collector
30 PM | The purpose of the present invention is to provide an air-purifying device for a vehicle that uses an ozone purifier including activated carbon. This air-purifying device for a vehicle, provided by the present invention, includes an ozone purifier which includes activated carbon and being disposed on the surface of an on-vehicle component arranged on a portion where an air flow passage is formed while a vehicle is traveling. The ozone purifier is prepared so that the mean pore size of the activated carbon is preferably 10 nm or less so as to be smaller than the mean particle size of the particulate matter from the vehicle. | 1 |
FIELD OF THE INVENTION
The present invention is generally directed to a utility tray for attaching to a horizontally extending surface. The tray may be used to support tools, electrical equipment and the like. In particular, the utility tray attaches to the horizontally extending ledge of a circuit breaker panel and can be conveniently used by electricians during the installation and/or repairs of the circuit breaker panel.
BACKGROUND OF THE INVENTION
The installation and/or repair of devices which are mounted on a vertical surface is rendered more difficult because there is no convenient area to place tools and equipment needed to complete the job. For example, in the installation and/or repair of circuit breaker panels, the electrician may place his tools and component parts of the panel on the floor. Every time a new tool is needed or component part must be inserted into the panel, the electrician must stop work, reach down to the floor and obtain the tool or component part, and then stand erect to begin work again. This procedure results in considerable loss of work time.
Electricians often wear tool belts to house at least some of the tools needed to install or repair a circuit breaker panel. The tool belts are typically worn around the waist and a variety of slots and pockets for holding hammers, pliers, screwdrivers and the like.
While such tool belts are useful for keeping the tools off the floor, they do not provide a place for easy access to the component parts of the circuit breaker. All too often the electrician places the component parts on the horizontally extending ledge of the circuit breaker panel. However, the area formed by the horizontally extending ledge is inadequate to store all the component parts needed during a routine installation and/or repair. In addition, component parts stored in this area can interfere with the electricians movements within the panel and can result in the component parts accidentally falling to the ground.
It would, therefore, be of considerable benefit to provide a convenient place for storing tools and component parts of a device to be installed on a wall, such as, for example, a circuit breaker panel which can be readily installed and removed as desired.
SUMMARY OF THE INVENTION
The present invention is generally directed to an apparatus which is adapted to attach to a horizontally extending ledge of a wall mounted device. By way of example only, the wall mounted device can be a circuit breaker panel which typically has a horizontally extending ledge beneath the panel door which is exposed when the panel door is opened.
The apparatus comprises a tray having a base and an attachment means operatively connected to one edge of the tray for engaging the ledge of the wall mounted device while maintaining the tray substantially parallel to the ledge. The present apparatus therefore provides an area for the storage of tools, component parts of the wall mounted device and the like which is convenient and eliminates the need for placing objects on the floor or on the ledge of the wall mounted device. The apparatus is also portable so that it may be readily moved from one job site to another.
In a preferred form of the invention, the attachment means comprises a clamping means which operatively engages the ledge to secure the tray in its horizontally extending position. A variety of clamping devices may be used which will depend, in part, on the degree of support needed for the tray and the dimensions of the ledge of the wall mounted device.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of embodiments of the invention and are not intended to limit the invention as encompassed by the claims forming part of the application.
FIG. 1 is a perspective view of one embodiment of the invention shown in proximity to a circuit breaker panel;
FIG. 2 is a top view of the embodiment of the invention shown in FIG. 1;
FIG. 3 is a bottom view of the embodiment of the invention shown in FIG. 1;
FIG. 4 is a side view of the embodiment of the invention shown in FIG. 1 in which a clamp for attaching the device to the ledge of a circuit breaker panel is in a non-engaged position; and
FIG. 5 is a side view similar to FIG. 4 showing the clamp in the engaged position and the tray secured in a horizontally extending position substantially parallel to the ledge of the circuit breaker panel.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and in particular to FIGS. 1 and 2, there is shown a wall mountable device in the form of a circuit breaker panel 2 having a housing 4 including sides 6, a ceiling 8 and a back wall 10. The back wall 10 houses the circuit breakers and related electrical components shown generally for ease of illustration by numeral 12. The panel 2 also has a ledge 14 extending outwardly from the bottom of the back wall 10. In the customary installation and/or repair of circuit breaker panels 2, an electrician will often store circuit breakers and related electrical equipment, as well as tools, on the surface of the ledge 14. The ledge, however, does not provide sufficient surface area for this purpose and therefore the electrician is almost always forced to use other means (e.g., the floor) to store electrical equipment and tools which is time consuming and inefficient.
In accordance with the present invention, a tray has an attachment means uniquely suited to securely attach the tray to the ledge 14 of the circuit breaker panel 2 to provide a work surface for the equipment needed to install and/or repair a circuit breaker panel.
Referring again to FIGS. 1 and 2, the tray device designated generally by numeral 20 includes a base 22 which provides a work surface area. Attached to the base is an attachment mechanism 24 including at least one pair of spaced apart bars constituted by an upper bar 26 and a lower bar 28 (two pairs of such bars are specifically shown in the drawings). The bars 26, 28 diverge at one end and thereby form an opening 30 for receiving the ledge 14 as the tray 20 is inserted into operative engagement with the circuit breaker panel 2. The distance between the bars 26, 28 and, therefore, the width of the opening 30 is sufficient to enable the tray 20 to be inserted in the direction of the arrows into operative engagement with the ledge 14.
The tray 20 includes the base 22 which is of sufficient area to provide a suitable work surface. The width of the base of the tray, for use in the repair and/or installation of circuit breaker panel 2, is preferably limited to a size which enables the electrician to reach over the tray and into the circuit breaker panel 2. The preferred width of the base is no greater than about 24 inches.
The base 22 may also be provided with an upwardly extending rim 32, which surrounds the base 22, to provide depth to the work area and to prevent tools and the like from sliding off of the tray 20. There may also be provided, either in the base 22 or the rim 32, slots 34 for holding tools in an upright position.
As shown best in FIGS. 3 and 4, the upper and lower spaced apart bars 26, 28 of each pair converge beneath the tray and are secured to the underside of the tray 20 in a customary manner such as by bolts 36a and 36b.
The attachment mechanism 24, illustrated in the drawing figures and best shown in FIGS. 4 and 5, includes a clamp 38 including a rotatable handle 40, a stem 42 and a flattened contact surface 44 which engages the ledge 14 to secure the tray 20 to the circuit panel 2. The clamp 38 extends through a hole 46 in each of the upper bars 26.
The operation of the device of the present invention will now be explained.
Referring again to FIG. 1, the handle 40 of the clamp 38 is rotated in a counterclockwise manner so that the clamp 38 assumes the position shown in FIG. 4. As a consequence, a gap 48 is formed of sufficient height between the contact surface 44 and the lower bar 28 to enable the try 20 to enter into operative engagement with the ledge 14. The handle 40 of the clamp 38 is then rotated in a clockwise manner to lower the contact surface 44 so that it engages the surface of the ledge 14 as shown specifically in FIG. 5. The pressure exerted by the clamp 38 on the ledge 14 is sufficient to maintain the tray in a horizontally extending position, even with tools and component parts of the circuit breaker panel stored thereon.
The electrician may then place tools, component parts and the like on the tray as shown in FIG. 1 to install and/or repair the circuit breaker panel. When the work is complete, the electrician merely rotates the handles 40 of the clamp 38 in a counterclockwise direction so that the stem 42 moves from the engaged position shown in FIG. 5 to the disengaged position shown in FIG. 4. The tray 20 is then removed by withdrawing the tray 20 in the direction opposite to the direction of the arrows shown in FIG. 1.
Various changes to the embodiments shown and described herein may be made within the spirit and scope of the invention. For example, other attachment mechanisms may be employed for maintaining the tray in the desired horizontal position including the use of set screws, spring loaded clamps and the like. | A device for attaching to a horizontally extending ledge of a wall mounted device which includes a tray and an attachment mechanism for securing the tray to the ledge in a position substantially parallel to the ledge. The device has particular application to the repair and/or installation of circuit breaker panels. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a disk drive for receiving a disk disposed within an inserted cartridge and a device that controls the distance that the cartridge is ejected from the disk drive. More particularly, the present invention relates to such a disk drive having a catching device that catches the ejected disk cartridge after the cartridge has traveled a predetermined distance along an eject path.
BACKGROUND OF THE INVENTION
[0002] A disk drive for receiving a removable disk cartridge is known. Examples of a disk drive include a conventional 3.5 inch ‘floppy’ disk drive, a “ZIP” disk drive as developed and marketed by IOMEGA Corporation of Roy, Utah, and the like. Such a disk drive is typically coupled to a processor or the like, and facilitates an exchange of information between the processor and a disk contained within the disk cartridge. The disk and the disk drive may be magnetically or optically based, for example.
[0003] The disk cartridge typically includes an outer casing or shell that houses the aforementioned disk therein. The disk is mounted on a hub and can rotate freely within the cartridge, and the hub of the disk is externally accessible by way of an access aperture defined in one of the planar panels of the cartridge. Typically, the disk drive includes a frame or chassis and a disk motor which is mounted thereto, wherein during operation of the drive, the motor engages the hub of the disk through the cartridge access aperture and applies a rotating force to such hub.
[0004] In one arrangement, the disk cartridge is inserted into, retained within, and ejected from the disk drive generally within an X-Y plane, and the motor is moved into contact with the retained disk in a direction generally perpendicular to the X-Y plane of such inserted disk, i.e., along a Z-axis. Such movement of such motor may be actuated as part of receiving and retaining the disk cartridge in the frame, and may for example be achieved by helically mounting the motor within the frame, by positioning the motor on a bi-level slide, or by pivoting the motor along an appropriate axis. Accordingly, the motor is moved relative to the disk along the Z-axis between a disk-engagement or loaded position and a disk-separation or unloaded position.
[0005] In at least some disk drives, the frame includes laterally arranged tracks on either side thereof for receiving corresponding lateral edges of the disk cartridge during cartridge insertion. Thus, the tracks guide the cartridge into the drive during insertion, hold the cartridge during retention, and guide the cartridge out of the drive during ejection. As may be appreciated, such tracks in the frame generally align with a cartridge opening in the disk drive, and the cartridge passes through the aligned opening during insertion and ejection thereof.
[0006] Typically, the ejection mechanism for a disk drive is mechanically based or electrically based. In the mechanical case, a mechanical eject button is externally positioned on the disk drive, where the mechanical button is the distal end of an ejection link that extends within the drive to a ejection mechanism, and physical pressure is applied to such mechanical button and transferred to the ejection mechanism by way of the ejection link to mechanically effectuate ejection of an inserted disk cartridge. In the electrical case, an electrical eject button may be externally positioned on the disk drive, where the electrical button electrically actuates an ejection mechanism within the disk drive, and the ejection mechanism as actuated effectuates ejection of an inserted disk cartridge. Note that in addition to or instead of the electrical button, electrical actuation of the ejection mechanism may occur by way of a signal received from the processor to which the disk drive is coupled. At any rate, ejection of a disk cartridge, be it mechanically or electrically based, is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail.
[0007] The distance that the disk cartridge travels during ejection from the disk drive is important to the proper function of the drive. If the cartridge eject distance is too small, the cartridge may not protrude through the cartridge opening far enough to be grasped and pulled out. If the eject distance is too large, the cartridge may completely exit the drive and fall or even be projected some distance. Due to the nature of the ejection mechanism in a disk drive, be it mechanically or electrically based, there are many variables and tolerances which affect the eject distance of the cartridge. In short, cartridge eject distance of a disk drive is subject to a relatively wide range in variation, and is relatively difficult to control within an acceptable range.
[0008] Accordingly, a need exists for a device in a disk drive that controls the cartridge eject distance to be within a relatively narrow acceptable range in a relatively simple and economical manner.
SUMMARY OF THE INVENTION
[0009] The present invention satisfies the aforementioned need by providing a disk drive for receiving a removable storage disk cartridge thereinto and retaining the received cartridge. The cartridge includes a shell and a storage media disposed within the shell. The drive has a motor for engaging the media within the retained cartridge and applying a motive force to the engaged media, and an ejection mechanism for ejecting the retained cartridge upon actuation. The drive also has a stopper for contacting the cartridge at least during ejection thereof and for co-acting with the ejecting cartridge to stop the ejecting cartridge at a predetermined ejection travel distance. The cartridge has a stop feature that co-acts with the stopper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing summary as well as the following detailed description of the present invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0011] [0011]FIG. 1 is a perspective view of the interior of a disk drive in accordance with one embodiment of the present invention;
[0012] [0012]FIG. 2 is a perspective view of a disk cartridge for being received into the disk drive of FIG. 1, and a catch device for being mounted to the disk drive of claim 1 in accordance with one embodiment of the present invention;
[0013] [0013]FIG. 3 is another perspective view of the disk cartridge of FIG. 2, and shows a catch feature for being caught by the catch device of FIG. 2 in accordance with one embodiment of the present invention; and
[0014] [0014]FIG. 4 is an enlarged view of the catch feature shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Certain terminology may be used in the following description for convenience only and is not considered to be limiting. For example, the words “left”, “right”, “upper”, and “lower” designate directions in the drawings to which reference is made. Likewise, the words “inwardly” and “outwardly” are directions toward and away from, respectively, the geometric center of the referenced object. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
[0016] Referring now to FIG. 1, there is shown a disk drive 10 in accordance with one embodiment of the present invention. As was discussed above, the disk drive 10 is for receiving a removable disk (not shown) such as a conventional 3.5 inch ‘floppy’ disk or a “ZIP” disk as developed and marketed by IOMEGA Corporation of Roy, Utah, and the like. The disk may be mounted on a generally coaxial hub (not shown) or may define a generally coaxial aperture (not shown) at the center thereof. As was discussed above, the disk is positioned within a cartridge 13 that includes an outer casing or shell 15 . The disk can rotate freely within the cartridge 13 , and the hub or aperture of the disk is externally accessible by way of an access aperture (not shown) defined in an appropriate one of the planar panels of the shell 15 of the cartridge 13 . Of course, the disk drive 10 may be for receiving any type of disk, magnetic, optical, or otherwise, with or without a hub, without departing from the spirit and scope of the present invention.
[0017] The disk drive 10 includes a frame or chassis 12 and a disk motor 14 which is mounted thereto, wherein during operation of the drive 10 , the motor 14 engages the disk at the hub or aperture thereof by way of the access aperture of the cartridge 13 and applies a rotating force thereto. The disk cartridge 13 and disk therein are inserted into (arrow A, FIGS. 1 - 3 ), retained within, and ejected from (arrow B, FIGS. 1 - 3 ) the drive 10 generally within an X-Y plane that is generally parallel to and within the general extent of the frame 12 of the drive 10 , and the motor 14 is moved relative to the disk cartridge and disk into a loaded position and into contact with the disk generally along a Z-axis generally perpendicular to the X-Y plane. Upon ejection of the disk cartridge and disk therein, the motor 14 is moved relative to the disk cartridge and disk back out to an unloaded position and out of contact with the disk along the Z-axis.
[0018] In one embodiment of the present invention, and as best seen in FIG. 1, the frame 12 includes laterally arranged tracks 16 on either side thereof for receiving and guiding corresponding lateral edges 17 of the disk cartridge 13 during insertion, retention, and ejection of the cartridge 13 . As seen, such tracks 16 in the frame 12 generally align with a cartridge opening 18 in the disk drive 10 , and the cartridge 13 with the disk therein passes through the aligned opening 18 during insertion and ejection thereof.
[0019] As was discussed above, and as seen in FIG. 2, the disk drive 10 includes an electrical or mechanical ejection mechanism 28 that ejects the retained cartridge 13 upon actuation. Again, ejection of a disk cartridge 13 , be it mechanically or electrically based, is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Accordingly, any appropriate ejection mechanism 28 may be employed without departing from the spirit and scope of the present invention.
[0020] In one embodiment of the present invention, to control the distance that the disk cartridge 13 travels during ejection from the disk drive 10 , the disk drive 10 is provided with a stopper 20 (FIG. 2) that contacts the cartridge 13 at least during ejection and that co-acts with the cartridge 13 to stop the cartridge 13 at a predetermined ejection travel distance. In one embodiment of the present invention, and as shown in FIG. 2, the stopper 20 is a bias spring mounted on the drive 10 . However, the stopper 20 may be any appropriate device without departing from the spirit and scope of the present invention as long as the stopper 20 performs the functions associated therewith as disclosed herein.
[0021] In one embodiment of the present invention, and as seen in FIG. 2, the disk drive 10 has a top wall 22 generally parallel to the retained disk cartridge 13 and on a side of the disk cartridge 13 opposite the motor 14 , and the stopper 20 is mounted to an inner side of the top wall 22 and extends down toward and into the path that the disk cartridge 13 travels during ejection. Thus, and as seen, a distal end 24 of the stopper 20 contacts a top surface 19 of the disk cartridge 13 as the disk cartridge 13 travels along the ejection path, and such contact by the stopper 20 halts the traveling disk cartridge at the aforementioned predetermined ejection travel distance.
[0022] Note that in the embodiment shown in FIG. 2, the bias spring stopper 20 as mounted to the inner side of the top wall 22 extends down toward and exerts a downward pressure on the disk cartridge 13 even as the disk cartridge 13 is retained within the disk drive 10 . Thus, the stopper 20 also acts to hold the retained cartridge 13 down against the motor 14 .
[0023] In one embodiment of the present invention, the stopper 20 positively co-acts with the cartridge 13 during ejection thereof to stop the cartridge 13 at the predetermined ejection travel distance, as is seen in FIG. 2. In particular, and as seen in FIGS. 3 and 4, the disk cartridge 13 at the top surface 19 thereof is provided with a stop feature 21 that is contacted by the distal end 24 of the stopper 20 as the disk cartridge 13 is being ejected. Importantly, when such contact occurs, further travel of the disk cartridge 13 along the ejection travel path is halted. Thus, such stopper 20 and stop feature 21 in combination define the predetermined ejection travel distance. Appropriate positioning of both the stopper 20 within the disk drive 10 and the stop feature 21 on the top surface 19 of the disk cartridge 13 to achieve the contact therebetween at the predetermined ejection travel distance should by now be appreciated by the relevant public and therefore need not be described herein in any detail.
[0024] In one embodiment of the present invention, the stop feature 21 on the top surface 19 of the disk cartridge 13 is a recess, as shown. Thus, contact with the stopper 20 comprises the distal end 24 thereof springing down and into the recess. Alternatively, the stop feature 21 may be a bump or a rough surface on the top surface 19 of the cartridge 13 , in which case the distal end 24 of the stopper 20 would spring up or frictionally co-act with the stop feature 21 , respectively.
[0025] In any case, the distal end 24 of the stopper 20 preferably comprises a contacting surface 26 that glides along the top surface 19 of the traveling cartridge 13 in areas away from the stop feature 21 , and that positively co-acts with the stop feature 21 to stop the ejecting cartridge 13 at the predetermined ejection travel distance. Also in any case, the distal end 24 of the stopper 20 and the contacting surface 26 thereof preferably do not interfere with grasping of the stopped cartridge 13 by a user or the like and continued removal of the disk cartridge 13 from the disk drive 10 through the cartridge opening 18 thereof. For example, and as seen, the contacting surface may comprise a generally convex curvature that generally is matched to the generally concave recess stop feature 21 . Such generally convex curvature also is amenable to the stop feature 21 in cases where such stop feature 21 is a bump or a rough surface.
[0026] In the foregoing description, it can be seen that the present invention comprises a new and useful stopper 20 in a disk drive that controls the cartridge eject distance to be within a relatively narrow acceptable range in a relatively simple and economical manner. It should be appreciated that changes could be made to the embodiments described above without departing from the inventive concepts thereof. For example, the stopper 20 may be located elsewhere, such as for example below or on a side of the retained disk cartridge 13 , and the co-acting stop feature 21 may be appropriately positioned based on the location of the stopper 20 . Likewise, the cartridge 13 may contain an item other than a disk, such as for example a tape. It should be understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | A drive receives a removable storage cartridge thereinto and retains the received cartridge. The cartridge includes a shell and a storage media disposed within the shell. The drive has a motor for engaging the media within the retained cartridge and applying a motive force to the engaged media, and an ejection mechanism for ejecting the retained cartridge upon actuation. The drive also has a stopper for contacting the cartridge at least during ejection thereof and for co-acting with the ejecting cartridge to stop the ejecting cartridge at a predetermined ejection travel distance. The cartridge has a stop feature that co-acts with the stopper. | 6 |
TECHNICAL FIELD
[0001] This invention relates generally to floor tiles, and more particularly to modular floor systems with a transition edge.
BACKGROUND OF THE INVENTION
[0002] Floor tiles have traditionally been used for many different purposes, including both aesthetic and utilitarian purposes. For example, floor tiles of a particular color may be used to accentuate an object displayed on top of the tiles. Alternatively, floor tiles may be used to simply protect the surface beneath the tiles from various forms of damage. Floor tiles typically comprise individual panels that are placed on the ground either permanently or temporarily depending on the application. A permanent application may involve adhering the tiles to the floor in some way, whereas a temporary application would simply involve setting the tiles on the floor. Some floor tiles can be interconnected to one another to cover large floor areas such as a garage, an office, or a show floor.
[0003] Various interconnection systems have been utilized to connect floor tiles horizontally with one another to maintain structural integrity and provide a desirable, unified appearance. In addition, floor tiles can be manufactured in many shapes, colors, and patterns. Some floor tiles contain holes such that fluid and small debris is able to pass through the floor tiles and onto a surface below. Tiles can also be equipped with special surface patterns or structures to provide various superficial or useful characteristics. For example, a diamond steel pattern may be used to provide increased surface traction on the tiles and to provide a desirable aesthetic appearance.
[0004] One method of making plastic floor tiles utilizes an injection molding process. Injection molding involves injecting heated liquid plastic into a mold. The mold is shaped to provide an enclosed space to form the desired shaped floor tile. The liquid plastic is allowed to cool and solidify, and the plastic floor tile is removed from the mold.
[0005] The perimeter of typical floor tiles generally comprises an abrupt step or edge. The size of the step is usually equal to the thickness of the floor tile. The thickness of typical floor tiles is generally ¼-¾ of an inch. For many purposes, however, the abrupt step presents a number of problems. For example, a step of ¼ to ¾ of an inch is enough to cause tripping. In addition, it can be difficult to move objects on rollers across the step and onto the floor tiles.
[0006] The present invention is directed to overcoming, or at least reducing the effect of, one or more of the problems presented above.
SUMMARY OF EMBODIMENTS OF THE INVENTION
[0007] In one of many possible embodiments, the present invention provides a modular floor edge system. The modular floor edge system comprises a first ramp, the first ramp comprising a leading edge, a major axis and a minor axis, and a substantially vertical back substantially parallel to the major axis. The substantially vertical back comprises a plurality of connecting members removably attachable to a modular floor tile. The first ramp may include a tapered surface, an open webbed structure supporting the tapered surface, and the ramp may be made of plastic. According to some embodiments, the leading edge may comprise a substantially straight portion and a rounded corner. The ramp may include a substantially vertical side surface adjacent to and perpendicular with the substantially vertical back, the side surface comprising a connecting member attachable to another ramp. The plurality of connecting members may include male tabs comprising a generally vertical component and generally horizontal component. The substantially vertical back may also include a female connecting member at one end that is connectable to another ramp. The plurality of connecting members may each comprise a semi-circular tab protruding laterally from the substantially vertical back, such that a curved portion of the semi-circular tab faces a floor. The modular floor edge system may include a second ramp removably attached longitudinally to the first ramp at an interface substantially parallel with the minor axis. The modular floor edge system may also include a second ramp having a major axis and minor axis, the second ramp removably attached perpendicularly to the first ramp at an interface substantially parallel to the minor axis of the first ramp and substantially parallel to the major axis of the second ramp.
[0008] Another embodiment of the present invention provides a modular flooring system. The modular floor system comprises a first modular floor panel having a top surface and a plurality of lateral edge connecting members, and a first modular ramp comprising a plurality of connecting members removably attached to one lateral edge of the first modular floor panel. The first modular ramp comprises a tapered surface extending from a leading edge adjacent to a floor to a trailing edge substantially flush with the top surface. The flooring system may comprise a plurality of modular floor panels removably connected with the first modular floor panel to create a polygonal shape having a perimeter. A plurality of modular ramps may be attached to one another and extend around or partially around the perimeter of the polygonal shape. The first modular ramp may comprise an angle ranging between approximately 20-60 degrees with respect to a floor or other support surface. According to some embodiments, the first modular ramp further comprises a top tapered surface and an open webbed structure supporting the top tapered surface. The first modular ramp may comprise injection molded plastic.
[0009] Another aspect of the invention provides a method of making a modular flooring edge. The method may include providing an injection mold and injection molding a modular ramp comprising a back having one or more connecting members attachable to a modular floor tile. The method may further include injection molding a side having one or more connecting members attachable to another modular ramp. The injection molding of the modular ramp may include creating an upper ramp surface and a lower webbed support structure. The injection molding of the modular ramp may further include creating a leading edge for placement adjacent to a floor, the leading edge comprising a generally straight portion and a rounded corner portion.
[0010] Another aspect of the invention provides a method of building a modular floor. The method may include providing a plurality of modular floor panels of generally rectangular shape comprising lateral edge connectors, and providing a plurality of modular ramps comprising back and side connectors. The method may further include connecting the plurality of modular floor panels to one another via the lateral edge connectors to form a polygonal shape, and connecting the plurality of modular ramps to the modular floor panels around a perimeter of the polygonal shape. Each of the plurality of modular ramps may also be connected to an adjacent one of the plurality of modular ramps.
[0011] The foregoing features and advantages, together with other features and advantages of the present invention, will become more apparent when referred to the following specification, claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings illustrate various embodiments of the present invention and are a part of the specification. The illustrated embodiments are merely examples of the present invention and do not limit the scope of the invention:
[0013] FIG. 1A is a top perspective view of a modular floor edge ramp according to one embodiment of the present invention;
[0014] FIG. 1B is a bottom perspective view of the modular floor edge ramp of FIG. 1A ;
[0015] FIG. 1C is a top perspective view of a modular floor edge ramp without a rounded corner according to one embodiment of the present invention;
[0016] FIG. 2 is a top perspective view of two modular floor edge ramps being attached to a modular floor panel according to one embodiment of the present invention;
[0017] FIG. 3A is a bottom perspective view of two modular floor edge ramps being attached to a modular floor panel according to one embodiment of the present invention;
[0018] FIG. 3B is a detailed inset of a corner of the modular floor panel shown in FIG. 3A ;
[0019] FIG. 3C is a bottom view of the two modular floor edge ramps attached to the modular floor panel according to one embodiment of the present invention.
[0020] FIG. 4 is a top view of two interconnected modular floor tiles according to one embodiment of the present invention;
[0021] FIG. 5A is a partial perspective view of a plurality of interconnected modular floor tiles with modular edge ramps attached to and extending around a perimeter of the modular floor tiles according to one embodiment of the present invention.
[0022] FIG. 5B is a side view of a portion of the tiles and ramps shown in FIG. 5A .
[0023] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION OF THE INVENTION
[0024] As mentioned above, modular flooring typically includes a top surface that sets above a support surface or floor. It is often difficult to move certain objects onto and off of the top surface of the modular flooring as a result of the step between the floor and the top surface. The sharp step around the perimeter of the modular floor can also result in tripping or other safety concerns. The present invention describes methods and apparatus that provide an edge around at least a portion of a modular floor perimeter. Consequently, ingress and egress to the modular floor is simplified and safer than prior flooring systems. While the edge and flooring systems shown and described below include embodiments, the application of principles described herein to are not limited to the specific devices shown. The principles described herein may be used with any flooring system. Therefore, while the description below is directed primarily to interlocking plastic modular floors, the methods and apparatus are only limited by the appended claims.
[0025] As used throughout the claims and specification the term “rectangle” or “rectangular” refers to a four-sided object with four right angles. “Modular” means designed with regular or standardized units or dimensions, as to provide multiple components for assembly of flexible arrangements and uses. The words “including” and “having,” as used in the specification, including the claims, have the same meaning as the word “comprising.”
[0026] Referring now to the drawings, and in particular to FIGS. 1A-1B , one component of a modular floor edge system according to principles of the present invention is shown. FIGS. 1A-1B illustrates a ramp, for example a first elongate ramp 100 . The first elongate ramp 100 comprises a major axis 102 and a minor axis 104 . The first elongate ramp 100 also includes a leading edge 106 arranged adjacent to a support surface such as the ground or a floor. Opposite of the leading edge 106 is a trailing edge 108 . The trailing edge 108 is spaced from the support surface. A top surface 110 extends between the leading edge 106 and the trailing edge 108 . Accordingly, the top surface 110 tapers from a first height above the support surface at the trailing edge 108 , to the second height adjacent to the support surface at the leading edge 106 as shown in FIG. 1A . The top surface 110 includes both an angled portion 111 and a substantially horizontal portion 113 .
[0027] The ramp 100 includes a first end 112 and a second end 114 . According to the embodiment of FIG. 1A , the leading edge 106 comprises a substantially straight portion 116 , and a rounded corner portion 118 at the second end 114 . Alternatively, according to some embodiments such as the embodiment shown in FIG. 1C , there is no rounded corner portion 118 at the second end 114 and the leading edge 106 is substantially identical at both the first and second ends 112 , 114 . As shown in FIG. 1A , the straight portion 116 is parallel to the major axis 102 .
[0028] The ramp 100 also includes a substantially vertical back 120 shown more clearly in FIG. 1B . FIG. 1B illustrates the ramp 100 from a bottom perspective view. The substantially vertical back 120 is generally parallel to the major axis 102 and comprises at least one connecting member, for example a plurality of male tabs 122 and a female tab 123 , protruding therefrom. The male and female tabs 122 , 123 are shown and described in more detail below with reference to FIGS. 3A-3C . The female tab 123 is shown adjacent to, but opposite of, the rounded corner 118 . The male tabs 122 are removably attachable to a modular floor tile, such as the modular floor tile 124 shown in FIG. 2 . The female tab 123 is connectable to another ramp.
[0029] Continuing to refer to FIG. 1B , the ramp 100 includes an open webbed structure 126 that supports the top surface 110 ( FIG. 1A ). The ramp 100 may comprise plastic or other material and is preferably injection molded. Accordingly, the ramp 100 is strong, lightweight, and inexpensive to manufacture.
[0030] Adjacent to the substantially vertical back 120 is a substantially vertical side surface 128 . The substantially vertical side surface 128 is generally perpendicular to the vertical back 120 . The substantially vertical side surface 128 includes one or more connecting members, such as male tab 130 , for attachment with another ramp similar or identical to the ramp 100 shown in FIG. 1B . The male tab 130 may be replaced with a mating female tab (e.g. 123 ), if desired, to provide for attachment to a ramp with a connecting member of the opposite type. Further, embodiments that do not include the rounded corner portion 118 (such as the embodiment of FIG. 1C ) may include either a male or female tab 122 , 123 opposite of the tab 130 shown protruding from the side surface 128 .
[0031] Referring next to FIG. 2 , two ramps 100 , 200 are shown in relation to the modular floor panel 124 . The modular floor panel 124 comprises a top surface 132 and a plurality of lateral edge connecting members. According to the embodiment of FIG. 2 , the plurality lateral edge connecting members comprise a plurality of female tabs 134 arranged on two adjacent sides 136 , 138 of the rectangular modular floor panel 124 , and a plurality of male tabs 140 arranged on another two adjacent sides 142 , 144 of the modular floor panel 124 . The first ramp 100 is shown connected to the modular floor panel 124 at the first lateral side 136 . Accordingly, female tabs 134 (not shown) extending from the first lateral side 136 are receptive of the male tabs 122 ( FIG. 1B ) of the first ramp 100 . Likewise, the female tabs 134 of the second lateral side 138 are receptive of the male tabs 222 of the second ramp 200 . The attachment of the ramps 100 , 200 to the modular floor panel 124 provides a convenient, tapered interface between the lateral sides 136 , 138 and the top surface 132 . Moreover, other ramps may also be added to the periphery of the modular floor panel 124 .
[0032] The connection of the first and second ramps 100 , 200 to the modular floor panel 124 is shown in more detail in FIGS. 3A-3C . The male tabs 122 , 222 include a generally vertical component which, according to the embodiment of FIGS. 3A-3C , comprises semi-circular posts 146 , 246 ( FIG. 3B ). The male tabs 122 , 222 also comprise generally horizontal components which, according to the embodiment of FIGS. 3A-3C , comprise semi circular discs 148 , 248 ( FIG. 3B ). A curved portion 150 of the semi-circular discs 148 , 248 faces the floor or ground. The semi-circular discs 148 , 248 are received through the looping female tabs 134 , and extend at least partially under the modular floor panel 124 to removably secure the ramps 100 , 200 to the modular floor panel 124 as shown in FIG. 3C . The looping female tabs 134 each comprise a rigid hoop structure that is completely receptive of the semi-circular discs 148 , 248 ( FIG. 3B ). The semi-circular posts 146 , 246 ( FIG. 3B ) and the semi-circular disc 148 , 248 ( FIG. 3B ) are also rigid but compressible toward one another. When inserted into the female tabs 134 , the semi-circular posts 146 , 246 ( FIG. 3B ) and the semi-circular discs 148 , 248 ( FIG. 3B ) maintain a constant pressure against the female tabs 134 , thereby securing a connection between desired components (e.g. between two or more modular floor panels 124 , between a modular floor panel 124 and a ramp 100 , between two or more adjacent ramps 100 , 200 , etc.). The connection members engage one another such that the different components are joined tightly to one another and provide a consistent upper surface.
[0033] According to the embodiment of FIGS. 3A-3C , a male tab 148 of the first ramp 100 is received by and engages the female tab 223 of the second ramp 200 to secure the first and second ramps 100 , 200 together. As shown in FIGS. 3A-3C , the second ramp 200 is removably attached perpendicularly to the first ramp 100 . Consequently, an interface 152 of the first ramp 100 with the second ramp 200 is substantially parallel to the minor axis 104 ( FIG. 1 ) of the first ramp 100 , and an interface 254 of the second ramp is substantially parallel to the major axis 102 ( FIG. 1 ) of the second ramp 200 . However, the first and second ramps 100 , 200 may be attached longitudinally as well. FIG. 5A illustrates a combination of ramps 100 arranged longitudinally and perpendicularly to one another around a modular floor 160 . The skilled artisan having the benefit of this disclosure will understand that the placement of the connecting members such as the male and female tabs 122 , 134 shown in FIG. 3B may be reversed between components.
[0034] Referring to FIG. 4 , two or more modular floor panels 124 may be interconnected to form any polygonal shape. Ramps such as the ramps 100 , 200 shown in FIGS. 3A-3B may then be attached at least partially around the perimeter of the polygonal shape as shown in FIG. 5A . The tapered surface 110 of the ramp 100 extends from the leading edge 106 adjacent to the support surface or floor to the trailing edge 108 that is preferably flush with the top surface 132 of the modular floor panels 124 . An angle α between the floor and the ramp 100 may range between approximately 20 and 60 degrees, preferably between approximately 30 and 50 degrees, more preferably about 45 degrees.
[0035] The preceding description has been presented only to illustrate and describe exemplary embodiments of invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the following claims. | The present invention provides a modular flooring system including a ramp to facilitate entry and exit from the flooring system. The ramp may be modular and interconnect with all or parts of a perimeter of the flooring system, and the ramp may also interconnect with adjacent ramp members. | 4 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with United States Government support under Contract W911NF-07-2-0083 awarded by the Army Research Laboratory (ARL) through the University of Oregon to Battelle Memorial Institute. The Government has certain rights in this invention.
FIELD OF THE INVENTION
[0002] The present invention relates generally to heat dissipation systems and more particularly to methods and systems for enhanced heat dissipation.
BACKGROUND OF THE INVENTION
[0003] Management of electronic system energy and cooling is gaining importance in development of future advanced lasers, radars, and power electronics. There is a general requirement to develop compact, light-weight, and low-cost thermal control and heat exchange systems. Requirements for such technologies and design techniques must dissipate ultra-high heat fluxes, reduce system energy usage, and increase system efficiencies. While a variety of combinations and various attempts have been made, new and better methods and systems are needed and desired. The present invention provides a new and improved system and process for meeting these needs.
[0004] Additional advantages and novel features of the present invention will be set forth as follows and will be readily apparent from the descriptions and demonstrations set forth herein. Accordingly, the following descriptions of the present invention should be seen as illustrative of the invention and not as limiting in any way.
SUMMARY OF THE INVENTION
[0005] The present invention is a system and method for performing heat dissipation characterized by contacting a heat transfer liquid with a heat exchange surface having raised hydrophilic nanoporous nanostructures disposed upon a substrate adjacent a central hydrophobic core. The heat transfer liquid forms a preselected contact angle when placed on the heat exchange surface. In preferred embodiments of the invention, the raised nanoporous nanostructures define interconnected voids and pathways within the nanoporous nanostructures, and have additional surface irregularities upon the nanostructures themselves. Various layers of these nanostructures can be constructed, resulting in, e.g., primary, secondary, tertiary, and other layers of the nanostructures. The structures are preferably formed by depositing metal oxides upon a substrate using a Microreactor-Assisted Nanomaterial Deposition process known as MAND™ (hereafter MAND).
[0006] In one embodiment of the invention, the metal oxide material is ZnO, NiO, or a zeolite material and the underlying substrate contains Cu, Ni, Si, Ti, Al, AlN, stainless steel, inconel alloys, carbon-copper composites, and various combinations and alloys thereof. In various embodiments, the surface coating includes nanoporous nanostructures composed of a preselected material including, but not limited to, e.g., ZnO, NiO, Ni, Au, Ag, Pt, Sn, including combinations of these materials. The raised nanoporous nanostructures comprise vanes that are centrally arranged around a central core in a generally flower-like arrangement, forming nanopores, crevices, gaps, and fissures that serve as nucleation sites for boiling. The raised nanoporous nanostructures preferably extend at least 10 nm above the substrate. In embodiments where water is the heat transfer liquid, a contact angle on the surface of between 15° and 25° is preferred. Critical heat flux (CHF) values for these nanostructured surfaces are at least about 63 W/cm 2 . And, boiling heat transfer coefficients for these nanostructured surfaces are as high as ˜23,000 W/m 2 K.
[0007] The nanoporous nanostructures are typically formed by mixing a preselected quantity of an aqueous solvent, a metal salt, and a complexing agent together to form an aqueous fluid. The aqueous fluid is flowed continuously across a surface of a substrate in a fluid reservoir at a preselected temperature below about 100° C. The aqueous fluid has a preselected residence time in contact with the substrate such that a plurality of nanoporous nanostructures form upon the substrate. The nanoporous nanostructures each have a plurality of surface protrusions with a plurality of random surface irregularities, forming nanopores, crevices, gaps, and fissures that serve as nucleation sites for boiling. The nucleation sites have a plurality of channels, interconnected voids, and passages that allow fluid to flow to the nucleation sites that allow for active boiling. In one embodiment, the surface protrusions have a height dimension measured from the surface between about 40 nm and about 50 nm. In other embodiments, the surface protrusions of the nanoporous nanostructures have a height dimension greater than or equal to about 50 nm. The nanoporous nanostructures include nanopores with a surface density in the range from about 30 pores per μm 2 to about 200 pores per μm 2 , and a pore density of from about 40 pores per μm 2 to about 100 pores per μm 2 . In various embodiments, the nanopores are of a size in the range from about 40 nm to about 100 nm. On average, the nanoporous nanostructures include nanopores with a mean diameter of about 50 nm.
[0008] The nanostructures can include nucleation sites that include a hydrophobic surface portion. The nanostructures can further include a hydrophilic surface that surrounds the hydrophobic surface portion that includes nanopores that effectively entrain fluids within the nanopores and transfer the fluids via strong capillary forces to the nucleation sites where active boiling takes place. In one embodiment, the nanoporous nanostructures include nucleation sites having a hydrophobic surface portion with a mean pore diameter of about 1 μm, surrounded by hydrophilic surfaces with nanoscale dimensions that facilitate rapid and effective fluid transfer and migration to the hydrophobic surface portion. The nanostructures have an average root-mean-square roughness (height) in the range of 200-600 nm. Formation of the various hydrophilic and hydrophobic surfaces is sequentially and/or alternately performed using a lithographic masking technique, where a first hydrophobic surface portion is masked off and a hydrophilic portion is formed. Then, the formed hydrophilic surface portion is masked off while the hydrophobic surface portion is formed, or vice versa, thereby forming nanoporous nanostructures that include both hydrophobic and hydrophilic surface portions. The hydrophobic surface portions include a contact angle in the range from about 10° to 30°. A preferred contact angle for the hydrophobic surface portions is about 20°. The hydrophobic surface portions aid the nucleation sites of the nanoporous nanostructures to form bubbles when a fluid is introduced under suitable fluid conditions. The hydrophobic and hydrophilic surface conditions may be variously altered by a variety of MAND processing actions including, but not limited, to, e.g., altering temperature, residence time, and concentrations of constituents in the aqueous fluid that contact the substrates in the MAND fluid reactor.
[0009] The purpose of the foregoing abstract is to enable the United States Patent and Trademark Office and the public generally, especially scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0010] Various advantages and novel features of the present invention are described herein and will become further readily apparent to those skilled in this art from the following detailed description. In the preceding and following descriptions the preferred embodiment of the invention is shown and described by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of modification in various respects without departing from the invention. Accordingly, the drawings and description of the preferred embodiment set forth hereafter are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 : shows various examples of nanoscale films prepared using Microreactor Assisted Nanomaterial Deposition (MAND) based on nanoscale building and assembly.
[0012] FIG. 2 is a Scanning Electron Micrograph (SEM) of a nanostructured surface utilized in one embodiment of the present invention.
[0013] FIG. 3 a shows an aluminum (Al) surface with ZnO nanostructures, according to another embodiment of the invention.
[0014] FIG. 3 b shows a copper (Cu) surface with ZnO nanostructures, according to another embodiment of the invention.
[0015] FIG. 4 : shows pool boiling curves for various nanostructured surfaces compared to neat Al and Si surfaces.
[0016] FIG. 5 : Measured critical heat flux as a function of static contact angle for nanostructured (red-filled squares) and plain surfaces.
[0017] FIG. 6 : Measured heat transfer coefficient as a function of nucleate boiling heat flux (log-log plot).
DETAILED DESCRIPTION OF THE INVENTION
[0018] In various embodiments of the present invention, various nanoporous nanostructures were created and tested with water as a heat transfer fluid. Results showed that the raised nanostructured materials provided enhanced boiling characteristics indicative of enhanced heat dissipation. Test results show that the present invention could be used in almost any application where transfer of very high heat fluxes (i.e., 200-1000 W/cm 2 ) across nearly isothermal material conditions are contemplated or required.
[0019] FIG. 1 shows various nanostructures that can be prepared using a solution-based deposition process known as Microreactor Assisted Nanomaterial Deposition, or MAND. The MAND process is detailed in U.S. patent application Ser. No. 11/490,966 filed 21 Jul. 2006, now published as U.S. Publication Number 2007-0020400 A1 published 25 Jan. 2007; and U.S. patent application Ser. No. 11/897,998 filed 31 Aug. 2007, now published as U.S. Publication Number 2008-0108122 A1 published 8 May 2008, which references are incorporated herein in their entirety. ZnO nanostructures of the invention were prepared using this process. The MAND process is a preferred process due to its cost-effectiveness and controllability, but is not limited thereto. MAND deposition processes can be controlled to create nanostructured ZnO surfaces that are, e.g., hydrophobic (i.e., contact angles of ˜50°-60°) or superhydrophilic (i.e., contact angles <20°) by changing MAND process parameters including, e.g., NaOH concentrations and residence times. More information regarding the preparation and use of the MAND process to create structures described in the present application is detailed by Jung et al. [Current Applied Physics, 8 (2008) 720-724], which reference is incorporated herein in its entirety.
[0020] In the present application, formation of flower-like structures of ZnO on aluminum (Al) was obtained by using a 0.05M NaOH solution in a 70° C. water bath, which were deposited on the Al substrate using a 250° C. holding temperature, a deposition time of 10 minutes, at a rotating speed of 2500 rpm, and a flow rate of 8.28 mL/min. This resulted in the attachment of ZnO structures on the Al surface having a pore density of 30-100 square micrometers (μm 2 ) and an average pore size of 50-100 nm. The contact angle of the overall surface was 20°. These same parameters on a copper (Cu) surface resulted in the formation of ZnO structures-on-Cu that gave a contact angle of 30°. Other configurations were obtained by altering these MAND processing parameters. For example, a ZnO-on-Al surface was formed through a similar process using a 0.15M NaOH solution, a 200° C. holding temperature, a 5 minute deposition time, a rotating speed of 1500 rpm, and an 8.28 mL/min flow rate, which resulted in a contact angle of 96°. In another exemplary case, a seed layer was applied, followed by a MAND process where 0.10M NaOH was applied in a 70° C. water bath, a 250° C. holding temperature, a 10 minute deposition time, a rotating speed of 2500 rpm, and a flow rate of 8.28 mL/min, which resulted in a contact angle of 18°. A zeolite on silicon (Si) surface was formed by mixing tetra-propyl-ammonium hydroxide (TPAOH) 0.60; tetra-ethyl-ortho-silicate (TEOS); deionized water 165 (molar ratios) synthesized at 165° C. for 2 hours in an autoclave. This process resulted in a material having a contact angle of 14°.
[0021] FIGS. 2 a - 2 b are scanning electron micrographs (SEMs) that give examples of ZnO nanostructures on aluminum ( FIG. 2 a ) and copper substrates ( FIG. 2 b ), respectively. Atomic Force Microscopy (AFM) was used to evaluate the surface structures and topologies. Nanostructures of ZnO-on-Cu have an average roughness of 162.29 nm. Pore sizes for ZnO-on-Al nanostructures are in the range from about 50 nm to about 100 nm; pore densities are in the range from about 30/μm 2 to about 100/μm 2 ; the feature structures are typically about 40 nm tall. The features result in an overall surface having a preferred contact angle between 15°-25°, most preferably around 20°. While this preferred range is anticipated when water is the transfer fluid, other fluids and nano-textured surfaces may have other optimal contact angles. For example, nano-textured surfaces composed of other material combinations can provide critical contact angles having different ranges depending on the chemical composition that provides different fluid properties such as surface tension, heat of vaporization, and density. Thus, no limitations are intended.
[0022] Contact angles are determined using a standard water droplet test. The water droplet, when placed on the surface, yields a contact angle that is measured as the inside angle the droplet contour surface makes with the planar surface it sits on at the point of contact (hence the term “contact angle”). Contact angle is a measure of the interfacial adhesion energy at the surface, a measure of the balance between the fluid surface tension forces on a surface, which is impacted by the presence of the nanostructures on the surface. This work has shown more particularly that the contact angle is a balance between fluid dynamic forces and bubble dynamic forces that occur during boiling at a selected surface. Hydrophilic properties of rough (e.g., nanostructured) surfaces can be characterized using Equation [1]:
[0000] ( r cos θ=cos γ) [1]
[0023] Here, the roughness factor (r) is the ratio of total surface area to total projected surface area; (γ) and (θ) are contact angles on nanostructured (roughened) and smooth (non-structured or non-deposited) surfaces, respectively. Roughened surfaces (where r>1) have a greater surface area. When a “wet” drop of fluid contacts a rough surface, the drop either wets the grooves (i.e., so-called “hydrophilic” state) or sits on the peaks of the rough surface (i.e., so-called “hydrophobic” state). Equation [1] predicts that textured surfaces of the invention become more hydrophilic as the surface area increases. The greater the surface density of surface features, the more hydrophilic the surface becomes. Nanostructures of the invention provide textured surfaces that increase the surface area, and hence, the hydrophilic character of the surface.
[0024] FIGS. 2 a - 2 b are SEM images that show various textured surfaces of the invention. These textured surfaces have: 1) porous microstructures and nanostructures that provide for control of hydrophobic and hydrophilic characteristics of the surfaces and allow in-flow of heated fluid to nucleation sites. “Nucleation sites” refers to locations in the nanoporous nanostructures where bubbles form when a heated fluid is introduced; 2) high pore densities that provide enhanced nucleation; and 3) features (i.e., protrusions) that protrude from the surface that provide an increase in the active boiling area and additional nucleation sites. Nanostructures of the invention have pore densities and nucleation site densities that are much greater than the “bare” substrates upon which the nanostructures are deposited. All of these characteristics affect the enhanced properties for heat transfer in a boiling fluid demonstrated by the invention. “Pool boiling” as defined herein refers to boiling that occurs at the heating surface under natural convection and nucleate boiling conditions, where the surface of interest is submerged in a large body of standing (i.e. “pooled”) liquid. The relative motion of bubbles in a liquid at a heating surface and the surrounding liquid is due primarily to buoyancy effects. “Flow boiling” as defined herein refers to boiling that occurs at the heating surface under conditions of a flowing fluid.
[0025] At critical heat flux (CHF) conditions, a fluid (e.g., water) on a heated surface transitions from fully developed nucleate boiling (NB) in which discrete columns or groups of coalesced columns of bubbles are in the fluid to the condition where bubble columns become large and merge to form a continuous column (or film) of vapor (so-called “vapor column” or “vapor film”) between the fluid and the heated (or heater) surface. Thermal resistance at the surface then increases sharply at this juncture due to: 1) the presence of the vapor film and 2) the lower thermal conductivity of the vapor compared to the liquid (e.g., water). The combination of factors at the surface sets the maximum CHF value for the surface of interest as a practical operation limit.
[0026] Conventional wisdom suggests that nanostructured surfaces will not improve heat transfer in a boiling fluid (so-called “boiling heat transfer”) because the bubble nucleation process is not expected to be enhanced by very small (i.e., nano-scale) cavities due principally to the large superheats needed for activation. Minimum cavity mouth radius (R c ) required for activation, is given by Equation [2], as follows:
[0000]
R
c
=
2
σ
T
sat
ρ
v
h
fg
Δ
T
s
[
2
]
[0027] Here, sigma (σ) is the surface tension; (T sat ) is the saturation temperature, density (ρ v ) is the vapor density [kg/m 3 ]; (h fg ) is the enthalpy of vaporization (J/kg); and (ΔT S ) is the surface or wall superheat temperature calculated as the difference between the temperature of the heated surface (T s ) and the saturation temperature (T sat ), i.e., (T s −T sat ), in units of [K]. The equation predicts that for a nanosized cavity of approximately 100 nm in a water environment at a saturation temperature (T sat ) of 100° C., the required superheat temperature (T surf −T sat ) will be 327 K (53.9° C.). Experiments were performed to test the predictions. The aim of these experiments was to obtain two key parameters: the wall super heat values (T s −T sat ) and the wall heat flux values (q″). Deionized water was used. Water was first boiled using, e.g., a microwave oven. Then, the water was sonicated for 20 minutes in an ultrasonic bath to remove dissolved gases. The sonicated water was then poured into a boiling chamber configured with two immersion heaters. Immersion heaters were then powered, reaching the water saturation temperature of 100° C. The water was degassed at this power level for about one hour. Boiling experiments were performed at atmospheric pressure and at the water saturation temperature. Experiments were carried out until a critical heat flux (CHF) was reached. At the onset of CHF, wall superheat values jumped to very high values. Experimental results were characterized using boiling curves that plotted the surface heat flux (q″) against the wall surface superheat values (T s −T sat ). Heat flux (q″) during nucleate boiling is given by Equation [3], as follows:
[0000] q″=K (π( k 1 σC p ) f ) 0.5 D b 2 N a ΔT w [3]
[0028] Here, (k 1 ) is the liquid thermal conductivity; (σ) is the surface tension; and (C p ) is the specific heat. (K) is a constant that represents the bubble diameter of influence, which is independent of contact angle and physical properties of the fluid. (D b ) is the bubble diameter at the moment of departure; (f) is the vapor bubble departure frequency; (D b f) is the mean velocity of vapor bubble growth; and (N a ) is the nucleation site density. (ΔT w ) is the wall superheat value, defined previously above.
[0029] FIG. 4 presents boiling curves for various nano-structured surfaces described herein against bare aluminum and copper surfaces in pool boiling tests conducted in water (T sat =100° C.) that show the dependence of dissipated heat flux (q″) on wall superheat (T s −T sat ) values. In the figure, ZnO nanostructured surfaces of the invention required a lower wall superheat for bubble nucleation, e.g., as observed at the onset (e.g., ˜10° C.) of nucleate boiling (ONB) compared to the bare Al surface. Partial nucleate boiling (PNB), where discrete bubbles are activated on the heater surface, also occurred at a lower superheat value for the ZnO nanostructured surfaces. Partial nucleate boiling (PNB) transitioned to fully-developed nucleate boiling (FNB) (e.g., at 20° C.-25° C.), where bubbles merged to form vapor columns, again at lower superheat values compared to the bare metal surfaces. At the critical heat flux (CHF) condition (e.g., ˜30° C.), bubbles were large and merged to form a continuous vapor film between the heater and the water (the heat transfer liquid). Each of the boiling conditions (ONB through CHF) was observed at a lower superheat value than that of the bare metal surface. In addition, the ZnO nanostructured surfaces exhibited enhanced boiling heat transfer (wall heat flux) values compared to the bare metal surfaces even at these lower superheat values. For example, a high CHF value of ˜82.5 W/cm 2 was observed for the ZnO nanostructures on Al compared to that for the bare Al surface, ˜23 W/cm 2 . In short, compared to the bare metal surfaces, the nano-structured surfaces on aluminum increased the wall heat flux, e.g., from ˜20 W/cm 2 to over 80 W/cm 2 . For nano-structured surfaces of ZnO-on-Cu (contact angle=30°), a CHF value of 63.5 W/cm 2 was observed at comparable low superheat values. TABLE 1 compares CHF values for various ZnO nanostructured surfaces of the invention and other surfaces measured in water as the boiling fluid.
[0000]
TABLE 1
CHF values for ZnO-structured surfaces.
Critical heat flux (CHF)
SURFACE
(W/cm 2 )
Bare aluminum
23
Super-hydrophilic
14
Hydrophilic
34
ZnO nanostructures on Al (flower-like)
80
Unique structure
79
ZnO nanostructures on Cu (flower-like)
63
[0030] In water, ZnO nanostructures on aluminum (Al) surfaces showed a pool boiling CHF value of from about 80 W/cm 2 to about 82.5 W/cm 2 . Bare Al, in contrast, gave a CHF of about 23.2 W/cm 2 . ZnO nanostructures on Al also showed a wall superheat reduction of from about 25° C. to about 38° C. for bubble nucleation compared to the bare Al surface. ZnO nanostructures prepared on a copper (Cu) surface also produced flower-like morphologies, giving a surface contact angle of about 30°. The ZnO nanostructures on copper (Cu) resulted in a CHF value of 63.5 W/cm 2 and a comparable reduction in superheat value for bubble nucleation compared to the bare Cu surface.
[0031] Data presented in FIG. 4 and in TABLE 1 contradict current understanding of bubble nucleation. As shown in the figure, for example, boiling curves for ZnO nano-structured surfaces display a unique staircase effect. And, wall superheat values increase steadily while heat flux remains constant. Then, a sudden increase in dissipated heat flux is observed concomitantly with increasing bubble nucleation population. Results are attributed to local higher superheat values that activate all of the smaller pore sizes surrounding a given nucleation site. In particular, ZnO nanostructured surfaces of the invention with higher contact angles (>10°) exhibit a high density of bubble formation across the boiling surface throughout the bubble nucleation boiling regime [i.e., all boiling conditions after the onset of nucleate boiling (ONB) including partial nucleate boiling (PNB)] compared to the bare aluminum surfaces. However, nano-structured surfaces with low contact angles (<10°) had lower bubble formation densities and had more difficulty forming bubbles uniformly across the boiling surface, as manifested by boiling curves with ‘high’ wall superheat values and low heat flux (CHF) values.
[0032] FIG. 5 shows the dependence of critical heat flux (CHF) on the contact angle, and the measured CHF values, for plain silicon and aluminum surfaces. Current understanding of CHF demarcates two limits. One limit is a function of the surface morphology that is controlled over a range of contact angles. The second limit is hydrodynamically controlled and is relevant to well-wetted surfaces. In the figure, for flower-like morphologies, measured CHF values increased with decreasing contact angle. CHF maxima were also obtained at contact angles of approximately 18° to about 20°. Values decreased on either side of the curve. By comparison, a super hydrophilic surface ( FIG. 1 ) having a different morphology (carpet like) with a contact angle of 0° showed a low CHF value and also a high superheat value.
[0033] Conventional theory predicts: 1) that bubble diameter decreases as a function of decreasing static contact angle, and 2) higher wall superheat values as a function of decreasing contact angles. Here, results show that critical boiling heat flux (q″) decreases as θ→0, but does not go to zero as conventional theory would suggest by Equation [3]. Results showing maxima for CHF dependence on contact angle are attributed to two competing effects: 1) CHF increases with decreasing contact angles down to 20°, but 2) a contrasting effect on CHF occurs where the critical heat flux value (q″) then decreases as (θ) decreases further to zero. With these nano-textured surfaces, the CHF dependence on contact angle is attributed to the balance between surface capillary fluid dynamics that brings fluid into the active nucleation sites, and the surface bubble dynamics that are governed by nucleation site densities and bubble diameters that ultimately lead to heat dissipation. Results suggest there is an optimum surface wettability condition that optimizes these two competing effects and causes the observed maxima in CHF as contact angle varies. The bubble nucleation frequency (1/f) is related to the bubble waiting period (t w ) and to the bubble-growth-time-to-departure value (t d ) by Equation [4], as follows:
[0000] [(1/ f )= t w +t d ] [4]
[0034] Smaller contact angles (and therefore better wettability) are hypothesized to decrease the bubble waiting period (t w ), which increases the bubble nucleation frequency. As the contact angle gets smaller, capillary surface forces increase thereby bringing fluid to the active nucleation sites more effectively (thereby potentially increasing the bubble frequency). However, as the contact angle decreases, bubble diameter also decreases (by Equation [3]) and the number of active nucleation sites decreases, meaning CHF values are ultimately degraded when the contact angle becomes too small. These competing effects lead to the observed CHF maximum. In tests reported herein, contact angles were investigated from about 104° down to about 0°. A maximum CHF was discovered at about 20°. Nano-structured surfaces of the invention both a critical contact angle for CHF, and an enhanced heat flux augmentation. Results indicate there is a particular critical contact angle that maximizes CHF for various nano-textured surfaces, as described herein.
[0035] FIG. 6 is a log-log plot that plots heat transfer coefficient (kW/m 2 K) vs nucleate boiling heat flux (kW/m 2 ) for selected surfaces. In the figure, curves are plotted only for the nucleate boiling regime. TABLE 2 compares Heat Transfer Coefficient (HTC) values of ZnO nanostructured surfaces and other selected surfaces.
[0000]
TABLE 2
Comparison of Heat Transfer Coefficient (HTC) values
for ZnO-nanostructured surfaces and other surfaces.
Heat transfer coefficient (HTC)
SURFACE
(kW/m 2 K)
Bare aluminum
3.3
Super-hydrophilic
5.2
Hydrophilic
5.0
ZnO nanostructures on Al (flower-like)
23
Unique structure
14.5
ZnO nanostructures on Cu (flower-like)
20.7
[0036] As shown, ZnO nanostructured surfaces show almost an order of magnitude increase in HTC compared to a bare Al surface. CHF values (described previously) for ZnO nanostructured surfaces correspond to a boiling heat transfer coefficient as high as ˜23,000 W/m 2 K, representing an increase in CHF values for nano-textured surfaces of almost 4 times, which is contrary to conventional boiling heat transfer theory. Significant increases in both CHF and heat transfer coefficient in FIG. 4 and FIG. 6 , respectively, have important and far-reaching ramifications on the use of ZnO nanostructured surfaces for cooling of high heat fluxes in advanced power electronics, advanced high-power radar, and advanced laser systems. ZnO nanostructured surfaces and other nanostructured surfaces of the invention are expected to have significant future impacts on flow-boiling environments and configurations, which may exhibit surface heat fluxes in the range of hundreds of W/cm 2 . Such heat fluxes have important potential for enhancing electronic cooling in critical commercial and military instruments, devices, and systems.
CONCLUSIONS
[0037] Pool-boiling experiments utilizing the method and system of the present invention on “bare” and nanostructured surfaces have demonstrated that nanostructured surfaces including, e.g., ZnO-on-Al and ZnO-on-Cu display superior heat transfer characteristics compared to bare Al and Cu substrates. A 10-fold improvement in heat transfer coefficients is observed for nanostructured surfaces compared with bare Al and Cu substrates. A 4-fold improvement in critical heat flux is also measured.
[0038] While preferred embodiments of the present invention have been shown and described, it will be apparent to those of ordinary skill in the art that many changes and modifications may be made with various material combinations without departing from the invention in its true scope and broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the spirit and scope of the invention. | A system and method for performing heat dissipation is disclosed that includes contacting a heat transfer liquid with a heat exchange surface having raised hydrophilic nanoporous nanostructures disposed adjacent a central core upon a substrate. The heat transfer liquid forms a preselected contact angle when placed on the heat exchange surface. The raised nanoporous nanostructures define channels, interconnected pathways, and voids within the nanoporous nanostructures. The nanoporous nanostructures have additional surface irregularities upon the nanostructures themselves. The nanostructures are preferably formed by depositing metal oxides or other materials upon a substrate using a Microreactor Assisted Nanomaterial Deposition (MAND) process. | 7 |
RELATED APPLICATIONS
This application is a continuation from PCT international application No. PCT/AU99/01011, having an international filing date of Nov. 24, 1999.
FIELD OF THE INVENTION
This invention relates generally to an insect control system and, more particularly, to an insect controls system built into a building.
BACKGROUND OF THE INVENTION
Insects in general, and more particularly, termites are destructive to structures, especially those made of wood. The termite is quiet and through in its job of causing major structural damage. This in turn could make an individual a financial hostage in their own home. Therefore, if they could eradicate the threat of termites with an effective pest control system, a homeowner can feel more secure in the investment they have made in their home.
Most termites enter the structure of a house through cracks in the concrete slab and drainage pipelines. From there, they travel up into the walls, roof, flooring and any other wooden structure. Because of this, an insect control system that was located within the structure of a building would be an important improvement in the art.
OBJECTS OF THE INVENTION
An object of the invention is to provide an apparatus for delivering insecticide to a building that overcomes some of the problems and shortcomings of the prior art.
Another object of the invention is to provide an apparatus for delivering insecticide to a building that eliminates the need for human exposure to the chemicals being used.
Another object of the invention is to provide an apparatus for delivering insecticide to a building that results in no direct contact between the apparatus and the soil.
Yet another object of the invention is to provide an apparatus for delivering insecticide at low pressure to a building.
Still another object of the invention is to provide an apparatus for delivering insecticide to a building that effectively delivers insecticide into the space beneath the roof.
Yet another object of the invention is to provide an apparatus for delivering insecticide under the foundation of a building. How these and other objects are accomplished will become apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION
The invention involves an insecticide dispensing apparatus for delivering insecticide from an outside source to a building having a foundation and a roof space thereunder. In the preferred embodiment, the apparatus is comprised of an access unit having an inlet port external to the building, an upper pipeline arrangement having at least one outlet is located in the roof space and extends to the access unit. A lower pipeline arrangement including at least one outlet is located under the foundation. This lower pipeline arrangement also extends to the access unit whereby insecticide is effectively distributed with respect to the building.
In practicing the invention, the building foundation can include a concrete slab, a basement floor, or any other base support the structure.
In one embodiment of the invention, the outlet in the upper pipeline arrangement is a spray head. In a version of this embodiment, a plurality of spray heads are joined together with the upper pipeline arrangement and fixed to support beams located within the roof space in order to evenly disperse powdered insecticide over a controlled distance. In this embodiment, the pipeline arrangement extends from the roof space through a cavity inside the house to the access unit, thereby allowing insecticide spray to be injected from outside the house through a powder injector connector to the system. In a more specific version of this embodiment, the spray heads are three-way spray heads. In yet another specific version, the three-way spray heads include a deflection plate and a flow control.
In another embodiment of the invention, at least three connection points are located at the access unit. The connection points include a plurality of dry powder spray connectors and at least one liquid insecticide injector connector. An overflow indicator is also included within the system.
In a preferred embodiment of the invention, the lower pipeline arrangement is built into a blue metal pebble soaker bed. In this embodiment, the pipeline arrangement is joined together with anchor spray heads. In such an embodiment, the blue metal pebble soaker bed is positioned under a concrete slab and around the perimeter of a house, and the soaker bed and spray heads are wrapped in a protective netting and soil proof casing, thereby preventing foreign material from contaminating the soaker bed and spray heads. In another version of this embodiment, the lower pipeline arrangement includes a plurality of holes and insecticide is dispersed from the holes in the pipeline as well as from the spray heads when a pressurized liquid insecticide is injected into the system. In this version, the liquid insecticide is injected from outside of the house.
In another version of the preferred embodiment, insecticides are injected via the liquid connector into the soaker bed to the overflow indicator located at the end of the pipeline system. In another version of the embodiment, only one liquid injector connector is located in the external-access unit.
In another embodiment of the invention, the insecticide dispensing apparatus is comprised of an access unit having an inlet port external to the building and a pipeline arrangement in the roof space and extending to the access unit. The pipeline arrangement includes at least one outlet in the roof space, whereby insecticide is effectively distributed within the roof space of the building. In a particular version of this embodiment, the outlet in the pipeline arrangement is a spray head.
In another version of this embodiment, a plurality of spray heads are joined together with the pipeline arrangement and fixed to support beams located within the roof space in order to evenly disperse powdered insecticide over a controlled distance and the pipeline arrangement extends from the roof space through a cavity inside the house to the access unit, thereby allowing insecticide spray to be injected from outside the house through a powder injector connector to the system. In a more specific version of this embodiment, the spray heads include three-way spray heads. These three-way spray heads may include a deflection plate and a flow control.
In still another version of this embodiment, at least three connection points are located at the access unit including a plurality of dry powder spray connectors, at least one liquid insecticide injector connector, and an overflow indicator.
In still another embodiment of the invention, the insecticide dispensing apparatus is comprised of an access unit having an inlet port external to the building and a pipeline arrangement under the foundation and extending to the access unit. The pipeline arrangement includes at least one outlet under the foundation, whereby insecticide is effectively distributed with respect to the building. In this embodiment, the foundation can include a concrete slab, a basement floor, or an base which supports the structure.
In a particular version of this embodiment, the lower pipeline arrangement is built into a blue metal pebble soaker bed. In this embodiment, the lower pipeline arrangement is joined together with anchor spray heads, the blue metal pebble soaker bed is positioned under a concrete slab and around the perimeter of a house, and the soaker bed and spray heads are wrapped in a protective netting and soil proof casing, thereby preventing any foreign material from contaminating the soaker bed and spray heads. In a more particular version of this embodiment, the lower pipeline arrangement includes a plurality of holes and insecticide is dispersed from the holes in the lower pipeline arrangement as well as from the spray heads when a low-pressurized liquid insecticide is injected into the system.
In another version of the embodiment, the liquid insecticide is injected from outside of the house. In a more specific version, insecticides are injected via a liquid connector into the soaker bed to an overflow indicator located at the end of the lower pipeline arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a housing structure showing the insect dispensing apparatus located within the roof space and the foundation.
FIG. 2 is a top view of the housing structure showing the pipeline arrangement installed in the roof space.
FIG. 3 is a cut-away perspective view showing the sidewall of a housing structure and the pipeline arrangement installed under the foundation.
FIG. 4 is a side view of a single-spray head.
FIG. 5 is a top view of a single-spray head.
FIG. 6 is a top view of a three-way spray head.
FIG. 7 is a side view of a three-way spray head.
FIG. 8 is a top view of a three-way spray head positioned on a deflector plate.
FIG. 9 is a perspective of a pipeline section and an anchor-spray head.
FIG. 10 is an isometric view of an anchor-spray head.
FIG. 11 is a side view of an anchor-spray head.
FIG. 12 is a view of an anchor-spray head with a pipeline connect thereto.
FIG. 13 is a cross section of a fully extended soaker bed system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention involves an insecticide dispensing apparatus 10 for delivering insecticide into a roof space 12 and under a housing foundation 14 . As shown in FIG. 1, the insecticide dispensing system 10 is comprised of a plurality of pipelines 16 located within the roof space 12 and under the construction slab 14 of a building 18 . The apparatus 10 is specially designed for all types of construction and is effective on most household insects e.g., termites, ants, spiders, and silverfish.
The apparatus includes two major components: (1) a dry powder pressure spray system 20 and (2) a termite proof soaker bed system 22 .
As shown in FIGS. 1 and 2, the dry powder pressure spray system 20 is installed inside the ceiling space 12 through a few specially designed single-spray heads 24 , such as those shown in FIGS. 4 and 5. The system can also be utilized with single-spray heads 24 in combination with three-way spray heads 26 with deflection plates 28 and flow control 30 , such as those shown in FIGS. 6-8. In such heads 26 , the flow control 30 is used to control the distance of the flow.
The spray heads 24 , 26 are joined together with pipelines 16 and fixed to rafters 32 or the top cord of trusses in order to evenly disperse powered insecticide so as to achieve a complete fumigation effect inside the roof space 12 .
In this system, as shown in FIGS. 1 and 3, the pipelines 16 from the roof space 12 extend down through the brick cavity 34 inside the house 18 (near ground level) and connect to the powder spray connector 36 which is located inside the unit 40 . Such an arrangement results in a very powerful way to disperse insecticide without any human exposure to the chemicals being used.
In one embodiment of the invention, a plurality of spray heads 24 , 26 are joined together with the pipelines 16 and fixed to support beams 32 located within the roof space 12 in order to evenly disperse powdered insecticide over a controlled distance. In this embodiment, the pipelines 16 extend from the roof space 12 through a cavity 34 inside the house 18 to an opening 38 in the foundation 14 , thereby allowing insecticide spray to be injected from outside the house 18 through a powder injector connector to the system. In one version of this embodiment, the spray heads 24 are three-way spray heads 26 .
The three-way spray heads 26 are specially designed spray heads having a flow control 30 . As shown in FIGS. 7 and 8, finned deflection plates 28 are built on top of the spray head unit 26 to allow for deflection and dispersal of powder insecticide down toward the desired spot. Furthermore, the flow control 30 on the individual spray head 26 will control the desired distance the insecticide in sprayed.
In a more specific version of this embodiment, at least three connection points (not shown) are located at an unit 40 . A plurality of dry powder spray connectors along with at least one liquid insecticide injector connector and an overflow indicator are also included within the system.
In another embodiment of the invention, as shown in FIG. 13, the insecticide dispensing apparatus 10 is in the form of a soaker bed 42 of insecticides that can only be installed before a house is built. The soaker bed 42 works by laying injection piping 16 , as shown in FIGS. 3 and 13, at approximately 50 mm under the concrete slab 14 around the perimeter area of a house 18 . All of this piping 16 is joined together with specially designed anchor-spray heads 44 such as those shown in FIGS. 10-12.
The anchor-spray head 44 is a unit that is preferably made of stainless steel. These spray heads 44 are capable of covering a very large underground area including up to the extent of the concrete slab 14 if required.
The function of the anchor-spray head 44 is to anchor the pipeline 16 firmly onto the blue metal pebbles plus offer spray function. There are also drip holes 46 at the bottom of the spray head 44 for clearing insecticide residue. A baffle having a narrow passage is built inside the unit thereby reducing and minimizing the pressure of the piping system. The anchor-spray head 44 can also collect the residue of the insecticide when clean air is pushed into the system after the insecticide is sprayed. This procedure will ensure the residue of insecticide drains into the anchor-spray head 44 and then completely away into the blue metal pebble soaker bed 42 .
In the soaker bed embodiment, piping 16 will preferably be buried into blue metal pebbles which will be wrapped by a layer of nylon netting and finally by layers of breathable nylon membrane 50 in order to stop any foreign material from mixing with the blue metal pebbles or going into the soaker bed system 42 . This burying and wrapping of the piping 16 results in a soil-proof casing that prevents the piping 16 from having any direct contact with the ground.
When pressurized liquid insecticide is injected into this underground system, insecticide will disperse from the holes 48 in the piping 16 , as shown in FIGS. 9 and 12, as well as from the anchor heads 44 before combining with the blue metal pebbles to form a large surface barrier that will stop all underground intruders that may creep into any cavities and cracks through the slab 14 . Such a system is far superior to other methods of direct soil insecticide spray system with piping buried directly into the soil which may eventually become clogged with prolong use. The inventive system does not interfere with any drainage or electrical systems under the construction slab, and has no direct contact with soil as the entire system is enclosed by the nylon membrane which reduces contamination of soil to a minimum. Therefore, the system is safe for children and all members of the household because of its environmentally friendly attributes.
The low pressure injection system is operable between 30 to 70 psi thus eliminating the risk of insecticide being flushed out at the overflow with other high pressurized methods. This enclosed piping system is joined to the same external opening 38 outside the house by going upward through the slab 14 to the external-access unit 40 (e.g., a stainless steel box having a door with the box mounted on the outside wall of the house). Such a system will allow for insecticide to be injected from outside the house, through the soaker bed 42 to the overflow indicator at the end of the pipeline system which is located next to the liquid insecticide injector connector in the external-access unit 40 .
When in operation, fresh insecticide can be injected periodically throughout the system to provide maximum effectiveness. Preferably, each treatment should be no more than 20 minutes. At the end of each treatment, high pressurized air will be used to clean the system and ensure that residual insecticides have been defused completely through the anchor heads 44 .
While the principles of the invention have been shown and described in connection with but a few embodiments, it is to be understood clearly that such embodiments are by way of example and are not limiting. | An insecticide dispensing apparatus for delivering insecticide from an outside source to a building having a foundation and a roof space thereunder. The apparatus includes an access unit having an inlet port external to the building, an upper pipeline arrangement having at least one outlet is located in the roof space and extends to the access unit. A lower pipeline arrangement including at least one outlet is located under the foundation. This lower pipeline arrangement also extends to the access unit whereby insecticide is effectively distributed with respect to the building. | 0 |
BACKGROUND OF THE INVENTION
The size requirements for tires utilized in earth-moving equipment has reached the point where the wheel member for mounting the tire must be constructed of several pieces. Generally, such rim assemblies consist of a rim base member on which the tire is mounted. Also included are flange members radially extending outwardly from either end of the rim base member and against which the side wall of the mounted tire abuts.
It has been found advantageous in larger wheel-tire combinations to taper the rim base member outwardly at each end thus providing a tight non-slipping fit between the tire bead and the wheel assembly. Tire size has reached the proportion that at least one taper must be removable in order to conveniently mount and dismount the tire. The removable tapered bead seat band fits between the rim base member and an associated flange with taper at the opposite end of the rim base member adjacent the second flange integrally formed in the rim base member. Utilization of a tapered bead seat band requires a lock ring removably associated with the rim base member to retain the bead seat band and its associated flange member on the base member.
Inflation of a mounted tire, generally through an aperture in the rim base member in the vicinity of the removable tapered bead seat band, requires a seal member between the removable tapered bead seat band and the rim base member to maintain air tight integrity of the cavity formed by the tire mounted on the wheel assembly. Improper positioning of the bead seat band or improper location and partial seating of the lock ring around the rim base member presents a particular hazard on inflation of the tire member as the various parts of the multi-piece rim assembly may become disassociated and be catapulated with considerable force toward maintenance personnel involved in the assembly and inflation of the tire. Accordingly, various methods have been devised to insure the rim assembly is properly assembled before inflation may take place. Even with these various methods, it has been found advantageous to place the entire assembled tire and wheel assembly in a cage prior to inflation in the event the multi-piece rim assembly has been improperly assembled and the subsequent inflation will cause explosive disassembly of the parts. Although use of safety cages is advantageous, such safety cages in the larger tires are particularly cumbersome to utilize in field assembly of tires and wheels. Accordingly, to provide a wheel assembly for large earth-moving equipment which may be assembled with a tire in the field without the use of safety cage during tire inflation would be most desirable.
SUMMARY OF THE INVENTION
It is an object of this invention to provide improvement to a multi-piece rim assembly which allows inflation of a mounted tire only if the rim assembly is properly assembled.
It is another object of this invention, while fulfilling the above object, to provide improvements to existing multi-piece rim assemblies which are economical and easily accomplished.
It is still a further object of this invention to provide a simple portable tool which insures the rim members are properly assembled before inflation may take place.
Broadly stated, the invention is an improvement to a wheel assembly, the wheel assembly having a rim base member and flange members removably associated therewith and formed to have an inflatable tire mounted therebetween, the rim base member defining first and second annular grooves circumferentially oriented adjacent to one end, the first annular groove being proximate to the end. A lock ring is adapted to fit and is positionable in the first annular groove. A seal member is positionable in the second annular groove. A seal member is positionable in the second annular groove. The improvement is in the bead seat band mounted on the rim base member adjacent the first annular groove and overlying the seal member. The lock ring retains the bead seat band on the rim base. The improved bead seat band defines a plurality of radial ports, the radial ports sealed by the seal member to block communication between the interior of a mounted tire and atmospheric air only while the bead seat band is urged against the lock ring seated in the first annular groove.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will become apparent from a study of the following specification and drawings in which:
FIG. 1 is an elevation view of a representative multi-piece rim arrangement having mounted thereon the portable tool which is part of this invention.
FIG. 2 is a side view partly in cross-section of a portion of the wheel arrangement showing the portable tool mounted thereon as illustrated in FIG. 1.
FIG. 3 is a detail view of one portion of FIG. 2 showing the relation of the bead seat band of this invention and the puller tool of this invention.
FIG. 4 is a cross-sectional view of the puller tool at lines IV--IV of FIG. 3.
FIG. 5 is a sectional view of the bead seat band and the flange member at V--V of FIG. 3.
FIG. 6 is a sectional view of a portion of the multi-piece rim arrangement shown in FIG. 1 at VI--VI.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an elevation view of a multi-piece rim arrangement 10 for a heavy construction or earth-moving vehicle is shown, having a flange member 12, a bead seat band 14 and a lock ring 16. A cover 18 is provided for the multi-piece rim arrangement 10, which is retained on the rim base member 20 by a plurality of bolts 22. A driver 19 is provided to prevent slippage of the assembled arrangement particularly bead seat band 14.
Referring to FIG. 2, the multi-piece rim arrangement is shown in section. A second flange member (not shown) is positioned on rim base member 20 at the opposite end thereof to retain an inflatable tire (not shown) between flange member 12 at the one end of rim base member 20 shown in FIG. 2 and the second flange member (not shown) on the opposite end of rim base member 20. Bead seat band 14 is mounted on rim base member 20 and retained thereon by lock ring 16. Lock ring 16 being of a split ring configuration, is adapted to fit and is properly positionable in an annular groove 24 circumferentially oriented around the perimeter of rim base member 20 proximate the one end thereof. A second annular groove 26 is similarly circumferentially oriented around the perimeter of rim base member 20 inwardly of the first annular groove. Annular groove 26 is adapted to receive seal member 28, to insure integrity of the cavity formed by the tire mounted on the rim arrangement. Bead seat band 14 which overlays seal member 28 provides a seat for the mounted tire, and is tapered inwardly as indicated in FIG. 3 toward the center portion of rim base member 20. A matching tapered bead seat (not shown) is integrally formed at the opposite end of rim base member 20 adjacent the second flange member (not shown). A plurality of radial ports 30 are provided in bead seat band 14 adjacent to seal member 28. Radial ports 30 will communicate air contained in the cavity of the mounted tire to atmospheric air if bead seat band 14 is displaced leftwardly as shown in FIG. 3, air contained in the cavity of the mounted tire passing through space 32 formed by bead seat band 14 and rim base member 20, thence port 30 to escape between the mounted tire and flange 12 or between flange 12 and bead seat band 14.
Referring to FIG. 6, bead seat band 14 is illustrated properly seated against lock ring 16, lock ring 16 being seated in annular groove 24. However, if lock ring 16 is displaced inwardly of rim base member 20 as shown by the leftward dotted lines depicting lock ring 16, bead seat band 14 would be similarly positioned leftwardly, allowing air to be vented through radial port 30 thus preventing proper inflation of the tire as long as lock ring 16 is not seated in annular groove 24.
Further, if lock ring 16 is displaced outwardly of rim base member 20 as shown by the rightward dotted lines depicting lock ring 16, bead seat band 14 would be similarly positioned rightwardly, allowing air to be vented through radial port 30.
Bead seat band 14 includes means for seating lock ring 16 comprising a plurality of protrusions 34 axially extending outwardly therefrom as shown in FIG. 6. A ramp portion 36 of each protrusion 34 acts to urge lock ring 16 into annular groove 24 if lock ring 16 is positioned leftwardly of annular groove 24. A face portion 37 of each protrusion 34 will urge lock ring 16 off rim base member 20 and cover 18 if lock ring 16 is positioned rightwardly of annular groove 24 as illustrated in FIG. 6. Ramp portion 36 is formed to clear lock ring 16 once lock ring 16 is properly seated.
Multi-piece rim arrangements currently available are provided with at least two slots 38 (see FIGS. 2 and 5), the slots 38 being diametrically opposed and primarily for the purpose of inserting a pry-bar therein to loosen flange 12 and the associated tire bead from bead seat band 14. A portable tool 40 utilizes slots 38 to urge bead seat band 14 outwardly against lock ring 16 and position bead seat band 14 over seal member 28 to seal ports 30. Portable tool 40 is comprised of telescoping members 42 and 44. Affixed at either end of portable tool 40 are support members 46 and 48 adapted to engage multi-piece rim arrangement 10 at a series of protrusions 50 circumferentially spaced around cover plate 18 and dispersed between the plurality of bolt members 22. Protrusions 50 protect bolts 22 from damage during operation of the earth-moving machine. Affixed to portable tool member 40 at the extreme ends are puller assemblies comprising guide sleeves 52 and 54, threaded rods 58 and 60 and nuts 66 engageable on threaded rods 58 and 60.
Guide sleeves 52 and 54 are cylindrical in form and have affixed therein pin members 56 extending inwardly of an axial bore 53 in guide sleeves 52 and 54. Slidably disposed in guide sleeves 52 and 54 are threaded rods 58 and 60, each having formed at one end a hook-shaped protrusion 62 and 64 adapted to fit in slots 38, the hook shaped protrusions 62 and 64 facing each other. An elongated groove or keyway 74 (see FIG. 4) receives pin members 56 to prevent rotation of threaded rods 58 and 60. Means for urging hook shaped protrusion 62 and hook shaped protrusion 64 inwardly of guide sleeves 52 and 54, respectively, are provided by nuts 66 threadably engaged on threaded rods 58 and 60. A socket-type wrench 68 may be utilized to provide torque to nut 66 and the associated nut located on threaded rod 60 to retract threaded rod 58 through guide sleeve 52.
Referring to FIG. 1, the telescoping members 42 and 44 may be rigidly spaced apart by means of a set screw arrangement 70 or any similar means of affixing the telescoping rods 42 and 44 one to the other.
In operation, the rim construction and tool apparatus is utilized as follows: The wheel arrangement is assembled as shown on FIG. 2, with flange member 12 mounted on bead seat band 14 adjacent to the plurality of radial ports 30. Bead seat band 14 is positioned on rim base member 20 with flange member 12 so mounted. An opposite flange (not shown) is positioned at the opposite end of rim base member 20. The tire mounted on rim base member 12 is retained between the two flange members. An inflation port 72 (FIG. 3) is provided in rim base member 20 for insertion of a conventional valve and valve stem member used to inflate pneumatic tires.
Referring to FIG. 1, portable tool 40 is fitted to bead seat band 14 at slots 38, as shown in cross-section in FIG. 2. Utilizing socket-type wrench 68, nut 66 on threaded rod 58 and the associated nut on threaded rod 60 are rotated to urge bead seat band 14 outwardly on rim base member 20. As described above, if lock ring 16 is inward of annular groove 24, ramp 36 will contact lock ring 16 forcing it into annular groove 24. However, if lock ring 16 has been positioned outward of annular groove 24, rotation of the nuts on threaded rods 58 and 60 will force lock ring 16 off rim base member 20 and cover 18, thereby preventing proper inflation of a tire mounted on the wheel arrangement by venting air through unsealed ports 30. If bead seat band 14 is not adequately pulled up against lock ring 16, as noted above, radial ports 30 will remain in communication with space 32; thus air inserted into the tire will be vented to atmospheric air through radial ports 30 around flange member 12. When bead seat band 14 is properly positioned as shown in FIG. 3, radial ports 30 are sealed by seal member 28 thereby preventing air from passing from space 32 through port 30 to atmospheric air.
Rotation of nut 66 would normally cause threaded rod 58 to rotate; however, threaded rod 58 as previously noted is provided with an elongated groove or keyway 74 (see FIG. 4) in which pin member 56 rides thereby preventing rotation of threaded rod 58. Threaded rod 60 is similarly provided with a keyway to prevent rotation.
It should be noted that the improvement disclosed herein is readily adaptable to bead seat bands available on the market. Such adaptation requires the drilling of the plurality of radial ports 30 and the addition of protrusions 34 to the bead seat band. Additionally, portable tool 40 is formed to be adapted to available commercial rims, the portable tool 40 providing proper register of the rim components. | In a multi-piece rim arrangement having a tapered base member and an associated tire bead seat band, the bead seat band is constructed to prevent tire inflation if the rim is improperly assembled. Included is a portable puller tool, adaptable to existing rim assemblies, that functions to pull the bead seat band against the lock ring of the multi-piece rim arrangement with sufficient force to insure proper positioning of the various rim members and establish air tight integrity with a mounted tire. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to FIFO (First-in/First-out) memories and more particularly relates to an improved FIFO serial shift-register memory which operates with decreased fall-through delay.
2. Description of Related Art
FIFO memories are widely used as intermediate buffers where there is a need to transfer binary data between systems or devices which operate at different frequencies and where the order of the data must remain unchanged. These devices are often constructed of multiple shift-register stages coupled for cascade operation. Data is clocked into the first shift register stage at some shift-in frequency, and after a certain latency time or fall-through delay, the data is clocked out of the last stage at a different shift-out frequency. The fall-through delay is the time it takes from data to propagate through the FIFO, from input to output.
It is desirable for a FIFO to have large storage capacity, or length, sufficient to hold an entire block of data from a slower data-handling device to a much faster one. However, where the capacity of the FIFO is large, typically 256 bytes, the fall-through delay becomes long, particularly when the FIFO is empty and new data is entered into it, negatively affecting performance and placing unwanted constraints on system design.
In the prior art, efforts to deal with the problems of FIFOs have been varied but only marginally effective. One approach has been to design FIFO buffers using random access memories. A device of this type is the MK4501 FIFO manufactured by Mostek, Inc. of Carrollton, Tex. In general, RAM-type FIFOs can buffer large blocks of data and recall the data quickly. However, in order to read from and write to the FIFO simultaneously, the RAM must be dual-ported or have sufficient control logic to simulate dual port operation. In addition, complex circuitry must be employed to keep track of the data locations in the RAM. The additional counter and control circuitry increases the complexity of the device and slows down the rate at which data can be accessed.
U.S. Pat. No. 4,314,361 to Jansen et al. discloses another FIFO memory device of the shift register type, having a single, fixed input and a variable output. In this patent, each memory stage is connected to an output bus and logic circuitry selects the stage from which data is extracted from the buffer. This device has reduced fall-through delay, since data need not travel through the entire FIFO; however, to buffer large blocks of data, it cannot easily be constructed in integrated circuit form, which would be highly desirable. Each memory stage requires independent transistors for driving an output bus, and the involved wiring, complexity, increased chip area, and the high-power dissipation problems would render such a device impractical. There is a need for a FIFO which is designed so as to minimize the fall-through delay, yet be simple and cost effective, while also lending itself to manufacture as an integrated circuit.
SUMMARY OF THE INVENTION
The present invention seeks to avoid the limitations and drawbacks of prior art FIFO memories.
Accordingly, a primary object of the present invention is to provide a FIFO data memory which can buffer full blocks of data with very fast fall-through time and with shift-in and shift-out rates that are faster than in most RAM-based FIFOs.
It is a further object of the present invention to provide a FIFO data memory that is simple in design, without the complex decoder and arbitration logic required in RAM-based designs.
It is a still further object of the present invention to provide a FIFO data memory which can buffer full blocks of data and still be implemented using integrated circuit techniques.
The foregoing and other objects are achieved in the present invention of a FIFO data memory which provides reduced fall-through delay and simple design. According to the present invention, a FIFO data memory comprises a plurality of shift register stages, or memory cells coupled for cascade operation. The shift register stages are sequentially arranged in sections. Each of these register sections has an associated input and output. Further, each register section is made up of a different number of register stages and can therefore be said to have a different length. The first section, closest to the input of the FIFO, has the longest length and successive sections have decreasing length, with the last section, closest to the output, having the smallest length.
The length of each section is optimized in order to decrease the fall-through delay through the buffer while ensuring a non-interrupted data stream, and these optimum section lengths are a function of the minimum required delay time, the bubble and shift time for each individual stage, the maximum allowed input and output clock rate, and the desired length of the FIFO data memory.
The shift register sections and the internal shift register stages are coupled output-to-input, so that data entering the input of the first stage will be shifted down the line, from stage-to-stage, until it reaches the output of the last stage in the last section.
Further, a bypass bus is selectively coupled to the input terminal of each register section, through which data pulses are introduced. Incoming data will internally bypass the FIFO register sections which are empty of data and enter the register section that is not full and closest to the output. In the case of an empty FIFO, this register section is also the empty section which is shortest in length.
Each register stage has status & control logic to initiate self-clocking, so that data will be shifted toward the output of the data memory. The status means detects the occurrence of an empty data condition for that stage and a full data condition for the preceding stage. When both conditions are detected, control logic within each memory stage initiates a self-clocking operation, and the data from the preceding stage is shifted to the present empty stage. Data will continue to shift by this process, stage-by-stage, until the status means for the stage then containing that data detects a full data condition for its own stage and the preceding one. By this self-clocking process, data entered at the left of the FIFO memory shifts to the right automatically, and is completely asynchronous from the external shift-in clock.
Further, status means is coupled to each register section for indicating either a full data condition or an empty condition of that section. Control logic means is coupled to each register section and is responsive to said status means for selecting which of said register sections is to receive data from the bypass bus. The control logic is designed such that data is always written into the register section that is not full and nearest the output stage of said data memory to decrease fall-through delay time.
The input and output stages have independent clock inputs, which are controlled by the sending subsystem and the receiving subsystem, respectively. The clock inputs control the rate at which data is written to or read from the FIFO memory. Data transfer is thus fully asynchronous, in that data can be written into the FIFO memory by a sending subsystem at the same time data is read out of the FIFO memory by a receiving subsystem.
The FIFO is a simple design consisting of a shift register, a bypass bus, and control circuitry. Because connections to the bypass bus occur only at the section level, rather than at the register stage level, driver and interconnect circuitry is minimized, allowing for practical implementation as an integrated circuit, with minimal power dissipation problems. The resulting FIFO data memory can operate at high clock rates with minimal fall through delay. The FIFO register internal self-clock rate can be very fast, limited only by the propagation delay of the circuitry used, which is dependent on the semiconductor technology used for an IC implementation. The foregoing and other objectives, features, aspects, and advantages of the present invention may be more fully appreciated by considering the following detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of an entire FIFO memory of the present invention;
FIG. 2 is a detailed block diagram of the Register block of the present invention,
FIG. 3 is an functional illustration, showing the internal structure of one register section;
FIG. 4 is a block diagram of input/output Port A, showing further circuitry used to input and output data to the FIFO;
FIG. 5 is a block diagram of input/output Port B, showing further circuitry used to input and output data to the FIFO;
FIG. 6 is a block diagram of the Control block;
FIG. 7 is a functional block diagram of the Data Recirculate block; and
FIG. 8 is a functional block diagram of the CRC Computation block.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The FIFO of the present invention is shown in FIG. 1, generally designated as 10. In its preferred embodiment, the FIFO can buffer data blocks ranging up to 265 9-bit words, and it is particularly suitable for implementation as a large-scale integrated circuit using NMOS or CMOS technology. An important use of the FIFO would be as a fully asynchronous interface device between two subsystems which operate at different data rates and do not share a common clock, for example, a computer memory and a slower peripheral device, such as a printer.
The FIFO is bidirectional, for storing and transferring full blocks of data in either direction. This is made possible by the use of an input bus 16, output bus 20, and I/O ports 12 and 14 that use conventional three-state devices. Referring now to FIG. 1, the FIFO is shown to have six main blocks. Data A 0- A 8 enters FIFO 10 by Port A 12, or data B 0 -B 8 enters by Port B 14, depending on the selected direction of the FIFO. Bidirectional data ports 12 and 14 have clock inputs ACLK and BCLK, respectively, for shifting in or shifting out data, to provide full asynchronous operation. Flag outputs ARFD/DAV and BRFD/DAV indicate the status of the first and last storage register stages of FIFO Register Block 18. Output enable inputs AOE and BOE are provided for three-state control of output buffers in the register block and will be described in more detail in what follows.
FIFO Input Bus 16 transfers data from either Port A 12 or Port B 14 to the input of the 265 word by 9 bit first-in/first-out Register Block 18. FIFO Register Block 18 comprises a number of shift register stages grouped into register sections of different lengths and a bypass bus 40 coupled to each register section. These important features of the present invention will be discussed in more detail in connection with FIG. 2. FIFO Output Bus 20 transfers output data from FIFO Register Block 18 to Port B 14 or Port A 12. The direction of FIFO operation is controlled by input DIR to the Control block 22.
Control block 22 provides means for controlling the programmable Data Recirculate block 24 and CRC Computation block 26. Control block 22 receives three input signals from the sending subsystem --MR (master reset), DIR (direction control), and CONT EN (control enable). Data Recirculate block 24 changes the FIFO into a large recirculating shift register on program command. CRC Computation block 26 provides conventional circuitry to compute cyclic redundancy check characters for the detection of bit errors.
Turning now to FIG. 2, Register Block 18 is shown in more detail. There is shown an input stage 38 which receives data from FIFO Input Bus 16. There are five FIFO Register Sections 28, 30, 32, 34, and 36 of different lengths. Together, the register sections form a 265 word by 9 bit array. The makeup of an individual register section is shown in detail in FIG. 3 and will be described more fully further on.
Register Sections 28 through 36 are coupled for cascade operation, with the output of one section joined to the input of the next section, and so on down the line. Data presented to the input of register section 28 begins to ripple toward register stage 36.
In addition, each register section is capable of receiving data from Input Stage 38 through Bypass Bus 40. Data coming from FIFO Input Bus 16 is presented to Bypass Bus 40 and each register section is filled in sequence, starting with Register Section 36 and ending with Register Section 28.
Data is unloaded from the FIFO array through Output Stage 42, and as this occurs, data in previous register sections will ripple through each successive section toward Output Stage 42. Incoming data from Input stage 42 will always be routed behind existing stored data in the array to maintain the order of data.
The destination of incoming data is determined by the state of the FIFO array at any given time. Each of Register Sections 28 through 36 generates local RFD (ready for data) and MT (empty) flag output signals, which are presented to the State Register & Control Logic 44 along with an FC (Full Cascade) control input. The input signals to the State Register & Control Logic 44 are state variables used in determining which register section, if any, will receive the input data.
Upon a valid shift-in (SI) clock edge, the state of the array will be latched into State Register & Control Logic 44 as data is clocked into FIFO Input Stage 38. The output of the State Register & Control Logic 44 enables the appropriate register section via the signals LDn (Load Data) to accept data from Input Stage 38. The RFD (ready for data) flag to FIFO Input Bus 16 bus will be invalid while data is being transferred from the Input Stage 38 to one of Register Sections 28 through 36 or the Output Stage 42.
The RFD flag is controlled by the output of OR gate 47, the inputs of which originate as clock signals in Register Sections 28 through 36. The RFD flag goes inactive on every clock cycle; as long as RFD becomes active, the FIFO is not full.
A control input FC (full cascade) is provided to allow for extending the FIFO by cascading multiple devices in the depth direction. If the FC input is inactive for an empty FIFO buffer in an array of cascaded devices, then data will undergo a fall through (FT) from Input Stage 38 directly to Output Stage 42 to minimize overall fall-through time for the entire array. Global tree logic 46 is simply combinational logic to provide signals FULL and EMPTY to indicate the state of the FIFO Register Block as a whole. These signals result from the local FL (full) and MT (empty) status inputs from every Register Section.
The following logic equations define the states required to select one of Register Sections 28 through 36 or Output Stage 42 to accept data from the Input Stage 38 upon a valid shift-in clock edge, where LDn (Load Data) is the select signal for that section. Signal FT (fall-through) is for bypassing the entire array as described above. For the purpose of these equations, Register Sections 28 through 36 are designated 5 through 1, respectively, where 5 is closest to the input and 1 is closest to the output: ##EQU1##
Data can be unloaded from Output Stage 42 upon a valid shift-out (SO) clock edge. A control latch in Output Stage 42 will inhibit data from being shifted out whenever the output buffers are three-stated, just as a similar control latch in Input Stage 38 inhibits incoming data whenever the FIFO is full or reset.
The master reset control MR, coming from Control Block 22 of FIG. 1, is provided to reset the control logic in each internal register stage, which will invalidate all existing data in the array.
FIG. 3 illustrates the internal structure of any one of FIFO Register Sections 28 through 36. Each FIFO Register Section consists of a number of internal register stages and supporting control input logic. Each stage contains Control Logic 48 to clock a Data Word Register 50, consisting of nine D-type latches, designating bits 0 through 8. Control Logic 48 also stores a status marker bit FL x , which goes active to indicate when its associated Data Word Register is full, or inactive to indicate when its associated Data Word Register is vacant. The marker bits allow Control Logic 48 to detect the status of the preceding Control Logic stage and communicate its own status to the succeeding Control Logic stage.
Local tree logic 49 is simply combinational logic to provide the FL and MT status signals for a register section as a whole; these outputs run to global tree logic 46.
Each Data Word Register 50 is self-clocked by its associated Control Logic 48. When Control Logic 48 indicates a vacant state in its own Data Word Register and at the same time detects a full state in the Data Word Register of preceding stage, it generates a clock pulse φ x that transfers data from the preceding Data Word Register into its own Data Word Register, setting its own marker bit FL x to active as well as resetting the marker bit in the preceding Control Logic Stage 48 to inactive.
Data can be entered into any of Register Sections 28 through 36 either through a normal Ripple Input 52 path from the previous Register Section or from Bypass Bus 40 through Multiplexer 54, controlled by signal LD n (Load Data) which originates at State Register & Control Logic 44 of FIG. 2. As data is shifted out of the FIFO, all preceding data will automatically ripple toward the output end. Since all valid input data to a given Register Section will ripple through to the output stage, the status FL x of the last Control Logic stage indicates when the FIFO is ready to output data. Similarly, since all vacant positions bubble automatically to the input end, the status of the first Control Logic stage input section indicates when the FIFO is ready to accept data.
There are two parameters of the internal stages that are crucial to choosing the optimum length of the individual Register Sections. These parameters are based on the principle that a datum, upon being input to the FIFO, shifts consecutively through empty stages until it reaches the output or a successor stage that already contains data.
The time for a datum or "drop" of data to move from one register stage to the next consecutive stage is defined as T drip , the "drip time." The time for a data vacancy or "bubble" to move from one register stage to the full stage preceding it is defined as T bubble , the "bubble time." Generally speaking, T drip is usually slightly smaller than T bubble , although conceptually they would appear to be equal. In the present embodiment T drip is 25 nanoseconds and T bubble is 28 nanoseconds due primarily to differences in gating paths for the circuit design and the semiconductor technology used.
Certain major parameters are dependent on the interaction of the sending subsystem and the receiving subsystem in order to achieve optimum performance. The global parameters of concern in choosing the optimum length of the Register Sections 28 through 36 are the desired fall-through time, T fallthru , and the required minimum input or output shift time, T shift .
Fall-through time should be as fast as possible for the particular system requirement, taking into account the required data block size. In the present embodiment, T fallthru was chosen to be 500 nanoseconds for a minimum data block size of 265 bytes.
The parameter T shift is important because the shift-in and shift-out clocks have speed limitations, i.e., data cannot be shifted into or out of the FIFO register block faster than the internal FIFO clock circuitry will operate. In the present embodiment T shift is 80 nanoseconds.
Data is shifted between the individual register stages at its own self-clocking rate, T drip , which is always faster than T shift . Therefore, data entering the FIFO will "catch up" with data already shifting through the FIFO, because the data moves internally faster than it can be shifted out.
It should also be noted the numbers given here for the present embodiment are worst case. The optimum number of stages (N 1 ) in Register Section 36, the section nearest the output, is simply:
N.sub.1 =T.sub.fallthru / T.sub.drip
Note that N1 is an integer, and must be rounded down to ensure that the actual fall-through time is at worst T fallthru . Also, for the purpose of these equations, Register Sections 28 through 36 are designated 5 through 1, where 5 is the closest to the input and 1 is the closest to the output. For the preceding register sections the following equation should be applied:
N.sub.j =(N.sub.1+ . . . +N.sub.(j-1))×(T.sub.shift -T.sub.bubble -T.sub.drip)/ T.sub.drip
The same note applies to N j , that it must be rounded down to an integer. It is unlikely that an optimal set of FIFO Register lengths could be found with commercial components; however, in a custom IC, these equations can be used to design a FIFO having a series of Register Section lengths which are optimally-sized for the particular application of the FIFO. If register section lengths are non-optimal with respect to the particular application, a continuously shifted input data stream could result in an output data stream: with gaps of time because of delayed data. However, data integrity is independent of register section length; only the timing of the output data would be affected by the sectioning.
In the present embodiment, the optimum lengths of Register Sections 28 through 36 are 130, 69, 33, 16, 14, respectively, for a total of 262 registers. In addition, Input Stage 38 requires 2 registers for gating in of data, and Output Stage 42 requires one additional register for gating out data. The total length is therefore 265 bytes.
Turning now to FIG. 4, there is shown a more detailed block diagram of Port A 12, which primarily contains bus switching logic to provide the FIFO with bidirectional operation using an internal unidirectional structure. Port A 12 receives data bytes A 0 -A 8 on a bidirectional data bus from the sending subsystem.
Input Control 58 receives CONT EN (control enable) and DIR (direction select) signals from Control block 22. When DIR select indicates A to B, and CONT EN is inactive, data bytes A 0 -A 8 will be routed through three-state buffer 60 to FIFO Input Bus 16. If CONT EN is active, buffer 60 will be disabled, and data bytes A 0 -A 8 will instead be routed to Data Recirculate Block 24 and CRC Computation Block 26.
Signals CONT EN (control enable) and DIR (direction select) signals from Control block 22 are also presented to Output Control block 64, which receives the additional signal input AOE (output enable) from the sending subsystem. Output Control block 64 will enable three-state buffer 66 only when DIR is set from B to A, when AOE is active, and when CONT EN is inactive. Together the three control signals will determine whether Port A 12 will be acting as a data input or data output port.
Clock line ACLK from the sending subsystem to Clock Generator 68 is at a suitable shift-in rate or shift-out rate. The clock signal from Clock Generator 68 is routed to FIFO Input Bus 16 as signal SI (shift in), to FIFO Output Bus 20 as signal line SO (shift out), and to CRC Computation Block 26 as signal line CRC CLK.
Status Indicator Logic 70 generates a Flag output ARFD/DAV to the sending or receiving subsystem. Signal ARFD/DAV indicates the status of the first and last storage register states of FIFO Register Block 18. The signal is designated RFD (ready for data) when Port A is acting as an input or DAV (data available) when Port A is acting as an output. Signal lines to Status Indicator Logic 70 are RFD, INHIBIT RFD, DIR, and DAV. If DIR is set for A to B and RFD active, the RFD/DAV flag will be set (active high); also if DIR is set for B to A and DAV active, the RFD/DAV flag will be set (active low).
FIG. 5 shows a more detailed block diagram of Port B 14, which, like Port A 12, primarily contains bus switching logic to provide the FIFO with bidirectional operation using an internal unidirectional structure. Port B 14 receives data bytes B 0 -B 8 on a bidirectional data bus from the sending subsystem. The structure of Port B 14 is identical and complementary to the structure of Port A with Input Control 72 to enable or disable thee-state buffer 74 to FIFO Input Bus 16. Output Control block 76 enables three-state buffer 78 only when DIR is set from A to B and when BOE is active. There is no CONT EN input in the logic of Port B 14 because the Recirculate and CRC computation functions are controlled through Port A 12 only, and this was simply a design choice. Clock line BCLK from the sending subsystem to Clock Generator 80 is at a suitable shift-in rate or shift-out rate. Status Indicator Logic 82 generates a Flag output BRFD/DAV to the sending or receiving subsystem.
Now, generally considering the operation of both Port A 12 and Port B 14, data can be entered into the FIFO whenever the RFD flag on the input port is active, by an appropriate clock transition for the the clock input of that port. Subsequently, the RFD flag will go inactive for a moment, until the data has been transferred from the first to the second of the internal FIFO register stages, and then will return to an active state. When all 265 word locations are filled with valid data, the RFD flag will remain inactive, at which time the FULL flag will go active to indicate a full condition for the device. Clock transitions on the CLK input will be ignored by the device while the RFD flag is inactive.
As soon as the first valid data have rippled through to the output of the FIFO register, the DAV flag on the output port will go active. Data can be removed by an appropriate clock transition on the CLK input for that port. This will cause the DAV flag to go inactive momentarily while the preceding data are transferred to the output register stage. When the FIFO is empty, the DAV, flag will remain inactive and the EMPTY flag will go active. Clock transitions on the CLK input will be ignored by the device while the DAV flag is inactive.
FIG. 6 illustrates in more detail the functions of control block 22. The control logic has two major sections dedicated to control of the Data Recirculate Block 24 and to the Cnc Computation block 26. Each section has logic to decode a command byte presented to Port A 12 on data Input A 0 -A 8 , but only when a CONT EN (control enable) signal is received. Signal CONT EN is transferred to PORT A 12 through driver 92. Command bytes originate at the Port A subsystem.
The Recirculate Command Interpret Logic 84 decodes the command byte and generates appropriate control signals for the Data Recirculation block 24. The command byte has one state-bit associated with recirculation control, which sets State Register 86, generating a recirculation enable signal. In response to a command from the Port A subsystem, the pulsed control signal RECIRC DELETE allows the last byte of data shifted out of the FIFO to be deleted from the recirculation path.
The CRC Command Interpret Logic 88 also decodes the command byte and generates appropriate control signals for Cyclic Computation block 26. There are two state bits associated with the cyclic redundancy check function in State Register 90, which define the output signals for CRC clock enable and CRC polynomial select. These two functions can be set or cleared independently by the proper command byte from the Port A subsystem. Pulsed control signals, cnc Reset and CRC dump, are output to signal lines in response to the proper command byte.
When the MR (master reset) signal is received from the Port A subsystem, all the state bits in state registers 86 and 90 are cleared to zero and three pulsed control signals are output to control lines Reset, Cnc reset, and Recirculate Delete. The master reset (MR) command, through driver 94, puts all circuitry of the FIFO into the appropriate initial state.
Signal DIR (direction select) also originates in the sending subsystem, and is routed to Port A 12 and Port B 14, through driver 96, to select the direction that data will be routed through the FIFO, either in the A to B direction or in the B to A direction. FIFO Register 18 must be empty before the direction of data transfer is changed, or else the results of the change will be unpredictable. If the FIFO register status is unknown when a direction change is to be made, a master reset (MR) pulsed should be applied to the FIFO first, in order to clear the registers.
Data Recirculate Block 24 is shown in more detail in FIG. 7. Data read out of the FIFO will automatically be re-entered into the FIFO, to provide the data recirculation feature. The A and B data lines must be connected together externally, and recirculation occurs only in the direction A to B, the FIFO becoming, essentially, a large shift register. Signal RECIRC IN is the recirculate clock for data being recirculated into Port A 12 data lines.
In response to a command byte and the resulting Recirculate Delete signal from Control Block 22, a data byte can be explicitly deleted to decrease the amount of data in the FIFO. But new data bytes can be entered into the FIFO, without a special command byte, to increase the amount of circulating data. The insert and delete operations can be performed for the same byte, resulting in the replacement of a data byte without affecting the total length of circulating data. If a Recirculate Enable is asserted on an active edge of the RECIRC IN clock, 9 bits of A port data will be clocked into Hold Register 102 and the old contents of Hold Register 102 will be clocked into the Hold register 100. Recirculate Control 106 marks the Hold Register 102 as full after a RECIRC IN Clock with Recirculate Enable asserted and will mark Register 102 as empty after a Recirculate Delete. If Register 102 was marked full when the RECIRC IN clock was active, then the contents of the hold Register 100 will be driven onto the FIFO Input Bus 16 via three-state buffer 104 and entered into the FIFO. During the transfer of data into the FIFO, inhibit RFD is asserted to prevent conflicts on the FIFO Input Bus.
FIG. 8 shows the CRC Computation Block 26 in more detail. The computation of Cyclic Redundancy Check characters is provided for Port A 12 of the FIFO, and data bytes moving into or out of Port A 12 will be used for Cnc accumulation. The CRC circuitry is conventional, providing for the accumulation of a 16-bit CRC with either of two standard polynomials. The resultant CRC error output is provided either as two bytes entered into the FIFO by way of FIFO Input Bus 16 for a transmit operation, or as an error check signal on the CRCNZ (non zero) signal line.
First, the 16-bit CRC Register 108 is cleared to zero asynchronously when the CRC RESET is active. Two standard CRC polynomials are implemented in exclusive-OR logic 110 and 112, and two CRC computations are made as a function of the previous 16-bit CRC and the current 8-bit data input. Multiplexer 114 selects one of the two CRC computations via the POLY SELECT control signal. The new CRC value loads a 16-bit Register 108 with that polynomial code on the active edge of the Port A Clock input, only if the CLK ENABLE control input is active. Upon receipt of the DUMP Cnc control signal, Register/MUX 116 becomes active and performs the following actions: INHIBIT RFD is asserted to prevent any inputs from entering the FIFO until the operation is complete; the most significant byte of the CRC is entered into the FIFO via the FIFO Input Bus 18; the least significant byte of the CRC is entered into the FIFO via the FIFO Input Bus 18; and finally INHIBIT RFD is negated.
It is understood that various modifications may be made to the FIFO described without departing from the scope of the invention as claimed. For example, although NMOS or CMOS technology is preferred for implementation, other appropriate chip technologies may be used. Or, the FIFO of the present invention could be implemented using a set of chips, rather than one as described herein. Moreover, the FIFO could be made of different register lengths and widths to those hereabove, to suit the specific system requirements of a designer. | A first-in, first out data memory minimizes fall-through delay. The FIFO memory has a plurality of cascaded register stages arranged in sections, with the input of each section selectively coupled to a bypass bus. Data is introduced on the bypass bus, and control logic writes the data into the section nearest the output which is currently not full. The individual register stages are self-clocked, so that data is then shifted toward the output through any vacant registers. In another aspect, the register stages are arranged in sections of different length, with the shortes section closest to the output and the longest section closest to the input. Decreased fall-through delay is achieved by minimizing the length of the FIFO buffer actually traversed by the data while insuring that the order of the data remains unchanged. | 6 |
FIELD OF THE INVENTION
The present invention relates to a valve of a faucet.
BACKGROUND OF THE INVENTION
A valve of a faucet is incorporated in the faucet, and opens and closes a passage of a liquid such as cold or hot water to control the flow rate of the liquid.
A typical conventional valve of a faucet is described below with reference to the drawings.
FIG. 1 is an exploded perspective view illustrating a cold-hot water mixed type faucet in which a conventional valve of a faucet is incorporated; and FIG. 2 is a perspective view illustrating a rotary disk shown in FIG. 1.
As shown in FIGS. 1 and 2, the cold-hot water mixed type faucet a comprises a bottom lid 3; a valve of a faucet 1, which comprises a stationary disk 1b and a rotary disk 1a; a top lid 4; a lever 6; a face cover 5; and a cock 12. The disk-shaped bottom lid 3 is provided with a through-hole 7 for forming a passage allowing the inflow of cold water, a through-hole 8 for forming a passage allowing the inflow of hot water, and a through-hole 9 for forming a passage allowing the outflow of cold water and/or hot water. The lower opening of the through-hole 7 is provided with a duct 10 for the inflow of cold water, the lower opening of the through-hole 8 is provided with a duct 11 for the inflow of hot water, and the lower opening of the through-hole 9 is provided with a cock 12 for the outflow of cold water and/or hot water.
The stationary disk 1b is provided with a through-hole 13 for forming a passage allowing the inflow of cold water, a through-hole 14 for forming a passage allowing the inflow of hot water, and a through-hole 15 for forming a passage allowing the outflow of cold water and/or hot water. The respective lower openings of the through-holes 13, 14 and 15 of the stationary disk 1b have the same size as that of the respective upper openings of the through-holes 7, 8 and 9 of the bottom lid 3. The stationary disk 1b is water-tightly secured onto the upper surface of the bottom lid 3 so that the respective lower openings of the through-holes 13, 14 and 15 of the stationary disk 1b are aligned with the respective upper openings of the through-holes 7, 8 and 9 of the bottom lid 3. In FIG. 1, 18, 18 are packings arranged between the upper openings of the through-holes 7, 8 and 9 of the bottom lid 3, and the lower openings of the through-holes 13, 14 and 15 of the stationary disk 1b.
The diameter of the rotary disk 1a is slightly smaller than that of the stationary disk 1b. As shown in FIG. 2, the lower surface of the rotary disk 1a is provided with a groove 16 having prescribed shape and depth, for forming a passage of cold water and/or hot water. The rotary disk 1a is arranged in a water-tight so as to form the passage of cold water and/or hot water by means of the groove 16 on the lower surface of the rotary disk 1a, and the through-holes 13, 14 and 15 of the stationary disk 1b.
The lower inner peripheral surface of the top lid 4 is provided with a plurality of projections not shown matching with the shape of a plurality of recesses 17 provided on the side of the stationary disk 1b. The top lid 4 is stationarily secured to the upper surface of the bottom lid 3, and the projections of the top lid 4 engage with the respective recesses 17 of the stationary disk 1b.
The lever 6 comprises a vertical lever 6b and a horizontal lever 6a fixed at right angles to the upper end of the vertical lever 6b. The vertical lever 6b passes through the center portion of the top lid 4, and is connected to the top lid 4 via a movable pin not shown at the portion where the vertical lever 6b passes through the top lid 4. The lower end of the vertical lever 6b is connected to the upper surface of the rotary disk la via a pin not shown. In FIGS. 1 and 2, 22 and 23 are projections and recesses provided on the upper surface of the rotary disk 1a for connecting the lower end of the vertical ever 6b to the upper surface of the rotary disk 1a. The face cover 5 covers the stationary disk 1b, the rotary disk la, the top lid 4, and the vertical lever 6b, and is stationarily secured to the upper surface of the bottom lid 3.
By moving the horizontal lever 6a to the right or to the left, the rotary disk la rotates while sliding along the sliding face formed between the upper surface of the stationary disk 1b and the lower surface of the rotary disk 1a. Furthermore, by tilting the horizontal lever 6a upwardly or downwardly, the vertical lever 6b inclines, and the rotary disk la is pushed by the lower end of the vertical lever 6b, which has displaced by tilting. Thus, the rotary disk 1a displaces in the direction in which the rotary disk 1a is pushed by the lower end of the vertical lever 6b, while sliding along the sliding face.
Cold water flowing through the duct 10, the through-hole 7 of the bottom lid 3 and the through-hole 13 of the stationary disk 1b into the groove 16 provided on the lower surface of the rotary disk 1a, and hot water flowing through the duct 11, the through-hole 8 of the bottom lid 3 and the through-hole 14 of the stationary disk 1b into the groove 16, flow through the through-hole 15 of the stationary disk 1b and the through-hole 9 of the bottom lid 3 out from the cock 12. By displacing the rotary disk 1a through the operation of the lever 6, to cause the relative displacement of the stationary disk 1b and the rotary disk la along the sliding face, the passages for cold water and/or hot water are opened and closed, thus permitting control of the flow rate of cold water, hot water, and mixed cold and hot water.
Each of the rotary disk 1a and the stationary disk 1b is made of any one of a ceramics such as alumina, silicon carbide, silicon nitride, mullite and a mixture thereof, and a metal such as stainless steel and copper.
The lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b, which are in a water-tight contact with each other to form the sliding face therebetween, are polished into smooth surfaces like a mirror. A lubricant such as silicone grease is present between the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b to improve lubricity of the sliding face.
Now, another conventional valve of a faucet is described below with reference to the drawing. FIG. 3 is an exploded perspective view illustrating a faucet exclusively for cold water or hot water, in which a conventional valve of a faucet is incorporated.
As shown in FIG. 3, the faucet B exclusively for cold water or hot water comprises a bottom lid 3; a valve of a faucet 2, which comprises a stationary disk 2b and a rotary disk 2a; a top lid 4; a lever 6; a face cover 5; and a cock 12. The disk-shaped bottom lid 3 is provided with a through-hole 7 for forming a passage allowing the inflow of cold or hot water. A duct 10 for the inflow of cold or hot water is fitted to the lower opening of the through-hole 7.
The stationary disk 2b is provided with a through-hole branched into two upper openings 13, for forming branched passages allowing the inflow of cold or hot water. The stationary disk 2b is water-tightly secured onto the upper surface of the bottom lid 3 so that the lower opening of the through-hole 13 of the stationary disk 2b is aligned with the upper opening of the through-hole 7 of the bottom lid 3. In FIG. 3, 20 is a packing arranged between the upper opening of the through-hole 7 of the bottom lid 3 and the lower opening of the through-hole 13 of the stationary disk 2b.
The rotary disk 2a is provided with two through-holes 21 of the same size as the two upper openings 13 of the through-hole of the stationary disk 2b. The rotary disk 2a is arranged in a water-tight contact with the upper surface of the stationary disk 2b so that the through-holes 21 of the rotary disk 2a and the through-holes 13 of the stationary disk 2b form passages for cold or hot water.
The top lid 4 is stationarily secured to the upper surface of the bottom lid 3, and the inner surface of the top lid 4 is in a firm contact with the peripheral edge of the stationary disk 2b. The cock 12 is fitted to the outside of the top lid 4. The lever 6 comprises a columnar vertical lever 6b and a horizontal lever 6a fixed at right angles to the upper end of the vertical lever 6b. The vertical lever 6b passes through the center portion of the top lid 4, and the lower end of the vertical lever 6b is fixed to a recess 24 provided at the center of the upper surface of the rotary disk 2a. The face cover 5 covers the stationary disk 2b, the rotary disk 2a, the top lid 4, and the vertical lever 6b, and is stationarily secured to the upper surface of the bottom lid 3.
By moving the horizontal lever 6a to the right or to the left, the rotary disk 2a rotates while sliding along the sliding face formed between the upper surface of the stationary disk 2b and the lower surface of the rotary disk 2a. Cold or hot water flowing through the duct 10, the through-hole 7 of the bottom lid 3, the through-holes 13 of the stationary disk 2b and the through-holes 21 of the rotary disk 2a into the top lid 4, flows out from the cock 12. By displacing the rotary disk 2a through the operation of the lever 6, to cause the relative displacement of the stationary disk 2b and the rotary disk 2a along the sliding face, the passage for cold or hot water is opened and closed, thus, permitting control of the flow rate of cold or hot water.
Each of the rotary disk 2a and the stationary disk 2b is made of any one of a ceramics such as alumina, silicon carbide, silicon nitride, mullite and a mixture thereof, and a metal such as stainless steel and copper.
The lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b, which are in a water-tight contact with each other to form the sliding face therebetween, are polished into smooth surfaces like a mirror. A lubricant such as silicone grease is present between the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b to improve lubricity of the sliding face.
However, the above-mentioned conventional valves of the faucet 1 and 2 have the following problems:
In the above-mentioned conventional valves of the faucet 1 and 2, the sliding of the rotary disk along the sliding face formed between the lower surface of the rotary disk and the upper surface of the stationary disk, which are in a water-tight contact with each other, and a hydraulic pressure of cold water and/or hot water passing through the passages cause, with the lapse of time, gradual removal of a lubricant such as grease present between the lower surface of the rotary disk and the upper surface of the stationary disk. According as the lubricant decreases, a torque required for the sliding becomes larger, and finally, the rotary disk and the stationary disk adhere to each other, thus preventing the rotary disk from moving. This is referred to as the "adhesion phenomenon".
Under such circumstances, there is a demand for the development of a valve of a faucet, which comprises a stationary disk and a rotary disk, and permits a smooth sliding of the rotary disk along the sliding face formed between the upper surface of the stationary disk and the lower surface of the rotary disk without the need of a lubricant such as grease between the upper surface of the stationary disk and the lower surface of the rotary disk, and does not cause the adhesion phenomenon, but such a valve of a faucet has not as yet been proposed.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide a valve of a faucet, which comprises a stationary disk and a rotary disk, and permits a smooth sliding of the rotary disk along the sliding face formed between the upper surface of the stationary disk and the lower surface of the rotary disk without the need of a lubricant such as grease between the upper surface of the stationary disk and the lower surface of the rotary disk, and does not cause the adhesion phenomenon.
In accordance with one of the features of the present invention, there is provided a valve of a faucet, which comprises a stationary disk and a rotary disk;
each of said stationary disk and said rotary disk being made of any one of a ceramics and a metal; one surface of said stationary disk and one surface of said rotary disk being in contact with each other to form a sliding face therebetween; and said valve of the faucet opening and closing a passage of a liquid by means of a relative displacement of said stationary disk and said rotary disk along said sliding face, to control the flow rate of said liquid; wherein:
at least one of said one surface of said stationary disk and said one surface of said rotary disk, which form said sliding face, has a film substantially comprising diamond-like carbon thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view illustrating a cold-hot water mixed type faucet in which a conventional valve of a faucet is incorporated;
FIG. 2 is a perspective view illustrating a rotary disk shown in FIG. 1;
FIG. 3 is an exploded perspective view illustrating a faucet exclusively for cold water or hot water, in which a conventional valve of a faucet is incorporated;
FIG. 4 is an exploded perspective view illustrating a cold-hot water mixed type faucet, in which a valve of a faucet of the first embodiment of the present invention is incorporated;
FIG. 5 is an exploded perspective view illustrating the valve of the faucet of the present invention shown in FIG. 4;
FIG. 6 is a perspective view illustrating a rotary disk of the valve of the faucet of the present invention shown in FIG. 5;
FIG. 7 is an exploded perspective view illustrating a faucet exclusively for cold water or hot water, in which a valve of a faucet of the second embodiment of the present invention is incorporated;
FIG. 8 is an exploded perspective view illustrating the valve of the faucet of the present invention shown in FIG. 7;
FIG. 9 is a graph illustrating the relationship between a sliding frequency and a torque required for the sliding of a valve of a faucet; and
FIG. 10 is another graph illustrating the relationship between a sliding frequency and a torque required for the sliding of a valve of a faucet.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
From the above-mentioned point of view, extensive studies were carried out to develop a valve of a faucet, which comprises a stationary disk and a rotary disk, and permits a smooth sliding of the rotary disk, and does not cause the adhesion phenomenon over a long period of time.
As a result, the following findings were obtained: By forming a film comprising diamond-like carbon on at least one of the lower surface of the rotary disk and the upper surface of the stationary disk, which are in a water-tight contact with each other to form the sliding face therebetween, it is possible to hold a frictional force acting on the sliding face to a level of the. frictional force acting on the sliding face in the conventional valve of the faucet using the lubricant, and to improve wear resistance of the rotary disk and the stationary disk. It is therefore possible to obtain a valve of a faucet, which permits a smooth sliding of the rotary disk along the sliding face, and does not cause the adhesion phenomenon over a far longer period of time than before, without the need of a lubricant present between the lower surface of the rotary disk and the upper surface of the stationary disk.
The present invention was made on the basis of the above-mentioned findings. The valve of the faucet of the first embodiment of the present invention, which comprises a stationary disk and a rotary disk, is described below with reference to the drawings.
FIG. 4 is an exploded perspective view illustrating a cold-hot water mixed type faucet, in which a valve of a faucet of the first embodiment of the present invention is incorporated; FIG. 5 is an exploded perspective view illustrating the valve of the faucet of the present invention shown in FIG. 4; and FIG. 6 is a perspective view illustrating a rotary disk of the valve of the faucet of the present invention shown in FIG. 5.
As shown in FIGS. 4, 5 and 6, the cold-hot water mixed type faucet A comprises a bottom lid 3; a valve of a faucet 1, which comprises a stationary disk 1b and a rotary disk 1a; a top lid 4; a lever 6; a face cover 5; and a cock 12. The cold-hot water mixed type faucet A shown in FIG. 4 is different from the conventional cold-hot water mixed type faucet A shown in FIG. 1 only in that the valve of the faucet 1 of the present invention is different from the conventional valve of the faucet 1, as described later.
Each of the stationary disk 1b and the rotary disk 1a, which form the valve of the faucet 1 of the present invention, is made of any one of a ceramics such as alumina, silicon carbide, silicon nitride, mullite and a mixture thereof, and a metal such as stainless steel and copper.
The lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b, which are in a water-tight contact with each other to form the sliding face therebetween, are polished into smooth surfaces like a mirror. A film 19 comprising diamond-like carbon is formed on each of the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b.
Now, the film comprising diamond-like carbon used in the valve of the faucet 1 of the present invention is described.
Carbon displays polymorphism such as diamond-like carbon, diamond, amorphous carbon and graphite. Diamond-like carbon, popularly known as i-carbon, has properties distinctly different from those of the other carbon. For example, diamond-like carbon has a chemical composition comprising carbon and hydrogen, with an amorphous structure. Diamond-like carbon has a micro-Vickers hardness of from 1,000 to 5,000, which is higher than those of amorphous carbon and graphite. In terms of electrical properties, diamond-like carbon is an insulator, not having conductivity as amorphous carbon or graphite.
By forming the film 19 comprising diamond-like carbon having the properties as described above on the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b, which are in a water-tight contact with each other to form the sliding face therebetween, it is possible to hold a frictional force acting on the sliding face to a level of the frictional force acting on the sliding face in the conventional valve of the faucet using the lubricant, and to improve wear resistance of the rotary disk 1a and the stationary disk 1b. The film comprising diamond-like carbon is formed on the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b mainly by means of a gas-phase synthesizing process such as CVD (abbreviation of Chemical Vapor Deposition) or PVD (abbreviation of Physical Vapor Deposition).
The film 19 comprising diamond-like carbon, formed on each of the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b, should have a thickness within a range of from 0.1 to 50 μm. With a thickness of the film 19 of under 0.1 μm, the sliding of the rotary disk 1a along the sliding face causes wear of the film 1a and easy wear-out thereof. With a thickness of the film 19 of over 50 μm, on the other hand, a shock exerted on the faucet and a sudden change in the water temperature cause the film 19 to peel off and finally come off. The film 19 comprising diamond-like carbon may be formed only on one of the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b.
Now, the valve of the faucet of the second embodiment of the present invention, which comprises a stationary disk and a rotary disk, is described below with reference to the drawings.
FIG. 7 is an exploded perspective view illustrating a faucet exclusively for cold water or hot water, in which a valve of a faucet of the second embodiment of the present invention is incorporated; and FIG. 8 is an exploded perspective view illustrating the valve of the faucet of the present invention shown in FIG. 7.
As shown in FIGS. 7 and 8, the faucet B exclusively for cold water or hot water comprises a bottom lid 3; a valve of a faucet 2, which comprises a stationary disk 2b and a rotary disk 2a; a top lid 4; a lever 6; a face cover 5; and a cock 12. The faucet B exclusively for cold water of hot water shown in FIG. 7 is different from the conventional faucet B exclusively for cold water or hot water shown in FIG. 3 only in that the valve of the faucet 2 of the present invention is different from the conventional valve of the faucet 2, as described later.
Each of the stationary disk 2b and the rotary disk 2a, which form the valve of the faucet 2 of the present invention, is made of any one of a ceramics such as alumina, silicon carbide, silicon nitride, mullite an a mixture thereof, and a metal such as stainless steel and copper.
The lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b, which are in a water-tight contact with each other to form the sliding face therebetween, are polished into smooth surfaces like a mirror. A film 19 comprising diamond-like carbon is formed on each of the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b.
In the valve of the faucet 2 of the second embodiment, the film 19 comprising diamond-like carbon, formed on each of the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b, should have a thickness within a range of from 0.1 to 50 μm, for the same reasons as described concerning the film 19 comprising diamond-like carbon used in the above-mentioned valve of faucet 1 of the first embodiment. The film 19 comprising diamond-like carbon may be formed only on one of the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b.
Now, the valve of the faucet of the present invention, which comprises the rotary disk and the stationary disk, is described further in detail by means of examples while comparing with examples for comparison.
EXAMPLE 1
Three sets of a valve of a faucet 1, comprising a rotary disk 1a and a stationary disk 1b and having a shape as shown in FIGS. 5 and 6, were prepared from a ceramics comprising 92 wt.% alumina(Al 2 O 3 ), 3 wt.% Silica (SiO 2 ), 3 wt.% magnesia(MgO), and 2 wt.% titanium oxide (TiO 2 ). Then, the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b of each valve of the faucet 1, were polished into a surface roughness expressed by a center-line mean roughness(Ra) of 0.08 μm as specified by the JIS Standard. In the valve of the faucet 1 of the first set, a film 19. comprising diamond-like carbon was formed on each of the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b to prepare a sample within the scope of the present invention (hereinafter referred to as the "sample of the invention") No. 1. In the valve of the faucet 1 of the second set, a film 19 comprising diamond-like carbon was formed only on the lower surface of the rotary disk 1a to prepare a sample within the scope of the present invention (hereinafter referred to as the "sample of the invention") No. 2.
The film 19 comprising diamond-like carbon was formed by means of the conventional microwave plasma CVD process, as follows.
More specifically, a target comprising metallic titanium(Ti), and the rotary disk 1a and/or the stationary disk 1b were placed in a vacuum vessel having a microwave plasma generator, and the pressure in the vacuum vessel was decreased to up to 10 -5 Torr. Then, an argon gas and an acetylene gas were supplied into the vacuum vessel at a prescribed flow rate. Then, the microwave plasma generator was operated to cause the spattering of titanium (Ti) from the target and the decomposition of the acetylene gas, thereby to form a TiC film having a thickness of 0.1 μm on the lower surface of the rotary disk 1a and/or the upper surface of the stationary 1b. Then, the flow rate of the acetylene gas was increased, thereby to form a diamond-like carbon film 19 having a thickness of 5 μm on the TiC film. In the valve of the faucet 1 of the third set, the above-mentioned CVD process for the formation of the diamond-like carbon film was not carried out, and the valve of the faucet 1 of the third set, which did not have the diamond-like carbon film, was used as a sample outside the scope of the present invention (hereinafter referred to as the "sample for comparison") No. 1.
Each of the thus prepared samples of the invention Nos. 1 and 2 and the sample for comparison No. 1 was incorporated into the faucet A shown in FIG. 4. In the sample for comparison No. 1, silicone grease was provided between the lower surface of the rotary disk 1a and the upper surface of the stationary disk 1b. Then, a device for operating the lever 6 was attached to the faucet A to move the lever 6 to cause the sliding of the rotary disk 1a. More specifically, while continuously supplying cold water at a temperature of 20° C. and hot water at a temperature of 78° C. to the faucet A under a pressure of 3 Kgf/cm 2 , the lever 6 was moved to the hot water closing side, the hot water opening side, the cold water opening side, the cold water closing side, and then to the hot water closing side in this sequence, and the number of sliding runs of the rotary disk 1a was counted with this sequence as one run of sliding.
For every certain number of sliding runs of the rotary disk 1a, the torque required for moving the lever 6 from the hot water opening side to the cold water opening side so as to cause the sliding of the rotary disk 1a, and the occurrence of the adhesion phenomenon were investigated. The results of the investigation are illustrated in FIG. 9.
In FIG. 9, the abscissa represents the number of sliding runs of the rotary disk 1a, and the ordinate represents the torque required for the sliding. Also in FIG. 9, the mark "o" indicates the sample of the invention No. 1, the mark "x" indicates the sample of the invention No. 2, and the mark "Δ" indicates the sample for comparison No. 1.
As is clear from FIG. 9, in the sample for comparison No. 1, the torque required for the sliding was under 3.0 Kg·cm before the number of sliding runs of 70,000 was reached. In the sample for comparison No. 1, however, the torque required for the sliding began to sharply increase and an abnormal sound caused by the friction between the rotary disk 1a and the stationary disk 1b was produced, when the number of sliding runs of 90,000 was reached. When the number of sliding runs of 110,000 was reached, the torque required for the sliding amounted to about four times as large as the initial torque.
In the samples of the invention Nos. 1 and 2, in contrast, the torque required for the sliding was under 3.0 Kg·cm in the initial stage of the sliding, and there was almost no change in the torque required for the sliding even when the number of sliding runs of 500,000 was reached. The thickness of the film 19 comprising diamond-like carbon of each of the samples of the invention Nos. 1 and 2 was measured when the number of sliding runs of 500,000 was reached. As a result, the film 19 of the sample of the invention No. 1 had a thickness of 4.5 μm, and the film 19 of the sample of the invention No. 2 had a thickness of 3 μm. This revealed that wear of the film 19 comprising diamond-like carbon was very slight. In the samples of the invention Nos. 1 and 2, there was produced no abnormal sound caused by the friction between the rotary disk 1a and the stationary disk 1b until the number of sliding runs of 500,000 was reached.
EXAMPLE 2
Two sets of a valve of a faucet 2, comprising a rotary disk 2a and a stationary disk 2b and having a shape as shown in FIG. 8, were prepared from the same ceramics as in the Example 1. Then, the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b of each valve of the faucet 2, were polished into a surface roughness expressed by a center-line mean roughness(Ra) of 0.1 μm as specified by the JIS Standard. In the valve of the faucet 2 of the first set, a film 19 comprising diamond-like carbon was formed on each of the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b to prepare a sample within the scope of the present invention (hereinafter referred to as the "sample of the invention") No. 3.
The film 19 comprising diamond-like carbon was formed by means of the conventional microwave plasma CVD process as in the Example 1, as follows.
More specifically, a target comprising metallic titanium(Ti), and the rotary disk 2a and the stationary disk 2b were placed in a vacuum vessel having a microwave plasma generator, and the pressure in the vacuum vessel was decreased to up to 10 -5 Torr. Then, an argon gas, a nitrogen gas and an acetylene gas were supplied into the vacuum vessel at respectively prescribed flow rates. Then, the microwave plasma generator was operated to cause the spattering of titanium(Ti) from the target and the decomposition of the nitrogen gas, thereby to form a TiN film having a thickness of 0.1 μm on the lower surface of the rotary disk 2a and the upper surface of the stationary disk 2b. Then, the flow rate of the nitrogen gas was decreased and the flow rate of the acetylene gas was increased, thereby to form a TiC film having a thickness of 0.1 μm on the TiN film. Then, the flow rate of the nitrogen gas was extremely decreased and the flow rate of the acetylene gas was further increased, thereby to form a diamond-like carbon film having a thickness of 3 μm on the TiC film.
In the valve of the faucet 2 of the second set, the above-mentioned CVD process for the formation of the diamond-like carbon film was not carried out, and the valve of the faucet 2 of the second set, which did not have the diamond-like carbon film and was not applied with a lubricant such as silicone grease on the sliding face, was used as a sample outside the scope of the present invention (hereinafter referred to as the "sample for comparison") No. 2.
Each of the thus prepared sample of the present invention No. 3 and the sample for comparison No. 2 was incorporated into the faucet B shown in FIG. 7. Then, a device for operating the lever 6 was attached to the faucet B to move the lever 6 to cause the sliding of the rotary disk 2a. More specifically, while continuously supplying hot water at a temperature of 75° C. to the faucet B under a pressure of 0.6 Kgf/cm 2 , the lever 6 was moved to the hot water opening side, the hot-water closing side and then to the hot water opening side in this sequence, and the number of sliding runs of the rotary disk 2a was counted with this sequence as one run of sliding.
For every certain number of sliding runs of the rotary disk 2a, the torque required for moving the lever 6 from the hot water closing side to the hot water opening side so as to cause the sliding of the rotary disk 2a, and the occurrence of the adhesion phenomenon were investigated. The results of the investigation are illustrated in FIG. 10.
Furthermore, after measuring the above-mentioned torque required for the sliding of the rotary disk 2a at a certain number of sliding runs, the lever 6 was stopped at the hot water closing side. Then, after the lapse of one hour, the sliding of the rotary disk 2a was resumed, and the torque required for the resumption of sliding of the rotary disk 2a. The difference in torque required for the sliding of the rotary disk 2a between the moment of the stoppage of the sliding and the moment of the resumption of the sliding after the lapse of one hour, was investigated. The reason of this investigation was as follows: When the rotary disk is left in the non-sliding state, the frictional force acting on the sliding face between the rotary disk 2a and the stationary disk 2b increases along with the lapse of time, and it becomes gradually difficult to move the lever 6 so as to cause the sliding of the rotary disk 2a, thus leading to the occurrence of the adhesion phenomenon. The results of the above-mentioned investigation are also illustrated in FIG. 10.
In FIG. 10, the abscissa represents the number of sliding runs of the rotary disk 2a, and the ordinate represents the torque required for the sliding. Also in FIG. 10, the mark " " indicates the sample of the invention No. 3 at the moment of the stoppage of the sliding, the mark " " indicates the sample of the invention No. 3 at the moment of the resumption of the sliding after the lapse of one hour, the mark "o" indicates the sample for comparison No. 2 at the moment of the stoppage of the sliding, and the mark "Δ" indicates the sample for comparison No. 2 at the moment of the resumption of the sliding after the lapse of one hour.
As is clear from FIG. 10, in the sample for comparison No. 2, the torque required for the sliding increased suddenly in a short period of time. In addition, there was observed a very large difference in torque required for the sliding between the moment of the stoppage of the sliding and the moment of the resumption of the sliding after the lapse of one hour. In the sample for comparison No. 2, an abnormal sound caused by the friction between the rotary disk 2a and the stationary disk 2b was produced when the number of sliding runs of 5,000 was reached.
In the sample of the invention No. 3, in contrast, the torque required for the sliding was under 1.0 Kg·cm in the initial stage of the sliding, and there was almost no change in the torque required for the sliding even when the number of sliding runs of 600,000 was reached. In addition, in the sample of the invention No. 3, there was almost no difference in torque required for the sliding between the moment of the stoppage of the sliding and the moment of the resumption of the sliding after the lapse of one hour. In the sample of the invention No. 3, there was produced no abnormal sound caused by the friction between the rotary disk 2a and the stationary disk 2b until the number of sliding runs of 600,000 was reached.
According to the present invention, as described above in detail, it is possible to obtain a valve of a faucet, which comprises a stationary disk and a rotary disk, and permits a smooth sliding of the rotary disk along the sliding face formed between the upper surface of the stationary disk and the lower surface of the rotary disk without the need of a lubricant such as grease between the upper surface of the stationary disk and the lower surface of the rotary disk, and does not cause the adhesion phenomenon for a far longer period of time than before, thus providing industrially useful effects. | A valve of a faucet comprises a stationary disk and a rotary disk. Each of the stationary disk and the rotary disk is made of a ceramics or a metal, and one surface of the stationary disk and one surface of the rotary disk are in contact with each other to form a sliding face therebetween. The valve of the faucet opens and closes a passage of a liquid by means of a relative displacement of the stationary disk and the rotary disk along the sliding face to control the flow rate of the liquid. At least one of the one surface of the stationary disk and the one surface of the rotary disk, which form the sliding face, has a film substantially comprising diamond-like carbon thereon. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This patent application claims the benefit of provisional patent application Ser. No. 61/550,786, filed Oct. 24, 2011, the complete subject matter of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a flexible light using light emitting diodes (LEDs).
BACKGROUND AND SUMMARY
A highly shapeable lighting device includes sturdy casings for light emitting diodes, flexible wires between the eases of diodes, a shapeable spine, a rechargeable battery pack, and a compact handle holding the batteries and charging port. The shapeable spine allows the device to be straightened for use in a deep dark area, and it can be tightly balled up or folded for easy storage. The flexible outer tube makes it easy to wrap an end around a nearby object, grasping it tightly, casting light all around it. The lights are bright enough to provide good lighting for projects where space to hang or position other trouble lights or flashlights is difficult. The material holding the LEDs also holds the two wires that come out of each end of the LED plug. The device may or may not be rechargeable.
In an embodiment, the lighting device comprises a sealed transparent flexible outer tube having a handle at a first end, the handle having a power source; a flexible wire, the wire plastically deformable and shapeable, the flexible wire inside the flexible outer tube and extending from and attached to the handle, the wire extending the length of the outer tube to an opposite end of the flexible outer tube; multiple small lengths of inflexible interior tubing, the interior tubing lengths having at least one light emitting diode (LED) and at least one resistor inside an interior of the interior tube, each resistor connected electronically in series to a corresponding LED, each resistor/LED combination connected via a circuit board electronically in parallel to each other; each resistor/LED/circuit board in each length connected to each other in parallel and to the power source, the multiple small lengths of interior tubing inside the outer tube and running at least a partial length of the flexible outer tube. In an embodiment, more than one LED is wired to a single resistor. In an embodiment, a dimmer control is interconnected electronically to the power source and the diodes. In an embodiment, a voltage booster and a charging circuit are interconnected electronically to the power source and the diodes. In an embodiment, each interior tubing length comprises a swivel joint connecting that interior tubing length to the next interior tubing length.
In an embodiment, the diodes have a 120 degree viewing angle and are arranged such that the light emits through the tubes at a 120 degree arc.
In an embodiment, the outer tube is made of a highly flexible vinyl material, the length of the first flexible tubing is about 25-26″, the outer tube having a wall thickness of about 1/16″, an inner diameter of about ½″ and an outer diameter of about ⅝″; the interior tubing made of a hard plastic, having a length of about 1″ and having an inner diameter of about ¼″ and an outer diameter of about ⅜″.
In an embodiment, the lighting device comprises an additional diode having a smaller viewing angle located at a second end of the first flexible tube. The additional diode viewing angle is positioned in a different direction than the multiple diodes.
In an embodiment, the handle comprises a connecting apparatus that releasably engages the outer flexible tube. In an embodiment, the interior tubing comprises a cover that extends the length of the tubing, the cover covering a portion of a diameter of the tubing. the interior tubing may be translucent or be coated or infused with a tint or color or the circuit board comprises a switch that changes the color of the light emitted by the diode.
In an embodiment, a lens that magnifies and directs light emitting from the diode is adjacent to each diode.
In an embodiment, the interior tubing lengths are spaced about 2″ apart on center.
Other devices that are similar in their composition and could be considered prior art are either the led trouble light stick which is a solid stick, or a strand of LEDs on a flexible circuit board. There is also a flat, somewhat large flexible square with LEDs mounted to the flexible substrate. These lights are restrictive in their usefulness. The flexible mat can be shaped, but is too large to fit into crevasses. The light tube fits into crevasses, but its lack of flexibility makes it difficult to position for hands-free use.
Unfortunately, the limpness and lack of formability of a normal rope light made it less than friendly to use. Also, rope lights produce very little light outside of the tube they are extruded inside of.
Previous art describes flexible LEDs in a continuous strand. This method works great for gently wrapping around banisters, but will not stand up to the stress created by repeatedly bending and shaping around objects.
What is needed is a trouble light that can more easily and dynamically be positioned to provide appropriate lighting for everyday tasks. No other product or patent combines flexibility, recharge ability, a series of plugs with LEDs, and holding power like this device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an embodiment of the invention.
FIG. 2 is a sectional view of a tube.
FIG. 3 is a sectional view of a tube containing an LED and wiring.
FIG. 4 is a side view showing the wiring of the circuit board.
FIG. 5 depicts alternate arrangements of the invention used with a base.
FIG. 6 is a diagram of the design of a circuit board of an embodiment.
FIG. 7 is a diagram of the design of a double-sided circuit of an embodiment.
FIG. 8 depicts a side see-through view of a disassembled handle of an embodiment.
FIG. 9 is a side view of a barbed fitting with a disc circuit board.
FIG. 10 is a depicts an side exploded view of the barbed fitting in relation to the tube.
FIG. 11 is a perspective view of a barbed fitting showing the hole to contain the bendy wire.
FIG. 12 is a top view of a string of LEDs of an embodiment.
FIG. 13 is a top view an alternately wired string of LEDs.
FIG. 14 is a perspective view of the small plastic container containing the resistor of an embodiment.
FIG. 15 is a schematic diagram of the wiring of an embodiment of the device.
FIG. 16 depicts two alternate schematic diagrams of wiring of resistors (in series and in parallel).
FIG. 17 depicts a top view of an embodiment using through-hole style bulbs that fit inside a plug.
FIG. 18 is a perspective view of an embodiment depicting leads coming off the LED.
FIG. 19 is a perspective view of an embodiment having the LED encased in a clear plug with wiring.
FIG. 20 depicts an assembled embodiment of the invention.
DETAILED DESCRIPTION
This device is so flexible it can be looped several times around a single pipe or tube. It can be wrapped around its own handle, creating a very small profile, easy to store in a toolbox. The small size of the tube allows it to easily be placed inside of areas no other flashlight will fit. This device provides better portable illumination in tight areas than any other current device. The smooth outside of the tube allows it to easily be inserted and withdrawn from tight areas like engine compartments or inside of furnaces.
The round aluminum wire used to provide flexibility and holding power is able to move 360 degrees, any direction from the handle.
There is optionally an additional LED at the tip to provide extremely easy to direct directional lighting.
There is slack in the sets of wires between the LED plugs so using the device will not pull on the wire.
The LEDs used are Cree, surface mount, 120 degree viewing angle. This allows the light to be cast widely, but not all the way around the device. The size of the LED is small enough to fit inside a ¼ I.D. vinyl tube along with the wires needed for the circuit. The inside tube is used to create LED/resistor/hot glue “plugs,” and is made up often small pieces of tube, each one measuring about an inch in length. The second tube (interior tube) is not flexible, because it protects the circuitry parts.
The aluminum wire is secured into the same barbed fitting the tube is attached to. This keeps it attached to the handle, and will not separate from the handle.
The outer tubing is made of a highly flexible vinyl material with a 1/16″ wall thickness, ½″ ID and ⅝″ OD.
The inner tubing pieces used to encase the LEDs is ¼″ I.D., ⅜″ O.D.
The bendy wire is aluminum approx=0.07″ wire, uncoated.
Resistors are connected in series to the LED, resistor and LED combinations are then wired in parallel.
The battery life from three AAA batteries can be over 4000 mah. That is enough power to support the light for a minimum of 5 hours without using resistors.
The plugs are encased with clear hot glue inside of a thin walled tube. Two wires come out of each end of the plug, each plug connected by the wires. Only two 18 awg wires are used. It uses tight fitting, strong tubes as the plug around the LED, and just a dab of glue to hold them in place. The fit is tight enough to hold the wires and keep the LED, and the wires they are soldered to, from moving.
The barbed fitting used to attach the tube to the handle is a ½″ barb.
The aluminum wire is looped at the end opposite the handle to keep it from poking through the tube.
The power switch for the light is located so that it will not be accidentally switched while positioning the device.
Extra measures are taken to secure the circuit board and barbed fitting to the handle. Without a locking washer or very low tolerance fit, the ground could come loose from the body of the handle, wherein the ground is attached to the switch and battery.
The aluminum wire is looped at the end of the device furthest from the handle, and encased in glue or plastic. This forms a cap for the tube so that debris cannot enter the tube. This style cap allows the end of the tube furthest from the handle remains the same diameter as the rest of the tube.
The aluminum wire inside the tube used to position the device is large enough to hold the light into position when wrapped, but as small as possible to avoid damaging the light plugs and the tube. A small diameter wire makes the device easy for anyone to bend into position. Ideally, there is a harmonious balance between flexibility and rigidity.
A barbed fitting is used to secure the tube to the handle, and a small hole is molded into the handle to provide a place for the end of the bendy wire to be secured. The wire is bent and forced into the hole.
A LED with a smaller viewing angle is used at the tip opposite the handle for more directional light.
The LED plugs are spaced about 2″ apart on center, and about 2″ from the barbed fitting by the handle to allow for the most flexibility at the handle joint.
The overall length of the device is about 25-26″. The length of the first tube is about 21″. The outside diameter of the handle is about 1.08″
The LEDs are wired in parallel, and an appropriate battery is used to avoid the use of resistors.
Glow in the dark plastic is optionally incorporated into the handle to make the device easy to locate.
One embodiment uses a rubber plug for the charging port, o-rings around the battery door, and the end of the tube sealed to make the device submersible. In one embodiment, the handle is made of aluminum, using the body of a cheap aluminum flashlight. This handle holds a battery holder, which holds three AAA size batteries. A firm glue and tight fitting barbed fitting are enough to hold the tube end of the light onto the cheap aluminum handle. Another embodiment uses a barbed fitting at the tip of the light instead of hot glue to seal the end opposite the handle. In another embodiment, each of the LEDs in the circuit is wired in parallel. This allows several LEDs to be powered by a low voltage power supply, specifically small batteries. Another embodiment uses as small as possible circuit boards inside the “plugs” instead of only a bulb and/or resistor. Another embodiment is a floor lamp, table lamp, or wall fixture, which includes a larger base, big enough to keep the tube from falling over. This embodiment uses multiple tubes and a single base, or a single tube and multiple bases, or a single tube and single base, or multiple tubes and multiple bases. It is powered by 120 v standard plug outlet. In another embodiment, the overall size of the device could be as tall as 10 ft, when used as a lamp or a semi-permanently installed task light. Another embodiment is an extremely long version that could be any length, with any number of LEDs. In another embodiment, it is as small as the smallest available LED's and batteries will allow. The size of the LEDs and batteries are complimentary to one another. For example, if 3.2 v max LEDs are used, 2 AA or 2 AAA batteries provide sufficient voltage for their operation. Using only 2 AA or AAA batteries with 3.8 v LEDs does not utilize the full potential luminous output of the LED. Another embodiment uses any size tubing, different size inside and outside dimensions of tube can make the device usable in more applications. Also, different wall thicknesses of tubing can be used to create a different feel. Using UV bulbs in manufacturing creates a highly adaptable material curing device. Another embodiment joins the tip of the device with the handle, creating a doughnut shape. Another embodiment uses a small device permanently installed on the handle or the tip of the light to allow the two ends to be joined together, creating the doughnut shape. Another embodiment uses a sleeve to cover part of the device if some part shined in the user's eyes during use. This is cloth or plastic piece, entirely black, or half black and half clear.
The type and capacity of the battery can greatly impact the amount of time the device will stay its brightest. Because the circuit will operate for longer periods of time more consistently with resistors, one embodiment does not have resistors. Resistors are used in series with ground on each LED in a parallel circuit. This requires the use of a specialized resistor or resistor housing, a circuit board, or a third wire with resistors made into plugs similar to the LED plugs. In another embodiment, through-hole style LEDs are used similarly, their leads connected to each other inside a “plug” then wired in parallel, with or without resistors. Another embodiment uses different color or shapes of handles. Another embodiment is an extra loop or wrist wrap at the handle to allow the user to affix the handle to their hand without gripping the light. Another embodiment uses a very small diameter tube.
As LED technology develops smaller, brighter LEDs, smaller versions of this device are possible to manufacture. Since there is no way to know how small the LEDs can get, there is no way to know how small this device will be able to be in the future, however, it will become more useful to industries specializing in small materials or processes as the device gets smaller.
Another embodiment uses any style or color of light bulb. Another embodiment uses a translucent tube instead of transparent. Another embodiment is a deep-water submersible version. The difference would be quality, tested seals. The tube is filled with something other than air so that it does not expand at deep water depths. Another embodiment uses a tint, colored, smoked, or a hazed tube. It is included in the material the tube is constructed from, it may be applied after extrusion, and it may take the form of an outer most jacket for the device. Another embodiment uses Nitinol wire instead of aluminum for the bendy wire. Nitinol is bent to shape, heat treated, then attached to the handle and a power supply that provides enough voltage to heat the Nitinol to return it to its originally formed shape. One embodiment has the entire circuit inside of a solid tube. It is extruded along with the circuit. There are any number of LED's spaced any distance apart. The LED's are wired in sets of two or three per resistor. One embodiment uses an LED circuit wired in series using a voltage booster to up the voltage from the batteries to enough to power the circuit. Using 10 LEDs with forward voltage rating of 3.8 requires increasing the voltage to over 38 volts, and the use of one resistor. Another embodiment uses sections of plastic housings for the LEDs, each connected with a swivel or flexible joint giving it the same abilities as the version in the tube. One version uses a dimmer control. LED's are dimmed by sending pulses of electricity to quickly turn them on and off. Because they are able to change so quickly from on to off, they can appear to be dim. This is done by regulating the current to the circuit. Another embodiment uses a circuit board to control color changing LEDs. A readily available selector switch changes colors allowing the device to produce any RGB color. Another embodiment does not use plugs, but instead the entire tube is solid, with the bendy wire and circuitry extruded directly into a tube shape. This embodiment requires a different method for securing the tube to the handle. Instead of a barbed fitting, it is a reversed barb or simply glued, stapled, riveted or melted. Another embodiment uses the aluminum wire for the ground in the electrical circuit. Another embodiment uses LEDs custom made to be able to be stapled onto wires. If the leads off the LEDs are made sharp and strong, they can pierce the insulation on a wire, then curl underneath to secure the connection. One embodiment uses two pieces of plastic fitted together to encapsulate the LEDs and form the plugs that protect the bulbs. There are two ways to do this, either two stacked pieces or two side-by-side pieces. Both pieces could be clear or semi-clear, the piece covering the bulb incorporates a lens to magnify or direct the light emitting from the device.
In any embodiment the battery is an appropriate size for the number and type of LEDs and lighting circuit. One embodiment uses a any battery voltage or wall plug-in 120 v. One embodiment uses UV coating is used on the tube to keep the LEDs from deteriorating in the sunlight.
It's the perfect trouble light for finding bolts in engine compartments, changing brakes, finding socks under your bed, or keeping the kids entertained for a while. Because it can be shaped into anything and hold its position, its uses are endless. I like to cram it up under the dash of my car so I can see my carpet when I'm vacuuming it. It doesn't shine in my eyes because it's tucked under the dash. I straighten it and make a 90 degree bend about 3 inches from each end so it fits, and then I push it up under the dash. The bend n stay wire makes the device one big spring, so it stays tucked up where I can't see it, but I can see the light. The device can be positioned so the light is directed toward the work area and not the eyes of the worker. I can't wait to change my brakes next time and not have to fumble around for fifteen minutes with a flashlight to find the two bolts to take off my calipers. I'll just wrap my light around the spring and shock. The light is out of my way but still shining right where I need it.
The need for this device came from trying to position and reposition different trouble lights and flashlights while working underneath the dashboards of cars and trucks. There was simply not a product you could set in place once, finish your job, and then easily remove it from the vehicle. From this, the thought of making a rope light with a battery pack seemed like the solution.
As used herein, “approximately” means within plus or minus 25% of the term it qualifies. The term “about” means between ½ and 2 times the term it qualifies. The compositions of the present invention can comprise, consist of, or consist essentially of the essential elements and limitations of the invention described herein, as well as any additional or optional ingredients, components, or limitations described herein or otherwise useful in compositions and methods of the general type as described herein.
Numerical ranges as used herein are intended to include every number and subset of numbers contained within that range, whether specifically disclosed or not. Further, these numerical ranges should be construed as providing support for a claim directed to any number or subset of numbers in that range or to be limited to the exact conversion to a different measuring system, such, but not limited to, as between inches and millimeters.
All references to singular characteristics or limitations of the present invention shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made.
All combinations as used herein can be assembled in any order, unless otherwise specified or clearly implied to the contrary by the context in which the referenced combination is made. Terms such as “top,” “bottom,” “right,” “left,” “above”, “under”, “side” “front” and “back” and the like, are words of convenience and are not to be construed as limiting.
Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. In accordance with an embodiment of the present invention as depicted in FIG. 1 , the end of the memory wire 10 close to the barb is kinked at an about 90 degree angle and fitted into a small hole drilled inside the plastic barb. The wire is an aluminum “bend n stay” wire that goes inside the tube (not shown). When you put an unprotected circuit board inside a tube with an aluminum wire, and apply enough force to the tube to wrap it tightly or bend it 180 degrees, the board and components will be destroyed. Similar products in design to this are used for decoration, to be wrapped around banisters and such, and to be left in place. Any protection they provide against damage is minimal, and not enough to allow such a device to be used as a tool, aggressively wrapped and unwrapped multiple times a day. Leaving the circuit boards 20 a - n separate from the memory wire, allows them to move freely from one another, extending the life of the memory wire, and reducing the stress created when contorted. Extra slack is left in the wires 30 a - n between each circuit board to eliminate the stress caused to them by contorting the light 40 . A small loop 50 at the end of the memory wire creates part of the cap (not shown) for the device. When a glue or epoxy is filled around the loop, it holds together the loop, the circuit board, and the end of the tube.
As shown in FIG. 2 , a firm glue and tight fitting barbed fitting 60 are enough to hold the tube end of the light onto the handle. The fitting is a thin, flat locking washer with four cuts at 12, 3, 6, & 9 o'clock. One embodiment uses this to hold the circuit board firmly in place, so ground stays connected to the body of the handle.
FIG. 3 depicts a circuit board 70 with a spring 80 to connect the positive end of the battery pack 90 . It also has holes where the positive and negative wires from the light strand are soldered onto the board in a through-hole method. This circuit board could also hold the charging circuit and/or the voltage boosting circuit. In another embodiment, only a positive contact is used and the negative wire is secured directly to the handle providing ground. FIG. 4 shows the wires coming through the circuit board.
FIG. 5 depicts an embodiment as a floor lamp, table lamp, or wall fixture, which includes a larger base 100 , big enough to keep the tube 110 from falling over. This embodiment optionally use multiple tubes and a single base, or a single tube and multiple bases, or a single tube and single base, or multiple tubes and multiple bases. It could be powered by 120 v standard plug outlet.
FIG. 6 depicts the design of the circuit board, allowing four wires to be attached to allow several lights to be wired in parallel. FIG. 7 depicts a double-sided circuit used to reduce the size of the footprint of the led plug.
FIG. 8 depicts a disassembled handle 130 . A switch 120 located in the bottom of a handle to avoid accidental operation. Contact from the switch is made at the battery spring and the body of the light, switching the ground. A soft, water tight button cover (not shown) is used in the bottom cap. The handle may be different sizes depending on the size of the tool. The handle is round, flat, or polygon shaped. In an embodiment, the handle is constructed of plastic and the barbed fitting is molded into the handle. A charging circuit 140 is in the bottom of the handle as well, along with a voltage booster 150 to allow for rechargeable batteries and the LEDs to be wired in series.
FIG. 9 depicts the barbed fitting 160 with a disc 170 that is a circuit board where the positive and negative terminals are attached from the strip of LEDs (see FIG. 12 ). The barbed fitting could also be glued in place instead of having a specially machined top for the handle. A normal flashlight handle may be used.
FIG. 10 depicts an exploded view of the barbed fitting in relation to the tube 180 . The barbed fitting that is secured in the handle of the device is fitted to the tube to create a water-tight seal. The tube can be extruded with the lights inside, and/or with the bendy wire inside. This is done within the walls of the tube, or within the inside of the tube, making the tube somewhat solid. The end 190 of the tube is filled around the last LED circuit board to seal the other end of the device making it water resistant, and enclosing the circuit boards and memory wire. In an embodiment, the tube itself is sealed shut to itself, folded, stapled, glued or melted. A plug (not shown) made of plastic or other suitable material is optionally used to seal the end as well. Another embodiment uses a barbed fitting with a swivel, allowing the tube to swivel opposite the handle. The swivel joint is located under the barbs and on top of the flange. In another embodiment, a barbed fitting is used to secure the tube to the handle, and a small hole 200 is drilled or molded into the fitting to provide a place for the end of the bendy wire to be secured. The wire is bent and forced into the hole (see FIG. 11 ).
FIG. 12 depicts a string of LEDs. Each LED 210 a - n is encapsulated, such as by using two pieces of plastic 220 a - n fitted together, to protect the LED from the stress created by use of the device from the outer tube and the aluminum wire squeezing the LED circuit board. Each encapsulated LED is connected by wires 230 a - n , 231 a - n (positive and negative) and to each circuit board 240 a - n . In an embodiment, the wires are soldered directly to the LED bulb. One wire for positive, another for negative, to achieve a series circuit. One embodiment uses a through-hole style resistor 250 a - n laid on the negative contact of the LED, the other end attached to the negative wire, allowing the use of only two wires. Another embodiment (depicted in FIG. 13 ), uses a third wire 232 a - n and resistor plugs 250 a - n as well as led plugs. In this version, the resistors lie in between each LED plug. The LED plug is in close proximity to the supporting resistor plug. This keeps the amount of wire used to a minimum, and saves space inside the tube. In an embodiment depicted in FIG. 14 , the resistor is potted into a small plastic container. The resister is wired in series to improve battery life. Contacts 260 , 261 are on the top and bottom of the resistor block.
FIG. 15 is a diagram of the wiring of an embodiment of the device. In an embodiment, the device comprises a voltage booster 270 and a charging circuit 280 . The voltage booster allows the circuit to operate at low current, but higher voltage than batteries alone could provide. 3.7 v is a standard cell size for Lithium Ion batteries. They are small and can be charged thousands of times. These components add longevity and usefulness to the device. in an embodiment. the battery 290 , charging circuit, and voltage booster are located in the handle of the device. In an embodiment, the device uses replaceable batteries without a voltage booster.
FIG. 16 depicts diagrams of various wiring of resistors wired in series and with each parallel resistor.
FIG. 17 depicts through-hole style bulbs used in low profile to fit inside a plug.
FIG. 18 depicts an embodiment where the leads 300 a - n coming off the LED are lengthened and made into a staple shape, allowing them to be stapled into the wire. When carefully pressed into a die similar to a normal stapler, the ends will curl under creating a tight connection with the wire, as a normal staple does when stapled through paper.
FIG. 19 is a detailed depiction of an LED encased in a clear plug.
FIG. 20 depicts an alternate handle 310 and through-hole style bulbs. In an embodiment, the device comprises a selectable dimmer switch 320 .
The foregoing descriptions of specific embodiments and examples of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. It will be understood that the invention is intended to cover alternatives, modifications and equivalents. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A lighting device comprising a sealed transparent flexible outer tube having a handle at a first end. The handle includes a power source. Inside the tube is a flexible wire extending from and attached to the handle. The wire extending the length of the outer tube. Also inside the tube are multiple small lengths of inflexible interior tubing running at least a partial length of the flexible outer tube. Each interior tubing having at least one light emitting diode and at least one resistor inside. The resistors and diodes are connected electronically to a circuit board and the power source. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an isolated DC-DC converter that has a configuration for indirectly detecting an output voltage supplied to the exterior and performing stabilizing control of the output voltage on the basis of the detected voltage.
[0003] 2. Description of the Related Art
[0004] FIG. 6 shows main circuit components of a typical isolated DC-DC converter. The isolated DC-DC converter 1 includes a transformer 2 . A main switching device (for example, a MOS-FET) Q and an input filter circuit 3 are provided on the side of a primary coil N 1 of the transformer 2 . Energy is supplied to the primary coil N 1 from an external power supply 4 via the input filter circuit 3 by the switching operation of the main switching device Q.
[0005] A secondary-side rectifying and smoothing circuit 5 is provided on the side of a secondary coil N 2 of the transformer 2 . The secondary-side rectifying and smoothing circuit 5 includes a rectification-side synchronous rectifier (for example, a MOS-FET) 6 , a commutation-side synchronous rectifier (for example, a MOS-FET) 7 , a synchronous-rectifier driving circuit 8 , and a smoothing circuit 9 . The voltage output from the secondary coil N 2 corresponds to the voltage generated in the primary coil N 1 . The secondary-side rectifying and smoothing circuit 5 rectifies and smoothes the output voltage from the secondary coil N 2 to produce a direct-current voltage and outputs the direct-current voltage to an external load S as an output voltage Vout.
[0006] A tertiary-side rectifying and smoothing circuit 10 is provided on the side of a tertiary coil N 3 of the transformer 2 . The tertiary-side rectifying and smoothing circuit 10 includes a rectification-side diode 11 , a commutation-side diode 12 , a choke coil 13 , a smoothing capacitor 14 , and voltage-dividing resistors 15 and 16 . The tertiary-side rectifying and smoothing circuit 10 rectifies and smoothes the output voltage from the tertiary coil N 3 to produce a direct-current voltage and detects and outputs the direct-current voltage as a detected voltage Vk of the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 .
[0007] The isolated DC-DC converter 1 further includes an error amplifier 18 . The error amplifier 18 outputs a voltage corresponding to the difference between the detected voltage Vk output from the tertiary-side rectifying and smoothing circuit 10 and a reference voltage Vs from a reference supply 17 . The isolated DC-DC converter 1 further includes a control circuit 20 . The control circuit 20 has circuitry for controlling the switching operation of the main switching device Q by, for example, the PWM control method on the basis of the output voltage from the error amplifier 18 (i.e., on the basis of the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 ) so that the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 is stabilized at a predetermined voltage. In this example, the control circuit 20 uses a direct-current voltage Vcc output from the smoothing capacitor 14 of the tertiary-side rectifying and smoothing circuit 10 as a supply voltage.
[0008] Patent Document 1: Japanese Patent No. 3391320.
[0009] Patent Document 2: Japanese Patent No. 3339452.
[0010] In the aforementioned isolated DC-DC converter 1 , it is desirable that the output voltage Vout be completely proportional to the detected voltage Vk output from the tertiary-side rectifying and smoothing circuit 10 to achieve satisfactory accuracy of the output voltage. However, in the configuration of the isolated DC-DC converter 1 shown in FIG. 6 , there is a problem such that the proportional relationship between the output voltage Vout and the detected voltage Vk is broken due to the circuit operation that is described below in the period in which the main switching device Q is switched off.
[0011] An example of the circuit operation in the period in which the main switching device Q is switched off will now be described using the wave form chart of FIG. 7 . For example, when the main switching device Q is switched off (time t 0 ), LC resonance due to parasitic capacitance generated in parallel between the source and drain of the main switching device Q and excitation inductance of the transformer 2 begins. This generates a pulse voltage of the LC resonance as shown in FIG. 7 at the drain of the main switching device Q. When a half cycle of the LC resonance has elapsed (time t 1 ), resetting of the transformer 2 is completed.
[0012] The drain voltage of the main switching device Q is in a state in which the drain voltage is clamped at a voltage Vd described below during the period between the time when resetting of the transformer 2 is completed and the time when the main switching device Q is turned on (the period between time t 1 and time t 2 ). Moreover, a driving voltage is applied to the gate of the commutation-side synchronous rectifier 7 by the synchronous-rectifier driving circuit 8 so that the commutation-side synchronous rectifier 7 is controlled so as to be in an on-state during the period in which the main switching device Q is switched off. Moreover, no driving voltage is applied to the gate of the rectification-side synchronous rectifier 6 so that the rectification-side synchronous rectifier 6 is controlled so as to be in an off-state during the period in which the main switching device Q is switched off.
[0013] Energy due to excitation inductance of a choke coil (not shown) that defines a smoothing circuit 9 is applied along a path A as shown in FIG. 6 so that power is supplied to the load S during the period in which the main switching device Q is switched off. The rectification-side synchronous rectifier 6 is controlled so as to be in an off-state as described above during the period in which the main switching device Q is switched off. However, due to a parasitic diode generated in parallel between the drain and source of the rectification-side synchronous rectifier 6 , an excitation current of the transformer 2 circulates around a path through the secondary coil N 2 of the transformer 2 , the commutation-side synchronous rectifier 7 , the parasitic diode of the rectification-side synchronous rectifier 6 , and the secondary coil N 2 when resetting of the transformer 2 is completed. This generates a forward drop-down voltage Vf of the parasitic diode across both ends of the rectification-side synchronous rectifier 6 . Thus, the voltage at both ends of the secondary coil N 2 is clamped at the forward drop-down voltage Vf of the parasitic diode of the rectification-side synchronous rectifier 6 during the period between the time when resetting of the transformer 2 is completed and the time when the main switching device Q is turned on (the period between t 1 and t 2 (transformer-excitation-current circulation period)).
[0014] Accordingly, in a case where Vin is an input voltage supplied from the external power supply 4 to the isolated DC-DC converter 1 , N 1 is the number of turns of the primary coil N 1 , N 2 is the number of turns of the secondary coil N 2 , and N 3 is the number of turns of the tertiary coil N 3 , a clamp voltage Vd of the drain of the main switching device Q during the transformer-excitation-current circulation period (the period between t 1 and t 2 ) is calculated by an expression Vd Vin−(N 1 /N 2 )×Vf. A voltage V 3 generated in the tertiary coil N 3 is clamped at a voltage calculated by an expression V 3 =(N 3 /N 2 )×Vf.
[0015] In the tertiary-side rectifying and smoothing circuit 10 , current is applied along a path B that passes through the choke coil 13 and the commutation-side diode 12 as shown in FIG. 6 due to energy stored in the choke coil 13 during the period in which the main switching device Q is switched off. The voltage V 3 is generated in the tertiary coil N 3 as described above during the period in which the main switching device Q is switched off. In the tertiary-side rectifying and smoothing circuit 10 , the diode 12 having one-way conductivity is provided as a rectifying device on the commutation side. Thus, current due to the voltage V 3 of the tertiary coil N 3 does not follow a path that sequentially passes through the commutation-side diode 12 and the rectification-side diode 11 but follows a path C that passes through the choke coil 13 , the rectification-side diode 11 , and the tertiary coil N 3 , as shown in FIG. 6 . In the tertiary-side rectifying and smoothing circuit 10 , the detected voltage Vk during the period in which the main switching device Q is switched off is obtained by superimposing a voltage caused by applying current along the path B on a voltage caused by applying current along the path C.
[0016] During the aforementioned period in which the main switching device Q is switched off, the voltage Vout output from the secondary-side rectifying and smoothing circuit 5 to the load S is not affected by the voltage Vf generated in the secondary coil N 2 . In contrast, the detected voltage Vk output from the tertiary-side rectifying and smoothing circuit 10 is affected by the voltage V 3 of the tertiary coil N 3 due to the voltage Vf of the secondary coil N 2 . Thus, the correlation between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is broken.
[0017] That is to say, the correlation between the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 and the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 is weakened by a voltage V 2 given by the following expression:
[0000] V 2 =Vf ×( N 3 /N 2)×( Tcy/Tsw ).
[0018] Here, Vf is a forward drop-down voltage of the parasitic diode of the rectification-side synchronous rectifier 6 during the period in which the main switching device Q is switched off, N 2 is the number of turns of the secondary coil N 2 , N 3 is the number of turns of the tertiary coil N 3 , Tcy is the length of the transformer-excitation-current circulation period, and Tsw is the length of one switching cycle.
[0019] In the isolated DC-DC converter 1 having the circuitry shown in FIG. 6 , the length of the transformer-excitation-current circulation period depends on the magnitude of the input voltage Vin. Thus, a change in the input voltage Vin changes the relationship between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 . The forward drop-down voltage Vf of the diode increases as the environmental temperature becomes low and decreases as the environmental temperature becomes high. Accordingly, the relationship between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is changed by a change in the environmental temperature.
[0020] In this way, the relationship between the output voltage Vout and the detected voltage Vk is changed by a change in the input voltage Vin and a change in the environmental temperature. Thus, it is quite difficult to correct the detected voltage Vk so that the detected voltage Vk is proportional to the output voltage Vout. That is to say, in the circuitry of the isolated DC-DC converter 1 shown in FIG. 6 , it is quite difficult to achieve a completely proportional relationship between the output voltage Vout and the detected voltage Vk, and there is a problem such that satisfactory accuracy of the output voltage. Vout cannot be achieved. In particular, the ratio of the number of turns of the tertiary coil N 3 to the number of turns of the secondary coil N 2 (N 3 /N 2 ) has tended to increase recently. Accordingly, the correlation between the output voltage Vout and the detected voltage Vk has been weakened, and it is increasingly difficult to hold the range of variation in the output voltage Vout within a predetermined tolerance in an isolated DC-DC converter 1 that has a low output voltage Vout and is low-powered.
SUMMARY OF THE INVENTION
[0021] In order to overcome the problems described above, preferred embodiments of the present invention provide an isolated DC-DC converter which includes a transformer that includes a primary coil, a secondary coil, and a tertiary coil that are electromagnetically coupled, a main switching device that is provided on the side of the primary coil of the transformer and controls energy supplied from an external power supply to the primary coil by a switching operation to control a voltage generated in the primary coil, a secondary-side rectifying and smoothing circuit that rectifies and smoothes an output voltage from the secondary coil corresponding to the voltage of the primary coil of the transformer and outputs a rectified and smoothed voltage to the outside, a tertiary-side rectifying and smoothing circuit that rectifies and smoothes an output voltage from the tertiary coil to produce a direct-current voltage and detects and outputs the direct-current voltage as a detected voltage of the output voltage from the secondary-side rectifying and smoothing circuit, and a control circuit that controls the switching operation of the main switching device on the basis of the detected voltage output from the tertiary-side rectifying and smoothing circuit so that the output voltage from the secondary-side rectifying and smoothing circuit is stabilized. The secondary-side rectifying and smoothing circuit includes a rectification-side synchronous rectifier and a commutation-side synchronous rectifier that perform a switching operation in synchronization with the switching operation of the main switching device as rectifying devices that rectify the output voltage from the secondary coil, and the tertiary-side rectifying and smoothing circuit includes a commutation-side synchronous rectifier as a rectifying device that rectifies the output voltage from the tertiary coil, the commutation-side synchronous rectifier being switched on when the main switching device is turned off.
[0022] According to the present preferred embodiment, the tertiary-side rectifying and smoothing circuit includes a commutation-side synchronous rectifier (for example, a FET) that is switched on when the main switching device is turned off as a rectifying device that rectifies the output voltage from the tertiary coil. In the isolated DC-DC converter according to the present preferred embodiment, there is a period (a transformer-excitation-current circulation period) in which an excitation current for keeping energy excited by the transformer circulates around a path through the commutation-side synchronous rectifier and rectification-side synchronous rectifier of the secondary-side rectifying and smoothing circuit and the secondary coil during the period in which the main switching device is switched off. The commutation-side synchronous rectifier is provided as a rectifying device of the tertiary-side rectifying and smoothing circuit. Thus, during the transformer-excitation-current circulation period, a current caused by an induced voltage of the tertiary coil due to the application of the excitation current to the secondary coil circulates through the commutation-side synchronous rectifier of the tertiary-side rectifying and smoothing circuit and the tertiary coil and does not pass through to the output side of the tertiary-side rectifying and smoothing circuit. That is to say, the voltage of the tertiary coil is not involved in the detected voltage output from the tertiary-side rectifying and smoothing circuit to the control circuit during the transformer-excitation-current circulation period in which the main switching device is switched off.
[0023] That is to say, in the known configuration, the detected voltage from the tertiary-side rectifying and smoothing circuit includes a voltage component that breaks the correlation between the output voltage from the secondary-side rectifying and smoothing circuit and the detected voltage from the tertiary-side rectifying and smoothing circuit (i.e., a voltage component due to the induced voltage of the tertiary coil). In contrast, in the present preferred embodiment, the voltage component, which breaks the correlation, can be prevented from being included in the detected voltage from the tertiary-side rectifying and smoothing circuit. Thus, a satisfactory correlation between the output voltage from the secondary-side rectifying and smoothing circuit and the detected voltage from the tertiary-side rectifying and smoothing circuit can be achieved.
[0024] Thus, the output voltage from the secondary-side rectifying and smoothing circuit can be accurately controlled by the switching control of the main switching device of the control circuit based on the detected voltage from the tertiary-side rectifying and smoothing circuit. Accordingly, accuracy of the output voltage from the isolated DC-DC converter can be improved.
[0025] Other features, elements, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a circuit diagram showing main circuit components of an isolated DC-DC converter according to a first preferred embodiment of the present invention.
[0027] FIG. 2 is a graph illustrating an effect achieved by the configuration shown in FIG. 1 .
[0028] FIG. 3 is a circuit diagram showing main circuit components of an isolated DC-DC converter according to a second preferred embodiment of the present invention.
[0029] FIG. 4 is a circuit diagram showing main circuit components of an isolated DC-DC converter according to a third preferred embodiment of the present invention.
[0030] FIG. 5 is a circuit diagram showing main circuit components of an isolated DC-DC converter according to a fourth preferred embodiment of the present invention.
[0031] FIG. 6 is a circuit diagram showing main circuit components of a known isolated DC-DC converter.
[0032] FIG. 7 is a wave form chart illustrating an example of the circuit operation of the main circuit components of the isolated DC-DC converter shown in FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] Preferred embodiments according to the present invention will now be described on the basis of the drawings.
[0034] FIG. 1 shows main circuit components of an isolated DC-DC converter according to a first preferred embodiment. In the description of the first preferred embodiment, the same reference letters and numerals are assigned to the same components as in the isolated DC-DC converter shown in FIG. 6 , and a duplicate description of the common components is omitted.
[0035] In the first preferred embodiment, a synchronous rectifier (for example, a MOS-FET) 24 is provided in the tertiary-side rectifying and smoothing circuit 10 as a rectifying device on the commutation side. A driving circuit 25 that turns on and off the synchronous rectifier 24 is also provided. The driving circuit 25 has a configuration for switching off the commutation-side synchronous rectifier 24 when the main switching device Q is switched on and switching on the commutation-side synchronous rectifier 24 when the main switching device Q is switched off, using a voltage generated in the tertiary coil N 3 .
[0036] In the first preferred embodiment, components other than the aforementioned components are the same as those shown in FIG. 6 . In the first preferred embodiment, the commutation-side synchronous rectifier 24 is provided as the rectifying device on the commutation side of the tertiary-side rectifying and smoothing circuit 10 . Thus, when the main switching device Q is switched off and when the transformer excitation current is applied to the secondary coil N 2 (the transformer-excitation-current circulation period), the current due to the voltage V 3 of the tertiary coil N 3 corresponding to the voltage Vf of the secondary coil N 2 circulates through the commutation-side synchronous rectifier 24 , the rectification-side diode 11 , and the tertiary coil N 3 .
[0037] In the known configuration, the current due to the voltage V 3 of the tertiary coil N 3 passes through to the choke coil 13 side. Thus, an unnecessary voltage corresponding to the voltage V 3 of the tertiary coil N 3 is superimposed on the voltage due to the excitation energy of the choke coil 13 . Accordingly, the correlation between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is broken. The control circuit 20 has circuitry for performing control operation so that the detected voltage Vk is stabilized, assuming that the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 . Thus, the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is substantially stabilized by the control operation of the control circuit 20 as shown by solid line A in the graph of FIG. 2 even when the input voltage or the environmental temperature changes. However, in the known configuration, the correlation between the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 and the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 is broken. Thus, although the control circuit 20 performs control operation so that the output voltage Vout is stabilized, the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 is changed by a change in the input voltage and a change in the environmental temperature, as shown by dotted lines a to c in the graph of FIG. 2 .
[0038] In contrast, in the configuration of the first preferred embodiment, the current due to the voltage V 3 of the tertiary coil N 3 can be prevented from flowing into the choke coil 13 side during the transformer-excitation-current circulation period. Thus, a voltage component that breaks the correlation between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 (i.e., a voltage component due to the voltage V 3 of the tertiary coil N 3 corresponding to the voltage Vf of the secondary coil N 2 ) can be prevented from being included in the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 . Thus, a satisfactory correlation between the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 and the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 can be achieved. Thus, regardless of a change in the input voltage and a change in the environmental temperature, the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 and the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 can be stabilized by the control operation of the control circuit 20 assuming that the detected voltage Vk from the tertiary-side rectifying and smoothing circuit 10 is the output voltage Vout from the secondary-side rectifying and smoothing circuit 5 , as shown by solid lines A and B in the graph of FIG. 2 . Accordingly, accuracy of the output from the isolated DC-DC converter 1 can be improved.
[0039] A second preferred embodiment will now be described. In the description of the second preferred embodiment, the same reference letters and numerals are assigned to the same components as in the first preferred embodiment, and a duplicate description of the common components is omitted.
[0040] FIG. 3 shows main components of an isolated DC-DC converter according to the second preferred embodiment. In the second preferred embodiment, the synchronous rectifier 24 is provided as a rectifying device on the commutation side of the tertiary-side rectifying and smoothing circuit 10 , as in the first preferred embodiment. A primary coil 27 of a driving transformer 26 is provided on a current path from the control circuit 20 to the gate of the main switching device Q. A diode 28 is provided in parallel with the primary coil 27 .
[0041] The transformer 2 further includes a quartic coil N 4 . One end of the quartic coil N 4 is connected to the gate of the commutation-side synchronous rectifier 7 of the secondary-side rectifying and smoothing circuit 5 . A driving switch device (for example, a MOS-FET) 31 is provided on the side of the other end of the quartic coil N 4 . The drain, source, and control terminal (gate) of the driving switch device 31 are connected to the other end of the quartic coil N 4 , the source of the commutation-side synchronous rectifier 7 , and one end of a secondary coil 30 of the driving transformer 26 , respectively. The other end of the secondary coil 30 is connected to the source of the rectification-side synchronous rectifier 6 . A capacitor 32 is provided between the gate of the synchronous rectifier 6 of the secondary-side rectifying and smoothing circuit 5 and the secondary coil N 2 .
[0042] The driving transformer 26 further includes a tertiary coil 33 . The transformer 2 further includes a quintic coil N 5 . A driving switch device (for example, a MOS-FET) 34 is also provided. One end of the quintic coil N 5 is connected to the gate of the commutation-side synchronous rectifier 24 , and the other end of the quintic coil N 5 is connected to the drain of the driving switch device 34 . The source of the driving switch device 34 is connected to the source of the commutation-side synchronous rectifier 24 . The control terminal (gate) of the driving switch device 34 is connected to one end of the tertiary coil 33 . The other end of the tertiary coil 33 is connected to a connection portion between the source of the driving switch device 34 and the anode of the rectification-side diode 11 .
[0043] Components other than the aforementioned components in the second preferred embodiment are the same as those in the first preferred embodiment. An example of the circuit operation of the aforementioned circuit components in the second preferred embodiment will now be described. In the second preferred embodiment, an input capacitance of the commutation-side synchronous rectifier 7 is charged by a voltage induced by the quartic coil N 4 of the transformer 2 and is switched on during the period in which the main switching device Q is switched off. An input capacitance of the commutation-side synchronous rectifier 24 is also charged by a voltage induced by the quintic coil N 5 of the transformer 2 and is switched on.
[0044] For example, when the control circuit 20 outputs a turn-on signal for switching on the main switching device Q to the gate of the main switching device Q, the turn-on signal is applied to the primary coil 27 of the driving transformer 26 and an input capacitance of the main switching device Q. The charge of the input capacitance of the main switching device Q is started by this operation. The main switching device Q is turned on when the input capacitance of the main switching device Q has been charged in response to the turn-on signal output from the control circuit 20 . In the second preferred embodiment, the primary coil 27 of the driving transformer 26 is provided on a path for charging the input capacitance of the main switching device Q. Thus, the charge rate of the input capacitance of the main switching device Q is decreased, and the turn-on of the main switching device Q is delayed.
[0045] On the other hand, in the driving transformer 26 , the following voltage is induced by the secondary coil 30 due to the applied turn-on signal when the application of the turn-on signal output from the control circuit 20 to the primary coil 27 has started. That is to say, the voltage induced by the secondary coil 30 can turn on the driving switch device 31 by instantaneously charging an input capacitance of the driving switch device 31 when the application of the turn-on signal to the primary coil 27 has been started. The driving switch device 31 is turned on by the voltage induced by the secondary coil 30 just after the control circuit 20 starts to output the turn-on signal.
[0046] The electric charge in the input capacitance of the commutation-side synchronous rectifier 7 is discharged through the quartic coil N 4 and the driving switch device 31 by turning on the driving switch device 31 . The commutation-side synchronous rectifier 7 is switched off by this operation.
[0047] In the second preferred embodiment, the number of turns of the primary coil 27 of the driving transformer 26 and the like are designed so that the charge of the input capacitance of the main switching device Q is not completed when the commutation-side synchronous rectifier 7 has been switched off. Thus, the commutation-side synchronous rectifier 7 of the secondary-side rectifying and smoothing circuit 5 is switched off during a period for charging the input capacitance between the time when the control circuit 20 starts to output the turn-on signal and the time when the input capacitance of the main switching device Q is charged to turn on the main switching device Q, i.e., before the main switching device Q is turned on.
[0048] The commutation-side synchronous rectifier 24 of the tertiary-side rectifying and smoothing circuit 10 is also turned off as in the aforementioned case before the main switching device Q is switched on. That is to say, when the control circuit 20 starts to output the turn-on signal to the main switching device Q and when the turn-on signal is applied to the primary coil 27 of the driving transformer 26 , a voltage is induced in the tertiary coil 33 of the driving transformer 26 due to the applied turn-on signal. The charge of an input capacitance of the driving switch device 34 is instantaneously completed by this induced voltage, and the driving switch device 34 is switched on. Then, the electric charge in the input capacitance of the commutation-side synchronous rectifier 24 is discharged through the quintic coil N 5 and the driving switch device 34 . The commutation-side synchronous rectifier 24 is switched off by this operation before the main switching device Q is turned on.
[0049] That is to say, in the second preferred embodiment, the driving transformer 26 , the driving switch device 31 , and the path of the driving switch device 31 for discharging the electric charge in the input capacitance define an early-turn-off circuit of the commutation-side synchronous rectifier 7 of the secondary-side rectifying and smoothing circuit 5 . Moreover, the driving transformer 26 , the driving switch device 34 , and the path of the driving switch device 34 for discharging the electric charge in the input capacitance define an early-turn-off circuit of the commutation-side synchronous rectifier 24 of the tertiary-side rectifying and smoothing circuit 10 .
[0050] In the second preferred embodiment, the early-turn-off circuits are provided, which switch off the commutation-side synchronous rectifier 7 of the secondary-side rectifying and smoothing circuit 5 and the commutation-side synchronous rectifier 24 of the tertiary-side rectifying and smoothing circuit 10 before the main switching device Q is turned on. Thus, since the commutation-side synchronous rectifiers 7 and 24 have been already switched off when the main switching device Q is turned on, various types of problems due to the delayed turn-off of the commutation-side synchronous rectifiers 7 and 24 , for example, a decrease in the circuit efficiency, can be prevented.
[0051] A third preferred embodiment will now be described. In the description of the third preferred embodiment, the same reference letters and numerals are assigned to the same components as in the first and second preferred embodiments, and a duplicate description of the common components is omitted.
[0052] In the third preferred embodiment, a rectification-side synchronous rectifier (for example, a MOS-FET) 36 is provided as a rectifying device on the rectification side of the tertiary-side rectifying and smoothing circuit 10 , as shown in FIG. 4 . The gate of the rectification-side synchronous rectifier 36 is connected to the tertiary coil N 3 via a capacitor 37 . The rectification-side synchronous rectifier 36 is switched on due to a voltage of the tertiary coil N 3 during the period in which the main switching device Q is switched on, and the rectification-side synchronous rectifier 36 is switched off during the period in which the main switching device Q is switched off.
[0053] Components other than the aforementioned components are the same as those in the second preferred embodiment. In the third preferred embodiment, a synchronous rectifier is used not only as the rectifying device on the commutation side of the tertiary-side rectifying and smoothing circuit 10 but also as the rectifying device on the rectification side of the tertiary-side rectifying and smoothing circuit 10 . Thus, a discontinuous current mode can be eliminated from the tertiary-side rectifying and smoothing circuit 10 . Thus, a choke coil that has a small inductance can be provided as the choke coil 13 , which defines the tertiary-side rectifying and smoothing circuit 10 , without consideration of the occurrence of the discontinuous current mode. Accordingly, the cost of the choke coil 13 of the tertiary-side rectifying and smoothing circuit 10 can reduced. Moreover, since the incidence of damage to the choke coil 13 can be reduced, the reliability of the choke coil 13 can be improved.
[0054] A fourth preferred embodiment will now be described. In the description of the fourth preferred embodiment, the same reference letters and numerals are assigned to the same components as in the first to third preferred embodiments, and a duplicate description of the common components is omitted.
[0055] In the fourth preferred embodiment, the choke coil 13 of the tertiary-side rectifying and smoothing circuit 10 is provided between the drain (the positive electrode) of the commutation-side synchronous rectifier 24 and the capacitor 14 , as shown in FIG. 5 . The circuit configuration can be simplified by using this configuration for the following reason.
[0056] That is to say, for example, when the choke coil 13 is provided between the source (the negative electrode) of the commutation-side synchronous rectifier 24 and the capacitor 14 , as shown in FIG. 4 , the source of the driving switch device 34 and the source of the rectification-side synchronous rectifier 36 are connected to a portion between the tertiary coil N 3 and the choke coil 13 . Thus, the potentials of the individual sources of the driving switch device 34 and the rectification-side synchronous rectifier 36 depend on a change in the voltage of the tertiary coil N 3 . In the circuitry shown in FIG. 4 , a configuration for controlling the switching operation of the driving switch device 34 and the rectification-side synchronous rectifier 36 is provided with consideration of variation in the potentials of the individual sources of the driving switch device 34 and the rectification-side synchronous rectifier 36 . That is to say, the driving transformer 26 includes the tertiary coil 33 for controlling the switching operation of the driving switch device 34 , and the tertiary coil 33 is provided in parallel between the gate and source of the driving switch device 34 . The switching operation of the driving switch device 34 is controlled by a voltage generated in the tertiary coil 33 . The capacitor 37 is provided on a conduction path from the tertiary coil N 3 to the gate of the rectification-side synchronous rectifier 36
[0057] In contrast, since the choke coil 13 is provided on the side of the positive electrode in the fourth preferred embodiment, as described above, the individual sources of the driving switch device 34 and the rectification-side synchronous rectifier 36 are directly grounded. Thus, the potentials of the individual sources of the driving switch device 34 and the rectification-side synchronous rectifier 36 are stabilized at a ground potential. Accordingly, circuitry for controlling the switching operation of the driving switch device 34 and the rectification-side synchronous rectifier 36 can be provided without consideration of variation in the potentials of the individual sources of the driving switch device 34 and the rectification-side synchronous rectifier 36 . That is to say, in the fourth preferred embodiment, the tertiary coil 33 of the aforementioned driving transformer 26 and the capacitor 37 are eliminated. Moreover, the gate of the driving switch device 34 and the gate of the rectification-side synchronous rectifier 36 are connected to an output portion that outputs a switching control signal from the control circuit 20 to the main switching device Q.
[0058] In this configuration, the same signal as the switching control signal output from the control circuit 20 to the main switching device Q is applied to the gate of the driving switch device 34 and the gate of the rectification-side synchronous rectifier 36 . Thus, the rectification-side synchronous rectifier 36 is switched on when the main switching device Q is switched on, and the rectification-side synchronous rectifier 36 is switched off when the main switching device Q is switched off. In the circuitry of the fourth preferred embodiment, the driving transformer 26 is provided on a conduction path of a signal from the control circuit 20 to the main switching device Q, as in the second and third preferred embodiments. Thus, when the control circuit 20 outputs the turn-on signal (the switching control signal) for switching on the main switching device Q, the main switching device Q is not immediately turned on, and the turn-on of the main switching device Q is delayed. In contrast, the turn-on signal is directly applied to the gate of the driving switch device 34 . Thus, the driving switch device 34 is switched on before the main switching device Q is turned on. Accordingly, the commutation-side synchronous rectifier 24 is switched off during the period between the time when the control circuit 20 outputs the turn-on signal and the time when the main switching device Q is turned on.
[0059] Components other than the aforementioned components in the fourth preferred embodiment are the same as those in the third preferred embodiment. Since the tertiary coil 33 of the driving transformer 26 and the capacitor 37 can be eliminated in the fourth preferred embodiment, circuitry that is simple compared with that of the third preferred embodiment can be achieved. Moreover, since the parts costs can be reduced, the cost of the isolated DC-DC converter can be reduced.
[0060] The present invention is not limited to the first to fourth preferred embodiments, and can be implemented in various preferred embodiments. For example, in the third and fourth preferred embodiments, examples of circuit configurations have been described, in which the commutation-side synchronous rectifier 24 and the rectification-side synchronous rectifier 36 are respectively provided as the commutation-side device and rectification-side device of the tertiary-side rectifying and smoothing circuit 10 in an isolated DC-DC converter that includes the early-turn-off circuit. Alternatively, the commutation-side synchronous rectifier 24 and the rectification-side synchronous rectifier may be respectively provided as the commutation-side device and rectification-side device of the tertiary-side rectifying and smoothing circuit 10 in an isolated DC-DC converter that does not include the early-turn-off circuit.
[0061] The isolated DC-DC converters according to the preferred embodiments have excellent stability of the output voltage. Thus, the isolated DC-DC converter can be effectively used in a configuration in which the isolated DC-DC converter is connected to a circuit that requires a stabilized voltage.
[0062] While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims. | A secondary-side rectifying and smoothing circuit rectifies and smoothes an output voltage from a secondary coil of a transformer and outputs a rectified and smoothed voltage to the outside. A tertiary-side rectifying and smoothing circuit rectifies and smoothes an output voltage from a tertiary coil to produce a direct-current voltage and detects and outputs the direct-current voltage as a detected voltage of the output voltage from the secondary-side rectifying and smoothing circuit. A control circuit controls the switching operation of a main switching device on the basis of the detected voltage so that the output voltage is stabilized. The secondary-side rectifying and smoothing circuit includes a rectification-side synchronous rectifier and a commutation-side synchronous rectifier as rectifying devices. The tertiary-side rectifying and smoothing circuit includes a commutation-side synchronous rectifier as a rectifying device that rectifies the output voltage from the tertiary coil, the commutation-side synchronous rectifier being switched on when the main switching device is turned off. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods of stabilizing traumatized teeth and more particularly to a system and method for reimplanting and stabilizing avulsed teeth using a dental splint that removably engages the dental arcade from where the tooth was avulsed.
2. Description of the Prior Art
Tooth avulsion occurs when an entire tooth is forcefully dislodged from its socket. This type of traumatic injury is quite common, especially among children. While it is possible to save an avulsed tooth, a rapid response with proper procedures and tooth care is crucial. If the periodontal membrane of an avulsed tooth has not been substantially damaged, and if the cells are still alive, the tooth can many times be successfully reimplanted in the socket. Several days must pass before the tooth can have a chance to naturally reaffix to the socket. Accordingly, several attempts at providing systems for stabilizing the traumatized tooth have been developed. However, these attempts have provided mixed results and require procedures that are not easily implemented by emergency medical personnel within the narrow opportunity for reimplanting the tooth.
One prior art dental splint is disclosed within U.S. Pat. No. 3,337,957. That particular device teaches the attachment of a plurality of separate plates to the labial surfaces of the crown portions of the traumatized tooth and the teeth on either side thereof. Each of the plates are provided with outwardly extending T-shaped lugs that are imbedded into an arched bar or wire, which secures the separate plates and the adjacent teeth to one another. Ligature wires are used to couple the plates to the individual teeth. Wire must be passed around each tooth and then twisted closed into a secure position. This prior art system is too complex and cumbersome for most emergency medical personnel to implement in the field or in an emergency room setting. Moreover, the system depends upon well-anchored adjacent teeth and does not easily lend itself to a situation where a plurality of teeth from a single location of the dental arcade are avulsed at once. Moreover, such a system may anchor a single avulsed tooth in a manner that prohibits even the slightest movement with respect to the socket and adjoining teeth. Unfortunately, minor amounts of movement can be important for promoting the healing process, favoring ligament growth and inhibiting bone tissue development adjacent the root.
A slightly improved but similar system is taught within U.S. Pat. No. 5,087,202. The system is comprised of a plurality of individual rings that are cemented to the crown of the avulsed tooth and the adjacent teeth. Elongated connecting bars are secured to the individual rings, locking the adjoined teeth to one another in a stable position. While this system is less labor intensive than previous systems, it still suffers from the shortcomings experienced previously, such as over-immobilization of the teeth, and providing an undesirable level of technical involvement between emergency medical personnel and the avulsed teeth.
Accordingly, what is needed is a system and method for reimplanting avulsed teeth that may be quickly and easily used by emergency medial personnel without complex and laborious custom fitting procedures. However, such a system and method should adequately stabilize the avulsed teeth, without over-immobilization of the same.
SUMMARY OF THE INVENTION
The system and method for reimplanting one or more avulsed teeth of the present invention is provided with a dental splint that is releasably secured to the dental arcade from which the teeth were avulsed. Once the avulsed teeth are reinserted into their respective sockets, the dental splint may be applied. A first surface of the dental splint is provided with a channel that is generally shaped and sized to releasably receive at least a portion of the dental arcade. The dental splint is retained in position until a generally firm reattachment of one or more of the avulsed teeth occurs. The dental splint is provided to be worn continuously, including those periods which involve eating, drinking and sleeping.
In a preferred embodiment, the dental splint is constructed to engage only one of the upper or lower arcades of teeth. The channel of the dental splint should be preformed to approximate a wide range of individuals. The channel should also be formed to extend a sufficient distance along the labial or buccal and lingual surfaces of the teeth in order to provide a position that is sufficiently secure to permit the user to eat and drink while wearing the dental splint without unintentionally uncoupling the same from the dental arcade. Where the user will not generally be able to apply periodic pressure to the dental splint, whether due to age or incapacity, a temporary dental adhesive may be applied within the channel to adhere the dental splint to the teeth.
In one preferred embodiment, a second surface of the dental splint, opposite the channel, is provided with a plurality of facets that face in a plurality of different directions so that an irregular surface is provided. The irregular surface may be shaped to generally mimic masticatory surfaces of teeth in order to enable a user to more easily chew food while the dental splint is being worn. In still another embodiment, the second surface of the dental splint may be comprised of a generally rigid material while the first surface and channel may be comprised of a generally resilient material. This configuration may provide a wider range of fitting opportunities for different individuals as well as provide a snug, custom fit.
It is therefore a principle object of the present invention to provide a method for reimplanting one or more avulsed teeth that incorporates the use of a removable dental splint.
A further object of the present invention is to provide a method for reimplanting one or more avulsed teeth that incorporates the use of a dental splint having a preshaped channel that can fit a wide array for different users.
Still another object of the present invention is to provide a method for reimplanting one or more avulsed teeth that incorporate the use of a dental splint which covers a substantial portion of a single dental arcade from which the one or more avulsed teeth originated.
Yet another object of the present invention is to provide a method for reimplanting one or more avulsed teeth that incorporates the use of a dental splint having an outwardly facing surface that is shaped to provide masticatory surfaces that may be used for chewing food.
A further object of the present invention is to provide a method for reimplanting one or more avulsed teeth that incorporates the use of a dental splint which covers a substantial portion of a dental arcade and uses a resilient upper layer that releasably engages the dental arcade.
Still another object of the present invention is to provide a method for reimplanting one or more avulsed teeth that may be quickly and easily implemented by emergency medical professionals or the injured individual.
Yet another object of the present invention is to provide a system for reimplanting one or more avulsed teeth that is relatively simple and inexpensive to manufacture.
These and other objects of the present invention will be apparent to those having skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of one preferred embodiment of the dental splint of the present invention;
FIG. 2 is a partial, side elevation view of one embodiment of the dental splint of the present invention as the same may be positioned for use with a dental arcade having an avulsed tooth;
FIG. 3 is a partial, side elevation view of the dental splint of FIG. 2 as the same may be coupled with the dental arcade;
FIG. 4 is an isometric view of one embodiment of the dental splint of the present invention and one manner in which it might be used;
FIG. 5 is an isometric view of another embodiment of the dental splint of the present invention;
FIG. 6 is a partial, side elevation view of another embodiment of the dental splint of the present invention as the same may be positioned for use with a dental arcade having an avulsed tooth;
FIG. 7 is a partial, side elevation view of the dental splint of FIG. 6 as the same may be coupled with the dental arcade; and
FIG. 8 is a bottom isometric view of still another embodiment of the dental splint of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following detailed description of exemplary embodiments, reference is made to accompanying FIGS. 1-8 , which form a part hereof and show, by way of illustration, exemplary embodiments of the present invention. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other embodiments may be utilized, however, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims.
In a preferred embodiment, the method for reimplanting one or more avulsed teeth of the present invention is first provided with an avulsed tooth that remains a viable candidate for reimplantation. Preferably, the avulsed tooth has no substantial damage, particularly to the periodontal membrane and the root. It is contemplated that the reimplantation will be attempted within moments of the tooth becoming avulsed or within a couple of hours thereafter. While it is possible to reimplant a tooth that is properly cared for several hours after the initial injury, the chances for success decrease rapidly as time progresses. After proper inspection of an avulsed tooth 2 , it may be reinserted within the socket 4 of the dental arcade 6 from which it came. Depending upon the condition of the socket 4 and the bone adjacent thereto, the avulsed tooth 2 should encounter slight resistance before “clicking” into place.
In a preferred embodiment, a dental splint 10 is provided for stabilizing the avulsed tooth 2 . While the dental splint 10 will be described herein as it could be used with a single avulsed tooth, the dental splint 10 may be used for the simultaneous reimplantation of a plurality of teeth, whether the teeth adjoin one another or are spaced from one another. The dental splint 10 should be formed to have a first surface 12 having a channel 14 formed therein. As depicted in FIG. 1 , the channel 14 should be shaped and sized to releasably receive at least a portion of an upper or lower arcade of teeth that includes the avulsed tooth 2 . Accordingly, the channel 14 may be provided in a generally U-shape, depending upon the total area of the dental arcade that will be engaged with the dental splint 10 . Generally opposite side walls are provided, consisting of a forward wall 16 that engages the lingual or buccal surfaces of the teeth and a rearward wall 18 that engages the lingual surface of the teeth. A bottom wall 20 extends between lower end portions of the forward wall 16 and rearward wall 18 , engaging the masticatory surfaces of the teeth. It is contemplated that the dental splint 10 may be formed to engage substantially all of the dental arcade or only a portion thereof.
In one preferred embodiment, the dental splint 10 is fabricated from a generally rigid material that is appropriate for temporary use within a patient's mouth for a week or longer. Accordingly, several polymers, such as polypropylene, polyethylene and polyvinalchloride may be used. It is contemplated that the dental splint 10 will be provided in a plurality of different sizes that will closely fit individuals of various ages and having various sizes of dental arcades. Accordingly, the dental splints may be precast from several different size models. Preferably, the generalized fit will be such that at least one of a plurality of different sizes will fit the dental arcade of a particular individual in a manner that provides a secure frictional engagement between the channel 14 and the crowns of the individual teeth. In a preferred embodiment, the dental splint 10 is provided to engage only a single arcade of teeth, permitting the individual to eat and drink while the dental splint 10 is engaged with the dental arcade. While the dental splint 10 should be removably engaged with the dental arcade, it is contemplated that blood and foreign debris may become packed within small crevices of the channel 14 around the individual teeth and in particular the avulsed tooth 2 . Therefore, if an individual were to attempt to remove a dental splint that covered both the upper and lower dental arcades simultaneously, the avulsed tooth 2 may be extracted from the socket 4 , being cemented within the channel 14 by the blood and foreign debris.
In another embodiment, depicted in FIGS. 6 and 7 , the dental splint 10 may be formed to have at least two layers of different materials. A second surface 22 may be substantially comprised of a generally rigid material, such as a polymer of the types discussed previously herein. This generally rigid material will form a base layer 24 and may extend upwardly along the forward wall 16 and rearward wall 18 . It is further contemplated that the base layer 24 may form a portion of the bottom wall 20 . The first surface 12 of the dental splint 10 is comprised of a layer of deformably resilient material and defines a substantial portion of the groove 14 . In this particular embodiment, the channel 14 will be simply viewed as a narrow slit when the dental splint 10 is not in use. When the dental splint 10 is engaged with the dental arcade, however, the resilient material will provide an engagement layer 26 that will closely conform to the shape of the individual teeth within the dental arcade. The resilient nature of the material will apply a slight gripping pressure on the surfaces of the teeth. Having the channel 14 formed into the engagement layer 26 will substantially prevent the layer of resilient material from pushing the dental splint 10 off of the dental arcade. It is contemplated that several different known materials may be used for the engagement layer 26 . For example, different closed-cell foams of various rigidity or a resiliently deformable polymer or resin based material will be sufficient for most applications. The resilient material will permit the avulsed tooth 2 to move slightly in response to minor movements of the dental splint 10 , thereby assisting in the healing of the area and the reimplantation of the tooth without permitting excessive movement.
It is contemplated that situations may arise where, due to the age or physical condition of the individual, the individual may have difficulty maintaining the dental splint 10 in an engaged position with the dental arcade 6 . Accordingly, a temporary dental adhesive 30 may be applied between the dental arcade 6 and the channel 14 . It is preferred, however, that the adhesive be applied to those areas of the channel 14 that will not come into contact with the avulsed tooth 2 . Even after a generally firm reattachment of the avulsed tooth 2 is achieved, removal of the dental splint 10 , with the avulsed tooth 2 adhered thereto, may cause the unwanted loosening or extraction of the avulsed tooth 2 .
In still another embodiment of the dental splint 10 , the second surface 22 may be provided with a plurality of facets 28 that are shaped and positioned to face in different directions. By arranging the facets 28 in this manner and allowing the edges of the facets to form generally pointed ridges, the second surface 22 may be shaped to generally mimic masticatory surfaces of teeth within a dental arcade. Accordingly, the facets 28 will provide the user with some assistance in eating while wearing the dental splint 10 . It is contemplated that the facets may be formed along substantial portions of the second surface 22 or only in certain locations as depicted in FIG. 8 .
Regardless of the embodiment of dental splint 10 worn by the user, it will be preferred that the user wear the dental splint 10 continuously for a period of at least 7-10 days. Of course this duration will vary from individual to individual and from injury to injury. However, it is contemplated that the present invention will be used and practiced contemporaneously with the care and treatment of the user's dentist. The dental splint 10 may be removed after routine examination of the dental splint 10 has indicated that the avulsed tooth has attained a generally firm reattachment. However, if a period of 10 or more days passes and the avulsed tooth 2 has not attained a generally firm reattachment, reimplantation of the avulsed tooth 2 may not be possible.
In the drawings and in the specification, there have been set forth preferred embodiments of the invention and although specific items are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and proportion of parts, as well as a substitution of equivalents, are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
Thus it can be seen that the invention accomplishes at least all of its stated objectives. | A system for reimplanting avulsed teeth includes a dental splint having a pre-shaped channel that releasably engages a dental arcade having one or more avulsed teeth. The avulsed teeth are reinserted into their sockets and the dental splint is positioned over the dental arcade. The dental splint is worn continuously until reattachment is substantially attained. One embodiment provides masticatory surfaces to the dental splint that assist a user in eating while wearing the dental splint. Another embodiment provides a resilient layer to an engagement surface of the dental splint, which conforms to and engages the dental arcade. Adhesives may be disposed between the dental splint and the dental arcade when necessary. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 09/407,658, filed Sep. 28, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to treating body tissue, particularly to treating body tissue by altering the shape, density, relative geometry or tension of that body tissue using energy or substances deployed from an interstitial location in the body.
[0004] 2. Related Art
[0005] Urinary incontinence results from a number of factors. Increasing age, injury from childbirth and related stresses can cause the relative tone of the bladder and accessory muscles to weaken, which, in turn, causes an impaired inability to retain urine. Weight gain and overall deterioration of muscle tone can cause increased abdominal pressure which overcomes sphincter resistance. Nerve pathways that cause the “urge” to urinate can be hyperactive. The relative tension of the urethra can change with age, causing poor urinary control. Injury to the detrusor muscles or to the trigone area also results in impaired urinary continence.
[0006] These factors do not usually occur by themselves. The typical patient usually presents with two or more of them. Therefore, it is desirable to provide a treatment that can address many of these factors.
[0007] Given the complex etiology of varied causal factors, the ideal treatment for urinary incontinence requires a device that can perform many different functions. For example, a treatment for female urinary incontinence might rely upon some or all of the following:
[0008] (1) reshaping the bladder to alter the urethro-vesical angle and re-suspend the bladder neck, (2) manipulation of the detrusor muscles, (3) mapping and modulating nervous pathways responsible for urinary urgency, (4) reducing strain on he bladder neck by changing the structural geometry, (5) shrinking discrete and non-discrete areas of the bladder by creating thermal lesions, (6) three-dimensional modeling of tissue by adding bulk so as to achieve better closure, (7) strengthening the structure integrity of a tissue by providing a pattern of scar tissue, and (8) application of pharmaceutical agents both as a curative and to promote healing post treatment.
[0009] The use of a catheter to apply radio frequency (RF) and other types of energy to ablate tissue in the body (such as heart muscle tissue) is known in the art of cardiac treatment. However, known systems using RF and other types of energy are still subject to several drawbacks.
[0010] A first problem in the known art involves providing a device that can perform all of the aforementioned functions. While known systems can perform one or more of these functions, nothing in the related art is capable of performing all of these functions. Patients are frequently required to return for multiple treatments until a cure is finally effected.
[0011] A second problem in the known art involves identification, modulation and/or stimulation of nerves in a targeted tissue. Known systems do not provide for protection of sensitive nerves during treatment or allow nerves during treatment or allow nerves to be identified and stimulated. This is particularly problematic because many tissue disorders, especially those involving tone or contractile ability of a sphincter, arise from afferent and efferent nerves are either under-stimulated or over-stimulated.
[0012] A third problem in the known art involves providing a treatment surface that can reach all of the desired treatment areas, such as the entire surface of the detrusor muscles. While the use of a catheter to deploy energy is known, none is disposed to flexibility adapt to the interior shape of an organ so as to provide optimal uniform treatment.
[0013] A fourth problem is the known art involves removal of tissue and substances used in treatment. Known systems do not provide for removal of excess substances used in treatment such as cooling fluids, collagen or bulking substances. Similarly, known systems do not provide for removal of substances that hinder or otherwise obstructs the healing process such as pus, purulent discharges, suppuration and pockets of infection.
[0014] A fifth problem in the known art involves directing and positioning the electrodes in the body cavity orifice. Difficulties in accurately positioning the electrodes in the target orifice detract from treatment. Frequently; unhealthy tissue remains untreated while healthy tissue is compromised. Difficulties in directing and positioning the electrodes are particularly problematic because one of the goals of treatment is to minimize collateral damage to healthy tissue and to completely treat diseased tissue.
[0015] A sixth problem in the known art involves minimizing thermal injury to the patient. Some known systems rely upon simultaneous application of energy and infusion of a cooling liquid into the targeted area for treatment. While such infusion of liquid minimizes thermal injury to the patient, it is not applicable to all parts of the body. For example, infusion of cooling liquids into an internal body cavity such as a bladder, uterus, or stomach can rupture the targeted organ or cause osmotic imbalance within the tissue.
[0016] A seventh problem in the known art involves difficulty in the simultaneous use of complimentary technology. Known systems do not provide for optimal, simultaneous use of auxiliary tools for visualization, monitoring pH and pressure or drug administration.
[0017] An eighth problem in the known art is that it can be difficult to block the flow of body fluids and gases into an area of the body where tissue ablation is taking place. Bodily fluids can dissipate and detrimentally absorb the energy to be applied to the tissue to be ablated. Dissipation of bodily fluids detracts from the goal of treatment of diseased tissue.
[0018] Accordingly, it would be advantageous to provide a method and apparatus for treatment or body structures, especially internal body structures involving unwanted features or other disorders, that does not require relatively invasive surgery, and is not subject to other drawbacks noted with regard to the known art. This advantage is achieved in an embodiment of the invention in which a relatively minimally invasive catheter is inserted into a body, a variety of different treatments of the body structures is applied using electrodes and a cooling element, and the unwanted features or disorders are relatively cured.
SUMMARY OF THE INVENTION
[0019] The invention provides a method and system for treating disorders of the genitourinary tract and other disorders in other parts of the body. A particular treatment can include one or more of, or some combination of ablation, nerve modulation, three-dimensional tissue shaping, drug delivery, mapping, stimulating, shrinking (by creation of a pattern of thermal lesions) and reducing strain on structures by altering the geometry thereof and providing bulk to particularly defined regions.
[0020] The particular body structures or tissues can include one or more of, or some combination of regions, including the bladder, esophagus, vagina, penis, larynx, pharynx, aortic arch, abdominal aorta, thoracic aorta, large intestine, small intestine, sinus, auditory canal, uterus, vas deferens, trachea and all associated sphincters.
[0021] In one aspect of the invention, a catheter is deployed in the body. It may enter the body via orifice, a stoma, or surgically created opening that is made for the purpose of inserting the catheter. Insertion may be facilitated with the use of a guide or wire or a generic support structure or visualization apparatus.
[0022] In a second aspect of the invention, the treatment can include application of energy and substances to effect changes in the target tissue. Types of energy that can be applied include radio frequency, laser, microwave, infrared waves, ultrasound or some combination thereof. Types of substances that can be applied include pharmaceutical agents such as analgesics, antibiotics and anti-inflammatory drugs, bulking agents such as biologically nonreactive particles, cooling fluids, and dessicants such as liquid nitrogen for use in cryo-based treatments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a block drawing of a system for treatment of female urinary incontinence using a first device;
[0024] [0024]FIG. 2 is a process flow drawing of a method for treatment of female incontinence using a first device;
[0025] [0025]FIG. 3 is a block drawing of a system for treatment of female urinary incontinence using a second device;
[0026] [0026]FIG. 4 is a process flow drawing of a method for treatment of female urinary incontinence using a second device;
[0027] [0027]FIG. 5 is a block drawing of system for treatment of female urinary incontinence using a third device; and
[0028] [0028]FIG. 6 is a flow drawing of a method for treatment of female urinary incontinence using a third device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] In the following description, a preferred embodiment of the invention is described with regard to referred process steps and data structures. Embodiments of the invention can be implemented using general-purpose processors or special purpose processors operating under program control, or other circuits, adapted to particular process steps and data structures described herein. Implementation of the process steps and data structures described herein would not require undue experimentation or further invention.
[0030] System Elements
[0031] [0031]FIG. 1 is block drawing of a system for treatment of female urinary incontinence using a first device.
[0032] A system 100 includes a catheter 110 , a treatment element 114 , a control assembly 130 and a shielding element 140 . In an alternate embodiment, the shielding element 140 is not present.
[0033] The Catheter
[0034] The catheter 110 includes a distal segment 111 and a proximal segment 112 The distal segment 111 and proximal segment 112 form one continuous piece. Two or more lumens 113 (not shown) run the entire interior length of the catheter 110 and are coupled to the control assembly 140 . It is through these lumens 113 that energy is conducted and flowable substances are exuded.
[0035] The distal segment 111 includes a treatment element 114 and a tapered tip 115 . In a preferred embodiment, the tapered tip 115 is rigid so as to allow easy insertion into a urethra. In other preferred embodiments, the tapered tip 115 may be of varying degrees of flexibility depending where it is in the body it is deployed. In alternative embodiments, the catheter 110 may be introduced into the target tissue using an introducer sheath 116 or guide wire 117 (not shown). The most distal end of the tapered tip 115 includes an aperture 118 . Substances that flow through the lumens 113 may be applied to the tissue through this aperture 118 .
[0036] In the preferred embodiment, the distal segment 111 is disposed for insertion into a cavity of the body such as a female urethra and bladder. In alternative embodiments, the cavity may include one or more of, or some combination of the following:
[0037] any portion of the bronchial system, the cardiovascular system, the genito-urinary tract, the lymphatic system, the pulmonary system, the vascular system, the locomotor system, the reproductive system or other systems in the body; any biological conduit or tube, such as a biologic lumen that is patent or one that is subject to a stricture;
[0038] any biologic operational structure, such as a gland, or a muscle or other organ (such as the colon, the diaphragm, the heart, a uterus, a kidney, a lung, the rectum an involuntary or voluntary sphincter);
[0039] any biologic structure, such as a herniated body structure, a set of diseased cells, a set of dysplastic cells, a surface of a body structure, (such as the sclera) a tumor, or a layer of cells (such as fat muscle or skin); and
[0040] any biologic cavity or space or the contents thereof, such as a cyst, a gland, a sinus, a layered structure, or a medical device implanted or inserted into the body.
[0041] The Treatment Element
[0042] The treatment element 114 includes a set of curvilinear electrodes 119 and three sets of irrigation and aspiration ports 124 .
[0043] The electrode 119 contained in the set of electrodes are evenly spaced around the tapered tip 115 . Each electrode 119 includes a metallic tube 120 defining a hollow lumen 121 and is disposed so that it curves away from the tapered tip 115 and has a barbed end, much like a fishhook. Being arced in this direction allows the device to be inserted easily into an orifice without causing unintended tissue damage. Once the device is inserted, the barbed ends of electrodes 119 grab the tissue of the bladder neck and upper urethra in a claw-like manner and bunch it together. Energy is delivered through the electrodes to the bunched tissue, causing shrinkage to occur in the area surrounding the treatment element 114 . This three dimensional shaping improves continence by improving the structural integrity of the tissue.
[0044] In a preferred embodiment, there are four electrodes 119 . Other preferred embodiments may have more or less than four electrodes. Each electrode 119 is coupled to at least one sensor 122 capable of measuring such factors as temperature, conductivity, pressure, impedance and other variables. In a preferred embodiment, each electrode is also coupled to a radiopaque marker 123 for use in fluoroscopic visualization.
[0045] In a preferred embodiment, the electrodes 119 can be operated separately or in combination with each other. Treatment can be directed at a single area or several different areas of a bladder or other orifice by operation of selective electrodes. Different patterns of sub-mucosal lesions, mucosal lesions, ablated, bulked, plumped desiccated or necrotic regions can be created by selectively operating different electrodes. Production of different patterns of treatment makes it possible to remodel tissues and alter their overall geometry with respect to each other.
[0046] Each electrode 119 can be disposed to treat tissue by delivering one or more of, or some combination or any of the following in either a unipolar or bipolar mode:
[0047] Radiofrequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0048] Chemical treatments, such as acids, antibiotics enzymes, radioactive tracers or other bioactive substances;
[0049] Infrared energy, such as from an infrared laser or diode laser;
[0050] Microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0051] Sonic energy, including ultrasound;
[0052] Photodynamic therapy (PDT)
[0053] Non-infrared laser energy
[0054] Cryothermia
[0055] In addition to treating tissues by delivering energy, the set of electrodes 119 are disposed to delivery at least one flowable substance to the area of the body where treatment is to take place. In a preferred embodiment, the flowable substance includes water which aids in cooling of body structures during RF application. However, in alternative embodiments, the deliverable flowable liquids include other substances, including saline, anesthetic drugs, anti-inflammatory agents, chemotherapeutic agents, systemic or topical antibiotics, collagen and radioactive substances such as labeled tracers. In one alternative embodiment, saline is used to increate the local conductivity of tissue, enhancing the penetration of RF energy so as to create larger lesions. The saline can be delivered through the needle submucosally so as to achieve greatest effect.
[0056] Three rings of irrigation and aspiration ports 124 circle the distal end of the catheter 110 . Each ring contains numerous irrigation and aspiration ports 124 , evenly distributed around the width of the catheter. One ring of irrigation and aspiration ports 124 lies between the aperture 118 and the set of electrodes 119 ; the other two rings of irrigation and aspiration ports 124 are located on the proximal side of the electrodes 119 . Application of positive pressure makes irrigation and cooling of tissues is possible. Alternatively, application of negative pressure causes the tissue to be uniformly conformed around the treatment element 114 , thereby achieving the most optimal therapeutic value of the energy and substances.
[0057] The Control Assembly 130
[0058] The control assembly 130 includes a visualization port 131 , an apparatus port 132 , an electrical energy port 133 , an electrode selection and control switch 134 , one or more irrigation and aspiration control ports 135 , an therapeutic energy port 136 and a handle 137 .
[0059] The visualization port 131 can be coupled to visualization apparatus, such as fiberoptic device, flouroscopic device, an oscope, a laparoscope or other type of catheter.
[0060] The apparatus port 132 can be coupled to other medical devices that may be useful during treatment such as a pH meter, a pressure monitor, drug administration apparatus, or other device used to monitor or treat the patient.
[0061] In a preferred embodiment, devices coupled to both the visualization port 131 and the apparatus ports 132 are controlled from a location outside the body, such ss by an instrument in an operating room or an external device for manipulating the inserted catheter 110 .
[0062] In an alternative embodiment the apparatus port 132 may be coupled to devices that are implanted or inserted into the body during a medical procedure. For example, the apparatus port 132 may be coupled to a programmed AICD (artificial implanted cardiac defibrillator), a programmed glandular substitute (such as an artificial pancreas) or other device for use during surgery or other medical procedures.
[0063] The electrical energy port 133 includes conductive element such as an electrical adapter that can be coupled to a source of alternating or direct current such as a wall socket, battery or generator.
[0064] The electrode section and control switch 134 includes an element that is disposed to select and activate individual electrodes 119 .
[0065] The irrigation and aspiration control ports 135 can be coupled to a pump or other apparatus to deliver fluid through the aperture 118 or apply suction through the set of irrigation and aspiration ports 134 .
[0066] The therapeutic energy port 136 includes a receptor port for coupling to a source of any of the following types of therapeutic energy:
[0067] radiofrequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0068] chemical treatments, such s acids, antibiotics, enzymes, radioactive tracers or other bioactive substances;
[0069] infrared energy, such as from an infrared laser or diode laser;
[0070] microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0071] sonic energy, including utrasound;
[0072] photodynamic therapy (PDT);
[0073] non-infrared laser energy; and
[0074] cryothermia
[0075] The handle 137 is disposed for manipulation by medical or veterinary personnel and can be shaped for being held in the hand. The visualization port 131 , the apparatus port 132 , the electrical energy port 133 , the electrode selection and control switch 134 and the one or more irrigation and aspiration control ports 135 and the therapeutic energy port 136 are all mounted in the handle 137 to allow for easy operation.
[0076] The Shielding Element
[0077] The shielding element 140 lies on the proximal side of treatment element 114 and is disposed to isolate the treatment area. It can also help position the catheter 110 in the body. For example, in a preferred embodiment in which the catheter 110 is inserted into the urethra, the shielding element 140 can prevent the catheter 110 from being inserted further into the urethral canal and prevent substances used in treatment from escaping. In an alternative embodiment, the shield element 140 is optional.
[0078] [0078]FIG. 2 is a process flow drawing of a method for treatment of female urinary incontinence using a first device.
[0079] A method 200 is performed by a system 100 , including a catheter 110 and a control assembly 140 . Although the method 200 is described serially, the steps of the method 200 can be performed by separate elements in conjunction or in parallel, whether asynchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 200 be performed in the same order in which this description lists the steps, except where so indicated.
[0080] At a flow point 200 , electrical energy port 133 is coupled to a source of electrical energy. The patient has voided and is positioned on a treatment table, in an appropriate position such as horizontal, jackknife or lithotomy. Due to the potential for inducing pain, the area surrounding the urinary meatus may be pretreated with a topical anesthetic before insertion of the catheter 110 ; depending upon the circumstances, a muscle relaxant or short term tranquilizer my be indicated. The position of the patient and choice of pharmaceutical agents to be used are responsive to judgments by medical personnel.
[0081] At a step 201 , the patient's external genitalia and surrounding anatomy are cleansed with an appropriate agent such as BETADINE, or benzalkonium chloride.
[0082] At a step 202 , the visualization port 131 is coupled to the appropriate visualization apparatus, such as a fluoroscope, an endoscope, a display screen or other visualization device. The choice of visualization apparatus is responsive to judgments by medical personnel.
[0083] At a step 203 , the apparatus port 132 is coupled to an external medical device such as a pH meter, a pressure gauge, or other such equipment. The choice of apparatus is responsive to judgments by medical personnel.
[0084] At a step 204 , the therapeutic energy port 136 is coupled to a source of any of the aforementioned types of therapeutic energy.
[0085] At a step 205 , the tapered tip 115 is well lubricated and introduced into the urethral meatus in an upward and backward direction, in much the same way a Foley catheter 110 is introduced.
[0086] In a step 206 , the catheter 110 is threaded through the urethra until the treatment element 114 is at the further reaches of the trigone region. An introducer sheath 116 or guidewire 117 may also be used to facilitate insertion.
[0087] In a step 207 , the position of the catheter 110 is checked using visualization apparatus coupled to the visualization port 131 . The position of the treatment element 114 is adjusted, if necessary, so that the electrodes 119 have grabbed onto the tissue and are bunching it together. This apparatus can be continually monitored by medical professionals throughout the procedure.
[0088] In a step 208 , irrigation and aspiration control port 135 is manipulated so as to exude a cooling liquid such as sterile water, saline or glycerin from the aperture 118 into the lower region of the bladder. This cooling fluid lowers the relative temperature of the targeted tissues and prevents collateral thermal damage. In alternative embodiments, other devices may be coupled to the apparatus port 132 to chill the cooling fluid or to cause sonic cooling, gas expansion, magnetic cooling or others cooling methodologies. The choice of cooling fluid or methodology is responsive to judgments by medical personnel.
[0089] In a step 209 , electrodes 119 are selected using the electrode selection and control switch 134 . In a preferred embodiment, all electrodes are deployed at once. In another preferred embodiment, electrodes may be individually selected. This step may be repeated at any time prior to step 217 .
[0090] In a step 210 , suction apparatus is coupled to the irrigation and aspiration control ports 135 so that suction may be effected through the irrigation and aspiration ports 124 . The tissue surrounding the treatment element 114 may be aspirated so as to conform it to the treatment element 114 . The aspiration also removes excess cooling fluid that was supplied in step 209 .
[0091] In a step 211 , the therapeutic energy port 136 is manipulated so as to cause a release of energy from the electrodes 119 . The duration and frequency of energy are responsive to judgments by medical personnel. This release of energy creates a pattern of lesions in the mucosal and sub-mucosal tissues of the trigone region. The affected area shrinks and is relatively strengthened, so as to better retain urine. Alternatively, a different method of treatment can be affected by partially or completely ablating nerves responsible for the sensation of urinary urgency.
[0092] In a step 212 , the catheter 110 is repositioned so that the treatment element 114 is closer to the bladder neck. Prior to repositioning the catheter 110 , the electrodes 119 are either retracted or covered by the introducer sheath 116 to prevent unintended damage to tissue while the catheter is being moved.
[0093] In a step 213 , the energy port 137 is manipulated so as to cause a release of energy from the electrodes 119 . The duration and frequency of energy are responsive to judgments by medical personnel. This release of energy creates another pattern of lesions in the mucosal and sub-mucosal tissues of the trigone area. The affected tissue shrinks and is relatively strengthened, so as to better retain urine. By creating a selective pattern of lesions in various areas as in steps 211 and 115 , the three-dimensional modeling of the trigone area can be affected. Alternatively, a different method of treatment can be effected by partially or completely ablating nerves responsible for the sensation of urinary urgency.
[0094] In a step 214 , the catheter 110 is re-positioned for a final time so that the treatment element 114 is immediately adjacent to the bladder neck. Prior to repositioning the catheter 110 , the electrodes 119 are either retracted or covered by the introducer sheath 116 to prevent unintended damage to tissue while the catheter is being removed.
[0095] In a step 215 , the energy port 137 is manipulated so as to cause a release of energy from the electrodes 119 . The duration and frequency of energy are responsive to judgments by medical personnel. This release of energy creates another pattern of lesions in the sub-mucosal and mucosal tissues around the bladder neck. The affected tissue shrinks and is relatively strengthened, so as to better retain urine. Taken together with the lesions, created in step 211 , and 213 , the trigone area has been completely remodeled so that the bladder has shrunk and re-suspended itself. The relative pressure on the bladder neck is relieved. The scar tissue created by application of the energy is stronger and better able to resist abdominal pressure on the sphincter.
[0096] In a step 216 , the irrigation and aspiration control port 135 is manipulated so as to stop the flow of cooling liquid from the aperture 118 .
[0097] In a step 217 , pharmaceutical agents may be locally administered by manipulating the irrigation and aspiration control ports 135 . These agents may include lubricants, anesthetics, anti-spasmodics, anti-inflammatories, antibiotics or other agents as deemed appropriate by the judgment of medical personal. This step may occur any time prior to withdrawal of the catheter 110 , to either pre-treat tissue or post treat tissues.
[0098] In a step 218 , the catheter 110 is withdrawn from the urethra.
[0099] [0099]FIG. 3 is a block drawing of a system for treatment of female urinary incontinence using a second device.
[0100] A system 300 includes a catheter 310 , a microporous treatment balloon 320 , a control assembly 330 , and a shielding element 340 (not shown). In an alternative embodiment, the shielding element 340 is not present.
[0101] The Catheter 310
[0102] The catheter 310 includes two or more lumens 311 (not shown) and a translation member 312 . The two or more lumens 311 and translation member 312 traverse the entire interior length of the catheter 310 . The catheter 310 and lumens 311 are coupled at a distal end to a treatment balloon 320 ; they are coupled at a proximal end to a control assembly 330 . The translation member 312 is coupled to the distal end of the treatment balloon 320 ; it is coupled at the proximal end to a control assembly 330 .
[0103] In a preferred embodiment, the catheter 310 and treatment balloon 320 are introduced into cavity of the body, such as a female urethra and bladder using an introducer sheath 313 or a guide tube 314 . In alternative embodiments, the cavity may include one or more of, or some combination of the following:
[0104] any portion of the bronchial system, the cardiovascular system, the genito-urinary tract, the lymphatic system, the pulmonary system, the vascular system, the locomotor system, the reproductive system or other systems in the body;
[0105] any biological conduit or tube, such as a biologic lumen that is patent or one that is subject to a stricture;
[0106] any biologic operational structure, such as a gland, or a muscle or other organ (such as the colon, the diaphragm, the heart, a uterus, a kidney, a lung, the rectum, an involuntary or voluntary sphincter);
[0107] any biologic structure, such as a herniated body structure, a set of diseased cells, a set of dysplastic cells, a surface of a body structure, (such as the sclera) a tumor, or a layer of cells (such as fat, muscle or skin); and
[0108] any biologic cavity or space or the contents thereof, such as a cyst, a gland, a sinus, a layered structure, or a medical device implanted or inserted in the body.
[0109] The Microporous Treatment Balloon 320
[0110] The microporous treatment balloon 320 is comprised of a relatively flexible and heat resistant material such as Kevlar, polyurethane, polyvinyl chloride (PVC), polyamide, PET, nylon or other materials. The shape of the balloon can be manipulated by varying the degree of inflation and the amount of tension placed on the translation member 312 . By varying the degree of inflation and the tension on the translation member, the surface of the treatment balloon can be brought in contact with the entire interior surface of the muscles, including the detrusor muscles and the top of the bladder. In this way, it is possible to treat the entire organ simultaneously.
[0111] The treatment balloon 320 also includes a flexible basket-like structure 321 and a set of surface electrodes 322 . The basket-like structure 321 has horizontal and vertical members that completely encompass the balloon 320 . The set of surface electrodes 322 are evenly distributed on all the members of the basket-like structure 321 . Each electrode 322 includes a sensor 323 to measure temperature, pressure, impedance, flow, nervous activity, pH, conductivity or other property of the tissue or treatment. Each surface electrode 322 is also coupled to a radiopaque marker 324 for use in fluoroscopic visualization.
[0112] In an alternative embodiment, the surface electrodes 322 and sensors 323 are embedded directly into the exterior surface of the microporous treatment balloon 320 . In this preferred embodiment, the basket-like structure 321 is optional.
[0113] In both the preferred and alternative embodiments, the electrodes 322 can be operated separately or in combination with each other. Treatment can be directed at a single area, several different areas, or the entire interior of a bladder or other orifice by operation of selective electrodes. Different patterns of sub-mucosal lesions, mucosal lesions, ablated, bulked or plumped, desiccated or necrotic regions can be created by selectively operating different electrodes. Production of different patterns of treatment makes it possible to remodel tissues and alter their overall geometry with respect to each other.
[0114] Each electrode 322 can be disposed to treat tissue by delivering one or more of, or some combination or any of the following in either a unipolar or bipolar mode:
[0115] radiofrequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0116] chemical treatments, such as acids, antibiotics, enzymes, radioactive tracers or other bioactive substances;
[0117] infrared energy, such as from an infrared laser or diode laser;
[0118] microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0119] sonic energy, including ultrasound;
[0120] photodynamic therapy (PDT);
[0121] non-infrared laser energy; and
[0122] cryothermia
[0123] In addition to treating tissues by delivering energy, the set of electrodes 322 and the micropores in the balloon 320 are disposed to deliver at least one flowable substance to the area of the body where treatment is to take place. In a preferred embodiment, the flowable substance includes sterile water, which aids in cooling and hydration of body structures. In other preferred embodiments, the flowable substance includes saline with a concentration of less than about 10% NaCl, which locally enhances tissue conductivity, resulting in selective areas of ablation or creation of thermal lesions at or below the surface of the tissue. However, in alternative embodiments, the deliverable flowable liquids include other substances, including anesthetic drugs, anti-inflammatory agents, chemotherapeutic agents, systemic or topical antibiotics, collagen and radioactive substances such as labeled tracers. In other alternative embodiments, the sensors on the electrodes are used for mapping the foci or pathways of electrical activity in the bladder, the bladder neck or urethra. This information is used to guide delivery of energy.
[0124] In other alternative embodiments, the balloon 320 is not microporous. In this alternative embodiment, electrodes 322 or other energy delivery devices may be mounted upon or proximate to a surface of the balloon.
[0125] The Control Assembly 330
[0126] The control assembly 330 includes a visualization port 331 , an apparatus port 332 , an electrical energy port 333 , an electrode selection and control switch 334 , one or more irrigation and aspiration control ports 335 , an therapeutic energy port 336 and a handle 337 .
[0127] The visualization port 331 can be coupled to visualization apparatus, such as a fiber optic device, a fluoroscopic device, an anoscope, a laparoscope, an endoscope or other type of catheter.
[0128] The apparatus port 332 can be coupled to other medical devices that may be useful during treatment such as a pH meter, a pressure monitor, drug administration apparatus, or other devices used to monitor or treat the patient.
[0129] In a preferred embodiment, devices coupled to both the visualization port 331 and the apparatus ports 332 are controlled from a location outside the body, such as by an instrument in an operating room or an external device for manipulating the inserted catheter 310 .
[0130] In an alternative embodiment the apparatus port 332 may be coupled to devices that are implanted or inserted into the body during a medical procedure. For example, the apparatus port 332 may be coupled to a programmed AICD (artificial implanted cardiac defibrillator), a programmed glandular substitute (such as an artificial pancreas) or other device for use dozing surgery or other medical procedures.
[0131] The electrical energy port 333 includes a conductive element such as an electrical adapter that can be coupled to a source of alternating or direct current such as a wall socket, battery or generator.
[0132] The electrode selection and control switch 334 includes an element that is disposed to select and activate individual electrodes 322 .
[0133] The irrigation and aspiration control ports 335 can be coupled to a pump or other apparatus to inflate or deflate the balloon and deliver fluids through the micropores of the treatment balloon 320 .
[0134] The therapeutic energy port 336 includes a receptor port for coupling to a source of any of the following types of therapeutic energy:
[0135] radio frequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0136] chemical treatments, such as acids, antibiotics, enzymes, radioactive tracers or other bioactive substances;
[0137] infrared energy, such as from an infrared laser or diode laser; microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0138] sonic energy, including ultrasound;
[0139] photodynamic therapy (PDT);
[0140] non-infrared laser energy; and
[0141] cryothermia
[0142] The handle 337 is disposed for manipulated by medical or veterinary personnel and can be shaped for being held in the hand. The visualization port 331 , the apparatus port 332 , the electrical energy port 333 , the electrode selection and control switch 334 and the one or more irrigation and aspiration control ports 335 and the therapeutic energy port 336 are all mounted in the handle 337 to allow for easy operation.
[0143] The Shielding Element 340
[0144] The shielding element 340 lies on the proximal side of the microporous treatment balloon 320 and is disposed to isolate the treatment area. It can also help position the catheter 310 in the body. For example, in a preferred embodiment in which the catheter 310 is inserted into the urethra, the shielding element 340 can prevent the catheter 310 from being inserted further into the urethral canal or bladder and prevent substances used in treatment from escaping. In an alternative embodiment, the shielding element 340 is optional.
[0145] [0145]FIG. 4 is a process flow drawing of a method for treatment of female urinary incontinence using a second device.
[0146] A method 400 is performed by a system 300 including a catheter 310 , a treatment balloon 320 and a control assembly 330 . Although the method 400 is described serially, the steps of the method 400 can be performed by separate elements in conjunction or in parallel, whether asynchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 400 be performed in the same order in which this description lists the steps, except where so indicated.
[0147] At a flow point 400 , electrical energy port 333 is coupled to a source of electrical energy. The patient has voided and is positioned on a treatment table, in an appropriate position such as horizontal, jackknife or lithotomy. Due to the potential for inducing pain, the area surrounding the urinary meatus may be pretreated with a topical anesthetic before insertion of the catheter 310 ; depending upon the circumstances, a muscle relaxant or short term tranquilizer may be indicated. The position of the patient and choice of pharmaceutical agents to be used are responsive to judgments by medical personnel.
[0148] At a step 401 , the patient's external genitalia and surrounding anatomy are cleansed with an appropriate agent such as BETADINE, or benzalkonium chloride.
[0149] At a step 402 , the visualization port 431 is coupled to the appropriate visualization apparatus, such as a fluoroscope, an endoscope, a display screen or other visualization device. The choice of visualization apparatus is responsive to judgments by medical personnel.
[0150] At a step 403 , the apparatus port 332 is coupled to an external medical device such as a pH meter, a pressure gauge, or other medical equipment. The choice of apparatus is responsive to judgments by medical personnel.
[0151] At a step 404 , the therapeutic energy port 336 is coupled to a source of any of the aforementioned types of therapeutic energy.
[0152] In a step 405 , suction, inflation or fluid infusion apparatus is coupled to the irrigation and aspiration control ports 335 so that the treatment balloon may be later be inflated and deflated and substances may be administered.
[0153] At a step 406 , the most distal end of the treatment balloon 320 is lubricated and introduced into the urethral meatus in an upward and backward direction, in much the same way a Foley catheter is introduced. The choice of lubricant is responsive to judgments by medical personnel. In a preferred embodiment, the balloon 320 is completely deflated during insertion.
[0154] In a step 407 , the catheter 310 is threaded through the urethra until the microporous balloon 320 has completely passed the bladder neck and is entirely in the bladder. An introducer sheath 313 or guide tube 314 may also be used to facilitate insertion.
[0155] In a step 408 , the position of the catheter 310 is checked using visualization apparatus coupled to the visualization port 331 . This apparatus can be continually monitored by medical professionals throughout the procedure.
[0156] In a step 409 , the irrigation and aspiration control port 335 is manipulated so as to inflate the microporous treatment balloon 320 . In a preferred embodiment, the treatment balloon 320 is inflated with a cooling liquid such as sterile water, saline or glycerin. This cooling fluid lowers the relative temperature of the targeted tissues that are in physical contact and prevents collateral thermal damage. In alternative embodiments, other devices may be coupled to the apparatus port 132 to chill the cooling fluid or cause sonic cooling, gas expansion, magnetic cooling or others cooling methodologies. The choice of cooling fluid or methodology is responsive to judgments by medical personnel.
[0157] In a step 410 , electrodes 322 are selected using the electrode selection and control switch 334 .
[0158] In a step 411 , the translation member 312 is manipulated to alter the shape of the most distal end of the balloon so as to bring the distal end of the balloon in optimal physical contact with the top of the bladder.
[0159] In a step 412 , individual nerves within the bladder are identified using sensors 323 . This step is optional.
[0160] In a step 413 , the therapeutic energy port 336 is manipulated so as to cause a release of energy from the electrodes 322 . The duration and frequency of energy are responsive to judgments by medical personnel. This release of energy creates a pattern of lesions in the mucosal or sub-mucosal tissues of the bladder or portions thereof. The affected area shrinks and is relatively strengthened, so as to better retain urine.
[0161] In a step 414 , the therapeutic energy port 336 is manipulated, so as to cause a release of energy from the electrodes 322 that is directed at the nerves that were identified in step 412 . Manipulation and modulation of these nerves may directly or indirectly affect incontinence related to an uncontrolled urge to urinate. This step is optional.
[0162] In a step 415 , bulking agents such as organic microspheres, collagens, silicone, PVC and other organic breathable and unbreathable polymers are exuded from selected electrodes 322 positioned near the base of the bladder. The type of microspheres and bulking substances and the locations where they are exuded are responsive to judgment by medical personnel. These bulking agents can be used to strengthen these structures so as to prevent incontinence caused by stress.
[0163] In a step 416 , pharmaceutical agents may be locally administered by manipulating the irrigation and aspiration control ports 335 . These agents may help include lubricants, anesthetics, anti-spasmodics, anti-inflammatories, antibiotics or other agents as deemed appropriate by the judgment of medical personal. This step may occur any time prior to withdrawal of the catheter 310 , to either pre-treat tissue or post-treat tissues.
[0164] In a step 417 , the irrigation and aspiration control port 335 is manipulated so as to reverse the flow of cooling liquid into the microporous treatment balloon 320 and cause it to deflate.
[0165] In a step 418 , the catheter 310 is withdrawn from the urethra.
[0166] [0166]FIG. 5 is a block drawing of a system for treatment of female urinary incontinence using a third device.
[0167] A system 500 includes a catheter 510 , treatment element 520 , a control assembly 530 and a shielding element 540 . In an alternative embodiment, the shielding element 540 is not present.
[0168] The Catheter 510
[0169] The catheter 510 includes two or more lumens 511 , a translation member 512 and a tapered tip 513 . The lumens 511 and translation member 512 run the entire interior length of the catheter 510 . The proximal end of the lumens 511 is coupled to the control assembly 530 ; the distal end of the lumens 511 is coupled to the treatment element 520 . It is through these lumens 511 that energy is conducted and flowable substances are exuded. The proximal end of the translation member 512 is coupled to the control assembly 530 ; the distal end of the translation member 512 is coupled to the taper tip 513 .
[0170] In a preferred embodiment, the tapered tip 513 is rigid so as to allow easy insertion into a urethra. In other preferred embodiments, the tapered tip 513 may be of varying degrees of flexibility depending where it in the body it is deployed. In alternative embodiments, the catheter 510 may be introduced into the target tissue using an introducer sheath 514 or a guide wire 515 .
[0171] Ina preferred embodiment, the tapered tip 513 is disposed for insertion into a cavity of the body such as a female urethra and bladder. In alternative embodiments, the cavity may include one or more of, or some combination of the following:
[0172] any portion of the bronchial system, the cardiovascular system, the genito-urinary tract, the lymphatic system, the pulmonary system, the vascular system, the locomotor system, the reproductive system or other systems in the body;
[0173] any biological conduit or tube, such as a biologic lumen that is patent or one that is subject to a stricture;
[0174] any biologic operational structure, such as a gland, or a muscle or other organ (such as the colon, the diaphragm, the heart, a uterus, a kidney, a lung, the rectum and or voluntary sphincter);
[0175] any biologic structure, such as a herniated body structure, a set of diseased cells, a set of dysplastic cells, a surface of a body structure, (such as the sclera) a tumor, or a layer of cells (such as fat, muscle or skin); and
[0176] any biologic cavity or space or the contents thereof, such as a cyst, a gland, a sinus, a layered structure, or a medical device implanted or inserted in the body.
[0177] The Treatment Element 520
[0178] The treatment element 520 includes a set of umbrella-like struts 521 , a set of electrodes 522 , a set of irrigation and aspiration ports 525 and a set of sensors 526 . The set of umbrella-like struts 521 are several centimeters long. One end of the struts 521 is not attached to any part of the device. The other end of the strut 521 is coupled to the distal end of the translation member 512 at the tapered tip 513 in such a way that when tension is applied to the proximal end of the translation member 512 , the umbrella-like struts 521 open up in much the same way as an umbrella.
[0179] A set of electrodes 522 is evenly distributed on the outer surface of each strut 521 . Each free-floating end of a strut 521 includes at least one electrode 522 . Each electrode 522 includes a metallic tube 523 defining a hollow lumen 524 . In a preferred embodiment, the set of electrodes 522 are needle electrodes; other preferred embodiments include surface electrodes or a combination of needle electrodes and surface electrodes.
[0180] Each electrode 522 is coupled to at least one sensor 526 capable of measuring such factors as temperature, conductivity, pressure, impedance and other variables. In a preferred embodiment, each electrode 522 is also coupled to a radiopaque marker 527 for use in fluoroscopic visualization.
[0181] In a preferred embodiment, the electrodes 522 can be operated separately or in combination with each other. Treatment can be directed at a single area or several different areas of a bladder or other orifice by operation of selected electrodes. Different patterns of sub-mucosal lesions, mucosal lesions, ablated, bulked, plumped, desiccated or necrotic regions can be created by selectively operating different electrodes. Production of different patterns of treatment makes it possible to remodel tissues and alter their overall geometry with respect to each other.
[0182] Each electrode 522 can be disposed to treat tissue by delivering one or more of, or some combination or any of the following in either a unipolar or bipolar mode:
[0183] radiofrequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0184] chemical treatments, such as acids, antibiotics, enzymes, radioactive tracers or other bioactive substances;
[0185] infrared energy, such as from an infrared laser or diode laser;
[0186] microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0187] sonic energy, including ultrasound;
[0188] photodynamic therapy (PDT)
[0189] non-infrared laser energy; and
[0190] cryothermia
[0191] In addition to treating tissues by delivering energy, the set of electrodes 522 are disposed to deliver at least one flowable substance to the area of the body where treatment is to take place. In a preferred embodiment, the flowable substance includes sterile water which aides in cooling and hydration of body structures. In another preferred embodiment, the flowable substance includes saline with a concentration of less than about 10% NaCl. Saline is used to increate the local conductivity of tissue, enhancing the penetration of RF energy so as to create larger lesions. The saline can be delivered through the needle electrode sub-mucosally so as to achieve greatest effect. However, in alternative embodiments, the deliverable flowable liquids include other substances, including anesthetic drugs, antiinflammatory agents, chemotherapeutic agents, systemic or topical antibiotics, collagen and radioactive substances such as labeled tracers.
[0192] A set of irrigation and aspiration ports 525 are also evenly distributed on the outer surface of each strut 521 . Each free-floating end of a strut 521 also includes at least one irrigation and aspiration port 525 . Suction can be applied through these ports so as to bring the targeted tissue in closer physical proximity to the electrodes 522 . The irrigation and aspiration ports 525 can also be used to administer cooling fluids in such a way as to minimize thermal damage. Drugs, bulking agents and other flowable substances can be infused through the irrigation and aspiration ports 525 .
[0193] The Control Assembly 530
[0194] The control assembly 530 includes a visualization port 531 , an apparatus port 532 , an electrical energy port 533 , an electrode selection and control switch 534 , one or more irrigation and aspiration control ports 535 , a therapeutic energy port 536 and a handle 537 .
[0195] The visualization port 531 can be coupled to visualization apparatus, such as a fiber optic device, a fluoroscopic device, an anoscope, a laparoscope, an endoscope or other type of catheter.
[0196] The apparatus port 532 can be coupled to other medical devices that may be useful during treatment such as a pH meter, a pressure monitor, drug administration apparatus, or other device used to monitor or treat the patient.
[0197] In a preferred embodiment, devices coupled to both the visualization port 531 and the apparatus ports 532 are controlled from a location outside the body, such as by an instrument in an operating room or an external device for manipulating the inserted catheter 510 .
[0198] In an alternative embodiment the apparatus port 532 may be coupled to devices that are implanted or inserted into the body during a medical procedure. For example, the apparatus port 532 may be coupled to a programmed AICD (artificial implanted cardiac defibrillator), a programmed glandular substitute (such as an artificial pancreas) or other device for use during surgery or other medical procedures.
[0199] The electrical energy port 533 includes a conductive element such as an electrical adapter that can be coupled to a source of alternating or direct current such as a wall socket, battery or generator.
[0200] The electrode selection and control switch 534 includes an element that is disposed to select and activate individual electrodes 522 .
[0201] The irrigation and aspiration control ports 535 can be coupled to a pump or other apparatus to deliver fluid through the irrigation and aspiration ports 525 or electrodes 522 or to apply suction through the set of irrigation and aspiration ports 525 .
[0202] The therapeutic energy port 536 includes a receptor port for coupling to a source of any of the following types of therapeutic energy:
[0203] radiofrequency (RF) energy, such as RF in about the 300 kilohertz to 500 kilohertz range;
[0204] chemical treatments, such as acids, antibiotics, enzymes, radioactive tracers or other bioactive substances;
[0205] infrared energy, such as from an infrared laser or diode laser;
[0206] microwave energy, such as electromagnetic energy in about the 915 megahertz or 2.45 gigahertz range;
[0207] sonic energy, including ultrasound;
[0208] photodynamic therapy (PDT);
[0209] non-infrared laser energy; and
[0210] cryothermia
[0211] The handle 537 is disposed for manipulated by medical or veterinary personnel and can be shaped for being held in the hand. The visualization port 531 , the apparatus port 532 , the electrical energy port 533 , the electrode selection and control switch 534 and the one or more irrigation and aspiration control ports 535 and the therapeutic energy port 536 are all mounted in the handle 537 to allow for easy operation.
[0212] The Shielding Element 540
[0213] The shielding element 540 lies on the proximal side of treatment element 520 and is disposed to isolate the treatment area. It can also help position the catheter 510 in the body. For example, in a preferred embodiment in which the catheter 510 is inserted into the urethra, the shielding element 540 can prevent the catheter 510 from being inserted further into the urethra canal and prevent substances used in treatment from escaping. In an alternative embodiment, the shielding element 540 is optional.
[0214] [0214]FIG. 6 is a process flow drawing of a method for treatment of female urinary incontinence using a third device. Although the method 600 is described serially, the steps of the method 600 can be performed by separate elements in conjunction or in parallel, whether asynchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 600 be performed in the same order in which this description lists the steps, except where so indicated.
[0215] A method 600 is performed by a system 500 including a catheter 510 , a treatment element 520 and a control assembly 530 .
[0216] At a flow point 600 , electrical energy port 533 is coupled to a source of electrical energy. The patient has voided and is positioned on a treatment table, in an appropriate position such as horizontal, jackknife or lithotomy. Due to the potential for inducing pain, the area surrounding the urinary meatus may be pretreated with a topical anesthetic before insertion of the catheter 510 ; depending upon the circumstances, a muscle relaxant or short term tranquilizer may be indicated. The position of the patient and choice of pharmaceutical agents to be used are responsive to judgments by medical personnel.
[0217] At a step 601 , the patient's external genitalia and surrounding anatomy are cleansed with an appropriate agent such as BETADINE, or benzalkonium chloride.
[0218] At a step 602 , the visualization port 531 is coupled to the appropriate visualization apparatus, such as a fluoroscope, an endoscope, a display screen or other visualization device. The choice of visualization apparatus is responsive to judgments by medical personnel.
[0219] At a step 603 , the apparatus port 532 is coupled to an external medical device such as a pH meter, a pressure gauge, or other medical equipment. The choice of apparatus is responsive to judgments by medical personnel.
[0220] At a step 604 , the therapeutic energy port 535 is coupled to a source of any of the aforementioned types of therapeutic energy.
[0221] In a step 605 , suction, inflation or fluid in fusion apparatus is coupled to the irrigation and aspiration control ports 535 so that cooling fluids and pharmacological agents may be administered.
[0222] At a step 606 , the tapered tip 513 is lubricated and introduced into the urethral meatus in an upward and backward direction, in much the same way a Foley catheter is introduced. The choice of lubricant is responsive to judgments by medical personnel. In a preferred embodiment, the treatment element 520 is completely closed to facilitate insertion.
[0223] In a step 607 , the catheter 510 is threaded through the urethra until the treatment element 520 has completely passed the bladder neck and is entirely in the bladder. An introducer sheath 513 or guide tube 514 may also be used to facilitate insertion.
[0224] In a step 608 , the position of the catheter 510 is checked using visualization apparatus coupled to the visualization port 531 . This apparatus can be continually monitored by medical professionals throughout the procedure.
[0225] In a step 609 , the irrigation and aspiration control port 535 is manipulated so as to exude a cooling fluid. In a preferred embodiment, the cooling fluid may include sterile water, saline or glycerin. This cooling fluid lowers the relative temperature of the targeted tissues that are in physical and prevents collateral thermal damage. In alternative embodiments, other devices may be coupled to the apparatus port 532 to chill the cooling fluid or cause sonic cooling, gas expansion, magnetic cooling or others cooling methodologies. The choice of cooling fluid or methodology is responsive to judgments by medical personnel.
[0226] In a step 610 , tension is applied to the translation member 512 to cause extension of the struts 522 . Extension of the struts 522 brings the electrodes 522 into physical proximity with the walls of the bladder.
[0227] In a step 611 , the irrigation and aspiration control ports 535 are manipulated so as to apply suction through the irrigation and aspiration ports 525 and bring the walls of the bladder in even closer proximity to the treatment element 520 .
[0228] In a step 612 , electrodes 522 are selected using the electrode selection and control switch 534 . In a preferred embodiment, all electrodes are selected. In another embodiment, individual electrodes may be deployed.
[0229] In a step 613 , individual nerves within the bladder are identified using sensors 526 . This step is optional.
[0230] In a step 614 , the therapeutic energy port 536 is manipulated so as to cause a release of energy from the electrodes 522 . The duration and frequency of energy are responsive to judgments by medical personnel. This release of energy creates a pattern of lesions in the mucosal and/or sub-mucosal tissues of the bladder or portions thereof. The affected area shrinks and is relatively strengthened, so as to better retain urine.
[0231] In a step 615 , the therapeutic energy port 536 is manipulated so as to cause a release of energy from the electrodes 522 that is directed at the nerves that were identified in step 613 . Manipulation and modulation of these nerves may directly or indirectly affect incontinence related to an uncontrolled urge to urinate. This step is optional.
[0232] In a step 616 , bulking agents such as organic microspheres, collagens, silicone, PVC and other organic breathable and unbreathable polymers are exuded from selected electrodes 522 into tissues near the base of the bladder. The type of microspheres and bulking substances and the locations where they are exuded are responsive to judgment by medical personnel. These bulking agents can be used to strengthen these structures so as to prevent incontinence caused by stress. This step is optional.
[0233] In a step 617 , pharmaceutical agents may be locally administered by manipulating the irrigation and aspiration control ports 535 . These agents may help include lubricants, anesthetics, anti-spasmodics, anti-inflammatories, antibiotics or other agents as deemed appropriate by the judgment of medical personnel. This step may occur any time prior to withdrawal of the catheter 510 , either to pre-treat tissue or post-treat tissues.
[0234] In a step 618 , the irrigation and aspiration control port 535 is manipulated so as to reverse the flow of cooling liquid.
[0235] In a step 619 , tension is applied to the translation member 512 to cause the umbrella like struts 521 to collapse and close around the catheter 510 .
[0236] In a step 620 , the catheter 510 is withdrawn from the urethra.
GENERALITY OF THE INVENTION
[0237] The invention has substantial generality of application to various fields for biopsy or treatment of medical conditions. These various fields include, one or more of, or a combination of, any of the following (or any related fields):
[0238] As noted above, the invention can be used in any area of the body, including the biologic systems and locations noted herein. The invention can be used for the general purpose of reducing, plumping, or reshaping body structures, tissues, or regions of the body otherwise empty (or filled with biologic substances).
[0239] For examples, the invention can be used in one or more of, or some combination of, the following:
[0240] in the head and neck, such as the cheeks, eyes, sinuses, middle ear, nostrils, inner ear, Eustachian tubes, pharynx, larynx, or other structures;
[0241] for the purpose of reforming damaged body parts, for the purpose of reshaping misshapen body parts, dilating occluded tissues, or for cosmetic affects; and
[0242] for the purpose of replacing the volume filled by body parts that are missing, whether due to congenital defect, infection, or surgery.
ALTERNATIVE EMBODIMENTS
[0243] Although preferred embodiments are disclosed herein, many variations are possible which remain within the concept, scope, and spirit of the invention, and these variations would become clear to those skilled in the art after perusal of this application. | The invention provides a method and system for treating disorders in parts of the body. A particular treatment can include on or more of, or some combination of: ablation, nerve modulation, three-dimensional tissue shaping, drug delivery, mapping stimulating, shrinking and reducing strain on structures by altering the geometry thereof and providing bulk to particularly defined regions. The particular body structures or tissues can include one or more of or some combination of region, including: the bladder, esophagus, vagina, penis, larynx, pharynx, aortic arch, abdominal aorta, thoracic, aorta, large intestine, sinus, auditory canal, uterus, vas deferens, trachea, and all associated sphincters. Types of energy that can be applied include radiofrequency, laser, microwave, infrared waves, ultrasound, or some combination thereof. Types of substances that can be applied include pharmaceutical agents such as analgesics, antibiotics, and anti-inflammatory drugs, bulking agents such as biologically non-reactive particles, cooling fluids, or dessicants such as liquid nitrogen for use in cryo-based treatments. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a double-walled vessel having an outer vessel body and an inner vessel body arranged therein, so that a gas-filled, heat-insulating interspace is present between the vessel bodies. A double-walled vessel of this kind can be made, in particular, from glass.
PRIOR ART
[0002] EP-A-0 717 949 discloses a double-walled vessel, the outer vessel body of which has a through-hole. The latter serves, following connection of the inner and the outer vessel body, to introduce a gas with low thermal conductivity into the interspace between the vessel bodies. After this gas exchange, the opening is sealed by a drop of glue and optionally, in addition, by a sealing plate.
[0003] When a vessel of this type is exposed to strong temperature fluctuations, the pressure of the gas present in the interspace between the vessel bodies changes. These pressure changes lead, on the one hand, to stresses in the material of the vessel, which in the extreme case can cause the vessel to burst. On the other hand, constant pressure fluctuations can result in leaking of the glue plug upon extended use and hence in possible penetration of liquid into the interspace. The vessel thereby becomes practically unusable.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is therefore to make available a double-walled vessel which in a simple manner prevents excessive pressure fluctuations in the interspace between the vessel bodies. This object is achieved by a double-walled vessel having the features of claim 1 .
[0005] A further object of the present invention is to make available a method for producing a double-walled vessel of this type. This object is achieved by a method having the features of claim 9 .
[0006] Advantageous embodiments are given in the dependent claims.
[0007] A double-walled vessel is thus provided, which has an outer vessel body and an inner vessel body. The inner vessel body is arranged in the outer vessel body in such a way that a gas-filled interspace is formed between the inner and the outer vessel body. In a wall of at least one of the vessel bodies, preferably in that wall of the outer vessel body which forms the base, a pressure compensation opening is present, which in particular serves to permit a gas exchange, for pressure compensation between the interspace and the exterior, when the two vessel bodies are joined together. This pressure compensation opening is sealed by a plug to prevent moisture from penetrating into the interspace. In order nevertheless to continue to allow a pressure compensation between the interspace and the exterior, the plug has at least one gas passage channel extending through it, which gas passage channel, in case of pressure differences, allows a passage of gas, in particular of air, while preventing a passage of liquids, in particular of water.
[0008] Such a vessel is preferably produced by providing, first of all, the outer and the inner vessel body, at least one of these vessel bodies having a limit wall containing a pressure compensation opening. The inner vessel body is next arranged in the outer vessel body and connected thereto. This is preferably done by the inner and the outer vessel body, in at least one region, preferably in an upper marginal region, of the two vessel bodies, being fused or welded together. A gas-filled interspace is hereby formed between the two vessel bodies. While the vessel bodies are being mutually connected, the pressure compensation opening allows a gas exchange between the interspace and the exterior, so that no overpressure or underpressure can arise in the interspace. After the vessel bodies have been mutually connected, the interspace can optionally be flushed with a gas, for example air or an inert gas such as nitrogen, through the pressure compensation opening. After this, the pressure compensation opening is sealed by the plug.
[0009] The present invention offers particular advantages if the inner and the outer vessel body are made from glass. In this case, the pressure compensation opening is particularly important to prevent stresses during the production and, in particular, during the fusion of the two vessel bodies. In principle, it is also conceivable, however, for the two vessel bodies to consist of another material, for example of stainless steel or plastic.
[0010] The plug can consist, for example, of an elastic plastics material and can be produced in an injection molding process, a compression molding process or a transfer molding process, i.e. in a process in which a plastic or a precursor of this plastic is poured into a mold and then hardened. In particular, it is advantageous to form the gas passage channel only once the plug material has at least partially hardened, for example by piercing of the plug with a needle.
[0011] In order to ensure that no water can make its way through the gas passage channel, the plug is preferably made of a hydrophobic material (i.e. of a material which forms with water a contact angle of more than 90°). The dimensions of the gas passage channel are in this case chosen such that the capillary effect in the channel effectively prevents the passage of water. The diameter of the gas passage channel is, for example, at most about 0.1 mm, combined with a length of at least about 1 mm, for silicone plastic or a material having similar hydrophobic properties. Of course, other dimensions are also possible.
[0012] The pressure compensation channel can in particular be conFigured such that it is self-sealing, i.e. opens only due to a pressure difference between the interspace and the exterior and, without any such pressure difference, is sealed. This property can be achieved, in particular, by virtue of the above-described production of the channel by means of piercing. Following the withdrawal of the needle, such a channel automatically reseals, given appropriate elasticity of the plug material. As soon as a certain pressure difference arises between the interspace of the vessel bodies and the exterior, the gas passage channel widens, due to this pressure difference, sufficiently to allow a passage of gas. The channel nevertheless remains at all times sufficiently small in its diameter that, due to the hydrophobic properties of the material and the resultant negative capillarity, no passage of water is possible.
[0013] As material for the plug, a silicone-based plastic or a material with comparable properties is particularly preferably selected. Due to its high elasticity and its hydrophobic properties, in a silicone plastic plug a gas passage channel which allows a passage of gas, while preventing a passage of water, can be particularly well formed. The use of a silicone plastic plug is particularly advantageous when the vessel bodies are made from glass, since glass and silicone plastic, due to their similar chemical composition, can be permanently connected to each other very well.
[0014] The plug is preferably glued to that vessel body in which the pressure compensation opening is present and, in particular, is fastened to this vessel body with an acetoxy-silicone-based adhesive. Due to its composition, which is chemically related to silicone rubber, such an adhesive is particularly suitable for establishing a permanent connection to a silicone plug. In particular, such an adhesive is also eminently suitable for a connection to a glass vessel body, glass likewise having a similar chemical composition.
[0015] The plug can be conFigured, in particular, in the form of a flat plate having a pin-like (or peg-like) main portion extending from this plate into the pressure compensation opening. In other words, the plug in this case comprises a main portion, through which the gas passage channel extends, and a fastening flange, which laterally surrounds the main portion and which, at least in some areas, rests flat on the wall of the vessel body and is preferably glued to this wall. The pin-like main portion is preferably of cylindrical form and preferably has a maximum outer diameter which is smaller than the minimum inner diameter of the pressure compensation opening, so that a lateral gap is present between the main portion and that wall region of the vessel body which delimits the pressure compensation opening. This offers advantages, in particular, when the pressure compensation opening has considerable tolerances in its dimensions, as is the case, in particular, with glass vessels. The pin-like main portion can then be inserted without force into the pressure compensation opening, regardless of the precise dimensions of the latter. The connection of the plug to the vessel wall is then realized solely via the fastening flange.
[0016] In an alternative embodiment, the plug is disk-shaped or cylindrical and has on its circumferential shell surface a circumferential annular groove, into which that wall region of the vessel body which delimits the pressure compensation opening projects. The plug is thus in this case held in the pressure compensation opening at least partially by form closure, with the aid of the annular groove. In addition, in this embodiment, the plug is also preferably glued to the vessel wall. Such an embodiment of the plug is suitable, in particular, for pressure compensation in shape and dimensions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the invention are described below with reference to the drawings, in which:
[0018] FIG. 1 shows a central longitudinal section through a double-walled vessel;
[0019] FIG. 2 shows a perspective part-view of the vessel of FIG. 1 in partial section;
[0020] FIG. 3 shows an enlarged detailed view of the base region of FIG. 1 ; and
[0021] FIG. 4 shows an enlarged detailed view of the base region of a double-walled vessel according to an alternative embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] In FIGS. 1 to 3 , a first illustrative embodiment of a double-walled vessel according to the present invention is indicated. The vessel 1 is formed from an outer vessel body 2 of silicate glass and an inner vessel body 3 , accommodated therein, of the same material. The two vessel bodies are fused together at their respective upper ends 23 , 33 . The two vessel bodies hence jointly delimit a gas-filled interspace 5 . The vessel bodies thus form, with the outer base 21 , the outer side wall 22 , the inner base 31 and the inner side wall 32 , limit walls for the interspace. In one of these limit walls, here in the outer base 21 , a pressure compensation opening 24 is present. In the present example, this has a diameter of about 1.5 to 3.5 mm. Since the vessel bodies consist of glass, the shape and dimensions of this pressure compensation opening can be subject to considerable variations, even within a production series. The pressure compensation opening is in any event, however, sufficiently large to allow a rapid pressure compensation between the interspace and the exterior in the fusion of the vessel bodies.
[0023] Following the connection of the vessel bodies, this pressure compensation opening is sealed with a plug 4 . This has the shape of a flat, circular disk, which has a central pin-like main portion 42 extending into the pressure compensation opening. In the present example, the outer diameter d of the main portion is about 1.5 mm. It is in this case smaller throughout than the inner diameter D of the pressure compensation opening, even when the production tolerances are taken into account. From this pin-like main portion, a disk-like fastening flange 43 extends laterally outward and rests flat on the outer side of the base 21 . This fastening flange 43 is glued to the base 21 by means of an adhesive.
[0024] The main portion 42 has a central gas passage channel 41 . This channel has been formed by piercing of the main portion with a needle having a diameter of, for example, about 0.6 mm. Other dimensions of the needle are, of course, possible. Once the needle has been withdrawn, the gas passage channel is essentially resealed due to the elastic properties of the plug material. In the event of pressure differences between the interspace and the exterior, the elasticity of the material, however, enables the channel to widen sufficiently to allow gas to pass through.
[0025] The plug preferably consists of a silicone-based plastic, in the present example of silicone having a hardness of Shore A 70. The plug has been produced by means of injection molding. Due to its hydrophobic properties and the resultant negative capillary effect, the plug, despite the presence of the gas passage channel, prevents water from penetrating into the interspace 5 . This is the case even under the aggressive chemical conditions in a dishwasher and when dishes are washed by hand with or without detergent. If hot water is put into the vessel, then the expanding air in the interspace 5 can escape through the gas passage channel 41 and, upon cooling, can force its way back in correspondingly.
[0026] In order to fasten the plug to the base 21 , a silicone-based glue is used, in the present example in particular an acetoxy-silicone-based glue, as is available, for example, from the company Henkel Loctite Europe under the name Loctite™ 5366. This glue, on the one hand, exhibits very good adhesion on the silicone material of the plug and, on the other hand, allows very good connection to the glass material of the outer vessel body.
[0027] An alternative embodiment is represented in FIG. 4 . In contrast to the first embodiment, the pressure compensation opening is here not arranged centrally in the base 21 , but is offset to the center axis of the vessel. The plug 4 ′ has a substantially cylindrical-disk-shaped basic form. On the cylindrical shell surface there is formed a circumferential annular groove 44 , into which a region of the base 21 , which delimits the pressure compensation opening, projects. The plug 4 ′ is thus held in the region of the pressure compensation opening in the base 21 , with the aid of this groove, at least partially by form closure. In addition, the plug 4 ′ is also glued to the base 21 in the region of the annular groove. The gas passage channel 41 ′ is formed in the same way as in the first embodiment, by piercing of the at least partially hardened plug 4 ′ by a needle. In comparison to the first embodiment, the second embodiment demands far smaller tolerances for the shape and dimensions of the pressure compensation opening, since the plug is fastened directly in the region of this opening.
[0028] Of course, a large number of modifications are possible, and the invention is in no way limited to the above-discussed illustrative embodiments. For instance, the double-walled vessel can have a different shape than the shape, represented here, of a tall drinking glass, for example as a cup with handle or as a jug with pouring spout. The pressure compensation opening sealed by the plug can also be present in another region of the outer wall of the vessel. Though the vessel is preferably made from glass, it can also be made from another material. Correspondingly, other materials for the plug and for the adhesive are also conceivable. Instead of just a single gas passage channel, a plurality of such channels can also be formed. | A double-walled vessel ( 1 ) is disclosed, which has a pressure equalization opening ( 24 ). Said opening is closed by a stopper ( 4 ), which has at least one gas passage channel ( 41 ). Said channel is configured such that it allows air to pass, while it prevents the penetration of water into the intermediate space. The stopper is preferably made from a silicone-based plastic and fastened to the vessel by means of an adhesive based on acetoxy silicone. For fastening purposes, it may comprise a disk-like fastening flange ( 43 ). | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 61/184,397 filed Jun. 5, 2009, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to reagents and kits, and the use of such reagents and kits, for the amplification of nucleic acids. More specifically, the present invention relates to the use of reagents and kits in recombinase polymerase amplification processes.
BACKGROUND OF THE INVENTION
[0003] Recombinase Polymerase Amplification (RPA) is a process in which recombinase-mediated targeting of oligonucleotides to DNA targets is coupled to DNA synthesis by a polymerase (U.S. Pat. No. 7,270,981 filed Feb. 21, 2003; U.S. Pat. No. 7,399,590 filed Sep. 1, 2004; U.S. Pat. No. 7,435,561 filed Jul. 25, 2006 and U.S. Pat. No. 7,485,428 filed Aug. 13, 2007, as well as, U.S. application Ser. No. 11/628,179, filed Aug. 30, 2007; Ser. No. 11/800,318 filed May 4, 2007 and 61/179,793 filed May 20, 2009; the disclosures of the foregoing patents and patent applications are each hereby incorporated by reference in its entirety). RPA depends upon components of the cellular DNA replication and repair machinery. The notion of employing some of this machinery for in vitro DNA amplification has existed for some time (Zarling et al., U.S. Pat. No. 5,223,414), however the concept has not transformed to a working technology until recently as, despite a long history of research in the area of recombinase function involving principally the E. coli RecA protein, in vitro conditions permitting sensitive amplification of DNA have only recently been determined (Piepenburg et al. U.S. Pat. No. 7,399,590, also Piepenburg et al., PlosBiology 2006). Development of a ‘dynamic’ recombination environment having adequate rates of both recombinase loading and unloading that maintains high levels of recombination activity for over an hour in the presence of polymerase activity proved technically challenging and needed specific crowding agents, notably PEG molecules of high molecular weight (e.g., Carbowax 20M molecular weight 15-20,000 and PEG molecular weight 35,000), in combination with the use of recombinase-loading factors, specific strand-displacing polymerases and a robust energy regeneration system.
[0004] The RPA technology depended critically on the empirical finding that high molecular weight polyethylene glycol species (particularly >10,000 Daltons or more) very profoundly influenced the reaction behavior. It has previously been discovered that polyethylene glycol species ranging in size from at least molecular weight 12,000 to 100,000 stimulate RPA reactions strongly. While it is unclear how crowding agents influence processes within an amplification reaction, a large variety of biochemical consequences are attributed to crowding agents and are probably key to their influence on RPA reactions.
[0005] Crowding agents have been reported to enhance the interaction of polymerase enzymes with DNA (Zimmerman and Harrison, 1987), to improve the activity of polymerases (Chan E. W. et al., 1980), to influence the kinetics of RecA binding to DNA in the presence of SSB (Lavery P E, Kowalczykowski S C. J Biol Chem. 1992 May 5; 267(13):9307-14). Crowding agents are reported to have marked influence on systems in which co-operative binding of monomers is known to occur such as during rod and filament formation (Rivas et al., 2003) by increasing association constants by potentially several orders of magnitude (see Minton, 2001). In the RPA system multiple components rely on co-operative binding to nucleic acids, including the formation of SSB filaments, recombinase filaments, and possibly the condensation of loading agents such as UvsY. Crowding agents are also well known to enhance the hybridization of nucleic acids (Amasino, 1986), and this is a process that is also necessary within RPA reactions. Finally, and not least, PEG is known to drive the condensation of DNA molecules in which they change from elongated structures to compact globular or toroidal forms, thus mimicking structures more common in many in vivo contexts (see Lerman, 1971; also see Vasilevskaya. et. al., 1995; also see Zinchenko and Anatoly, 2005) and also to affect the supercoiling free energy of DNA (Naimushin et al., 2001).
[0006] Without intending to be bound by theory, it is likely that crowding agents influence the kinetics of multiple protein-protein, protein-nucleic acid, and nucleic acid-nucleic acid interactions within the reaction. The dependence on large molecular weight crowding agents for the most substantial reaction improvement (probably greater than about 10,000 Daltons in size) may reflect a need to restrict the crowding effect to reaction components over a certain size (for example oligonucleotides, oligonucleotide:protein filaments, duplex products, protein components) while permitting efficient diffusion of others (say nucleotides, smaller peptides such as UvsY). Further, it may also be that the high molecular weight preference might reflect findings elsewhere that as PEG molecular weight increases the concentration of metal ions required to promote DNA condensation decreases. In any case it is an empirical finding that RPA is made effective by the use of high molecular weight polyethylene glycols.
[0007] In addition to a need for specific type of ‘crowded’ reaction conditions as described above (reaction in the presence of crowding agents), effective RPA reaction kinetics depend on a high degree of ‘dynamic’ activity within the reaction with respect to recombinase-DNA interactions. In other words, the available data which includes (i) reaction inhibition by ATP-γ-S, or removal of the acidic C terminus of RecA or UvsX, and (ii) inhibition by excessive ATP (Piepenburg et al., 2006) suggest that not only is it important that recombinase filaments can be formed rapidly, but also important that they can disassemble quickly. This data is consistent with predictions made in earlier U.S. Pat. No. 7,270,981. Rapid filament formation ensures that at any given moment there will be a high steady state level of functional recombinase-DNA filaments, while rapid disassembly ensures that completed strand exchange complexes can be accessed by polymerases.
SUMMARY OF THE INVENTION
[0008] The invention provides a kit and reagents for, as well as methods of, DNA amplification, termed RPA. RPA comprises the following steps (See FIG. 1 ): First, a recombinase agent is contacted with a first and a second nucleic acid primer to form a first and a second nucleoprotein primer. Second, the first and second nucleoprotein primers are contacted to a double stranded target sequence to form a first double stranded structure at a first portion of said first strand and form a double stranded structure at a second portion of said second strand so the 3′ ends of said first nucleic acid primer and said second nucleic acid primer are oriented towards each other on a given template DNA molecule. Third, the 3′ end of said first and second nucleoprotein primers are extended by DNA polymerases to generate first and second double stranded nucleic acids, and first and second displaced strands of nucleic acid. Finally, the second and third steps are repeated until a desired degree of amplification is reached.
[0009] In one aspect, embodiments of the present invention provide compositions and kits for recombinase polymerase amplification processes of DNA amplification of a target nucleic acid molecule, which include one or more freeze dried pellets. For example, each freeze dried pellet includes a combination of the following reagents in the following concentrations (which unless otherwise indicated can be the concentration either when reconstituted or when freeze dried): (1) 1.5%-5% (weight/lyophilization mixture volume) of polyethylene glycol (e.g., 2.28% (weight/lyophilization mixture volume) of polyethylene glycol with a molecular weight of 35 kilodaltons); (2) 2.5%-7.5% weight/volume of trehalose (e.g., 5.7%); (3) 0-60 mM Tris buffer; (4) 1-10 mM DTT; (5) 150-400 μM dNTPs; (6) 1.5-3.5 mM ATP; (7) 100-350 ng/μL uvsX recombinase; (8) optionally 50-200 ng/μL uvsY; (9) 150-800 ng/μL gp32; (10) 30-150 ng/μL Bacillus subtilis Pol I (Bsu) polymerase or S. aureus Pol I large fragment (Sau polymerase); (11) 20-75 mM phosphocreatine; and (12) 10-200 ng/μL creatine kinase.
[0010] In another aspect, rehydration buffers for reconstituting freeze dried pellets for nucleic acid amplification are provided. In some embodiments, the rehydration buffer for reconstituting the freeze dried pellets are included with the kits described herein and, the rehydration buffer includes 0-60 mM Tris buffer, 50-150 mM Potassium Acetate, and 2.5%-7.5% weight/volume of polyethylene glycol. In certain embodiments, the kits further include a 160-320 mM Magnesium Acetate solution.
[0011] In certain embodiments of the compositions and kits described herein, the freeze dried pellets also include the first and/or the second nucleic acid primers for the RPA process. In certain embodiments of the foregoing kits, the freeze dried pellets also include a nuclease. For example, the nuclesase is exonuclease III (exoIII), endonuclease IV (Nfo) or 8-oxoguanine DNA glycosylase (fpg).
[0012] In certain embodiments of the compositions and kits described herein, the kits or compositions may further include positive control primers and target DNA to test the activity of the kit components. For example, the kit can include a positive control DNA (e.g., human genomic DNA) and first and second primers specific for the positive control DNA.
[0013] In another aspect, methods of recombinase polymerase amplification are provided comprising the following steps: First, one of the kits or compositions described herein that include one or more freeze dried pellets and rehydration buffer is provided. Second, at least one of the freeze dried pellets is reconstituted, in any order, with the rehydration buffer, the first and the second nucleic acid primers for the RPA process, the target nucleic acid, and optionally water to a desired volume. Third, Magnesium (e.g., Magnesium Acetate solution) is added to initiate the reaction. Finally, the reaction is incubated until a desired degree of amplification is achieved. In some embodiments, this last step comprises mixing the sample several minutes after the reaction is initiated.
[0014] In yet another aspect, embodiments of the present invention also provide methods to control RPA reactions, achieved by initiating the RPA reaction with the addition of Magnesium (e.g., with Magnesium Acetate). For example, the methods include at least three steps. In the first step, the following reagents are combined in a solution in the absence of Magnesium: (1) at least one recombinase; (2) at least one single stranded DNA binding protein; (3) at least one DNA polymerase; (4) dNTPs or a mixture of dNTPs and ddNTPs; (5) a crowding agent (e.g., polyethylene glycol); (6) a buffer; (7) a reducing agent; (8) ATP or ATP analog; (9) optionally at least one recombinase loading protein; (10) a first primer and optionally a second primer; and (11) a target nucleic acid molecule. In the second step, Magnesium is added to initiate the reaction. In the third step, the reaction is incubated until a desired degree of amplification is achieved. In certain embodiments, one or more of the reagents are freeze dried before the first step.
[0015] In yet another aspect, embodiments of the present invention also include nucleic acid amplification mixtures for isothermal nucleic acid amplification. For example, the mixtures include at least: (1) at least one recombinase; (2) at least one single stranded DNA binding protein; (3) at least one strand displacing polymerase DNA polymerase; (4) dNTPs or a mixture of dNTPs and ddNTPs; (5) ATP or ATP analog; (6) trehalose; (7) optionally at least one recombinase loading protein; (8) optionally polyethylene glycol (9) optionally a first primer and optionally a second primer; and (10) optionally a target nucleic acid molecule.
[0016] In another aspect, embodiments of the present invention include kits for nucleic acid amplification processes, such as isothermal nucleic acid amplification processes (e.g., RPA amplification of DNA) a target nucleic acid molecule, which include one or more freeze dried pellets. In some embodiments, the freeze dried pellets comprise polyethylene glycol.
[0017] For example, the amount of polyethylene glycol in the freeze dried pellets is an amount to allow the amplification process to proceed (0.3%-7.5% weight/lyophilization mixture volume of PEG). In some embodiments, the freeze dried pellets comprise trehalose. For example, the amount of trehalose in the freeze dried pellets is 2.5%-7.5% weight/lyophilization mixture volume of trehalose.
[0018] In yet another aspect, embodiments of the present invention include any of the freeze dried pellets described herein. In some embodiments, the freeze dried pellets comprise polyethylene glycol. For example, the amount of polyethylene glycol in the freeze dried pellets is an amount to allow the amplification process to proceed (0.3%-7.5% weight/lyophilization mixture volume of PEG). In some embodiments, the freeze dried pellets comprise trehalose. For example, the amount of trehalose in the freeze dried pellets is 2.5%-7.5% weight/lyophilization mixture volume of trehalose.
[0019] In yet another aspect, embodiments of the present invention include rehydration buffers for reconstituting the freeze dried pellets described herein. In some embodiments, the rehydration buffer comprises polyethylene glycol (e.g., 0.3%-7.5% weight/ volume of PEG). In some embodiments, a kit comprising any of the foregoing rehydration buffers is provided.
[0020] Other embodiments, objects, aspects, features, and advantages of the invention will be apparent from the accompanying description and claims. It is contemplated that whenever appropriate, any embodiment of the present invention can be combined with one or more other embodiments of the present invention, even though the embodiments are described under different aspects of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 schematically depicts an RPA reaction.
[0022] FIG. 2 depicts the structure of an annealed Exo-probe. The abasic THF residue is cleaved by exonuclease only when the probe is bound. Cleavage by exonuclease separates the fluorophore and quencher and generates fluorescent signal.
[0023] FIG. 3 depicts the structure of an annealed LF-probe. The abasic THF residue is cleaved by Nfo only when the probe is bound.
[0024] FIG. 4 depicts the structure of an annealed Fpg-probe. The abasic dR residue is cleaved by fpg only when the probe is bound. Cleavage by fpg releases the fluorophore from the probe and generates fluorescent signal.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Brief Description of RPA
[0026] RPA is a method (process) for amplifying DNA fragments. RPA employs enzymes, known as recombinases, that are capable of pairing oligonucleotide primers with homologous sequence in duplex DNA. In this way, DNA synthesis is directed to defined points in a sample DNA. Using two gene-specific primers, an exponential amplification reaction is initiated if the target sequence is present. The reaction progresses rapidly and results in specific amplification from just a few target copies (such as less than 10,000 copies, less than 1000 copies, less than 100 copies or less than 10 copies) to detectable levels within as little as 20-40 minutes.
[0027] RPA reactions contain a blend of proteins and other factors that are required to support both the activity of the recombination element of the system, as well as those which support DNA synthesis from the 3′ ends of olignucleotides paired to complementary substrates. The key protein component of the recombination system is the recombinase itself, which may originate from prokaryotic, viral or eukaryotic origin. Additionally, however, there is a requirement for single-stranded DNA binding proteins to stabilize nucleic acids during the various exchange transactions that are ongoing in the reaction. A polymerase with strand-displacing character is required specifically as many substrates are still partially duplex in character. Reduction to practice has established that in order to make the reaction capable of amplifying from trace levels of nucleic acids precise in vitro conditions are required that include the use of crowding agents and loading proteins. A system comprising a bacteriophage T6 UvsX recombinase (e.g., T6UvsXH66S), a bacteriophage Rb69 UvsY loading agent, a bacteriophage Rb69 gp32 and a S. aureus Pol I large fragment has proven to be effective.
[0028] Embodiments of the present invention provide for Recombinase Polymerase Amplification (RPA)—a method for the amplification of target nucleic acid polymers. They also provide for a general in vitro environment in which high recombinase activity is maintained in a highly dynamic recombination environment, supported by ATP. One benefit of RPA is that it may be performed without the need for thermal melting of double-stranded templates. Therefore, the need for expensive thermocyclers is also eliminated.
[0029] Throughout this specification, various patents, published patent applications and scientific references are cited to describe the state and content of the art. Those disclosures, in their entireties, are hereby incorporated into the present specification by reference.
[0030] In Recombinase Polymerase Amplification single-stranded, or partially single-stranded, nucleic acid primers are targeted to homologous double-stranded, or partially double-stranded, sequences using recombinase agents, which form D-loop structures. The invading single-stranded primers, which are part of the D-loops, are used to initiate polymerase synthesis reactions. A single primer species will amplify a target nucleic acid sequence through multiple rounds of double-stranded invasion followed by synthesis. If two opposing primers are used, amplification of a fragment—the target sequence—can be achieved.
[0031] The target sequence to be amplified, in any of the embodiments of the present invention, is preferably a double stranded DNA. However, the embodiments of the present invention are not limited to double stranded DNA because other nucleic acid molecules, such as a single stranded DNA or RNA can be turned into double stranded DNA by one of skill in the art using known methods. Suitable double stranded target DNA may be a genomic DNA or a cDNA. An RPA of the invention may amplify a target nucleic acid at least 10 fold, preferably at least 100 fold, more preferably at least 1,000 fold, even more preferably at least 10,000 fold, and most preferably at least 1,000,000 fold.
[0032] The terms ‘nucleic acid polymer’ or ‘nucleic acids’ as used in this description can be interpreted broadly and include DNA and RNA as well as other hybridizing nucleic-acid-like molecules such as those with substituted backbones e.g. peptide nucleic acids (PNAs), morpholino backboned nucleic acids, locked nucleic acid or other nucleic acids with modified bases and sugars.
[0033] In addition, nucleic acids of embodiments of the present invention may be labeled with a detectable label. A detectable label includes, for example, a fluorochrome, an enzyme, a fluorescence quencher, an enzyme inhibitor, a radioactive label and a combination thereof.
[0034] Lyophilization of the RPA Reaction
[0035] One advantage of RPA is that the reagents for RPA, may be freeze dried (i.e., lyophilized) before use. Freeze dried reagents offer the advantage of not requiring refrigeration to maintain activity. For example, a tube of RPA reagents may be stored at room temperature. This advantage is especially useful in field conditions where access to refrigeration is limited. Freeze dried reagents also offer the advantage of long term storage without significant activity loss. For example, a tube of RPA reagents may be stored at −20° C. for up to six months without significant activity loss.
[0036] While lyophilization is a well-established process there is no guarantee that all components of a reaction system will successfully be co-lyophilized and reconstituted under the same conditions. We have attempted to lyophilize RPA reactions with and without various of the final reaction components. The disaccharide sugar trehalose proves in these experiments to be required to stabilize the lyophilisate, permitting room temperature storage for at least 10 days. We have also found that it is preferable to exclude the salt (e.g., Potassium Acetate) and reduce the buffer concentration to 25 mM of Tris or less from the lyophilisate, to maximize its stability—particularly for storage above 0° C.
[0037] We have also found that, if salt is present in the lyophilisate, polyethylene glycol is required to stabilize the lyophilisate. By contrast, if salt is not present, then PEG is not required to stabilize the lyophilizate, and need only be provided in the rehydration buffer. A typical RPA reaction will have a final PEG concentration in the reaction of 5%-6% (w/v).
[0038] In addition trehalose and PEG, the reagents that can be freeze dried before use can include, at least, the recombinase, the single stranded DNA binding protein, the DNA polymerase, the dNTPs or the mixture of dNTPs and ddNTPs, the reducing agent, the ATP or ATP analog, the recombinase loading protein, and the first primer and optionally a second primer or a combination of any of these.
[0039] In some embodiments, the RPA reagents may be freeze dried onto the bottom of a tube, or on a bead (or another type of solid support). In use, the reagents are reconstituted with buffer (a) Tris-Acetate buffer at a concentration of between 0 mM to 60 mM; (b) 50 mM to 150 mM Potassium Acetate and (c) polyethylene glycol at a concentration of between 2.5% to 7.5% by weight/volume. If the primers were not added before freeze drying, they can be added at this stage. Finally, a target nucleic acid, or a sample suspected of containing a target nucleic acid is added to begin the reaction. The target, or sample, nucleic acid may be contained within the reconstitution buffer as a consequence of earlier extraction or processing steps. The reaction is incubated until a desired degree of amplification is achieved.
[0040] We have found that it is possible to increase the sensitivity of the RPA reaction by agitating or mixing the sample several minutes (e.g., two, three, four, five or six minutes) after reconstituting and initiating the reaction. For example, after reconstituting and initiating the RPA reaction, the tube containing the RPA reaction is placed into an incubator block set to a temperature of 37° C. and is incubated for 4 minutes. The sample is then taken out of the incubator, vortexed and spun down. The sample is then returned to the incubator block and incubated for an additional 15-40 minutes.
[0041] In one aspect, embodiments of the present invention comprise kits for performing RPA reactions. In certain embodiments, the kits include one or more freeze dried pellets each including a combination of reagents for performing RPA reactions. In certain embodiments, the kits comprise 8 freeze dried pellets. In some embodiments, the kits comprise 96 freeze dried pellets. If desired, the freeze dried reagents may be stored for 1 day, 1 week, 1 month or 1 year or more before use.
[0042] In certain embodiments, the pellets can be assembled by combining each reagent in the following concentrations (which unless otherwise indicated can be the concentration either when reconstituted or when freeze dried): (1) 1.5%-5% (weight/lyophilization mixture volume) of polyethylene glycol; (2) 2.5%-7.5% weight/volume of trehalose; (3) 0-60 mM Tris buffer; (4) 1-10 mM DTT; (5) 150-400 [ iM dNTPs; (6) 1.5-3.5 mM ATP; (7) 100-350 ng/μL uvsX recombinase; (8) optionally 50-200 ng/μL uvsY; (9) 150-800 ng/μL gp32; (10) 30-150 ng/μL Bsu polymerase or Sau polymerase; (11) 20-75 mM phosphocreatine; and (12) 10-200 ng/μL creatine kinase. For example, the reagents in the solution mixture frozen for lyophilization can have approximately the following concentrations: (1) 2.28% weight/volume of polyethylene glycol with a molecular weight of 35 kilodaltons; (2) 5.7% weight/volume of trehalose; (3) 25 mM Tris buffer; (4) 5 mM DTT; (5) 240 μM dNTPs; (6) 2.5 mM ATP; (7) 260 ng/μL uvsX recombinase; (8) 88 ng/μL uvsY; (9) 254 ng/μL gp32; (10) 90 ng/μL Bsu polymerase or Sau polymerase; (11) 50 mM phosphocreatine; and (12) 100 ng/μL creatine kinase. The reagents may be freeze dried onto the bottom of a tube or in a well of a multi-well container. The reagents may be dried or attached onto a mobile solid support such as a bead or a strip, or a well.
[0043] While it is often preferred that the volume of the reagent mixture that is frozen and lyophilized is the same as the final volume of the RPA reaction after rehydration, this is not necessary. For example, an 80 μL volume of reagents can be freeze dried, which can then be reconstituted to a final RPA reaction volume of 50 μL.
[0044] In certain embodiments, the kits further include a rehydration buffer for reconstituting the freeze dried pellets, where the rehydration buffer includes 0-60 mM Tris buffer, 50-150 mM Potassium Acetate, and 0.3%-7.5% weight/volume of polyethylene glycol. For example, the rehydration buffer includes approximately 25 mM Tris buffer, 100 mM Potasium Acetate, and 5.46% weight/volume of polyethylene glycol with a molecular weight of 35 kilodaltons. In certain embodiments, the kit will comprise 4 mL of rehydration buffer.
[0045] In certain embodiments, the kits further include a 160-320 mM Magnesium Acetate solution (e.g., about 280 mM Magnesium Acetate solution). In some embodiments, the kit will comprise 250 μL of the Magnesium Acetate solution. In other embodiments, the rehydration buffer itself will comprise 8-16 mM Magnesium Acetate (e.g., about 14 mM Magnesium Acetate).
[0046] In certain embodiments of the foregoing kits, the freeze dried pellets also include the first and/or the second nucleic acid primers for the RPA process. In certain embodiments of the foregoing kits, the freeze dried pellets also include 50-200 ng/μL of either exonuclease III (exoIII), endonuclease IV (Nfo) or 8-oxoguanine DNA glycosylase (fpg).
[0047] In any of the foregoing embodiments, the kit may further include positive control primers and target DNA to test the activity of the kit components. For example, the kit can include a positive control DNA (e.g., human genomic DNA) and first and second primers specific for the positive control DNA.
[0048] In yet another aspect, embodiments of the present invention also include nucleic acid amplification mixtures for isothermal nucleic acid amplification. For example, the mixtures include at least: (1) at least one recombinase; (2) at least one single stranded DNA binding protein; (3) at least one strand displacing polymerase DNA polymerase; (4) dNTPs or a mixture of dNTPs and ddNTPs; (5) ATP or ATP analog; (6) trehalose; (7) optionally at least one recombinase loading protein; (8) optionally polyethylene glycol (9) optionally a first primer and optionally a second primer; and (10) optionally a target nucleic acid molecule.
[0049] In another aspect, embodiments of the present invention include kits for nucleic acid amplification processes, such as isothermal nucleic acid amplification processes (e.g., RPA amplification of DNA) a target nucleic acid molecule, which include one or more freeze dried pellets. In some embodiments, the freeze dried pellets comprise polyethylene glycol. For example, the amount of polyethylene glycol in the freeze dried pellets is an amount to allow the amplification process to proceed (0.3%-7.5% weight/lyophilization mixture volume of PEG). In some embodiments, the freeze dried pellets comprise trehalose. For example, the amount of trehalose in the freeze dried pellets is 2.5%-7.5% weight/lyophilization mixture volume of trehalose.
[0050] In yet another aspect, embodiments of the present invention include any of the freeze dried pellets described herein. In some embodiments, the freeze dried pellets comprise polyethylene glycol. For example, the amount of polyethylene glycol in the freeze dried pellets is an amount to allow the amplification process to proceed (0.3%-7.5% weight/lyophilization mixture volume of PEG). In some embodiments, the freeze dried pellets comprise trehalose. For example, the amount of trehalose in the freeze dried pellets is 2.5%-7.5% weight/lyophilization mixture volume of trehalose.
[0051] In yet another aspect, embodiments of the present invention include rehydration buffers for reconstituting the freeze dried pellets described herein. In some embodiments, the rehydration buffer comprises polyethylene glycol (e.g., 0.3%-7.5% weight/ volume of PEG). In some embodiments, a kit comprising any of the foregoing rehydration buffers is provided.
[0052] RPA initiation by Magnesium
[0053] In another aspect, methods of recombinase polymerase amplification are provided comprising the following steps: First, one of the foregoing kits that include one or more freeze dried pellets and rehydration buffer is provided. Second, at least one of the freeze dried pellets is reconstituted, in any order, with the rehydration buffer, the first and the second nucleic acid primers for the RPA process, the target nucleic acid, and optionally water to a desired volume. Third, Magnesium (e.g., Magnesium Acetate solution) is added to initiate the reaction. Finally, the reaction is incubated until a desired degree of amplification is achieved.
[0054] RPA is a versatile method, but it can be improved by incorporation of features to control the RPA reaction. Embodiments of the present invention also provide methods to control RPA reactions, achieved by initiating the RPA reaction with the addition of Magnesium (e.g., with Magnesium Acetate). For example, the method includes at least three steps. In the first step, the following reagents are combined in a solution in the absence of Magnesium: (1) at least one recombinase; (2) at least one single stranded DNA binding protein; (3) at least one DNA polymerase; (4) dNTPs or a mixture of dNTPs and ddNTPs; (5) a crowding agent (e.g., polyethylene glycol); (6) a buffer; (7) a reducing agent; (8) ATP or ATP analog; (9) optionally at least one recombinase loading protein; (10) a first primer and optionally a second primer; and (11) a target nucleic acid molecule. In the second step, Magnesium is added to initiate the reaction. In the third step, the reaction is incubated until a desired degree of amplification is achieved. In certain embodiments, one or more of the reagents are freeze dried before the first step. Furthermore, it is possible to initiate a plurality of RPA reactions simultaneously by the simultaneous addition of Magnesium to each reaction.
EXAMPLES
[0055] The present invention is further defined in the following Examples. It should be understood that these Examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various uses and conditions.
Example 1
Reagents for RPA Reactions
[0056] To form a freeze dried reaction pellet for a typical single basic RPA reaction, the following RPA reagents with the indicated concentrations are freeze dried (lyophilized) onto the bottom of a tube:
Basic RPA Freeze Dried Reaction Pellet
[0057]
[0000]
Component
Concentration
PEG 35,000
2.28%
(w/v)
Trehalose
5.7%
(w/v)
UvsX recombinase
260
ng/μL
UvsY
88
ng/μL
Gp32
254
ng/μL
Sau polymerase
90
ng/μL
ATP
2.5
mM
dNTPs
240
μM
Tris buffer
25
mM
DTT
5
mM
Phosphocreatine
50
mM
Creatine kinase
100
ng/μL
[0058] For reconstituting the freeze dried reaction pellet, a rehydration solution is prepared from the following rehydration buffer:
Rehydration Buffer
[0059]
[0000]
Component
Concentration
Tris buffer
25
mM
Potassium Acetate
100
mM
PEG 35,000
5.46%
(w/v)
[0060] Unlike PCR, which requires small volumes for rapid temperature change, there is no limit to the reaction volume of RPA. Reaction volumes of 25 μL, 50 μL, 100 μL, 1 mL, 10 mL and 100 mL or larger may be performed in one vessel. For the examples given below, a reaction volume of 50 μL is used.
[0061] To permit monitoring of the RPA reaction, a nuclease may also be added to each freeze dried reaction pellet. For example, the “Exo RPA Freeze Dried Reaction Pellet” is the basic RPA freeze-dried reaction pellet plus 96 ng/μL exonuclease III (exoIII). Similarly, the “Nfo RPA Freeze Dried Reaction Pellet” is the basic RPA freeze-dried reaction pellet plus 62 ng/μL endonuclease IV (Nfo). Finally, the “Fpg RPA Freeze Dried Reaction Pellet” is the basic RPA freeze-dried reaction pellet plus 114 ng/μL 8-oxoguanine DNA glycosylase (fpg).
[0062] The tubes with the freeze dried pellets can be vacuum-sealed in pouches, for example in 12 strips of 8 pouches/strip for a total of 96 RPA reactions. While the vacuum-sealed pouches can be stored at room temperature for days without loss of activity, long term storage (up to at least about six months) at −20° C. is preferred. The rehydration buffer can be stored as frozen aliquots, for example 4×1.2 mL aliquots. For long term storage (up to at least about six months), storage at −20° C. is preferred. Unused rehydration buffer can be refrozen, or stored at 4° C. for up to 1 week. However, excessive freeze-thaw cycles should be avoided.
Example 2
Basic RPA Reaction
[0063] A basic RPA reaction for each sample is established by reconstituting the basic RPA freeze-dried reaction pellet of Example 1 with a suitable rehydration solution. The rehydration solution is prepared from the rehydration buffer of Example 1, amplification primers, and template (and water to a total volume of 47.5 μL per sample).
[0064] The components of the rehydration solution can be combined in a master-mix for the number of samples required. In some circumstances, for example when performing a primer screen, a number of different rehydration solutions are to be made (here according to the number of primer pairs being tested). In that case components common to all reactions (e.g., template, rehydration buffer, water) is prepared as a master-mix, distributed in a corresponding volume into fresh tubes, and is combined with the required volume of the different primer pairs. The different rehydration solutions are then used as normal according to the protocol below.
[0065] The reaction is initiated by the addition of 2.5 μL of a 280 mM Magnesium-Acetate solution, bringing the final reaction volume to 50 μL per sample.
[0066] For each sample, the rehydration solution is prepared by adding 2.4 μL of the first primer (10 μM), 2.4 μL of the second primer (10 μM), the Template and H 2 O to a total volume of 18 μL. 29.5 ηL of the rehydration buffer of Example 1 is added. The rehydration solution is then vortexed and is spun briefly.
[0067] For each sample, the 47.5 μL of rehydration solution is transferred to a basic RPA freeze-dried reaction pellet of Example 1. The sample is mixed by pipetting up and down until the entire pellet has been resuspended.
[0068] For each sample, 2.5 μL of 280 mM Magnesium-Acetate is added and is mixed well. One way to do this simultaneously for many samples is to place the Magnesium-Acetate into the lid of the reaction tubes and then spin it down into the tubes to initiate the reactions. The reaction mixture is vortexed briefly and is spun down once again.
[0069] The tubes are place into a suitable incubator block (e.g., set to a temperature of 37-39° C.) and are incubated for 4 minutes. For ultra-high sensitivity, after 4 minutes, the samples are taken out of the incubator, vortexed, spun down and returned to the incubator block. The total incubation time is 20-40 minutes. If a timecourse of the reaction is desired the incubation time is adjusted as required. After the reaction is completed, the outcome of each reaction is typically analyzed by an endpoint method, such as agarose-gel-electrophoresis.
Example 3
Detection Probes for Use with RPA Reactions
[0070] A detection probe can be used to monitor RPA reactions. The probe is a third oligonucleotide primer which recognizes the target amplicon and is typically homologous to sequences between the main amplification primers. The use of fluorophore/quencher with probes in real-time detection formats is a very convenient way to monitor amplification events in RPA reactions.
[0071] RPA technology is compatible with a variety of different types of oligonucleotide probes. The structures of three types—Exo-probes, LF-probes, and Fpg-probes—are each discussed below.
[0072] Exo-Probes
[0073] Exo-probes are generally 46-52 oligonucleotides long. Signal is generated by an internal dT fluorophore (Fluorescein or TAMRA) and quenched by an internal dT quencher (typically Black Hole Quencher (BHQ) 1 or 2) located 1-5 bases 3′ to the fluorophore. In this case, probes are restricted to contain sequences where two thymines can be found with <6 intervening nucleotides. One of the bases between the fluorophore and quencher is the abasic nucleotide analog, tetrahydrofuran (THF—sometimes referred to as a ‘dSpacer’). There should be at least 30 nucleotides placed 5′ to the THF site, and at least a further 15 located 3′ to it. When the probe has hybridized to the target sequence, Exonuclease III will recognize and cleave the THF, thereby separating the fluorophore and quencher and generating a fluorescent signal. The THF should be at least 31 bases from the 5′ end of the probe and 16 bases from the 3′ end. Finally, the probe is blocked from polymerase extension by a 3′-blocking group (e.g., Biotin-TEG). FIG. 2 depicts a typical annealed Exo-probe.
[0074] While there is no fixed rule describing the best position of a given probe relative to its corresponding amplification primers, care must be taken to avoid the possibility that primer artefacts can be detected by the probe. Although primers that have the same direction as the probe can even overlap its 5′ part, this overlap must not extend up to the fluorophore/abasic-site/quencher portion of the probe (i.e., the overlap of the primer should be restricted to the 5′-most 27 nucleotides of the probe or so). This design will prevent the inadvertent generation of hybridization targets for the ‘sensitive’ sequence element of the probe by primer artefacts. Primers opposing the direction of the probe should not overlap to avoid the occurrence of primer-probe dimers.
[0075] LF-Probes
[0076] LF-probes are often 46-52 oligonucleotides long and intended for detection of RPA reactions in simple sandwich assays such as lateral flow strips. The probe is blocked from polymerase extension by making the last nucleotide a dideoxy nucleotide. As in an Exo-probe, a THF is typically positioned about 30 bases from the 5′ end of the probe and 16 bases from the 3′ end. When the probe has annealed to the target sequence, Nfo nuclease will recognize and cleave the THF. This allows the 5′ portion of the cut probe to then act as a primer, ultimately leading to an amplicon containing the 5′ portion of the probe conjoined to the opposing primer. The amplicon is detected by virtue of labels attached to the 5′ end of the opposing primer (usually biotin) and to the 5′ end of the probe (usually FAM). The duplex formed is captured on a surface coated with the appropriate capture molecule (e.g., streptavidin for biotin or an anti-FAM antibody for FAM). RPA products are run on lateral flow strips, such as available from Milenia Biotec. FIG. 3 depicts a typical annealed LF-probe.
[0077] While there is no fixed rule describing the best position of a given probe relative to its corresponding amplification primers, care must be taken to avoid the possibility that primer artefacts can be detected by the probe. Although primers that have the same direction as the probe can even overlap its 5′ part, this overlap must not extend up to the abasic-site portion of the probe (i.e., the overlap of the primer should be restricted to the 5′-most 27 nucleotides of the probe or so). This design will prevent the inadvertent generation of hybridization targets for the ‘sensitive’ sequence element of the probe by primer artefacts. Primers opposing the direction of the probe should not overlap to avoid the occurrence of primer-probe dimers. The opposing amplification primer is usually labelled with biotin.
[0078] Fpg-Probes
[0079] Fpg-probes are generally 35 oligonucleotides long. At the 5′ end of the probe is a quencher (typically Black Hole Quencher (BHQ) 1 or 2). Signal is generated by a fluorophore (typically FAM or Texas Red) attached to the ribose of a base-less nucleotide analog (a so-called dR residue; a fluorophore/O-linker effectively replaces the base at the C1 position of the ribose) 4-6 bases downstream of the 5′ end. When the probe has annealed to the target sequence, fpg will recognize and cleave the dR, thereby releasing the fluorophore from the probe and generating a fluorescent signal. Finally, the probe is blocked from polymerase extension by a 3′-blocking group (e.g., Biotin-TEG). FIG. 4 is a schematic of a typical annealed Fpg-probe. FIG. 7 depicts the structure of an annealed Fpg-probe. The abasic dR residue is cleaved by fpg only when the probe is bound. This releases the fluorophore from the probe and generates fluorescent signal.
[0080] While there is no fixed rule describing the best position of a given Fpg-probe relative to the amplification primers with which it is used, care must be taken to avoid the possibility that primer artefacts can be detected by the probe. As a result any overlap between primers and the probe should be avoided.
Example 4
RPA Reaction with Real Time Monitoring Using Exonuclease III
[0081] A RPA reaction using exonuclease III is performed using a modified protocol of Example 2. Each sample is established by reconstituting the Exo RPA Freeze Dried Reaction Pellet of Example 1 with a suitable rehydration solution. The rehydration solution is prepared from the rehydration buffer of Example 1, amplification primers, template and an Exo-probe (and water to a total volume of 47.5 μL per sample). The reaction is initiated by the addition of 2.5 μL of a 280 mM Magnesium-Acetate solution, bringing the final reaction volume to 50 μL per sample.
[0082] For each sample, the rehydration solution is prepared by adding 2.4 μL of the first primer (10 μM), 2.4 μL of the second primer (10 μM), the Template and 0.6 μL of an Exo-probe (10 μM) as described in Example 3. H 2 O is added to bring the total volume of the foregoing components to 18 μt. 29.5 μL of the rehydration buffer of Example 1 is added. The rehydration solution is then vortexed and is spun briefly.
[0083] For each sample, the 47.5 μL of rehydration solution is transferred to an Exo RPA Freeze Dried Reaction Pellet of Example 1. The sample is mixed by pipetting up and down until the entire pellet has been resuspended. For each sample, 2.5 μL of 280 mM Magnesium-Acetate is added and is mixed well to initiate the reaction.
[0084] The tubes are place into a suitable thermal incubator/fluorometer (e.g., isothermally set to a temperature of 37-39° C.) and are incubated while fluorescence measurements are periodically taken. After 4 minutes, the samples are taken out of the incubator, vortexed, spun down and returned to the incubator/fluorometer. The total incubation/detection time is 20 minutes.
Example 5
RPA Reaction Using Nfo
[0085] A RPA reaction using Nfo is performed using a modified protocol of Example 2. Each sample is established by reconstituting the Nfo RPA Freeze Dried Reaction Pellet of Example 1 with a suitable rehydration solution. The rehydration solution is prepared from the rehydration buffer of Example 1, amplification primers, template and an LF-probe (and water to a total volume of 47.5 ηL per sample). The reaction is initiated by the addition of 2.5 μL of a 280 mM Magnesium-Acetate solution, bringing the final reaction volume to 50 μL per sample.
[0086] For each sample, the rehydration solution is prepared by adding 2.4 μL of the first primer (10 μM), 2.4 μL of the second primer (10 μM), the Template and 0.6 μL of an LF-probe (10 μM) as described in Example 3. H 2 O is added to bring the total volume of the foregoing components to 18 μL. 29.5 μL it of the rehydration buffer of Example 1 is added. The rehydration solution is then vortexed and is spun briefly.
[0087] For each sample, the 47.5 μL of rehydration solution is transferred to an Nfo RPA Freeze Dried Reaction Pellet of Example 1. The sample is mixed by pipetting up and down until the entire pellet has been resuspended. For each sample, 2.5 μL of 280 mM Magnesium-Acetate is added and is mixed well to initiate the reaction.
[0088] The tubes are place into a suitable incubator block (e.g., set to a temperature of 37-39° C.) and are incubated for 4 minutes. For ultra-high sensitivity after 4 minutes, the samples are taken out of the incubator, vortexed, spun down and returned to the incubator block. The total incubation time is 15-30 minutes. After the reaction is completed, the outcome of each reaction is typically analyzed by an endpoint method, such as a sandwich assay technique.
Example 6
[0089] RPA Reaction with Real Time Monitoring Using Fpg
[0090] A RPA reaction using fpg is performed using a modified protocol of Example 2. Each sample is established by reconstituting the Fpg RPA Freeze Dried Reaction Pellet of Example 1 with a suitable rehydration solution. The rehydration solution is prepared from the rehydration buffer of Example 1, amplification primers, template and an Fpg-probe (and water to a total volume of 47.5 μL per sample). The reaction is initiated by the addition of 2.5 μL of a 280 mM Magnesium-Acetate solution, bringing the final reaction volume to 50 μL per sample.
[0091] For each sample, the rehydration solution is prepared by adding 2.40 μL of the first primer (10 μM), 2.40 μL of the second primer (10 μM), the Template and 0.6 ηL of an Fpg-probe (10 μM) as described in Example 3. H 2 O is added to bring the total volume of the foregoing components to 18 μL. 29.5 μL of the rehydration buffer of Example 1 is added. The rehydration solution is then vortexed and is spun briefly.
[0092] For each sample, the 47.5 μL of rehydration solution is transferred to an Fpg RPA Freeze Dried Reaction Pellet of Example 1. The sample is mixed by pipetting up and down until the entire pellet has been resuspended. For each sample, 2.5 μL of 280 mM Magnesium-Acetate is added and is mixed well to initiate the reaction.
[0093] The tubes are place into a suitable thermal incubator/fluorometer (e.g., isothermally set to a temperature of 37-39° C.) and are incubated while fluorescence measurements are periodically taken. After 4 minutes, the samples are taken out of the incubator, vortexed, spun down and returned to the incubator/fluorometer. The total incubation/detection time is 20 minutes.
[0094] The details of one or more embodiments of the invention have been set forth in the accompanying description above. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
[0095] In the specification and the appended claims, the singular forms include plural referents unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Unless expressly stated otherwise, the techniques employed or contemplated herein are standard methodologies well known to one of ordinary skill in the art. All sequence citations, patents, patent applications and publications cited in this specification are hereby incorporated by reference herein, including the disclosures provided by U.S. Pat. No. 7,270,981 filed Feb. 21, 2003; U.S. Pat. No. 7,399,590 filed Sep. 1, 2004; U.S. Pat. No. 7,435,561 filed Jul. 25, 2006 and U.S. Pat. No. 7,485,428 filed Aug. 13, 2007, as well as, U.S. application Ser. No. 11/628,179, filed Aug. 30, 2007; Ser. No. 11/800,318 filed May 4, 2007 and 61/179,793 filed May 20, 2009. | This disclosure describes kits, reagents and methods for Recombinase Polymerase Amplification (RPA) of a target DNA that exploit the properties of re-combinase and related proteins, to invade double-stranded DNA with single stranded homologous DNA permitting sequence specific priming of DNA polymerase reactions. The disclosed kits, reagents and methods have the advantage of not requiring thermocycling or thermophilic enzymes, thus offering easy and affordable implementation and portability relative to other amplification methods. | 2 |
This is a divisional application of Ser. No. 08/024,224, filed Mar. 1, 1993 (now U.S. Pat. No. 5,496,471), which is a continuation-in-part of now abandoned application Ser. No. 07/873,215, filed Apr. 24, 1992 which is a continuation-in-part of now abandoned application Ser. No. 814,728, filed Dec. 19, 1991, which application is a division of application Ser. No. 671,967, filed Mar. 18, 1991 (now U.S. Pat. No. 5,080,800), which is a division of application Ser. No. 461,988, filed Jan. 8, 1990 (now U.S. Pat. No. 5,056,689).
BACKGROUND OF THE INVENTION
The present invention relates to a solution dispenser and more particularly to a dispenser in which preservatives and other components may be removed from a solution as the solution is dispensed. The invention also provides a method for the removal of preservatives and other components from a solution as the solution is dispensed. In one embodiment, the invention provides a dispenser and method for altering the pH of a solution or dispersion as it passes through a dispenser.
Many solutions are available for making contact lenses more comfortable, safer, and easier to wear. For example, wetting solutions facilitate the wetting of a lens, soaking solutions serve as anti-microbial storage medium and prevent dehydration and distortion of the lens, and cleaning solutions remove accumulated eye secretions and other contaminants from lenses. A large number of other solutions are also used by contact lens patients. These ophthalmic solutions are typically marketed in squeezable plastic containers or aerosol cans having a nozzle through which the solution is dispensed.
Because these solutions come in contact either directly or indirectly with the eye, it is very important that they be free of microbial growth. To this end, it is common practice for preservatives to be provided in these solutions. Among the preservatives used in ophthalmic solutions are polymoxin B sulfate, quaternary ammonium compounds, chlorobutanol, organic mercurials, p-hydroxybenzoic acid esters, and certain phenyls and substituted alcohols.
A problem exists, however, in that the preservatives used in the ophthalmic solutions can cause eye irritation if used in high concentrations. For example, benzalkonium chloride (BAK) is used as a preservative in ophthalmic solutions and has broad anti-bacterial and anti-fungal activity when used with other components, such as disodium ethylene diaminetetraacetic acid (EDTA). However, it has been reported that repeated use of BAK can denature the corneal protein and cause irreversible eye damage. Also, in addition to chemical sensitivity, a number of contact lens wearers have allergic reactions to the preservatives used in ophthalmic solutions, even at relatively low concentrations.
The typical remedy for overcoming chemical sensitivity and allergic reactions to preservatives in ophthalmic solutions entails switching the patients to an unpreserved solution. However, unpreserved solutions present problems in marketing, as well as in home storage, in that once the container housing the solution is opened, the solution quickly becomes contaminated and unsuitable for further use. They also tend to be very expensive to produce.
Therefore, there exists a need- for an apparatus which removes preservatives, as well as other components, from a solution as the solution is dispensed to a patient.
There exists a further need for such an apparatus which is easily manufactured and economical to use.
There exists a further need for an apparatus which may be attached to a standard solution container.
SUMMARY OF THE INVENTION
The present invention relates to a device for removing a component, including but not limited to preservatives, from ophthalmic and other solutions as the solution is dispensed from a container. As employed herein the term "solution" is employed in a broad sense to include dispersions of one or more of the active components in a liquid to be dispensed from the container. The device preferably comprises a container having squeezable sidewalls defining a solution retaining chamber, but may also be an aerosol can or other container. The container also preferably includes a neck portion and a dispensing head having a container outlet on its end through which the solution is dispensed. Means for removing the component from the solution as the solution is dispensed from the chamber through the container outlet are also provided.
In a first embodiment, the means for removing a component from the solution comprises a scavenging material provided within the path of the solution as the solution is dispensed. In this embodiment, the device is a standard solution container housing a solution having the component to be removed, and the scavenging material is held within the dispensing head. The scavenging material may have a positive charge for scavenging negatively charged components or it may have a negative charge for scavenging positively charged components or it may be a material which selectively scavenges components by a size exclusion mechanism or it may comprise any other means for removing a component from solution.
In an alternative embodiment, a fitment may be utilized having a fitment body which is releasably engageable with a standard solution container. The fitment includes passage means within its body for allowing passing of the solution from the container to a fitment outlet. In this embodiment, the means for removing a component may comprise a scavenging material provided within the fitment so as to be within the path of the solution as the solution is dispensed from the container outlet to the fitment outlet. The fitment has the advantage of being able to be adapted to standard solution containers.
Also, means for providing a control of the flow of solution out of the container may be provided. For example, a check valve may be provided within the final dispensing outlet to prevent backflow of solution into the container following use. Additionally, means for regulating the flow of air into the container, namely, a second check valve, may be placed within the neck portion of a squeezable container for allowing air to flow into a depressed container, thereby restoring the container to its original shape. This embodiment will minimize the incidence of microbial growth in the area of the dispensing head proximate the final dispensing outlet.
Another embodiment of the present invention provides a dispensing device which is capable of holding an ophthalmic solution at a first pH and dispensing the solution at a different pH. The term "ophthalmic solution" as used herein is intended to mean any solution used in or around the eye, such as a pharmaceutical, eye wash, contact lens solution, or otherwise. The device includes a container body defining a solution retaining chamber therein for retaining the solution having the predetermined first pH and an outlet for dispensing the solution from the chamber; as well as means for changing the pH of the solution as the solution is dispensed from the chamber through the container outlet. Preferably, the pH changing means are in the form of an ionic exchange material provided within the path of the solution as the solution travels from the chamber to the container outlet. For example, the pH changing means may be an anionic exchange material for removing positively charged ions from the solution to raise the pH of the solution as the solution is dispensed from the chamber through the container outlet, or may be a cationic exchange material for removing negatively charged ions from the solution to lower the pH of the solution as the solution is dispensed from the chamber through the container outlet. As with the other embodiments of the present invention, the pH changing means may be an integral part of the container or may be a fitment capable of being attached to a standard, off-the-shelf container.
In respect to the pH changing aspect of this invention, it is noted that a large number of pharmacologically active substances are stable only at pH values which are extreme in the acidic or alkaline region. These substances cannot be administered at such extreme pH values without causing pain and/or injury to the recipient. This is true whether the administration is to the eye or another portion of the body of the recipient. However, due to the chemical nature of these substances, they must be maintained at these extreme pH values for storage stability. Many new drug candidates have been "shelved" as not commercially viable due to this problem even though their pharmacological activity is good.
The present invention provides a solution to this problem since it permits the substance to be stored in solution or dispersion at an extreme pH value in the acidic or alkaline range where it is stable until the time of its administration. At administration, the solution or dispersion containing the active substance is dispensed through a chamber containing the necessary ion exchange material to change the pH to a value which is acceptable to the patient and which will not cause pain and/or injury.
Thus, the invention provides a method for the administration of a pharmacologically active substance which substance is stable only at a pH value which is extreme in the acidic or alkaline region and at which pH value the substance cannot be administered without causing discomfort and/or injury to a patient, which comprises maintaining the substance in a solution or dispersion at the pH at which the substance is stable until the time of administration and administering the substance to the patient by passing the solution or dispersion containing the substance through a chamber containing an ion exchange material which changes the pH of the solution or dispersion to a value which will not cause discomfort and/or injury to the patient.
Therefore, it is an object of the present invention to provide an apparatus which removes preservatives, as well as other components, from a solution as the solution is dispensed to a patient.
It is also an object of the present invention to provide such an apparatus which is easily manufactured and economical to use.
It is also an object of the present invention to provide such an apparatus which may be adapted to a standard solution container.
It is a further object to provide an apparatus and method for storing a solution or dispersion at a given pH value at which a pharmacological substance contained therein is stable but which is not optimal for administration and subsequently administering the substance through a chamber which changes the pH of the solution or dispersion to a value which is acceptable for administration.
These and other objects and advantages will be more apparent from the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a first embodiment of the present invention in which scavenging material is provided within a container;
FIG. 2 is a partial cross-sectional view of a first embodiment of the present invention in which scavenging material is provided within a container;
FIG. 3 is an exploded view of a second embodiment of the present invention in which scavenging material is provided within a fitment;
FIG. 4 is a partial cross-sectional view of a second embodiment of the present invention in which scavenging material is provided within a fitment;
FIG. 5 is a partial cross-sectional view of an embodiment of the present invention in which the dispensing head is snap-fitted onto a container;
FIG. 6 is a partial cross-sectional view of an embodiment of the present invention having means for providing one-directional flow of solution out of a container.
FIG. 7 is an exploded view of the present invention in which ionic exchange material is provided within the container;
FIG. 8 is a partial cross-sectional view of the present invention in which ionic exchange material is provided within the container;
FIG. 9 is an exploded view of the present invention in which the ionic exchange material is provided in a fitment;
FIG. 10 is a partial cross-sectional view of the present invention in which the ionic exchange material is provided in a fitment; and
FIG. 11 is a partial cross-sectional view of the present invention in which scavenging material and ionic exchange material are provided in the container.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures, a device 10 for removing components, such as preservatives, from solutions, such as an ophthalmic solution, is shown. The device 10 includes a container 12, preferably constructed of molded plastic, having resilient sidewalls 14 which define a solution retaining chamber and which preferably may be deformed by inward pressure to produce a pressure within the container 12 for using and dispensing its contents. The container 12 is provided with an upstanding neck portion 16 having external threads 18 thereabout. A dispensing head 20 is provided atop the neck portion 16, either integrally, as shown in FIGS. 1-4, by threading engagement, or by snap-fitting engagement as shown in FIGS. 5 and 6. A flange portion 22 is provided between the dispensing head 20 and the container neck 16. The dispensing head 20 has passage means, such as a duct or other passageway, through its length which in turn has a first end in communication with the chamber and a container outlet 24 at the other end.
In a first embodiment of the present invention, shown in FIGS. 1 and 2, means for removing preservatives or other components are placed directly within the dispenser head 20. In its preferred form, the preservative removing means comprise scavenging material 26 provided intermediate the chamber and the container outlet 24, so as to be within the path of the solution as the solution is dispensed from the container 12. The material 26 should be positioned as close as possible to the outlet 24 to minimize empty space in the upper portion of the dispensing head 20. The material 26 may be compressed into a porous mass which is preferably insert molded into the dispensing head 20. However, any other means of maintaining the material in the path of the solution may also be used. Alternatively, as shown in FIG. 2, the material 26 may be in the form of fine particles and held in place by porous supporting members 28 and 30. The members 28 and 30 may be made from porous plastic, such as porous polyethylene. In either case, it is important that the solution pass through the scavenging material 26 as it exits the container 12 so that the component is removed upon contact with the scavenging material 26.
A second embodiment of the invention, shown in FIGS. 3 and 4, includes a fitment 32 having a body 34 which is affixable to a standard-size container 12, such as described above but without the scavenging material 26 within its dispensing head 20. The lower portion 36 of the fitment 32 is provided with internal threads 38 which complimentarily mate with threads 18 on the outer surface of the neck portion 16 so that the fitment 32 may be releasably matable to the container 12. As seen in FIG. 4, when the fitment 32 is in threaded relationship with the container neck portion 16, an internal flange 40 of the fitment 32 rests atop the neck portion 16 to provide a seal between the fitment 32 and container 12. The fitment 32 has a fitment outlet 42 atop a tapered upper section 44, as well as a passage or duct through its length. The passage is preferably adjacent to and in flow registration with the container outlet 24 at one end and opens to the fitment outlet 42 at its other end. In this alternative embodiment, the scavenging material 26 is provided within the fitment 32, and removes the component, such as preservative, from the solution as the solution passes from the container outlet 24 to the fitment outlet 42. As in the first embodiment, the scavenger material 26 may be in solid mass or powder or other form.
FIG. 6 shows a device 10 of the present invention which includes means for providing one-directional flow of solution out of the container, such as a check valve 50. Preferably, the valve 50 is a deformable, polymeric valve that is positioned within the container outlet 24 so as to be in flow communication with the interior portion of the dispensing head 20 at one end and with the atmosphere at a second end. In its normal or closed position, the valve 50 does not allow air or solution to flow into or out of the container 12. However, as a result of the pressure exerted onto the container 12 during use, the valve moves to an open position that allows the solution to pass through to the atmosphere. When the pressure on the container 12 is stopped, the valve 50 closes and any solution remaining atop the valve 50 cannot be pulled back inside the container 12, thereby minimizing the incidence of organisms reentering the container 12 after use.
Also, when a squeezable container 12 is used, means for drawing air into the container 12 may be provided for returning the container 12 to its original shape. Preferably, a second one way check valve 54 is provided within the neck portion 16 and below the scavenging material 26. Upon release of the container 12 by the user, air is drawn into the container 12 by the valve 54, thereby restoring the container 12 to its proper shape. Also, because the valve 54 is one-directional, solution-from within the container 12 cannot leak out to the atmosphere through the valve 54. Furthermore, because the second valve 54 is below the scavenging material 26, any organism which should happen to be drawn from the air into the container will be deposited into the preserved solution and killed.
Both the dispensing head 20 of the first embodiment and the fitment 32 of the second embodiment may include a closure cap 46. The closure cap 46 may have internal threads 48 capable of matingly engaging with either the threads 18 of the neck portion 16, as shown in FIG. 1, or the external threads 50 of the fitment 32, as shown in FIG. 3, and resting on flange 22.
Of course, containers other than squeezable plastic types may be utilized. The scavenging material may be placed within an aerosol type dispenser, a solid bottle, or some other container.
Virtually any type of scavenging material 26 for removing a preservative or other component from solution may be used. For example, removal of benzalkonium chloride or other quaternary ammonium compounds can be accomplished by an ionic exchange mechanism or chemical affinity, for example, using fumed silica. The scavenging material 26 would preferably be an inert material with a negative charge, and the positively charged quaternary ammonium compound would adhere to the material 26 as it flows through the fitment 32 or dispensing head 20, depending on the embodiment. Examples of products capable of removing positively charged preservatives such as BAK include AG-50X-8, AG-50X-16, BIO-BS-SM2, and BIO REX70, all available from BIO-RAD Laboratories, Richmond, Calif. and Acropor 5A-6404 available from Gelman Sciences, Ann Arbor, Mich. Similarly, negatively charged components, such as acids, may be removed by using positively charged scavenging material 26. Examples of such scavenging material includes AG-1, AG-2XS, and AG-10 Alumina from BIO-RAD Laboratories. For example, it has been found that scavenging material 26 comprising Chelex 100 from BIO-RAD will remove Thimerosal from solution. Alternatively, the scavenging material may be porous plastic, such as porous polyethylene, imbedded with a cross-linked styrene divinyl benzene which is sulfonated to produce either a positively charged hydrogen form or a negatively charged sodium form. Other scavenging materials useful in the present invention are those relating to chemical affinity techniques, such as immunoassay, active site binding and affinity chromatography.
As one particular example, it has been found that a scavenging material comprised of a mixture of "Bio Rex 5" and "AG-4", both BIO-RAD products, in a 75 to 25 ratio will almost completely remove 0.1% sorbic acid from a solution and raise the pH of the solution from 4.0 to 7.0. This is important since sorbic acid is a commonly used preservative in contact lens solutions. In addition, sorbic acid is normally stored at pH=7.0, where it is not stable. At pH=4.0, it is very stable but cannot be instilled into the eye. The present invention will therefore allow solution to be stored at low pH and the pH raised to an ocularly acceptable level as the solution is administered.
Other preservatives that are not directly charged, such as chlorhexadine, could also be removed by the present invention. For example, a size exclusion mechanism may be utilized for removing certain types of preservative compounds. Overall, the term "scavenging material" as used herein refers to all material which will remove or change the nature of preservatives or other components in a solution exiting the container.
As examples of the ion-exchange resins which can be employed either in connection with the removal of preservative or pH change aspect of the present invention, there may be mentioned those which can safely be used in the treatment of food under conditions prescribed by the Food and Drug Administration. They are prepared in appropriate physical form and consist of one or more of the following:
(1) Sulfonated copolymer of styrene and divinylbenzene.
(2) Sulfonated anthracite coal meeting the requirements of ASTM-D388-38, Class I, Group 2.
(3) Sulfite-modified cross-linked phenol-formaldehyde, with modification resulting in sulfonic acid groups on side chains.
(4) Methacrylic acid-divinylbenzene copolymer.
(5) Cross-linked polystyrene, first chloromethylated then aminated with trimethylamine, dimethylamine, diethylenetriamine, or dimethylethanolamine.
(6) Diethylenetriamine, triethylenetetramine, or tetraethylenepentamine cross-linked with epichlorohydrin.
(7) Cross-linked phenol-formaldehyde activated with one or both of the following: Triethylene tetramine and tetraethylenepentamine.
(8) Reaction resin of formaldehyde, acetone, and tetraethylenepentamine.
(9) Completely hydrolyzed copolymers of methyl acrylate and divinylbenzene.
(10) Completely hydrolyzed terpolymers of methyl acrylate, divinylbenzene and acrylonitrile.
(11) Sulfonated terpolymers of styrene, divinylbenzene, and acrylonitrile or methyl acrylate.
(12) Methyl acrylate-divinylbenzene copolymer containing not less than 2 percent by weight of divinylbenzene, aminolyzed with dimethylaminopropylamine.
(13) Methyl acrylate-divinylbenzene copolymer containing not less than 3.5 percent by weight of divinylbenzene, aminolyzed with dimethylaminopropylamine.
(14) Epichlorohydrin cross-linked with ammonia.
(15) Sulfonated tetrapolymer of styrene, divinylbenzene, acrylonitrile, and methyl acrylate derived from a mixture of monomers containing not more than a total of 2 percent by weight of acrylonitrile and methyl acrylate.
(16) Methyl acrylate-divinylbenzene diethylene glycol divinyl ether terpolymer containing not less than 3.5 percent by weight of divinylbenzene and not more than 0.6 percent by weight of diethylene glycol divinyl ether, aminolyzed with dimethylaminopropylamine.
(17) Styrene-divinylbenzene cross-linked copolymer, first chloromethylated then aminated with dimethylamine and oxidized with hydrogen peroxide whereby the resin contains not more than 15 percent by weight of vinyl N,N-dimethylbenzylamine-N-oxide and not more than 6.5 percent by weight of nitrogen.
These are, of course, illustrative and not exhaustive of those ion exchange resins which can be employed. It is also apparent that the particular ion exchange resin to be employed will vary with the particular formulation which is to be passed through it in order to obtain optimal results.
To further illustrate the ion exchange resins for use in the invention the following exemplary information is set forth. The following listed resins were obtained from Rohm & Haas Company:
Carboxyl Resins
Amberlite® IRC-76
Modified acrylic polymers in the H + form
Amberlite® IRC-50
Divinylbenzene/methacrylic acid copolymer in the H + form
Dualite® C-433
Sulfonic Resins
Ambersep® 252 H Resin
Sulfonated divinylbenzene/styrene copolymer in the H + form
Amberlite® IR-120(H) -20+40 Resin
Sulfonated divinylbenzen/styrene copolymer in the H + form
Each of the resins was received in the H + form and, in the following described manner, each was converted to the Na + form. 30 Grams of the resin was placed in a column and 1.5 liters of 4% NaOH was passed through the column. Ultra pure H 2 O was then passed through the column until a constant pK b was reached.
______________________________________Resin pk.sub.b______________________________________CarboxylAmberlite ® IRC-76 ˜9.8Amberlite ® IRC-50 ˜9.9Dualite ® C-433 ˜9.7SulfonatedAmbersep ® 252 ˜9.5Amberlite ® IR-120 ˜9.6______________________________________
Each of these resins proved to be particularly suitable for incorporation in a device as shown in FIGS. 7 through 10 which is capable of holding an ophthalmic solution at a first pH and dispensing the solution at a different pH.
Various pharmacological agents such as drugs, diagnostic agents, ocular lubricants and the like can be administered in accordance with the invention. As examples, the following can be mentioned:
Antibacterial substances such as beta-lactam antibiotics, such as cefoxitin, ciprofloxacin, n-formamidoylthienamycin and other thienamycin derivatives, tetracyclines, chloramphenicol, neomycin, carbenicillin, colistin, penicillin G, polymyxin B, vancomycin, cefazolin, cephaloridine, chibrorifamycin, gramicidin, bacitracin and sulfonamides:
Aminoglycoside antibiotics such as gentamycin, kanamycin, amikacin, sisomicin and tobramaycin;
Naiidixic acid and its analogs such as norfloxacin and the antimicrobial combination fluoroalanine/pentizidone, nitrofurazones and analogs thereof;
Antihistaminics and decongestants such as pyrilamine, chlorpheniramine, tetrahydrazoline, antazoline and analogs thereof;
Anti-inflammatories such as diclofenac, ketorolac, cortisone, hydrocortisone, hydrocortisone acetate, betamethasone, dexamethasone, dexamethasone sodium phosphate, prednisone, methylprednisolone, medrysone, fluorometholone, prednisolone, prednisolone sodium phosphate, triamcinolone, indomethacin, suiindac, its salts and its corresponding sulfides, and analogs thereof;
Miotics and anticholinergics such as echothiophate, pilocarpine, physostigmine salicylate, diisopropylfluorophosphate, epinephrine, dipivaloylepinephrine, neostigmine, echothiopate iodide, demecarium bromide, carbamoyl choline chloride, methacholine, bethanechol, and analogs thereof;
Most cell stabilizers such as cromolyn sodium;
Mydriatics such as atropine, homatropine, scopolamine, hydroxyamphetamine, ephedrine, cocaine, tropicamide, phenylephrine, cyclopentolate, oxyphenonium, eucatropine, and analogs thereof;
Other drugs used in the treatment of conditions and lesions of the eyes such as:
Antiglaucoma drugs for example timolol, and especially its maleic salt and R-timolol and a combination of timolol or R-timolol with pilocarpine, as well as many other adrenergic agonists and/or antigonists; epinephrine and an epinephrine complex, or prodrugs such as bitartrate, borate, hydrochloride and dipivefrine derivatives and hyperosmotic agents such as glycerol, mannitol and urea: carbonic anhydrase inhibitors such as acetazolamide, dichlorphenamide, 2-(p-hydroxyphenyl)-thio-5-thiophenesulfonamide, 6-hydroxy-2-benzothiazolesulfonamide; and 6-pivaloyloxy-2-benzothiazolesulfonamide;
Antiparasitic compounds and/or anti-protozoal compounds such as ivermectin, pyrimethamine, trisulfapidimidine, clindamycin and corticosteroid preparations;
Compounds having antiviral activity such as acyclovir, 5-iodo-2'-deoxyuridine (IDU), adenosine arabinoside (Ara-A), trifluorothymidine, and interferon and interferon-inducing agents such as poly I:C;
Antifungal agents such as amphotericin B, nystatin, flucytosine, natamycin and miconazole;
Anesthetic agents such as etidocaine cocaine, benoxinate dibucaine hydrochloride, dyclonine hydrochloride, naepaine, phenacaine hydrochloride, piperocaine, proparacaine hydrochloride, tetracaine hydrochloride, hexylcaine, bupivacaine, lidocaine, mepivacaine and prilocaine;
Ophthalmic diagnostic agents, such as:
(a) those used to examine the retina such as sodium fluorescein;
(b) those used to examine the conjunctiva, cornea and lacrimal apparatus, such as fluorescein and rose bengal; and
(c) those used to examine abnormal pupillary responses such as methacholine, cocaine, adrenaline, atropine, hydroxyamphetamine and pilocarpine;
Ophthalmic agents used as adjuncts in surgery, such as alpha-chymotrypsin and hyaluronidase;
Chelating agents such as ethylenediaminetetraacetic acid (EDTA) and deferoxamine;
Immunosuppressants and anti-metabolites such as methotrexate, cyclophosphamide, 6-mercaptopurine and azathioprine; and combinations of the compounds mentioned above, such as antibiotics/antiinflammatories combinations such as the combination of neomycin sulfate and dexamethasone sodium phosphate, and combinations concomitantly treating glaucoma, for example a combination of timolol maleate and aceclidine.
The foregoing agents will be principally used in the embodiment of the invention where a preservative agent is removed from a solution containing the agent as the solution is passed through the chamber containing the "scavenging material". However, in those cases where these agents must be stored at an extreme pH--either acidic or alkaline--in order to be stable, they may be administered in accordance with the pH change aspect of the invention.
Particular examples of drugs which are suitable for administration according to the pH change aspect of the invention are the antibacterial agent tosufloxacin (stable at pH 11), the cholinergic agent pilocarpine hydrochloride (stable at pH 4.5), the antibacterial agent tobramycin (stable at pH 8) and diveprin hydrochloride (stable at pH 2-3).
Referring to FIGS. 7 through 10, a dispensing device 110 which is capable of holding an ophthalmic solution at a first pH and dispensing the solution at a different pH is provided. The device 110 includes a container 112, preferably constructed of molded plastic, having resilient walls 114 which define a solution retaining chamber and which preferably may be deformed by inward pressure to produce a pressure within the container 112 for using and dispensing its contents. Of course, containers other than squeezable plastic types may be used, such as aerosol type dispensers or solid bottles. The container 112 is provided with an upstanding neck portion 116 having external threads 118 thereabout. A dispensing head 120 is provided atop the neck portion 116, either integrally, by threading engagement or by snapfitting. The dispensing head 120 has passage means extending through its length, the passage means having a first end in communication with the chamber and a second end being the dispensing outlet 126. A cap 122 having threads 124 engageable with threads 118 may be provided for closing the container 112.
Means for changing the pH of the solution as the solution is dispensed from the chamber through the outlet 126 are provided. Preferably the pH changing means comprise an ionic exchange material 128 provided within the path of the solution as the solution travels from the chamber to the outlet 126. For example, as seen in FIG. 8, the ionic exchange material 128 may be located within the passage means of the dispensing head 120. Means for maintaining the ionic exchange material 128 in position within the passage means may also be provided. Such position maintaining means may be a first supporting member 130 located over the first end of the passage means and a second supporting member 132 located over the second end of the passage means. The ionic exchange material 128 will be held in position between the first and second supporting members 130 and 132, respectively. The supporting members 130 and 132 may be made from porous plastic, such as porous, non-woven polyethylene or polypropylene, or some other material which is permeable to the solution but which is impermeable to the ionic exchange material 128.
The type of ionic exchange material 128 used depends upon the characteristics of the solution to be dispensed and the desired pH change. For example, the ionic exchange material 128 is preferably an anionic exchange material capable of removing positively charged ions from the solution when it is desired to raise the pH of the solution as the solution is dispensed from the chamber through the outlet 126. Alternatively, the ionic exchange material 128 may be a cationic exchange material for removing negatively charged ions from the solution when it is desired to lower the pH of the solution as the solution is dispensed from the chamber through the outlet 126. The ionic exchange material 128 may be in the form of a powder, shavings, beads or otherwise so long as the solution can pass through as it is dispensed from the container 112. The amount of ionic exchange material 128 used depends upon a number of factors, including the length and diameter of the passage means, the hydrogen ion concentration of the solution, and the residence time of the solution in contact with the ionic exchange material 128. Overall, the length and diameter of the passage means must be enough to provide sufficient residence time for the hydrogen ion concentration of the solution to be changed to the desired final pH.
Another embodiment of the device 110 of the present invention, shown in FIGS. 9 and 10, includes a fitment 134 which is affixable to a standard-size, off-the-shelf container 112, such as described above but without the ionic exchange material 128 within its dispensing head 120. The lower portion of the fitment 134 is provided with internal threads 136 which complimentarily mate with the threads 118 on the outer surface of the neck portion 116 so that the fitment 134 may be releasably matable to the container 112. As seen in FIG. 10, when the fitment 134 is in threaded relationship with the container neck portion 116, a seal is provided between the fitment 134 and the container 112. The fitment 134 has a dispensing outlet 138 atop a tapered upper section 140, as well as a passage or duct through its length. The passage is preferably adjacent to and in flow registration with the standard container outlet 126 at one end and opens to the dispensing outlet 138 at its other end. The ionic exchange material 128, as described above and preferably held in place by position maintaining means 130 and 132, is provided within the fitment 134, and changes the pH of the solution as the solution passes from the container outlet 126 to the dispensing outlet 138.
The following example is illustrate of a specific type of device which can be made according to the above description, but should not be viewed as limiting any aspect of the invention.
Pilocarpine hydrochloride; chemical name 2 (3H)-furanone, 3-ethyldihydro-4-[(1-methyl-1H-imidazol-5-yl) methyl]-, monohydrochloride, (3S-cis)-; is a well known direct acting cholinergic (parasympatomimetic) agent causing the pupillary constriction and reduction of intraocular pressure. It is commonly dispensed in a buffered ophthalmic solution which may consist of boric acid, potassium chloride, hydroxypropyl methylcellulose, sodium, carbonate, EDTA, purified water, and preserved with benzalkonium chloride. A problem exists, however, in that the pilocarpine hydrochloride solution is formulated at a pH of about 4.5 in order for it to remain stable in solution, and such pH is ocularly uncomfortable or otherwise incompatible. The device 110 of FIGS. 7 and 8 may be used to solve this problem by allowing the solution to be maintained at a stabilizing pH of about 4.5 while in the retaining chamber of the container 112, yet being at an ocularly acceptable pH of about 6.5 to 7.0 upon exiting the outlet 126.
Since it is desired to raise the pH of the pilocarpine hydrochloride solution from a relatively low pH of about 4.5 to an ocularly acceptable pH of about 6.8, the ionic exchange material 128 is preferably an anionic exchange material capable of removing positively charged ions from the solution. One such anionic exchange material is Amberlite® IRA-68 (available from Rohm & Haas Company, Philadelphia, Pa., 19105), which is a gel type, weakly basic anion exchange resin possessing tertiary amine functionality in a crosslinked acrylic matrix. Other such material is BIO-RAD® AG4 and BIO-RAD® AG3, both from BIO-RAD Laboratories. The Amberlite® IRA-68 material is available in uniform, spherical particles which can be easily placed within the passage means of the dispensing head 120 and held in position by porous supporting members 130 and 132. It should be noted that because the Amberlite® IRA-68 material attracts acids, it may be necessary to extract the free bases out of the resin material before placing the Amberlite® IRA-68 into the dispensing head 120. Failure to do so may result in an unwanted rise in pH of the solution. This can be accomplished by washing the resin in isopropyl alcohol or methanol (i.e., 1 liter of isopropyl alcohol for each 100 grams of Amberlite® IRA-68), followed by washing with sufficient purified water to remove any residual alcohols. It should also be noted that the Amberlite® IRA-68 material may swell upon wetting and shrink upon subsequent drying. Therefore, change of the material size must be accounted for when filling the dispensing head 120. Means for compensating for changes in size of the ionic exchange material 128 during the dispensing of the solution may be provided. For example, the first supporting member 130 may be constructed of a deformable sponge-like material capable of occupying the space created during expansion of the Amberlite® IRA-68 material.
Additionally, it should be clear that the fitment 134, as illustrated in FIGS. 9 and 10, may also be used to change the pH of the pilocarpine hydrochloride. In such an instance, a fitment 134 having Amberlite® IRA-68 material is placed atop a standard, off-the-shelf container of stabilized, pH 4.5 pilocarpine hydrochloride solution. Upon dispensing, the solution exits outlet 126 and travels through the passage means of the fitment 134, where it contacts the Amberlite® IRA-68 material. The Amberlite® IRA-68 material removes a sufficient number of hydrogen ions from the solution so that the solution has a pH of about 6.8 upon exiting the dispensing outlet 138.
Also, the means for removing a component from the solution as the solution is dispensed from the chamber through the container outlet, as previously described herein, may be combined in the same container or fitment with the means for changing the pH of the solution as the solution is dispensed from the chamber through the container outlet, as described directly above. In such a device, illustrated in FIG. 11, the scavenging material 26 and the ionic exchange material 128 may both be placed within the passage means. For example, in the case of the above described typical pilocarpine hydrochloride solution, the scavenging material 26 would remove the benzalkonium chloride from the solution and the ionic exchange material 134 would raise the pH from about 4.5 to about 6.8. The resulting solution would therefore be preservative-free and ocularly compatible.
From the foregoing description of the invention, it should be seen that the present invention provides the ability to dispense preservative-free solutions from containers housing solutions that are preserved. Whereas the present invention has been described with respect to specific embodiments thereof, it should be understood that various changes and modifications will be suggested to one skilled in the art and it is intended that the invention encompass such changes and modifications that will fall within the scope of the appended claims. | A dispensing device having a container body defining a solution retaining chamber therein, the container having an outlet for dispensing the solution from the chamber and means for removing a component from the solution as the solution is dispensed from the chamber through the container outlet. A method is provided for administering to a patient a pharmacologically active substance which substance is stable only at a pH value which is extreme in the acidic or alkaline region and at which pH value the substance cannot be administered without causing discomfort and/or injury to the patient. The substance is maintained in a solution or dispersion at the pH at which it is stable until the time of administration. At this time the substance is administered through a chamber containing an ion exchange resin which changes the pH of the solution or dispersion to a value which will not cause discomfort and/or injury to the patient. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/977,680, filed Apr. 10, 2014, which is incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to a cable distribution assembly of the kind that controllably passes a cable through a bore on the ground or other surface, wherein the position of the cable distribution assembly in relation to the bore at least partially inhibits engagement between the cable and the bore edges.
BACKGROUND OF THE INVENTION
The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
It is well known that a cable is a linear, flexible member used to contain wiring, hoist loads, anchor objects, and fasten multiple items. For electrical purposes, cables are provided with a metallic wiring capable of conducting an electric current. Wiring may be formed by a single wire or may include two or more wires running side by side and bonded, twisted, or braided together to form a single assembly. Cables often include a protective polymer sheath that protects the wiring from moisture and physical contact with exterior surfaces.
Often, the wires in a cable corrode. Corrosion degrades the useful properties of the cable and wires, including strength, appearance and permeability to liquids and gases. For underground wiring, corrosion is the gradual destruction of metals by chemical reaction with the environment. In an underground bore, the environments that cause corrosion may include gases, water, acids that contact wiring to create an electrochemical oxidation with the wires in reaction with an oxidant such as oxygen. Wiring is often comprised of a copper material. Copper resists corrosion from moisture, humidity, industrial pollution, and other atmospheric influences.
Electrical cables are used in a countless number of applications. In many instances, electrical cables are arranged below ground level, concealed from the human eye and protected from weather hazards. For instance, airport runway lighting systems, consisting of a series of light bars or strobe lights that extend along both sides of the runway, generally provide electricity and/or electric signals to the lamps by underground cables. The underground environment is potentially corrosive for the cables. Because of this, frequent maintenance and replacement of the cables must be carried out in order to guarantee that cables, and thus the runway lighting system, work in optimal conditions.
Normally, runway lamps are installed over a bore on the ground through which cables extend from the lamp towards the underground environment. Electrical wiring maintenance or installation is usually carried out by removing the runway lamp and allowing the cable to slide through the bore and into the underground environment or by pulling the wire out of the underground environment. When sliding in or out of the bore, cables are prone to deteriorate due to friction against the bore edges, thus shortening cable lifetime undesirably and increasing the number of cable maintenance and replacement operations. Frequent operations on the runway lighting system can adversely impact an airport's runway traffic and lead to important economic loss. In addition, premature deterioration of airport runway lighting cables may result in nonoperational lighting along the runway and in a serious safety hazard.
Accordingly, there remains a need in the art for a cable distribution system that controllably and easily guides a cable through a bore, while restricting contact between the wiring and the bore edges, for optimizing cable installation and removal from airport lighting systems or other applicable lighting systems.
SUMMARY OF THE INVENTION
The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing a cable distribution assembly kind that can controllably pass a cable through a bore on the ground or other surface, wherein the position of the cable distribution assembly in relation to the bore at least partially inhibits engagement between the cable and a bore edge. The cable distribution assembly allows controllably inserting or removing cable including, without limitation, an electrical cable, wiring, a wire rope, an optical cable, fiber optics, a ribbon cable, a coaxial cable, a hose, and tubing.
Introducing a first embodiment of the invention, the present invention consists of a cable distribution assembly for controllably passing a cable through a bore on the ground or other surface, the cable distribution assembly including a support portion comprising a base supporting a pair of sidewalls spaced apart one from the other. One edge of the base extending between the sidewalls defines a concave contour; the concave contour delimits an inner space within. A shaft extends between the sidewalls and is rotatable with respect to the support portion about a longitudinal axis. A roller is coupled to the shaft and is rotatable with respect to the support portion. The roller and the shaft are positioned such that a vertical line tangent to a central portion of the roller lies within the inner space delimited by the concave contour defined by the base.
In a second aspect, the roller is affixed to the shaft and is jointly rotatable therewith with respect to the support portion.
In another aspect, the position of the shaft and the roller are adjustable with respect to the base.
In yet another aspect, the position of the shaft and the roller are vertically adjustable with respect to the base.
In a still further aspect, the position of the shaft and the roller are horizontally adjustable with respect to the base in a direction substantially perpendicular to the axis of rotation of the shaft.
In another aspect, each of the sidewalls defines a respective slot through which the shaft passes and further wherein the position of the shaft is adjustable within the slots.
In another aspect, the slots are arcuate.
In a still further aspect, the cable distribution assembly further includes a shaft end support on each end of the shaft wherein each shaft end support has an articulated first connection to a respective sidewall and a second connection engageable to different positions of the sidewall.
In yet another aspect, the base defines at least one hole therethrough proximate to a periphery of the concave contour for the insertion of fasteners to attach the base to a matching peripheral hole of the bore in the ground for securing the support portion to an edge of the bore.
In another aspect, the cable distribution assembly further includes a monitoring device operably connected to the shaft and configured to measure at least one parameter of a group consisting of the number of shaft rotations, angular velocity of the shaft, and length of a cable dynamically passed over the roller.
In another aspect, the roller comprises an external cable-retaining concave surface.
In still another aspect, the roller has an outer non-slip surface.
Introducing another embodiment of the invention, the present invention consists of a cable distribution assembly for controllably passing a cable through a bore in the ground, the cable distribution assembly including a support portion comprising a base supporting a pair of sidewalls spaced apart one from the other, wherein one edge of the base extending between the sidewalls defines a concave contour delimiting an inner space within, and wherein each sidewall defines a slot therein. A shaft extends between and is adjustable within the slots defined in the sidewalls and is rotatable with respect to the support portion about a longitudinal axis. A shaft end support is on each end of the shaft. Each shaft end support has an articulated first connection to a respective sidewall and a second connection engageable to different portions of the sidewall. A roller is affixed to the shaft and is rotatable with respect to the support portion. The roller and the shaft are positioned such that a vertical line tangent to a central portion of the roller lies within the inner space delimited by the concave contour defined by the base.
In a second aspect, the slots are arcuate.
In another aspect, the base defines at least one hole therethrough proximate to a periphery of the concave contour for the insertion of fasteners to attach the base to a matching peripheral hole of the bore in the ground for securing the support portion to an edge of the bore.
In yet another aspect, the cable distribution assembly further includes a monitoring device operably connected to the shaft and configured to measure at least one parameter of a group consisting of the number of shaft rotations, angular velocity of the shaft, and length of a cable dynamically passed over the roller.
Introducing yet another embodiment of the invention, the present invention consists of a cable distribution assembly for controllably passing a cable through a bore in the ground or other surface, including a support portion comprising a base supporting a pair of sidewalls spaced apart one from the other, wherein one edge of the base extends between the sidewalls and defines a concave contour. The concave contour delimits an inner space within. Each sidewall defines an arcuate slot therein. A shaft extends between and is adjustable within the slots defined in the sidewalls and is rotatable with respect to the support portion about a longitudinal axis. A shaft end support on each end of the shaft has an articulated first connection to a respective sidewall and a second connection engageable to different portions of the sidewall. A roller is affixed to the shaft and is rotatable with respect to the support portion wherein the roller and the shaft are positioned such that a vertical line tangent to a central portion of the roller lies within the concave contour defined by the base. A monitoring device is operably connected to the shaft and is configured to measure at least one parameter of a group consisting of a number of shaft rotations, angular velocity of the shaft, and length of a cable dynamically passed over the roller.
In a second aspect, the second connection includes a bolt passing through a hole defined by the shaft end support and further passing through a selected one of a plurality of holes defined in a respective sidewall for regulating the shaft in different positions.
In another aspect, the base defines at least one hole therethrough proximate to a periphery of the concave contour for the insertion of fasteners to attach the base to a matching peripheral hole of the bore in the ground for securing the support portion to an edge of the bore.
In yet another aspect, the roller has an outer non-slip concave surface.
These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, in which:
FIG. 1 presents a detailed perspective view of an exemplary cable distribution assembly according to the invention, viewed from a top front angle;
FIG. 2 presents a detailed perspective view of the cable distribution assembly of FIG. 1 , viewed from a top rear angle;
FIG. 3 presents a perspective view of the cable distribution assembly of FIG. 1 , positioned over an exemplary airport runway lamp bore and having a cable passing through according to the invention;
FIG. 4 presents a top view of the cable distribution assembly of FIG. 1 ;
FIG. 5 presents another perspective view of the assembly of FIG. 1 , wherein bolts have been pulsed out from opposite end shaft regulators in order to allow vertical and horizontal adjustment of the roller and shaft;
FIG. 6 presents the assembly of FIG. 5 , where the shaft and roller have been adjusted to a lower position, and the bolts have been inserted in lower bolt apertures on the sidewalls, securing the shaft in the position of the figure;
FIG. 7 presents a cross-sectional view of the cable distribution assembly of FIG. 1 , according to cross-sectional plane 7 - 7 indicated in FIG. 4 ; and
FIG. 8 presents a partial perspective view of the assembly of FIG. 1 , showing the monitoring device in a partially exploded view.
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1 . Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The illustrations of FIGS. 1 and 2 present a first embodiment of a cable distribution assembly 100 , shown from different angles. The cable distribution assembly 100 comprises a support portion 110 , which forms a foundation for the cable distribution assembly 100 . The support portion 110 includes a base 120 and a pair of sidewalls 130 that extend out from opposite ends of the base 120 . The base 120 comprises a concave contour 140 , configured to resemble the edge of a lighting system bore, which is usually round or curved. The cable distribution assembly 100 further comprises a shaft 150 that extends between the sidewalls 130 . In the present embodiment, the shaft 150 is rotatable with respect to the sidewalls 130 and the base 120 . In addition, the cable distribution assembly 100 comprises a roller 160 , which in the present embodiment is coupled to the shaft 150 and rotatable jointly with the shaft 150 . The roller 160 can include an external concave surface 164 on which a cable (not shown) can pass, the concave shape tending to retain the cable within. The cable distribution assembly 100 is configured so that the position of the shaft 150 and the roller 160 in relation to the concave contour 140 inhibits engagement between the concave contour 140 and a cable (not shown) that were passing transversally along the roller 160 and hanging downwards toward the concave contour 140 .
The illustration of FIG. 3 shows the cable distribution assembly 100 being used, for instance, to install new cable in an airport runway lighting system. The lighting system comprises a runway lamp 400 of the kind that is normally arranged over a bore 410 on the ground, on either side of the runway. A base 404 of the lamp 400 is configured to cover the bore 410 when the lamp 400 is installed in normal operating conditions over the bore 410 . In said normal operating conditions, the base 404 of the lamp 400 is secured to the ground by fastening a set of screws 420 through holes 408 in the base 404 and into corresponding peripheral holes 430 around the bore 410 . Cables operating the lamp 400 are located at underground level and reach the lamp 400 through the bore 410 and the base 404 . In the situation depicted in the figure, the screws 420 have been disconnected and the lamp 400 has been removed from the bore 410 , providing access to the bore 410 in order, for instance, to pass a new cable 440 through the bore 410 . As shown in the figure, the cable distribution assembly 100 of the present invention is advantageous in that it can be placed right on or at the bore 410 . This advantageous effect is achieved at least partly by having the base 120 include the concave contour 140 that resembles the shape of the edge 450 of the bore 410 . The cable distribution assembly 100 is configured so that the position of the shaft 150 and the roller 160 in relation to the concave contour 140 prevents the cable 440 passing transversally along the roller 160 from contacting the concave contour 140 . Thus, the cable distribution assembly 100 according to the invention guarantees that the cable 440 does not contact the bore edge 450 when being rolled into or out from the bore 410 , and that the insulation surrounding the inner electrical wiring does not deteriorate.
In the present embodiment, the base 120 of the cable distribution assembly 100 includes several through holes 170 configured to align with corresponding peripheral holes 430 along the bore edge 450 . The through holes 170 are preferably elongated or slot-shaped, as better shown in FIGS. 1 and 2 , to provide a mounting tolerance on the peripheral holes 430 . Fasteners 180 can be installed through one or more through holes 170 , as shown in FIGS. 1 and 2 , and connected to the peripheral holes 430 of the bore 410 as shown in FIG. 3 . The cable distribution assembly 100 can therefore be firmly secured to the bore 410 , preventing the assembly from moving and varying its position with respect to the bore 410 while the cable 440 is being rolled. Having the assembly firmly secured guarantees that the assembly is always correctly positioned and that there is no risk that the cable 440 frictions against the edge 450 of the bore 410 when being rolled, thus enhancing the beneficial effects of the invention. A person skilled in the art will understand that the fasteners 180 can take the form of any applicable releasable mechanical fastener, such as a cam-handle screw as shown in the figures, a regular screw, a rod, etc. Preferably, fasteners 180 should allow for easy and quick fastening and unfastening, so that the task of installing or removing cables from a plurality of bores 410 , such as along an airport runway having a string of lamps 400 and corresponding bores 410 , can be carried out time efficiently.
The illustration of FIG. 4 shows a top view of the cable distribution assembly 100 of FIG. 1 . As shown, the external concave surface 164 of the roller 160 includes a portion 168 that is arranged so that its horizontal projection, as shown in the figure, falls inside an inner space 190 delimited by the concave contour 140 of the base. Such an arrangement guarantees that a cable rolling vertically downward or upward along the roller 160 is directly inserted through the bore 410 , neither contacting the bore edge 450 nor contacting the concave contour 140 of base 120 —provided that the assembly is correctly placed on the bore—. Such an arrangement also provides a stable product that does not tend to fall over when cable 440 is being rolled.
Preferably, the shaft 150 can rotate in opposite directions. The assembly thus helps roll cable into the bore and also out of the bore.
Preferably, the position of the shaft 150 and roller 160 relative to the base 120 is adjustable. In the present embodiment, the shaft 150 and roller 160 are adjustable relative to the base 120 both horizontally and vertically. Vertical adjustment allows the cable to be rolled closer or farther apart from the base 120 . Horizontal adjustment allows bringing the roller 160 closer or farther apart from the concave contour 140 , so that the cable distribution assembly 100 adapts to different bore 410 sizes and to different cable 440 thicknesses. The invention contemplates alternative embodiments in which the shaft and roller are adjustable only horizontally or only vertically.
In the present embodiment, as shown in FIG. 2 , the shaft 150 passes through respective slots 200 on each sidewall 130 . The position of the shaft 150 along the slots 200 is adjustable. Having a shaft 150 adjustably connected along opposite slots provides a mechanically- and cost-effective solution for providing adjustability of the shaft 150 and roller 160 in relation to the base 120 .
As shown in FIG. 2 , the slots 200 are shaped in form of an arc of a circle, providing an efficient solution for vertical and horizontal adjustability. In addition, the cable distribution assembly 100 further comprises shaft end supports 210 whose function is to rotatably support the shaft 150 and also to connect the shaft 150 to the sidewalls 130 allowing the shaft 150 to vary its position along the slots 200 . A person skilled in the art will understand that the shaft end supports 210 preferably comprise internal rotation mechanisms such as bearings or the like, for providing rotational movement of the shaft 150 inside, and relative to, the shaft end supports 210 . In addition, each shaft end support 210 comprises a first connection 220 to the sidewall 130 and a second connection 230 to the sidewall 130 . The first connection 220 is an articulated connection, and in the present embodiment is formed by a screw 224 that passes through the shaft end support 210 and through a hole in the sidewall 130 and is secured by a nut 228 on the outer side of the sidewall 130 . The second connection 230 is formed by a bolt 234 that passes through the shaft end support 210 and through a hole 240 in the sidewall 130 . In order to provide vertical adjustability, the sidewall 130 comprises several holes 240 in which the bolt 234 of the second connection 230 can be inserted. The illustrations of FIGS. 5 and 6 show how these several holes 240 are used to adjust the position of the shaft 150 . As shown in FIG. 5 , the bolt 234 on each end of the shaft 150 can be pulled out of the hole 240 on the sidewall 130 , freeing the shaft end support 210 so that it can rotate around the articulated first connection 230 . In the figure, bolt 234 is shown completely pulled out of the shaft end support 210 , but a person skilled in the art will understand that it does not necessarily have to be completely pulled out in order to free the shaft end support 210 . The user wishing to adjust the roller 160 to a lower position simply pulls out the bolts 234 and pushes the shaft 150 downwards. The pushing force causes the unit formed by the shaft 150 , the roller 160 and the shaft end supports 210 to rotate with respect to the articulated first connection 230 , and the shaft 150 to move along the arc-shaped slots 200 . Once the unit has been rotated to its new position, the user only has to secure the bolts 234 back into a different pair of sidewall holes 240 matching the new position of the holes 340 of the shaft end supports 210 . For instance, FIG. 6 shows the unit having been secured to a lower position in which the bolts 234 are fastened to the lowermost holes 240 on the sidewalls 130 . The shaft end supports 210 could be adjusted to an additional intermediate position corresponding to the intermediate hole 240 on the sidewalls 130 . The number of sidewall holes 240 , and thus the number of discrete positions that the shaft end supports 210 can adopt, may vary.
As shown in the figures, the present embodiment further comprises a monitoring device 250 that is operatively attached to the shaft 150 . The monitoring device 250 counts the number of rotations of the shaft 150 , measures the angular velocity of the shaft 150 , and/or measures the length of the cable 440 being rolled on the roller 160 , and provides information on a display 254 for the user to be informed of the operation of rolling cable. This information may help assess the position of the cable 440 in the bore 410 , the time required to extract the cable 440 from the bore 410 , the depth of the bore 410 , or other parameters that can be relevant in underground electrical wiring maintenance.
The illustration of FIG. 7 presents a cross-sectional view of the cable distribution assembly 100 according to cross-sectional plane 7 - 7 indicated in FIG. 4 . As shown, the cable distribution assembly 100 further comprises two pairs of longitudinal stoppers 260 on each end of the shaft 150 . Each pair of longitudinal stoppers 260 embraces a sidewall 130 and a shaft end support 210 . Each longitudinal stopper 260 is fixed to the shaft 150 by a radial fastener 264 that slightly bites into the shaft 150 . Thus, the longitudinal stoppers 260 are rotatable jointly with the shaft 150 , and also prevent the shaft 150 from moving longitudinally when the cable is being rolled, increasing durability of the cable distribution assembly 100 . The figure also shows that, in the present embodiment, the roller 160 is similarly coupled to the shaft 150 by two radial fasteners 270 , so that the roller 160 rotates jointly with the shaft 150 .
The drawing of FIG. 8 shows a partial exploded view of the monitoring device 250 comprised in the cable distribution assembly 100 of the present embodiment. As shown, the monitoring device 234 is connected to the articulated first connection 220 so that its position is rotatably adjustable around said first connection 220 just as the shaft's 150 is. In addition, the monitoring device 250 includes an aperture 280 through which the shaft 150 couples internally to the monitoring device 250 .
While the cable distribution assembly 100 is especially indicated for rolling cables through bores on the ground or other horizontal surfaces, the invention could be used for rolling cables in different scenarios. For example, the assembly could be attached to inclined surfaces or even on vertical surfaces, for which additional securing elements such as a hook system could optionally be included to better secure the base to the surface. In another example, the cable distribution assembly 100 could be used to lay underwater cable 440 for telecommunications, electric power transmission, or other purposes. In this embodiment, the cable distribution assembly 100 could rest on a ship or submarine.
The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims. | A cable distribution assembly is operable to reel in and pay out a cable through a bore. The alignment of the cable in relation to the cable distribution assembly adjusts to restrict contact between the cable and the bole edge. In this manner, friction between the cable and the bore edge, which may damage the cable, is restricted. A base positions adjacent to the bore, aligning the cable in relation to the bore edge. The base includes a concave contour that enables the cable to pass next to the base from a roller that carries the cable through the bore. A shaft drives the roller. Shaft regulators adjustably move horizontally and vertically along a shaft slot in a sidewall to dictate the position of the shaft and the roller that carries the cable. Fasteners secure the shaft regulator into place. A monitoring device provides information on the use of the assembly. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of my earlier applications: (a) Ser. No. 422,711 filed Dec. 7, 1973, and its parent application Ser. No. 114,172 filed Feb. 10, 1971, now abandoned, and (b) Ser. No. 422,713 filed Dec. 7, 1973, and its parent application Ser. No. 114,171 filed Feb. 10, 1971, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an improved cyclic process for preparing a hydroxylammonium salt solution and converting a ketone to an oxime with the hydroxyl amine or hydroxylammonium salt. The invention further relates in particular to an improved process for the preparation of cyclohexanone oxime from cyclohexanone.
The cyclic process for the preparation of oximes from hydroxylamine or a hydroxylammonium salt is carried out in an acidic, buffered, aqueous reaction medium containing buffer acids such as phosphoric acid, bisulfate or buffer salts derived from these acid and mixtures thereof. The reaction medium is circulated between a hydroxylammonium salt synthesis zone, where nitrate ions, which have been added to the reaction medium, are catalytically reduced with molecular H 2 to hydroxylamine, and an oximation zone where a ketone is added to react with the hydroxylammonium salt to produce an oxime. The nitrate ions consumed in the hydroxylammonium synthesis zone are added to the circulating reaction medium just before the reaction medium is introduced into the hydroxylammonium salt synthesis zone. The nitrate ions are generally added in the form of nitric acid of approximately 60 weight percent.
The nitrate ions in the hydroxylamine synthesis zone are first converted into hydroxylamine which in turn reacts with the available buffer acid in the reaction medium, forming the corresponding hydroxylammonium salt. The resulting solution obtained, containing hydroxylammonium salt, is withdrawn from the hydroxylamine synthesis zone and circulated to the oximation zone, where the hydroxylammonium salt, together with a ketone, which is also fed to the oximation zone, forms the corresponding oxime, with liberation of acid. The oxime is removed from the oxime synthesis zone. The reaction medium withdrawn from the oxidation zone contains small amounts of oxime and ketone. This aqueous reaction medium is then returned to the hydroxylamine synthesis zone.
The chemical reactions taking place during the successive steps of the process for the preparation of cyclohexanone oxime wherein the reaction medium comprises a solution containing phosphoric acid, are as follows:
1. formation of hydroxylammonium salt in the hydroxylammonium salt synthesis zone:
2 H.sub.3 PO.sub.4 + NO.sub.3 .sup.- + 3 H.sub.2 → NH.sub.3 OH.sup.++ 2 H.sub.2 PO.sub.4 .sup.- + 2 H.sub.2 O
2. formation of cyclohexanone oxime in the oximation zone: ##SPC1##
3. make-up, in the form of HNO 3 , of nitrate ions consumed, after the oxime formed has been separated from the reaction mixture:
H.sub.3 PO.sub.4 + H.sub.2 PO.sub.4 .sup.- + HNO.sub.3 → 2 H.sub.3 PO.sub.4 + NO.sub.3.sup.-
following the make-up of HNO 3 , a solution is again available which, after removal of both the water formed by the reaction and the water introduced with the nitric acid make-up, will, theoretically, have the same composition as the initial solution used for the formation of hydroxylammonium salt. This solution is then circulated back to the hydroxylamine synthesis zone. The reduction of the nitrate ions in the hydroxylamine synthesis zone is accomplished in the presence of a catalyst; usually a palladium catalyst is used. The palladium is suspended on a carrier material of carbon or aluminum oxide. The carrier material usually has suspended thereon, for instance, 5-20 weight percent of palladium.
Organic substances, such as the ketone which is to be converted into oxime, and the resulting oxime itself, have an adverse effect on the activity of the catalyst if allowed to come into contact with the catalyst. To prevent the catalyst from being thus poisoned, the circulating reaction medium must be purged of the ketone and oxime contaminants prior to its entering into the hydroxylamine synthesis zone. The ketone and oxime content of the reaction medium should preferably be reduced to a value of not more than 0.02 percent by weight before the reaction medium is recirculated to the hydroxylamine synthesis zone.
In the processes disclosed in the prior art, the aqueous, weak acid reaction liquid coming from the cyclohexanone oxime synthesis zone is treated by means of a stripping process in an attempt to reduce the amount of organic compounds present.
Unfortunately, however, commercial operation of this process including purification of the reaction medium coming from the oxime synthesis zone by stripping, continues to be plaqued by residues of ketone or oxime in the aqueous reaction medium which are recycled to the hydroxylammonium synthesis zone. The processes are thus still severely hampered by poisoning of the catalyst.
In the stripping process the ketone is distilled off and the oxime is hydrolyzed according to the reaction ##SPC2##
Depending on the temperature, an equilibrium state slowly develops in the liquid being stripped with an equilibrium amount of oxime residue left, which is carried along with the bottom product withdrawn from the stripping column.
It has also been proposed to convert the organic residues into harmless products by heating the circulating reaction medium after the make-up by nitric acid for a time and at such a temperature that the harmful residues are decomposed or oxidized into compounds which are harmless to the activity of the catalyst. The time required to convert the residues to harmless compounds depends in particular on the degree of acidity of the solution and on the temperature; in general, a reaction time of about one hour has been found to be necessary. To maintain the extended reaction time required, the reaction solution circulating from the oxime synthesis zone to the hydroxylamine synthesis zone must be held up in a sizeable reservoir, requiring in addition to the large equipment an equally large volume of reaction solution.
To avoid poisoning the catalyst, the oxime residue must be removed from the circulation liquid or rendered harmless, for instance by an oxidation or decomposition process which converts the oximes to other compounds which do not poison the catalyst.
DETAILED DESCRIPTION OF THE INVENTION
A process has now been found wherein it is possible to shift the hydrolysis-equilibrium between oxime and the corresponding ketone much farther toward formation of the ketone by reacting the hydroxylamine produced by the hydrolysis of the oxime with nitrous gases according to the equation:
2 NH.sub.3 OH.sup.+ + NO + NO.sub.2 → 2 N.sub.2 O ↑ + 3 H.sub.2 O + 2 H.sup.+.
this may be accomplished using two different techniques, as described in more detail below.
THE NITROUS ACID CONTACT-STRIPPING EMBODIMENT
According to one embodiment of the present invention the circulating reaction medium from the oxime synthesis zone which contains oxime and ketone residues dissolved therein is heated to a relatively high temperature of, for instance, 80°C in the presence of nitrous gases. The oxime in the circulating reaction medium is converted by hydrolysis with the nitrous gases into the corresponding ketone during the heat treatment. The ketone produced by the hydrolysis reaction, together with any ketone which was contained in the reaction medium prior to the heat treatment, is removed from the reaction medium by subjecting the reaction medium to a stripping treatment subsequent to the heat treatment. The purified reaction medium can then be recycled to the hydroxylamine synthesis zone without poisoning the palladium catalyst.
This embodiment of the improved process of the present invention is explained in greater detail by reference to FIG. 1 of the accompanying drawings, which figure shows diagrammatically one embodiment of apparatus for performing this process.
Referring to FIG. 1, the hydroxylamine synthesis zone is represented by the letter A and the oxime synthesis zone by the letter B. Hydrogen is fed to the hydroxylamine synthesis zone A through line 1. The hydroxylamine synthesis zone is filled with a palladium catalyst supported on a particulate carrier such as carbon. Any unreacted hydrogen and possible off-gases from the hydroxylamine synthesis are vented through line 2.
The recirculating reaction medium comprising an aqueous solution of a buffer acid such as phosphoric acid or bisulfate, a buffer salt of these acids, or a mixture thereof to which a source of nitrate ions has been added, is introduced to the hydroxylamine synthesis zone A through line 12. The nitrate ions can be added in the form of nitric acid or in the form of nitrous gases wherein nitric acid is formed in the reaction medium in situ. The nitrate ions are catalytically reduced to hydroxylamine by molecular hydrogen. The reaction medium rich in hydroxylamine is withdrawn from hydroxylamine synthesis zone A and fed to the oxime synthesis zone B through line 3.
A ketone, such as cyclohexanone or a ketone dissolved in an organic solvent such as toluene, which is to be reacted with the hydroxylamine in the oxime synthesis zone B, is added to zone B through line 4. The oxime produced by the reaction of the ketone with the hydroxylamine is removed from the oxime synthesis zone B through line 5. If the ketone is fed to the oxime in an organic solvent such as toluene, the organic solvent is removed through line 5 also with the oxime dissolved therein. The aqueous, recirculating reaction medium is withdrawn from the oxime synthesis zone and fed to column F through line 6. The aqueous reaction medium coming from the oxime synthesis zone is impoverished in hydroxylamine, but contains remainders of the ketone and oxime.
Nitrous gases such as a mixture of nitrogen dioxide and nitrogen monoxide are introduced to column F through line 11 and valve 11b and intimately mixed with the aqueous reaction medium. The nitrous gases react with the oxime content of the reaction medium hydrolyzing the oxime back to the ketone. The aqueous reaction medium exiting from the column F through line 16 contains the ketone content which it contained as it came from the oxime synthesis zone as well as the added ketone produced in the column F. The aqueous reaction medium from column F is fed to stripping column C where the ketone is removed overhead as a vapor along with water vapor. The ketone-water vapor overheads are condensed in the form of a water-ketone-azeotrope in condenser D. The condensate passes to separator E wherein the ketone is separated and fed by line 8 back to the oxime synthesis zone B. Part of the water from separator E flows through line 9 to the top of column C and the remainder of the water from separator E being discarded. Condenser D is cooled with cooling water flowing through lines 14 and the stripping column is heated by heating coils 13.
The aqueous circulating reaction medium is withdrawn from the stripping column C and fed to absorber G where nitric acid is formed in situ by absorber G where nitric acid is formed in situ by absorption of nitrous gases supplied to the absorber G through line 11 and valve 11a. The aqueous reaction medium, rich in nitric acid, is then circulated to the hydroxylamine synthesis zone by line 12. Non-absorbed gases exit from the absorber G through line 15.
Instead of absorbing nitrous gases to form nitric acid in situ, a nitric make-up may be added directly to the aqueous recirculating reaction medium whereby the absorption column G can be deleted.
The quantities of nitrous gases to be supplied to column F and absorber G can be controlled by means of the valves 11a and 11b. The total of nitrous gases required could alternatively be fed to column F rather than be split as detailed above. Column F need not be an absorption column, but also can be any reaction vessel in which the aqueous reaction medium is adequately contacted with the nitrous gases.
By way of illustration, the composition of various streams in the process as shown in the drawing and described hereinbefore is given in the following table.
__________________________________________________________________________Process H.sub.3 PO.sub.4 NH.sub.4 H.sub.2 NH.sub.4 NO.sub.3 H.sub.2 O Oxime Cyclo- NO+ N.sub.2 O.sub.2 N.sub.2 O Cflow PO.sub.4 hexanone NO.sub.2__________________________________________________________________________ 6 112 88 195 3238 0.50 -- -- -- -- -- 5.216 113.5 86.5 196.5 3232 -- 0.50 -- -- -- -- 4.210 113.5 86.5 196.5 3224 -- -- -- -- -- -- 1.212 200 -- 275 3000 -- -- -- -- -- -- 1.011 -- -- -- -- -- -- 88.5 708 88.5 -- --via 11b 2 16 2 -- --15 -- 732 73.1 0.5 1.2 7 3 0.50 3.0__________________________________________________________________________
From the table, it is apparent that the carbon content of the various process streams is larger than would correspond due simply to oxime and ketone contents. This is because in the process some ketone or oxime is always oxidized into organic compounds, such as adipic acid, which have no deterimental effect on the activity of the palladium catalyst at all. Ultimately, these organic compounds are oxidized into water and carbon dioxide. These compounds are also discharged from the cycle with the oxime product.
The various zones in the process can be maintained at atmospheric, sub-atmospheric or at elevated pressures. The temperatures in the hydroxylamine synthesis zone A ranges from about 40°C to about 100°C, that in the oxime synthesis zone B from about 40°C to about 90°C. The stripping column C is operated at temperatures sufficient to remove the ketone-water vapor overhead which in turn depends upon the pressure at which the stripping column is operated. The absorber G is operated at temperatures from about 20°C to about 60°C. The temperature of the column wherein the oxime content of the recirculating, aqueous reaction medium is hydrolyzed to ketone can range between about 40°C to about 100°C.
An essential feature of the present invention is to prevent the noble catalyst from becoming poisoned by oxime and ketone contaminants returning in the recycled, aqueous reaction medium by removing both the oxime and the ketone from the reaction medium prior to its recycling to the hydroxylamine zone.
Instead of reducing nitrate ions in the hydroxylamine zone, nitrogen oxide can be introduced into the hydroxylamine synthesis zone in which a platinum catalyst replaces the palladium catalyst described hereinbefore. The nitrogen oxide is reduced to hydroxylamine in such a process. The platinum catalyst is subject to poisoning just as the palladium catalyst by any oxime or ketone contaminants in the recirculating, aqueous reaction medium. Removing these contaminants by the process as described hereinbefore prevents the poisoning of the platinum catalyst.
The nitrous gases which are added to the aqueous reaction medium during the heat treating step prior to the stripping process can be supplied by adding several varying compounds to the aqueous reaction medium which produce NO and NO 2 . Nitrous acid itself can be added or nitrous gases such as dinitrogen trioxide can be added which produces nitrous acid on solution in the aqueous reaction medium. Nitrous gases such as nitrogen dioxide and nitric oxide can be added which dissolve readily in the aqueous reaction medium.
The Heating in Contact with Nitrous Acid Embodiment
Another embodiment of my invention is described as follows. I have also found that when nitrous acid is added to the circulating reaction medium from the oxime synthesis zone during the heat treatment, decomposition of the harmful residues, ketones and oximes, can be accomplished at considerably shorter reaction times than for the prior art process described above. For instance, at temperatures of 50°C and higher, a reaction time of only a few minutes will completely decompose the harmful residues to harmless compounds. The nitrous acid can be added in the form of a nitrite solution, preferably an alkali nitrite or by adding nitrous gases.
While nitrous acid need be added only in an amount equal to the substances to be decomposed, an excess of nitrous acid can be used for convenience as it does not harm the activity of the catalyst in the hydroxylammonium salt synthesis zone and is itself converted to hydroxylamine. According to one embodiment of the present invention, nitrous gases are added to the recirculating reaction medium in an amount to supply in whole or in part the nitrate ions necessary in the make-up of the reaction solution fed to the hydroxylammonium salt synthesis zone. The nitrous gases form nitric acid in situ in the recirculating medium. When nitrous gases are used as a source of make-up nitrate, the portion of nitrous gas used to form nitric acid in the reaction medium is added at a relatively low temperature in the range of 20°-40°C. The nitrous gas used as a promoter for the decomposition of the harmful organic residues in the recirculating reaction medium is added to the solution in a reaction zone where the solution is at a higher temperature of 50°C and higher.
This embodiment of the present invention is further described in the following detailed description with reference to the drawing and the following example.
FIG. 2 is a graph showing the percent oxime in the recirculating reaction medium after various times of being heated to 50°C. The line denoted by the letter a represents the recirculating solution from the oxime synthesis zone which was not heated in the presence of nitrous acid and the line denoted by the letter b represents the same solution which was heated in the presence of nitrous acid.
FIG. 3 is a diagrammatic representation of one preferred process of the present invention in which the nitrous acid is added to the circulating reaction medium during the heat treatment step.
One mode of operation of the present invention is shown diagrammatically in FIG. 3 where A and B represent a hydroxylamine synthesis zone and an oxime synthesis zone respectively. Hydrogen is fed to zone A through line 1. The hydroxylamine synthesis zone A is filled with a palladium catalyst supported on a carbon carrier. Unreacted hydrogen and other off-gases are discharged from synthesis zone A through line 2. The recirculating reaction medium containing nitrate ions is introduced to synthesis zone A through line 12.
The hydroxylamine or hydroxylammonium salt enriched solution is withdrawn from synthesis zone A through line 3 and introduced into oxime synthesis zone B. A ketone or a solution of a ketone dissolved in an organic solvent such as toluene is fed to the oxime synthesis zone B through line 4. The oxime produced in the oxime synthesis zone B is withdrawn through line 5. Any solvent introduced with the ketone is also removed through line 5. The hydroxylamine or hydroxylammonium salt impoverished reaction medium is withdrawn from the oxime synthesis zone through line 6. The reaction medium is impoverished in hydroxylamine or hydroxylammonium salt but does contain small amounts of ketone and oxime. This solution is introduced into stripping column C by line 6. In the stripping column C, oxime is hydrolized to ketone. A large part of the ketone thus formed together with the ketone already present, is removed by condenser D where a water-ketone-azeotrope condenses. The condensate flows to separating vessel E, where the water and ketone separate into two phases. The ketone is returned through line 8 to the oxime synthesis zone B. Part of the water flows through line 9 to the top section of column C and the remainder of the water is discarded. Condenser D is cooled with cooling water flowing through cooling coils 14 and the stripping column is supplied heat by heating coils 13.
The reaction medium from stripping column C is fed by line 10 to absorption column G and then to treating reactor F. Nitrous gas is introduced to absorber G through lines 11 and valve 11a and forms nitric acid. Nitrous gas is also introduced into the treating reactor F through line 11 and valve 11b where the nitrous gases accelerate the oxidation and decomposition of the remaining ketone and oxime in the recirculating reaction medium. It is essential that the temperature in the treating reactor F is higher than that in the absorption column G. The temperature in column G ranges between 20° and 40°C and the temperature in treating reactor F being at least 50°C.
The various zones in the process can be maintained at atmospheric, sub-atmospheric or at elevated pressures. The temperature in the hydroxylamine synthesis zone ranges from about 40°C to about 100°C, that in the oxime synthesis zone from about 40°C to about 90°C.
A split nitrous gas feed is shown in FIG. 3 and described above, however, it is also possible for all the nitrous gas to be fed to the treating reactor F and subsequently through absorption column G. Non-absorbed gases are discharged through line 15.
The treating reactor F can be constructed as an absorption column in which the circulating reaction medium and nitrous gases meet in counter-current fashion. However, such a construction is not essential or necessary, any apparatus which provides adequate contact between the gases and the circulation liquid will suffice.
EXAMPLE
The unexpected improvement which accompanies the presence of a small quantity of nitrite ions in the reaction medium during a heat treatment to decompose ketone and oxime contaminants in the reaction medium is shown in the following comparative examples.
A solution exiting from the stripping column of a process as shown in FIG. 3 was found to be composed of H 3 PO 4 , NH 4 NO 3 and H 2 O having the molar proportions of 2 parts H 3 PO 4 , 2.75 parts NH 4 NO 3 and 30 parts h 2 O. The solution also contained 0.05 percent by weight of cyclohexanone oxime.
A portion of this solution was heated to a temperature of 50°C and the concentration of oxime measured at various time intervals. The results of these measurements are plotted as line a in FIG. 2. As can be seen, the concentration of the oxime remained essentially unchanged.
A second portion of the above-mentioned solution from the stripping column containing approximately 200 moles H 3 PO 4 , 275 moles NH 4 NO 3 , 3000 moles H 2 O and 0.05% by weight of oxime was heated to 50°C in the presence of 45 millimoles of NO 2 - per kilogram and the oxime concentration measured at various time intervals. The results are shown as line b of FIG. 2. As can be seen, the oxime concentration fell rapidly within the first few minutes to approximately 0.01 percent by weight.
The nitrous acid component which is added to the aqueous reaction medium during the heat treating step can be supplied by adding several varying compounds to the aqueous reaction medium which produce nitrite (NO 2 - ) ions. Nitrous acid itself can be added or nitrous gases such as dinitrogen trioxide can be added which produces nitrous acid on solution in the aqueous reaction medium. Nitrous gases such as nitrogen dioxide can be added which dissolve readily in the aqueous reaction medium forming a mixture of nitrate ions and nitrite ions. | An improved cyclic process for producing cyclohexanone oxime is provided wherein the circulating reaction medium is subjected to a heat treatment of at least 40°C in the presence of nitrous gases as it circulates between the oxime synthesis zone and the hydroxylamine synthesis zone. The residual cyclohexanone oxime is hydrolyzed to cyclohexanone in said heat treatment in the presence of nitrous gases. The reaction medium is then stripped of cyclohexanone prior to recirculating to the hydroxylamine synthesis zone. In another embodiment of the invention the recirculating reaction mixture is heated to at least 50°C in the presence of nitrous acid as the mixture circulates between the oxime synthesis zone and the hydroxylamine synthesis zone, thus reducing the amount of residual cyclohexanone oxime and cyclohexanone to an insignificant amount. | 2 |
[0001] This is a divisional of application Ser. No. 09/851,808, filed May 9, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to automated casting systems and more particularly to a casting system employing a plurality of casting units disposed on a rotating table or the like.
[0004] 2. Background Art
[0005] A casting system, besides a casting mold, typically includes a mechanism for opening and closing the mold and a variety of electrical, pneumatic, and/or hydraulic systems which serve to perform a variety of controlling functions in the overall molding process. Furthermore, lubrication systems and cooling systems may be required. A problem with prior art casting system is the difficulty encountered in substituting a different configuration mold in an existing system. Since molds of various different shapes and configurations may be required from time-to-time and connections for the various systems to control the molding apparatus may vary substantially between molds, the changeover from one set of molds to another results in significant and expensive downtime for the casting system. Such changeover may require re-routing of electrical cabling and connections for pneumatic and hydraulic as well as cooling systems. Furthermore, in typical prior art arrangement, a plurality of molds and the apparatus for opening and closing the molds are disposed on a rotating table or the like. In case of a breakdown or routine maintenance of the opening and closing mechanism for a particular mold or of the mold itself, the entire casting system must be shut down. Such a shut-down tends to be time-consuming since the system typically has to be cooled down for maintenance work and must be brought back to working temperature before operations can be resumed. A particular disadvantage of prior art systems is the costly downtime of the entire system for maintenance, repair or changeover of molds.
[0006] Routine molding operations typically require that a filter used in the casting operation be removed and replace before a next pouring of the molten metal or the like. This is commonly done manually. In order to avoid introducing the necessary delays in the casting operation, the filter is typically removed as soon as possible after the previous pouring operation, often while it is still very hot. The filter removal can be both difficult and time-consuming. A further difficulty in the routine operation of a casting system is that the mold is preferably laundered after a casting operation and coated with a specialized coating prior to the next pouring. The functions of laundering and coating are typically performed manually and tend to be difficult and time consuming adding to the cost of the casting operation.
[0007] A further difficulty in many casting operations is the removal of a casting from the mold, particularly from the drag of the mold, while the casting is hot.
SUMMARY OF THE INVENTION
[0008] These and other problems of the prior art are overcome in accordance with this invention in a modularized system comprising a plurality of casting modules, each of which may be removed from a casting system, such as a rotating table casting system, without affecting the operation of other modules. Each module is provided with on-board systems such as a lubrication system, a cooling system, etc., which operate independently from similar systems on other modules. Each module is provided with quick-disconnect connectors for connection to a main source of electrical power, hydraulic pressure, etc. The modules are preferably interchangeable and a variety of different modules may be installed in one main system and can be readily exchanged as required by production demands, without significant system downtime.
[0009] A particular advantage of the modular system is that a casting module may be removed and replaced in a relatively short period of time since only a few connections need to be made. Furthermore, periodic maintenance and repair of the modules may be performed off-line with a minimum of production line down-time.
[0010] Advantageously, in accordance with another aspect of the invention, a casting module of the system may be replaced by another module which has not only been set up and tested off-line, also warmed up off-line to bring the unit up to the desired operating temperature. In a system in accordance with this invention, the replacement of a casting module requires the casting operation be interrupted only for a period of time sufficient to disconnect a number of quick-disconnects connections, remove the casting module by means of a fork lift or the like, replace the removed module with a preheated casting module and make the necessary quick-disconnect connections. Advantageously, since the new unit has been warmed up off-line and since the other units are not taken out of operation for an extended period of time, no significant system warm-up time is required and system downtime is reduced substantially.
[0011] In accordance with another aspect of the invention, a casting unit is provided with a mechanism for mechanically removing a filter that is used in the casting process. In accordance with one specific aspect of the invention, the casting unit includes a pneumatic or hydraulic cylinder mounted on a pivoting bracket having spaced apart arms attachable by means of chain or the like to a filter to be removed. Advantageously, the filter may be raised during the pouring operation such that it is completely removed from the casting before the casting solidifies, thereby avoiding certain problems of the prior art associated with the removal of filters from a casting.
[0012] In accordance with another aspect of the invention, a cope of a casting system provided with a tilting launder tray, preferably mounted on the upper platen, that is readily moved aside during the pouring operation and quickly put in the appropriate position to direct a laundering liquid into a filler neck of the upper platen.
[0013] In accordance with another aspect of the invention, the upper platen of a casting system is provided with a swinging cope which is movable between the horizontal position, in which the cope is disposed adjacent a lower surface of the upper platen, and a vertical position in which the cope is extended at a 90 degree angle to the upper platen.
[0014] Advantageously, the movable platen greatly facilitates cleaning of the cope prior to a next pouring operation. In one specific embodiment of the invention, the cope is movable between the horizontal and vertical positions by one or more hydraulic or pneumatic cylinders and a hydraulic or pneumatically operated locking mechanism is provided to lock the cope in place adjacent to the upper platen.
[0015] In accordance with yet another aspect of the invention, the lower platen is advantageously provided with a pneumatic or hydraulic cylinder arrangement which serves to raise the lower platen for easier removal of a casting and is further provided with a mechanism for lifting a casting from the drag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a plan view of a casting table supporting a plurality of casting modules;
[0017] [0017]FIG. 2 is a front elevational view of a casting module in accordance with the invention;
[0018] [0018]FIGS. 3A and 3B are left and right elevational views, respectively, of the module FIG. 2;
[0019] [0019]FIG. 4A and 4B depict enlarged breakaway views of a filter lift mechanism in accordance with the invention;
[0020] [0020]FIG. 5 is a plan view of a bracket for mounting a filter lift cylinder in the mechanism of FIGS. 4A and 4B;
[0021] [0021]FIG. 6 is a side elevational view of a casting unit which is an alternate embodiment of the casting unit of FIGS. 2 - 5 ;
[0022] [0022]FIG. 7 is a plan view along line 7 - 7 of FIG. 6 showing a launder tray and a cope operating mechanism;
[0023] [0023]FIG. 8 is a partial breakaway side elevational view of the casting unit at FIG. 6 showing the launder tray in an operating position;
[0024] [0024]FIG. 9 is a partial breakaway side elevational view of the casting unit of FIG. 6 showing the swinging cope 203 in the closed position;
[0025] [0025]FIGS. 10 and 11 are partial cutaway right elevational views of FIG. 6 showing the cope locking mechanism in locked and unlocked states, respectively; and
[0026] [0026]FIG. 12 is a partial cutaway enlarged frontal elevational view of the dual action lower cylinder of FIG. 6.
DETAILED DESCRIPTION
[0027] [0027]FIG. 1 is a plan view schematic representation of a rotatable casting table 10 provided with a plurality of casting modules 100 and a central hub area 20 incorporating control and supply systems. The control and supply systems are connected to each of the modules 100 by means of control and supply lines 25 . Each of the casting modules 100 is preferably connected to an associated control supply line 25 by means of a quick-disconnect connector 30 . The central hub area 20 preferably includes an electronic controller 35 , a hydraulic unit 40 providing hydraulic fluid under pressure, an air supply unit 45 providing air under pressure and an electrical supply box 50 . The controller 35 may, for example, be a programmed logic array designed to provide electrical signals to various ones of the casting modules 100 to operate various air and/or hydraulic valves and/or relays. The programmed logic array may also receive signals from the various units 100 indicative of certain operations, such as actuation of limit switches, etc. The electric box 50 provides electrical power to the various units 100 , when required. A filling station 60 provides a source of molten material to be used in the casting modules 100 . The casting table 10 may be rotated to place a casting module 100 adjacent the filling station 60 . Molten material may be transferred from the filling station 60 to a casting module disposed adjacent the filling station through a transfer conduit 65 or ladle or the like.
[0028] [0028]FIG. 2 is a frontal view of a dual casting module 100 consisting of two independently operable casting units 102 , 104 . Each casting unit is provided with an upper platen 106 for supporting a cope of a mold (not shown in the drawing) and a lower platen 108 for supporting a drag of a mold (not shown in the drawing). For the sake of clarity, one of the casting units is shown in the open position in which the upper platen is spaced apart from the lower platen and the other of the casting units is shown in a closed position in which the upper platen is disposed adjacent the lower platen. The two casting units 102 , 104 operate in the same manner but are independently controlled by the controller 35 . By constructing dual unit casting modules, rather than single unit casting module, a substantial savings in construction material and system connections will be realized while obtaining modularity of the system. It will be apparent that single unit casting modules may be constructed as well. In one particular application, the dual casting modules are used to cast different parts of a unit to be assembled. A casting unit, such as the dual casting unit 102 , 104 consisting of two sets casting modules, may be readily moved by means of a forklift or other lifting equipment onto the rotating table 10 , such that the advantages of modularity are not lost by the use of a dual unit. It will be understood that the invention applies to single units in the same manner as it applies to dual units described herein.
[0029] The upper platen 106 , is moveable between a lowered position in which the cope of the mold (not shown in the drawing) supported on the upper platen 106 is disposed in immediately adjacent the drag of the mold (not shown in the drawing) supported on the lower platen 108 , and a raised position in which the cope is spaced apart from the drag. When the cope is in the lowered position, the cope and the drag together form a mold ready to receive molten metal from a ladle or the like. The raising and lowering of the upper platen 106 is achieved by means of a hydraulic lift cylinder 112 having a movable shaft 113 connected to cross beam 115 . The cross beam 115 is mounted to a pair of lift rods 117 extending from the cross beams 115 through guides 110 to the upper platen 106 . Upper guide bearings 119 and lower guide bearings 120 are provided on upper and lower ends, respectively, of the guides 110 . The guide bearings are preferably provided with a wiper seal or the like engaging the surface of the guide rods and a lubricating oil may be provided to the bearings for purpose of cooling and lubrication. The lift cylinders 112 are actuated via a control valve 121 which selectively applies hydraulic fluid under pressure from hydraulic unit 40 to the upper and lower ends of lift cylinders 112 via hydraulic quick disconnect 122 and control valve 121 , thereby controlling the movement of the upper platen 106 . The control valve 121 is actuated in response to signals from controller 35 applied via electrical quick disconnect 126 and electrical conductors 124 . Further shown in FIG. 2, associated with the raising and lowering mechanism of the upper platen 106 , is an upper platen trip rod 116 . The trip rod 116 is designed to activate a switch 111 when the upper platen is lowered to its desired position. The two switches 111 are connected to the electrical disconnect plug 126 to transmit appropriate signals to the controller 35 when the switches are actuated. For the sake of clarity, the various electrical and hydraulic connections are not shown in the drawings.
[0030] The lower platen 108 is supported on a lower platen lift cylinder 114 and lift cylinder shaft 130 . The lift cylinder 114 is operated to raise the lower platen to facilitate removal of a casting after the casting operation has been completed and the upper platen has been raised. The lift cylinder 114 is connected by means of hydraulic lines (not shown in the drawing) to the control valve 121 which, as mentioned earlier, is operated by electrical control signals from the controller 35 via the quick disconnect 126 and appropriate ones of the conductors 124 . The lower platen 108 is supported on guide rods 135 extending through bearings 136 . Connected to one of the guide rods 135 is a trip rod 138 which serves to actuate limit switches 139 , 140 to indicate the position of the lower platen. The limit switches are electrically connected by selected ones of the conductors 124 to quick disconnect 126 to provide an indication to the controller 35 of the position of the lower platen.
[0031] Further shown in FIG. 2 is a pair of oil pumps 142 and an oil supply reservoir 145 . The pumps and the reservoir, together with oil supply and return lines (not shown in the drawings) interconnecting the reservoir 145 , the pumps 142 and the bearings 119 , 120 and 136 are part of a closed bearing lubrication and cooling system in which oil is drawn from the reservoir 145 and supplied to the bearings by the pumps 142 under pressure and is returned to the reservoir. When the lower platen 108 is lowered to the normal position for casting, a lube cam 122 actuates the oil pump 142 which distributes the oil under pressure to the bearings 119 , 120 and 136 via oil supply lines and a series of standard distribution blocks (not shown in the drawings). The oil is returned from the bearings to the reservoir via the oil return lines to be reused.
[0032] Referring now to FIGS. 2 through 5, there is shown in FIG. 2 a filter element 150 in each of the casting units 102 , 104 . When a mold disposed between the upper and lower platens is in the closed position, a molten substance, such as a molten metal, is poured into the mold from a ladle or the like through an opening in the upper platen 106 . A filter element 150 is provided in alignment with such opening for filtering the molten metal. Such filter elements and the use thereof in the casting process are well known in the art. In the partially cut-away right side elevational view of FIG. 3B there is shown a filter removal unit 152 , for lifting the filter element 150 during a pouring. The filter element 150 is initially disposed adjacent the upper platen and is gradually lifted by the filter removal unit 152 during the pouring operation. Lifting the filters during the pouring operation facilitates removal of the filters before the casting begins to solidify avoids a significant problem encountered in prior art systems wherein the filter is removed after the pouring operations has been completed.
[0033] As shown in detail in FIGS. 4A, 4B and 5 , the filter removal unit 152 comprises a hydraulic lift cylinder 157 , mounted on cylinder support bracket 151 , and a piston rod 158 having a free end mounted to the frame 148 . The support bracket 151 comprises a pair of spaced apart lift arms 153 A, 153 B each pivotally mounted to an upstanding support bracket 163 mounted on the frame 148 . A chain 155 is connected from each of the lift arms to opposite sides of the filter element 150 . The cylinder 157 has fluid connections to control valve 121 and is operated in response to operation of the control valve 121 by controller 35 . FIG. 4A shows the filter removal unit 152 in the fully raised position and FIG. 4B shows the filter removal unit 152 in the fully lowered positions. The cylinder 157 has a piston rod 158 having an end engaging a flattened surface 161 of a spherical rod eye 159 , which is pivotally mounted on pivot 160 by a bracket 166 supported in a clevis bracket 162 mounted to the frame 148 . Cylinder 157 is mounted to a cylinder pivot pin 164 by means of brackets 165 . The cylinder pivot pin 164 is rotationally mounted to end brackets 166 , along the pivot centerline 154 , to allow the cylinder support bracket 151 to pivot relative to the lift cylinder 157 between the positions shown in FIGS. 4A and 4B. As the cylinder 157 is actuated, the support bracket 161 is pivoted on pivot point 156 and the lift arms 153 A, B are moved between the raised and lowered positions as shown in FIGS. 4A and 4B, respectively.
[0034] Referring now to FIGS. 6 through 12, there is shown an alternate embodiment of casting units 102 , 104 . The casting unit 201 is provided with a swinging cope 203 which is rotatably attached to the upper platen 205 . The upper platen is supported on lift rods 217 extending through guides 210 and is shown in FIG. 6 in the raised position. The swinging cope 203 is supported on a pivot 207 on the upper platen 205 . A pair of spaced apart hydraulic or pneumatic cylinders 209 is operable to move the cope from the open position shown in FIGS. 6 to a closed position, as shown in FIGS. 8 and 9, in which the upper surface 204 of the cope 203 is disposed immediately adjacent the lower surface 206 of the upper platen 205 . The lower surface of the cope is typically coated before each casting operation. In a production facility, such a coating may have to take place every three minutes. The swinging cope allows for quick and easy access for such coating purposes.
[0035] The cylinders 209 are each provided with a piston rod 240 having one end engaging the swinging cope at brackets 242 . Each of the cylinders 209 has a fixed end 244 mounted to the top surface of the upper platen 205 by means of a mounting bracket 246 . As readily apparent from the drawing, the cope 203 is disposed immediately adjacent the upper platen when the piston rod 240 is extended and is in the full down position when the piston rod 240 is retracted. The cope 203 is retained in a locked position with respect to the upper platen 205 by means of a locking mechanism 248 . FIG. 10 shows the locking mechanism in the locked position and FIG. 11 shows it in the released position. As shown in the drawing, the cope 203 is provided with a pair of pins 250 and a pneumatic or hydraulic cylinder 252 is used to actuate a pair of latches 254 , mounted on the upper platen 205 . The latches are pivotally mounted on the platen 205 by means of pivot pins 256 . The cylinder 252 is mounted to the two latches 254 by means of pivot pins 258 . When the cylinder 252 is in the extended position, as shown in FIG. 11, the latches 254 are in the released position and the upper platen 203 may be lowered to the open position as shown in FIG. 6. After the lower platen 203 has been rotated to the position shown in FIGS. 10 and 11, the cylinder 252 is operated to the retracted position which causes the latches 254 to be rotated about the pivot pins 256 thereby engaging the pivot pins 250 and drawing the cope 203 against the upper platen 206 .
[0036] Further shown in FIGS. 6 through 9 is a launder tray 220 . The launder tray 220 is pivotally mounted on axis 221 supported on a pair of spaced apart brackets 222 mounted to the upper platen 205 by fasteners 228 . The launder tray has a filler neck 225 engaging a filler opening 227 in the upper platen 205 A. Further shown in FIGS. 6 and 12 is a dual action lower cylinder arrangement 230 comprises an upper cylinder 231 for raising and lowering the lower platen and a lower cylinder 232 . The lower cylinder 232 engages a lower bracket 234 provided with vertically extending rods 235 and 236 engaging an upper bracket 238 . The bracket 238 is provided with vertically extending pins 236 extending into a lower portion of the lower platen 208 and engaging a plate 239 supporting pins 240 . When the hydraulic cylinder 232 is actuated, the brackets 234 and 238 are raised and pins 240 , extending through openings in the lower platen, serve to raise the casting in the mold to facilitate removal of a casting from the mold.
[0037] Shown in FIG. 12 is an enlarged breakaway view of the lower platen lift mechanism with a casting removal assist mechanism shown is FIG.6. An upper hydraulic or pneumatic cylinder 232 is mounted to cross-member 260 and, when operated, actuates the piston 262 to raise or lower the upper platen 205 , to facilitate removal of a casting from a mold 270 . A lower hydraulic or pneumatic cylinder 231 is mounted to the cylinder 232 by means of flanges 233 . When the lower cylinder 231 is actuated, a piston 264 raises a lower bracket 234 in the direction of the lower platen 208 . A pair of vertically extending rods 235 are mounted on the lower bracket 234 and engage an upper bracket 238 . Mounted on the upper bracket 238 are vertically extending rods 236 which extend through the lower platen 208 and engage a horizontally extending plate 239 . Vertically extending rods 240 are mounted on plate 239 and extend through the lower portion of the mold or drag. When lower cylinder 231 is actuated, rods 240 engage and raise a casting disposed on the drag to a position where it is lifted from engagement with the drag. Advantageously, this arrangement facilitates the removal of a casting from the drag.
[0038] Further shown in FIG. 6 is a dual action lower cylinder 230 having an upper portion 231 for raising and lowering the lower platen and a lower portion 232 . The lower portion 232 engages a horizontally extending bar 234 provided with vertical members 235 and 236 engaging a upper horizontal bar 238 . The bar 238 is provided with vertically extending pins 239 extending into a lower portion of the lower platen 208 . When the hydraulic cylinder 232 is actuated, the horizontal bars 234 and 238 are raised and the pins 240 extending through openings in the lower platen serve to eject the casting from the mold.
[0039] It is to be understood that the above-described arrangement is merely illustrative of the application of the principles of the invention and that other arrangements may be devised by those skilled in the art without departing from the spirit and scope of the invention as defined by the appendant claim: | A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise of the filter during the cooling operation and facilities removal of the filter upon completion of the pouring operation. The casting modules are provided with a tilting launder tray which facilitates laundering of the mold after a casting operation. The upper platen of a casting module is provided with a swinging cope which is movable between a horizontal position and a vertical position to facilitate cleaning of the cope. The lower platen is preferably provided with a pneumatic hydraulic cylinder arrangement including a mechanism for raising the casting from the drag. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image mutual transfer and succession method of a virtual image and real image, and more particularly to a method of transferring a virtual image display reflecting a real item on a half mirror into a real image display, or transferring a real image display into a virtual image display reflecting a real item on a half mirror.
2. Description of the Related Art
Conventionally, as a game machine employing an image display device using a virtual image, there is a target-hammering game device disclosed in the specification of Japanese Patent Application Laid-Open No. 8-323037.
This target-hammering game machine displays the target image projected on the CRT screen to the player by synthesizing the virtual image of the hammering table pursuant to the operation of a half mirror and the mirror image of the hammer held by the player.
Upon playing the game, the player plays the game while viewing the screen of the image display device, and swings the hammer such that the hammer, which is a mirror image, collides with the target image.
When the player hammers the target image successfully, the shock sensor detects this hammering motion and outputs a signal, and, based on such signal, the image control device switches the target image on the CRT screen to a direct hit effect image.
In addition, there is a synthesized image display device, game device and bowling game device disclosed in the specification of Japanese Patent Application Laid-Open No. 11-114221.
This synthesized image display device synthesizes an actual ball and an image ball and displays this to the observer, and comprises a CRT display for displaying images, and a mirror for forming a reflective virtual image of such image.
Upon playing the game, the actual ball rolled by the player rolls on the traveling face, passes by the mirror, and moves further toward the back.
Then, when the actual ball passes by the half mirror portion of the mirror, an image ball having the same outer appearance as the actual ball appears, and the actual ball switches to this image ball.
In other words, after the actual ball hides behind the mirror, the image ball as the reflective virtual image continues the movement.
In addition, the game device disclosed in the specification of Japanese Patent Application Laid-Open No. 11-104311 structures a variable display device with a rotational drum having a special design on the peripheral face thereof; a drum lamp capable of illuminating light to the special design of the rotational drum; a half mirror which visibly transmits the special design pursuant to the illumination from the drum lamp; and a projection display mechanism capable of projecting and displaying the projected image on the half mirror, and the projection display mechanism projects and displays the character design as the projected image on the half mirror.
According to the foregoing structure, provided is a mechanically variable display device capable of displaying a character design in addition to the display of a special design, and the ornamental visual effect is thereby improved.
Meanwhile, as described above, the target-hammering game machine disclosed in Japanese Patent Application Laid-Open No. 8-323037 executes the game with the virtual image of the hammer and the background image thereof by employing a half mirror, and merely represents the actual whack-a-mole game machine, which is a well-known and popular game, with an image. Thus, this merely displays a virtual image and does not have a switching structure.
With the synthesized image display device, game device and bowling game device disclosed in the specification of Japanese Patent Application Laid-Open No. 11-114221, when the actual ball rolled by the player hides behind the backside of the mirror, an image ball as the reflective virtual image continues the movement. Although this yields an advantage in that the occupancy space of the game device can be reduced and the device itself can be simplified by spatially disposing the portion of the real item and the portion of the reflective virtual image separately, the real item in the game machine is merely replaced with an image representation, and thereby lacks variety and diversity.
Moreover, since an actual ball is moved, a large space is required, and there is a problem in that the game device will become large.
With the game device disclosed in the specification of Japanese Patent Application Laid-Open No. 11-104311, the player visually recognizes the special design of the rotational drum via the half mirror. Although the projected image is overlapped on the special design of the rotational drum and projecting and displaying the same, the display to the player is mainly structured of the special design of the rotational drum, and this merely adds an image representation employing a virtual image to the periphery of the special design of the rotational drum.
SUMMARY OF THE INVENTION
The present invention was devised in view of the foregoing circumstances, and an object thereof is to provide an image mutual transfer and succession method of a virtual image and a real image capable of performing the smooth transfer from the display of a virtual image of a real item and the display of a real image, realizing the successful combination of the reality of the real item and the fantasy of the real image, and enabling a rich representation.
In order to achieve the foregoing object, the first aspect of the present invention provides an image mutual transfer and succession method between a virtual image and a real image which switches, as required, between display of a virtual image of a real item as a reflected image by a half mirror and display of a real image as a half mirror transmitted image from a display provided behind said half mirror; wherein mutual take-over control of images is performed by structuring the real image by said display to be apparently identical to said virtual image, displaying the real image on said display in synchronization with the dimming of illumination to said real item when displaying the real image, and brightening the illumination to said real item in synchronization with the stoppage of the real image display on said display device when displaying the virtual image.
According to the foregoing structure, the transfer and succession between the virtual image display and real image display can be conducted smoothly with the observer hardly noticing.
Further, similar to a structure of visually recognizing a real item, the successful combination of the reality of the real item and the fantasy of the real image is realized.
Moreover, by transferring the virtual image display of a real item to the display of a real image, realized is a display employing a real image for changes in the mode of the real item, which is not possible in a structure displaying the real item.
The image mutual transfer and succession method of a virtual image and a real image according to the second aspect of the present invention is the image mutual transfer and succession method of a virtual image and a real image of the first aspect described above, wherein the real item is a design drawn on the peripheral face of a mechanical reel.
According to this structure, the transfer and succession between the virtual image of the design on the mechanical reel peripheral face and real image can be conducted smoothly with the observer hardly noticing.
Therefore, by transferring the virtual image display of the design on the mechanical reel peripheral face to the display of a real image, realized is a display employing a real image for changes in the mode of the mechanical reel, which is not possible in a structure displaying the real item.
Further, similar to a structure of visually recognizing an actual mechanical reel, the successful combination of the realistic game display of the real item and the virtualistic game display of the real image is realized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the appearance of the slot game machine, which is an embodiment of the image mutual transfer and succession method of a virtual image and real image according to the present invention;
FIG. 2 is a longitudinal cross section from the side of the principal portion of the slot game machine illustrated in FIG. 1 ;
FIG. 3 is a diagram conceptually showing the structure of the principal portion of the slot game machine illustrated in FIG. 1 ;
FIG. 4 is a conceptual diagram showing the display during the game off the slot game machine illustrated in FIG. 1 ;
FIG. 5 is a diagram showing the structure of the control unit of the slot game machine illustrated in FIG. 1 ;
FIG. 6 is a conceptual diagram showing, in the slot game machine illustrated in FIG. 1 , the structure of a game display in which an image is displayed with a liquid crystal display panel at the upper half area in the game display, and a virtual image of the design of the mechanical reel peripheral face at the lower half area in the game display;
FIG. 7 is a conceptual diagram showing, in the slot game machine illustrated in FIG. 1 , the structure of a game display in which an image is displayed with a liquid crystal display panel at the upper half area in the game display, and an image design of the reel peripheral face image is displayed with a liquid crystal display panel at the lower half area in the game display;
FIG. 8 ( a ) and FIG. 8 ( b ) are respectively a processing flowchart when the mechanical reel is stopped and a processing flowchart when the mechanical reel is rotating during the transfer from the virtual image game display of the mechanical reel peripheral face design to the game display of an image design of the reel peripheral face image; and
FIG. 9 ( a ) and FIG. 9 ( b ) are respectively a processing flowchart when the mechanical reel is stopped and a processing flowchart when the mechanical reel is rotating during the transfer from the image design game display of the reel peripheral face image to the virtual image game display of the mechanical reel peripheral face design.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is now described in detail with reference to the drawings representing the embodiments.
FIG. 1 is a perspective view of the appearance of the slot game machine 1 employing the present invention. FIG. 2 is a longitudinal cross section from the side of such slot game machine 1 .
In the slot game machine 1 , as shown in FIG. 1 , FIG. 2 and FIG. 3 , a liquid crystal display panel (display) 5 is provided at a position facing the player p in a protective glass 1 g through which the player p sees, a half mirror 1 m is provided in front of the crystal display panel 5 in a lowered and inclined manner, and one set of mechanical reels 6 a , 6 b , 6 c is disposed within the top box 1 p above the half mirror 1 m.
An illumination-adjustable reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) for illuminating the designs (real item) 6 an , 6 bn , 6 cn drawn respectively on the peripheral face of the mechanical reels 6 a , 6 b , 6 c are disposed within the mechanical reels 6 a , 6 b , 6 c.
The slot game machine 1 comprises a virtual image display mode and a real image display mode as its game display mode.
For example, as shown in FIG. 4 , which is a conceptual diagram during the game, the slot game machine 1 foremost displays through the half mirror 1 m the image 5 e displayed on the upper area of the liquid crystal display panel 5 on the upper half area 1 Gu of the game display through the protective glass 1 g as the virtual image display mode, and displays the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the peripheral faces of the mechanical reels 6 a , 6 b , 6 c reflected on the half mirror 1 m on the lower half area 1 Gs of the game display.
Next, the reel lamps 6 al , 6 bl , 6 cl are turned off in order to stop the illumination to the designs 6 an , 6 bn , 6 cn of the respective peripheral faces of the mechanical reels 6 a , 6 b , 6 c so as not to display the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn , and, in synchronization therewith, as shown in FIG. 7 , a reel peripheral face image 5 el having image designs (real images) 6 an ″, 6 bn ″, 6 cn ″ identical with and positioned the same as the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the peripheral face of the mechanical reels 6 a , 6 b , 6 c is displayed on the lower half area 1 Gs of the liquid crystal display panel 5 , and transfers the virtual image display mode to the real image display mode by displaying the image 5 e and the reel peripheral face image 5 el on the entire area of the game display 1 G within the protective glass 1 g.
Contrarily, when transferring the real image display mode to the virtual image display mode, foremost, as the real image display mode, as shown in FIG. 7 , the image 5 e and the reel peripheral image 5 el having image designs 6 an ″, 6 bn ″, 6 cn ″ are displayed on the entire area of the liquid crystal display panel 5 , and the image 5 e and the reel peripheral face image 5 el are displayed across the entire area 1 G of the game display within the protective glass 1 g.
Next, as shown in FIG. 6 , the reel peripheral face image 5 el of the liquid crystal display panel 5 is non-displayed and a dark color is displayed in place thereof, and, in synchronization therewith, the reel lamps 6 al , 6 bl , 6 cl are turned on to illuminate the designs 6 an , 6 bn , 6 cn of the peripheral face of the mechanical reels 6 a , 6 b , 6 c so as to be reflected with the half mirror 1 m , and the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the peripheral face of the mechanical reels 6 a , 6 b , 6 c identical with and positioned the same as the non-displayed image designs 6 an ″, 6 bn ″, 6 cn ″ are displayed, thereby transferring the real image display mode to the virtual image display mode.
As described above, the slot game machine 1 comprises a virtual image display mode and a real image display mode as its game display mode, and is capable of transferring, when appropriate, the virtual image display mode to the real image display mode, or from the real image display mode to the virtual image display mode.
As shown in FIG. 1 and FIG. 2 , provided to the front face of the aforementioned slot game machine 1 is an operational table It which is protrusively provided in an anteriorly inclined manner at a position where the player p can manually operate the same with ease. Moreover, a transparent protective glass 1 g is provided above the operational table it so as to enable the player p to see the game space 1 s within the slot game machine 1 as well as to protect the same.
Further, as shown in FIG. 2 , a top box 1 p housing the mechanical reels 6 a , 6 b , 6 c is formed above the slot game machine 1 .
As shown in FIG. 2 and FIG. 3 , a liquid crystal display panel 5 , which is a flat panel display, is provided in the game space is protected with the protective glass 1 g at a position facing the player, and a half mirror 1 m is disposed at a declining and inclining angle of 45° toward the player side.
Moreover, although the inclination angle of the half mirror 1 m is set to 45°, it goes without saying that the inclination angle may be set to an angle other than 45° so as long as the designs 6 an , 6 bn , 6 cn of the peripheral face of the mechanical reels 6 a , 6 b , 6 c are reflected on the half mirror 1 m , and the player p is able to visually recognize each virtual image 6 an ′, virtual image 6 bn ′ and virtual image 6 cn′.
Further, although a liquid crystal display panel 5 is used as the image display device for displaying the game image in the present embodiment, needless to say, other image display devices, such as a plasma display panel, for example, may be used in place of the liquid crystal display panel 5 .
Moreover, as shown in FIG. 2 , the mechanical reels 6 a , 6 b , 6 c are housed in the top box 1 p and disposed above the half mirror 1 m , and, as shown in FIG. 4 , the player p visually recognizes the virtual images 6 an ′, . . . , 6 bn ′, . . . , 6 cn ′, . . . , in which the design 6 an , design 6 bn and design 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c are reflected on the half mirror 1 m , at the lower half area 1 Gs of the game display within the protective glass 1 g.
The aforementioned mechanical reels 6 a , 6 b , 6 c are formed having a contour of a drum shape, and, at the respective peripheral faces of the mechanical reels 6 a , 6 b , 6 c , attached thereto are a design sheet having as its material polycarbonate or the like to which the design 6 an , . . . is to be drawn, a design sheet having as its material polycarbonate or the like to which the design 6 bn , . . . is to be drawn, and a design sheet having as its material polycarbonate or the like to which the design 6 cn , . . . is to be drawn.
The aforementioned design 6 an , . . . , design 6 bn , . . . and design 6 cn , . . . are classified, for example, as a design with a specific hand such as the number 7, or other general designs.
The mechanical reels 6 a , 6 b , 6 c structured as described above are each axially supported rotatably around the concentric axis extending horizontally in the left and right directions of the slot game machine 1 , and they respectively have favorable consistency with digital control systems, and are rotatably driven independently in a direct drive with a stepping motor (not shown) which rotates in a prescribed angle.
And, in order to make each of the mechanical reels 6 a , 6 b , 6 c stop at a prescribed position determined with internal drawing, a position sensor I ( 22 a ), position sensor II ( 22 b ) and position III ( 22 c ) (c.f FIG. 5 ) are respectively applied for each mechanical reel 6 a , 6 b , 6 c for performing position control.
Moreover, light sensors such as photodiodes and phototransistors are suitably selected and used as the position sensors 22 a , 22 b , 22 c.
Further, needless to say, the rotational drive of the mechanical reels 6 a , 6 b , 6 c may suitably adopt a transmission mechanism employing a transmission belt or a gear mechanism.
And, as shown in FIG. 2 and FIG. 3 , a reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) for illuminating and conspicuously displaying the design 6 an , . . . , 6 bn , . . . , 6 cn , . . . on the peripheral face of the mechanical reels 6 a , 6 b , 6 c are disposed respectively within the mechanical reels 6 a , 6 b , 6 c.
Here, illumination of the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) can be adjusted pursuant to the increase or decrease of the current, and, by suitably adjusting the illuminance thereof, the design 6 an , . . . , 6 bn , . . . , 6 cn , . . . on the peripheral face of the mechanical reels 6 a , 6 b , 6 c can be displayed in various clearness as the virtual images 6 an ′, . . . , 6 bn ′, . . . , 6 cn ′, . . . by being reflected on the half mirror 1 m.
For example, sharp and clear virtual images 6 an ′, . . . , 6 bn ′, . . . , 6 cn ′, . . . can be displayed by increasing the illuminance of the reel lamp 6 al , 6 bl , 6 cl , and obscure and unclear virtual images 6 an ′, . . . , 6 bn ′, . . . , 6 cn ′, . . . can be displayed by decreasing the illuminance. Further, by reducing the illuminance to the lowest point, the designs 6 an , . . . , 6 bn , . . . , 6 cn , . . . on the peripheral face of the mechanical reels 6 a , 6 b , 6 c will no longer be displayed as the virtual images 6 an ′, . . . , 6 bn ′, . . . , 6 cn ′, . . . by being reflected on the half mirror 1 m , thereby realizing a non-display.
Moreover, although the reel lamps 6 al , 6 bl , 6 cl are respectively and internally disposed in the mechanical reels 6 a , 6 b , 6 c in the present embodiment, they may be provided outside the mechanical reels 6 a , 6 b , 6 c.
As shown in FIG. 1 , a coin slot 2 a for inserting a coin for the player p to bet on the slot game and a bill slot 2 b for inserting the bill for the player to bet on the slot game are provided on the operational table 1 t.
Further provided on the operational table 1 t are a unit bet button 3 p for betting a single unit each time a unit betting amount; for example, 5 cents, 25 cents, 1 dollar, is pressed per game established peculiarly to the slot game machine 1 ; a maximum bet button 3 m for betting a maximum unit betting amount; for example, 3 unit betting amount or 5 unit betting amount established peculiarly to the slot game machine 1 and simultaneously starting the rotation of the mechanical reels 6 a , 6 b , 6 c ; and a bet display unit 3 a for displaying how many units have been bet.
In addition, further provided to the operational table 1 t are a play button 3 s for starting the rotation of the mechanical reels 6 a , 6 b , 6 c ; a change button 3 c for calling a clerk to exchange money; and a cash out button 3 o for dispensing accumulated cash of the balance upon subtracting the amount used in the game from the wager inserted into the coin slot 2 a or bill slot 2 b by the player p, and the acquired dividend of the prize won in the slot game.
Moreover, a ticket out opening 4 o is provided to the lower wall face of the operational table 1 t at the front face of the slot game machine 1 , and there are cases where an exchange ticket of the payout amount is ejected from such ticket out opening 4 o instead of cash.
A payout receiver 4 u is provided at the lower part of the ticket out opening 4 o by protruding anteriorly from the wall face, and the exchange ticket ejected from the ticket out opening 4 o , or when the settlement of the game is made in cash, the paid out coins are retained in a hopper (not shown) when the game is finished.
Next, the structure of the control unit of the slot game machine 1 is described.
As shown in FIG. 5 , the control unit 20 for controlling the slot game machine 1 is structured by comprising a CPU (central processing unit) 20 a as the center of such control; an EPROM (Erasable and Programmable ROM) 20 b having written thereon a control program in advance; a RAM (Random Access Memory) 20 c for storing work data; an image control unit 20 d for controlling image data and converting this into an analog signal and outputting the same; and a RAM 20 e as a graphic memory, among others.
The series of movements of the slot game machine 1 is performed by the CPU 20 a executing the control program stored in the EPROM 20 b.
The foregoing control program processing are, for example, the drive and stop position control of the respective stepping motors for rotatably driving each mechanical reel 6 a , 6 b , 6 c ; game image output control, various processing such as the bet processing pursuant to the input operations of the player and calculation of the balance of the wager; control for printing and ejecting the exchange ticket; flashing operation control of various lamps; game sound output control, and so on.
Moreover, the EPROM 20 b has the control data and table for performing the rotational drive stoppage control of the mechanical reels 6 a , 6 b , 6 c.
The tables stored in the EPROM 20 b are a winning design combination table, stoppage control table of the mechanical reels, and so forth.
The foregoing winning design combination table stores data prescribing the winning combination design for determining the realization of winning hands, and stores data on the prize to the provided to the player in accordance with the realization of various winning hands.
Here, the realization of the winning hands determined by the combination of designs displayed on the respective mechanical reels 6 a , 6 b , 6 c in which the rotation has stopped is set by employing a random number arising in a prescribed probability among the random number generated with a random number generator.
The stoppage control table used in the stoppage control of the mechanical reel is recorded in association with the designs of the respective mechanical reels 6 a , 6 b , 6 c and the arrangement thereof, and, when the relative positional relationship among one of the designs of the respective mechanical reels 6 a , 6 b , 6 c is set forth, the mutual positional relationship of the other designs will be set forth naturally.
For example, when the number of designs of each mechanical reel 6 a , 6 b , 6 c is 16 , designs codes 1 to 16 are respectively provided to the designs 6 an , . . . , 6 bn , . . . , 6 cn , . . . of each mechanical reel 6 a , 6 b , 6 c , and, with the design of the design code 1 as the reference, the relative positional relationships of the other designs are recognized, and stoppage control is performed for the respective reels 6 a , 6 b , 6 c.
The foregoing RAM 20 c generates a work area upon executing the control program, temporarily stores variable data, and so on.
In other words, stored are data regarding whether the respective mechanical reels 6 a , 6 b , 6 c are rotating or stopped; what designs are displayed on the respective mechanical reels 6 a , 6 b , 6 c ; whether the image reel is rotating or stopped, what the image designs are among the designs displayed on the image reel; how much the player p inserted; betting information; balance; won prize; and so on.
By executing the control program stored in the EPROM 20 b , the CPU 20 a is able to comprehensively perform the overall control of the slot game machine 1 ; for instance, control of the respective stepping motors for rotatably driving each of the foregoing mechanical reels 6 a , 6 b , 6 c ; output processing of the image signal to the image control circuit 20 d ; and various processing according to the input operations of the player.
The control unit 20 is connected to an external storage device gm such as a CD-ROM, and the external storage device gm creates and stores in advance, as image data of the game, the same number and type of image designs 6 an ″, 6 bn ″, 6 cn ″ as the designs 6 an , 6 bn , 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c as well as the representation pattern used in the image 5 e.
Moreover, the control unit 20 is connected to a stepping motor M 1 , stepping motor M 2 and stepping motor M 3 for respectively driving the mechanical reels 6 a , 6 b , 6 c ; a reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) within the respective mechanical reels 6 a , 6 b , 6 c ; a position sensor I ( 22 a ), position sensor II ( 22 b ) and position sensor III ( 22 c ) for detecting the rotational position of the respective mechanical reels 6 a , 6 b , 6 c , via the interface 21 a including the motor drive circuit, sensor circuit, and so on.
Further, the control unit 20 is also connected to a speaker sp for generating game effect sounds via the interface 21 b , this interface 21 b is a sound circuit for decoding the sound signal and outputting this from the speaker sp as an audio signal.
In addition, the control unit 20 is also connected, via an interface 21 c such as a chattering prevention circuit or the like, to a bill validator 24 for reading the bill inserted from the bill slot 2 b ; a coin acceptor 25 for checking whether the coin inserted from the coin slot 2 a is genuine; a ticket printer 26 for printing the exchange ticket; a hopper 27 for paying coins at the end of the game in the case of cash settlement; a counter 28 which counts the amount inserted into or paid out from the slot game machine 1 for the game machine administrator; ornamental lamps 29 for providing game effect light; among others.
Further, the control unit 20 is also connected to structural elements 3 T of other buttons and the like via an interface 21 e.
Moreover, the CPU 20 a in the control unit 20 is connected to the liquid crystal display panel 5 via the image control circuit 20 d.
The CPU 20 a reads the image designs 6 an ″, 6 bn ″, 6 cn ″ and the image data of representation patterns and so on stored in the CD-ROM as the external storage device gm, creates an image signal thereby, and outputs such image signal to the image control circuit 20 d.
In other words, by employing the image data of the image designs 6 an ″, 6 bn ″, 6 cn ″, created are an image signal of the reel peripheral face image 5 el of the rotating or stopped image reel similar to the peripheral face of the mechanical reels 6 a , 6 b , 6 c having the designs 6 an , 6 bn , 6 cn ; and an image signal of the image 5 e employing the image data of the representation patter.
Here, the reel peripheral face image 5 el in rotation is created to be image-displayed at the same rotation angle speed as the rotation angle speed of the respective mechanical reels 6 a , 6 b , 6 c.
The image control circuit 20 d performs actual drawing processing, digital/analog conversion and the like by employing a RAM 20 e as the graphic memory from the image signal input from the CPU 20 a , outputs this as an RGB signal to the liquid crystal display panel 5 , and this is displayed as an image on the liquid crystal display panel 5 .
Next, the game display within the protective glass 1 g in the slot game machine 1 is explained.
For example, in the virtual image display mode, as shown in FIG. 6 , the image Se is displayed at the upper half area of the liquid crystal display panel 5 , and a dark color is display all across the lower half area.
Simultaneously, the illuminance of the reel lamp I ( 6 al ), reel lamp 11 ( 6 bl ) and reel lamp III ( 6 cl ) is increased in the respective mechanical reels 6 a , 6 b , 6 c in order to illuminate and conspicuously display the designs 6 an , . . . , 6 bn , . . . , 6 cn , . . . on the peripheral face of the mechanical reels 6 a , 6 b , 6 c , and reflects this on the half mirror 1 m in order to display the virtual images 6 an ′, 6 bn ′, 6 cn ′ on the lower half area 1 Gs of the game display corresponding to the dark colored lower half area of the liquid crystal display panel 5 .
In other words, the image 5 e as the real image and the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn are displayed on the same game display 1 G.
In this case, the player p visually recognizes the image 5 e on the upper half area of the liquid crystal display panel 5 at the upper half area 1 Gu of the game display and visually recognizes the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the respective mechanical reels 6 a , 6 b , 6 c at the lower half area 1 Gs of the game display through the protective glass 1 g.
Here, the designs 6 an , 6 bn , 6 cn of the respective mechanical reels 6 a , 6 b , 6 c are illuminated brighter by the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) the illuminance of which has been increased, reflected by the half mirror 1 m , and clearly projected as the virtual images 6 an ′, 6 bn ′, 6 cn ′, and at the same time the lower half area of the liquid crystal display panel 5 that constitutes the background of the virtual images 6 an ′, 6 bn ′, 6 cn ′ is made of a dark color. As a result, the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the respective mechanical reels 6 a , 6 b , 6 c are displayed clearly, and the player p will feel that he/she is visually recognizing the designs 6 an , 6 bn , 6 cn of the actual mechanical reels 6 a , 6 b , 6 c.
Next, as shown in FIG. 7 , while displaying the image 5 e on the upper half area of the liquid crystal display 5 , reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) within the mechanical reels 6 a , 6 b , 6 c are turned off, and, in synchronization therewith, a reel peripheral face image 5 el having the same visual recognition position as the image designs 6 an ″, 6 bn ″, 6 cn ″ which are the same as the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c is displayed at the lower half area of the liquid crystal display 5 . The image 5 e and the reel peripheral face image 5 el are displayed across the entire area of the game display within the protective glass 1 g upon transferring the mode to the real image display mode.
Here, it is difficult for the player p to notice that the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c visually recognized through the protective glass 1 g in the virtual image display mode has been switched to the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el of the real image display mode displayed by the liquid crystal display 5 , and will visually recognize that the virtual images 6 an ′, 6 bn ′, 6 cn ′ to be identical with the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el instantaneously synchronized and switched.
Therefore, by image-displaying a similar display of a virtual image of the mechanical reels 6 a , 6 b , 6 c by employing the reel peripheral face image 5 el displayed by the liquid crystal display 5 , it is possible to advance the game while transferring the virtual image display mode to the real image display mode in continuation without the player p hardly noticing.
Contrarily, when transferring the real image display mode to the virtual image display mode, the routine is as follows.
In the real image display mode (c.f. FIG. 7 ) in which the image 5 e and the reel peripheral face image 5 el are displayed with the liquid crystal display 5 , foremost, each of the mechanical reels 6 a , 6 b , 6 c is rotated to a rotational position capable of displaying the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c identical to the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el as the virtual images 6 an ′, 6 bn ′, 6 cn ′.
Then, in the liquid crystal display 5 , the reel peripheral face image 5 el is non-displayed, a dark color is displayed thereto in synchronization, the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) within the mechanical reels 6 a , 6 b , 6 c are turned off, the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c identical to the image designs 6 an ″, 6 bn ″, 6 cn ″ are illuminated, this is reflected on the half mirror lm so as to be displayed as the virtual images 6 an ′, 6 bn ′, 6 cn ′ at the visual recognition position identical to the image designs 6 an ″, 6 bn ″, 6 cn ″, and thereby transfers the mode to the virtual image display mode (c.f. FIG. 6 ).
Here, it is difficult for the player p to notice that the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el displayed with the liquid crystal display 5 visually recognized through the protective glass 1 g in the real image display mode has been switched to the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , and will visually recognize the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el to be identical with the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn instantaneously synchronized and switched.
Therefore, by displaying a virtual image similar to the reel peripheral face image 5 el display with the liquid crystal display 5 by employing the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , it is possible to advance the game while transferring the real image display mode to the virtual image display mode in continuation without the player p hardly noticing.
As described above, in the real image display mode, since the lower half area 1 Gs of the game display displayed to the player p is of a reel peripheral face image 5 el displayed on the liquid crystal display 5 , it becomes possible to display an image as though the actual mechanical reels 6 a , 6 b , 6 c deform limply or as though the actual mechanical reels 6 a , 6 b , 6 c are blown to pieces by employing the reel peripheral face image 5 el , thereby enabled is a game display impossible with the game machine structure in which the observer visually recognizes actual the mechanical reels 6 a , 6 b , 6 c.
Meanwhile, in the virtual image display mode, since the designs 6 an , 6 bn , 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c are reflected on the half mirror lm and displayed to the player p as the virtual images 6 an ′, 6 bn ′, 6 cn ′ at the lower half area 1 Gs of the game display displayed to the player p, the mechanical reels 6 a , 6 b , 6 c are visually recognized as in a game machine structured to directly view the actual mechanical reels, a realistic slot game can be displayed.
Further, the mutual transfer between the game display modes similar to the case where the mechanical reel and image reel are stopped is also possible between the virtual image display mode in which the mechanical reels 6 a , 6 b , 6 c are rotating and the real image display mode of the reel peripheral face image 5 el in which the image reel is rotating.
In this case, the image designs 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el are displayed to the player p having the same type and size of design as the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , the displayed to the player p in the same order as the virtual image 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn.
Moreover, the rotating reel peripheral face image 5 el is structured to be displayed to the player p by moving the image designs 6 an ″, 6 bn ″, 6 cn ″ at the same rotation angle speed as the rotation angle speed of the peripheral face of the mechanical reels 6 a , 6 b , 6 c.
For instance, when there are 16 designs for each of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , there are 16 image designs for each of the image designs 6 an ″, 6 bn ″, 6 cn ″ identical to the respective designs 6 an , 6 bn , 6 cn , and are displayed to the player p in the same order as the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn .
Further, the rotating reel peripheral face image 5 el is displayed to the player p by moving the 16 image designs 6 an ″, 6 bn ″, 6 cn ″ at the same rotation angle speed as the rotation angle speed of the peripheral face of the mechanical reels 6 a , 6 b , 6 c.
For example, in the virtual image display mode which displays the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the rotating mechanical reels 6 a , 6 b , 6 c , it is possible to transfer the mode to the real image display mode by displaying on the liquid crystal display 5 the reel peripheral face image 5 el in which the image reel is rotating synchronously with the mechanical reel, in synchronization with the extinguishment of the reel lamp I ( 6 al ), reel lamp U ( 6 bl ) and reel lamp III ( 6 cl ).
Contrarily, when transferring the real image display mode to the virtual image display mode, in the real image display mode which displays on the liquid crystal display 5 the reel peripheral face image 5 el in which the image reel is rotating, the reel peripheral face image 5 el is non-displayed, a dark color is displayed thereto in synchronization, the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) are turned off, the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c rotating in synchronization with the image reel in advance identical are displayed, and thereby transfers the mode to the virtual image display mode.
In the case of the rotating reel, also, it is possible to transfer the virtual image display mode to the real image display mode, or transfer the real image display mode to the virtual image display mode without the player p hardly noticing.
Next, the transfer control from the virtual image display mode (c.f. FIG. 6 ) to the real image display mode in the slot game machine 1 is described (c.f FIG. 7 ).
In the virtual image display mode shown in FIG. 6 , the case of the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , being displayed, and the mechanical reels 6 a , 6 b , 6 c are stopped is explained with reference to FIG. 8 ( a ).
By the foregoing control program being executed, as shown in FIG. 6 , the CPU 20 a reads and acquires from the storage area of the RAM 20 c the virtual image display design work data of the respective reels of a certain numerical value of 1 to 16 representing the design of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , which is the real image of the virtual images 6 an ′, 6 bn ′, 6 cn ′ visually recognized by the player p when the mechanical reels 6 a , 6 b , 6 c are stopped (step 1 ).
Thereafter, the CPU 20 a creates an image signal of the reel peripheral face image 5 el having the image designs 6 an ″, 6 bn ″, 6 cn ″ of the identical design corresponding to the virtual image display design work data at a visual recognition position identical to the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn from the image data stored in the external storage device gm by employing the virtual image display work data acquired in (step 1 ), and outputs this to the image control circuit 20 d . (step 2 ).
The image control circuit 20 d creates image information of the reel peripheral face image 5 el having the image designs 6 an ″, 6 bn ″, 6 cn ″ from the input image signal (step 3 ).
The CPU 20 a transmits the signal to the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ), and turns them off (step 4 ).
While the CPU 20 a transmits the signal to the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ), and turns them off (step 4 ), in synchronization therewith, the image control circuit 20 d outputs the image information of the created reel peripheral face image 5 el to the liquid crystal display panel 5 , and the liquid crystal display panel 5 displays the reel peripheral face image 5 el having the image designs 6 an ″, 6 bn ″, 6 cn ″ on the lower half area 1 Gs of the game display (step 5 ).
Meanwhile, in the virtual image display mode, the case of the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c being displayed, and the mechanical reels 6 a , 6 b , 6 c are rotating is explained with reference to FIG. 8 ( b ).
By the foregoing control program being executed, the CPU 20 a reads and acquires the reel rotational position data stored in the storage area of the RAM 20 c detected by the position sensor I ( 22 a ), position sensor II ( 22 b ) and position sensor III ( 22 c ) for detecting the rotation of the mechanical reels 6 a , 6 b , 6 c , and comprehends the respective rotational positions of the mechanical reels 6 a , 6 b , 6 c (step 1 ).
Next, the CPU 20 a creates an image signal for displaying the reel peripheral face image 5 el having the image designs 6 an ″, 6 bn ″, 6 cn ″ which rotate in synchronization with the same rotational position and rotational angle speed of the respective mechanical reels 6 a , 6 b , 6 c comprehended at (step 1 ) upon employing the image data stored in the external storage device gm, and outputs this to the image control circuit 20 d (step 2 ).
The image control circuit 20 d creates image information for displaying the reel peripheral face image 5 el having the image designs 6 an ″, 6 bn ″, 6 cn ″ which rotate in synchronization with the same visual recognition position and rotational angle speed of the mechanical reels 6 a , 6 b , 6 c from the input image signal (step 3 ).
The CPU 20 a transmits the signal to the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ), turns them off, and non-displays the virtual images 6 an ′, 6 bn ′, 6 cn ′ (step 4 ).
While the CPU 20 a transmits the signal to the reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ), and turns them off, in synchronization therewith, the image control circuit 20 d outputs the image information for displaying the rotating reel peripheral face image 5 el in synchronization at the same image design position and the identical rotational angle speed with the designs on the peripheral face of the mechanical reels 6 a , 6 b , 6 c to the liquid crystal display panel 5 , and the liquid crystal display panel S displays the rotating reel peripheral face image 5 el on the lower half area 1 Gs of the game display (step 5 ).
Next, the transfer control from the real image display mode (c.f. FIG. 7 ) to the virtual image display mode (c.f. FIG. 6 ) in the slot game machine 1 is described.
In the real image display mode shown in FIG. 7 , the case of the design images 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el being displayed, and the image reels are stopped is explained with reference to FIG. 9 ( a ).
By the foregoing control program being executed, as shown in FIG. 7 , the CPU 20 a reads and acquires from the storage area of the RAM 20 c the image display design work data of the respective image reels of a certain numerical value of 1 to 16 representing the design of the image designs 6 an ″, 6 bn ″, 6 cn ″ of the stopped reel peripheral face image 5 el visually recognized by the player p, and specifies the design (step 1 ).
Thereafter, the CPU 20 a sends a signal to the stepping motor M 1 , stepping motor M 2 and stepping motor M 3 and respectively rotates the mechanical reels 6 a , 6 b , 6 c , and stops the respective reels at a rotational position such that the image designs 6 an ″, 6 bn ″, 6 cn ″ corresponding to the image display design work data and the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn , which are identical to the foregoing image designs, are displayed at the same visible recognition position (step 2 ).
Then, the CPU 20 a sends a signal to the image control circuit 20 d and displays a dark color instead of the non-display of the reel peripheral face image 5 el in the lower half area of the liquid crystal display panel 5 (step 3 ).
While the CPU 20 a displays a dark color in place of the non-display of the reel peripheral face image 5 el and transmits the signal to the unlit reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ), and turns them on, it further illuminates and conspicuously displays the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c , reflects this on the half mirror 1 m , and displays the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn at the lower half area 1 Gs of the game display corresponding to the dark colored lower half area of the liquid crystal display panel 5 (c.f. FIG. 6 ) (step 4 ).
Meanwhile, in the real image display mode, the case of the design images 6 an ″, 6 bn ″, 6 cn ″ of the reel peripheral face image 5 el being displayed, and the image reels are rotating is explained with reference to FIG. 9 ( b ).
By the foregoing control program being executed, the CPU 20 a comprehends from the creation processing of the image signal the type and position of the respective image designs 6 an ″, 6 bn ″, 6 cn ″ rotating and displayed in the reel peripheral face image 5 el.
For example, it comprehends the type of each of such image designs 6 an ″, 6 bn ″, 6 cn ″ in a correct position against the player p (step 1 ).
Next, the CPU 20 a sends a signal to the stepping motor M 1 , stepping motor M 2 and stepping motor M 3 and rotates the mechanical reels 6 a , 6 b , 6 c such that the designs 6 an , 6 bn , 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c , which have the same designs as each of the rotating image designs 6 an ″, 6 bn ″, 6 cn ″, rotate in synchronization therewith.
In other words, in the reel peripheral face image 5 el , the mechanical reels 6 a , 6 b , 6 c are rotated in synchronization such that the virtual images 6 an ′, 6 bn ′, 6 cn ′, which has the same design as the respective designs 6 an , 6 bn , 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c displayed to the player p, rotate in the same visible recognition position, with respect to each of the rotating design images 6 an ″, 6 bn ″, 6 cn ″ displayed to the player p.
For example, the type of each of such image designs 6 an ″, 6 bn ″, 6 cn ″ positioned to be displayed correctly to the player p at a certain timing is comprehended (step 1 ), and the mechanical reels 6 a , 6 b , 6 c are rotates in synchronization such that the respective designs 6 an , 6 bn , 6 cn on the peripheral face of the mechanical reels 6 a , 6 b , 6 c having the same design are displayed as the virtual images 6 an ′, 6 bn ′, 6 cn ′ in a correct position to the player p at the same timing (step 2 ). Then, the CPU 20 a transmits a signal to the image control unit 20 d and non-displays the rotating reel peripheral face image 5 el displayed on the lower half area of the liquid crystal display panel 5 , and instead displays a dark color (step 3 ).
While the CPU 20 a displays a dark color in place of the non-display of the reel peripheral face image 5 el and transmits the signal to the unlit reel lamp I ( 6 al ), reel lamp II ( 6 bl ) and reel lamp III ( 6 cl ) and turns them on, it further illuminates and conspicuously displays the designs 6 an , 6 bn , 6 cn of the rotating mechanical reels 6 a , 6 b , 6 c , reflects this on the half mirror lm, and displays the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the rotating designs 6 an , 6 bn , 6 cn at the lower half area 1 Gs of the game display corresponding to the dark colored lower half area of the liquid crystal display panel 5 (step 4 ).
Moreover, in the embodiments described above, as illustrated in FIG. 4 , description was made on an example where the image 5 e of the liquid crystal display panel 5 is displayed on the upper half area 1 Gu of the game display to be visually recognized by the player p and the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c are displayed on the lower half area 1 Gs as the virtual images 6 an ′, 6 bn ′, 6 cn ′ reflected on the half mirror 1 m . However, in addition to this game display arrangement, for instance, the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c may be displayed on the upper half area 1 Gu as the virtual images 6 an ′, 6 bn ′, 6 cn ′ reflected on the half mirror lm and the image 5 e of the liquid crystal display panel 5 is displayed on the lower half area 1 Gs, or the game display area may be divided into an upper area, center area and lower area, such that the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c are displayed at the center area of the game display as the virtual images 6 an ′, 6 bn ′, 6 cn ′ upon being reflected on the half mirror 1 m , and the image 5 e of the liquid crystal display panel 5 may be displayed on the upper area and lower area. The arrangement of the virtual images 6 an ′, 6 bn ′, 6 cn ′ of the designs 6 an , 6 bn , 6 cn of the mechanical reels 6 a , 6 b , 6 c and the image 5 e of the liquid crystal display panel 5 may be suitably and arbitrarily selected.
According to the foregoing structure, in the game display area visually recognized through the protective glass, it is possible to play a slot game having the same realism as a game machine display actual mechanical reels since the mechanical reels are disposed inside the top box positioned above the game display unit, reflecting the designs of the mechanical reel peripheral face on the half mirror and displaying this as a virtual image.
Moreover, since the game display is started from the display of design the mechanical reel peripheral face as a virtual image by reflecting the same on a half mirror, and then images of the image design of the image reel peripheral face identical to the virtual image of the design of the mechanical reel peripheral face is displayed to the same visual recognition position by means of a liquid crystal display panel, in synchronization with extinguishing the reel lamps to stop the illumination to the designs on the mechanical reel peripheral face and thereby ending the display of the virtual image, it is possible to proceed the game while smoothly transferring the virtual image display mode which displays a virtual image of the design of the mechanical reel peripheral face to the real image display mode which displays the image design of the image reel peripheral face without the player p noticing such transfer.
Therefore, by transferring the virtual image display having a fantasy employing the virtual image of the design of the actual mechanical reel peripheral face to the real image display mode which displays the image design of the image reel peripheral face, in the real image display mode, it becomes possible to display an image as though the actual mechanical reels deform limply or as though the actual mechanical reels are blown to pieces.
Thus, enabled is a game display employing changes in the mode of the mechanical reels, which was impossible with the game machine structure in which the observer visually recognizes actual the mechanical reels.
Moreover, since a transfer is made from a real image display mode which displays the image designs on the liquid crystal display panel to a virtual image display mode in which the mechanical reels is rotated, the design on the peripheral face of the mechanical reels that are identical to the image designs displayed on the liquid crystal display panel are illuminated and displayed distinctly, in synchronization with ending the display of the image designs, and such displayed images are reflected by the half mirror to display the virtual images of the design, at the same visibly recognized position, it is possible to perform the transfer from the real image display mode which displays the image design on the peripheral face of the image reel to the virtual image display mode which displays virtual image of the design on the peripheral face of the mechanical reel so smoothly that such transfer is hardly recognized by the player p.
Therefore, the transfer between the game display by a virtual image of a real item and the game display by an image becomes possible, and thereby realized is an image mutual transfer and succession method of a virtual image and a real image capable of realizing the successful combination of the reality of the real item and the fantasy of the real image, and enabling a rich representation.
Further, although a slot game machine was exemplified in the foregoing embodiments, it goes without saying that the image mutual transfer and succession method according to the present invention may be effectively employed in displays of other game machines or displays of other equipment. | An object of the present invention is to provide an image mutual transfer and succession method between a virtual image and a real image capable of performing the smooth transfer between the display of a virtual image of a real item and the display of a real image, realizing the successful combination of the reality of the real item and the fantasy of the real image, and enabling a rich representation.
The image mutual transfer and succession method between a virtual image and a real image according to the present invention performs take-over control of mutual images by structuring the real image of the display to be apparently identical to the virtual image, displaying the real image on the display in synchronization with the dimming of illumination to the real item when displaying the real image, and brightening the illumination to the real item in synchronization with the stoppage of the real image display on the display device when displaying the virtual image. | 6 |
BACKGROUND AND SUMMARY OF THE PRESENT INVENTION
The present invention relates to a weft insertion device for use on a band-gripper weaving machine. The weft insertion device comprises a driven, rotationally oscillating band wheel cooperating with a flexible insertion band having a gripper head and executing an oscillating movement into and out of the warp shed as it correspondingly unwinds from the winds onto the circumference of the band wheel. A guide means is provided for preventing the insertion band from separating from the outside circumference of the band wheel. The guide means is in the form of a cable of appropriate length which rests or presses against the outside of the insertion band. Both ends of the cable are anchored to the band wheel.
In a device of this type as disclosed in U.S. Pat. No. 4,274,449, the insertion band is wound around the circumference of the band wheel to the extent of about 300°-330° when the gripper head is in the position in which the head is fully and maximally withdrawn from the warp shed. The distance around the entire circumference of the band wheel is thus always a little greater than the maximum amplitude or excursion of the gripper head. The excursion is in turn directly related to the width of the machine.
Each time the direction of rotation of the band wheel is changed, the band wheel must be stopped and then accelerated again. In the charging process a moment of inertia of the mass of the band wheel must be overcome. Since the diameter and mass of the band wheel increase as the width of the weaving machine increases, the moment of inertia of the band wheel increases as well, thus limiting the speed of the weaving machine. Accordingly, for some time there have been ongoing efforts to substitute lighter structures for the band wheels which were originally in the form of cast wheels with spokes.
The lighter-construction wheels have a disc-like wheel body which is directly connected to the hub and has a honeycomb structure. The material used is either a light metal or a plastic. While these band wheels have generally had successful performance in practice, they are relatively expensive to manufacture. In addition there is the possibility that as weaving machines become substantially larger than those commonly in use today there may be problems related to the rigidity of present band wheels.
Accordingly, an object of the present invention is a refinement of a device of the type described initially above, whereby even with a very wide weaving machine the moment of inertia of the band wheels can be kept as small as possible. Also the rigidity of the band wheels may be maintained as high as possible without increasing the cost of manufacture.
These objects and others are achieved according to the present invention by a band wheel having a circumference which is smaller than the maximum excursion of the gripper head. Also, the insertion band is wound around the circumference of the band wheel to the extent of more than 360° when the gripper head is in the position in which the head is fully and maximally withdrawn from the warp shed. Further, a cable rests or presses against the entire length of the insertion band which is wound onto the band wheel.
The invention deviates from the former approach of attempting to maintain high rotational speeds on wider machines by improving the design of the band wheels. Instead, it is proposed by the present invention to have an overlap in the winding of the insertion band around the circumference of the band wheel. By this technique, the diameter of the band wheel can be kept small, so that a wider machine will not entail either higher band wheel manufacturing costs or problems stemming from the inadequate rigidity of a larger diameter band wheel. The use of a band wheel with a lower moment of inertia also permits a higher rotational speed as well as a simplification and reduction in cost of the band wheel drive.
It should also be noted that with prior art devices wherewith the insertion band is wound around the band wheel to the extent of less than the total circumference of the wheel, the increased band wheel diameter accompanying increased machine width eventually leads to a condition where the necessary band wheel is too large for the machine. In other words, the machine is too short vertically to accommodate the band wheel. Also, an increased band wheel diameter itself adds to the overall width of the machine. Thus, the present invention affords significant dimensional advantages over the prior art. For example, the present invention limits the additional machine width occasioned by the band wheels when the basic machine width is increased. Further, the present invention permits the machine to be widened substantially without the machine having to be increased in height as well.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will be described in greater detail in the following description with reference to the accompanying drawings, wherein like members bear like reference numerals and wherein:
FIG. 1 is a schematic front view of parts of a band-gripper weaving machine which parts are necessary for an understanding of the invention;
FIGS. 2 and 3 are cross-sectional views through line II--II of FIG. 1, for two different operating states;
FIG. 4 is a front view partially cutaway of the band wheel of FIG. 2;
FIG. 5 is a cross-sectional view through line V--V of FIG. 4; and
FIG. 6 is a cross-sectional view through line VI--VI of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a portion of a band-gripper weaving machine of known construction includes on the left and right sides of a machine frame 1 respective base plates 2 each serving as mounting supports of a respective band wheel 3. Each of the band wheels 3 is covered by a removable cover (not shown). In FIG. 1, only the left band wheel 3 is shown, with the cover removed. The configuration for the right band wheel is a mirror image of the configuration of the left band wheel. Weft threads are held in a large yarn supply arrangement (not shown) at the right side of the weaving machine, and are fed to a first gripper head which is attached to one end of a flexible insertion band. The gripper head end of the flexible insertion band rests against the rim of the right band wheel, and the other end is connected to said rim. Similarly, a flexible insertion band 4 is attached to the left band wheel 3, and a second gripper head 5 is mounted on a free end of the band 4. The end of the band 4 opposite to the gripper heads is attached to the band wheel 3 by a screw 6.
The band wheels are driven in rotational directions, whereby the two gripper heads are continually moved toward the middle of the warp shed (not shown) and then back out of the shed again. The transfer of the weft thread from the first to the second gripper head 5 is effected in the middle of the warp shed. Thereafter, the weft thread is inserted into the second half of the warp shed from the middle of the shed by the second gripper head 5. After the insertion is completed, the weft thread is beaten-up by a reed 8 which is attached to a batten 7.
With reference to FIG. 1, the gripper head 5, in the illustrated position, is fully and maximally withdrawn from the warp shed. The insertion band 4 is wound around the band wheel 3 to the extent of more than the circumferential distance of the wheel 3 such that the band overlaps itself. The winding is approximately to the angular extent of about 460° around the band wheels whereas in the prior art the winding was only to the angular extent of around 320°. This overlapping of the insertion band 4 by about 100° has enabled a reduction in the diameter of the band wheels 3 by about 25-30%.
The band wheel 3 is of a known construction, preferably comprising a hub 9 and a wheel body 10 mounted at the middle of the hub 9. The wheel body 10 is of a suitable material and includes a plurality of holes 11 circularly aligned. The holes are for reducing the mass of the band wheel 3. A band wheel of this type is described in U.S. Pat. No. 3,987,822 and Swiss Pat. No. 629,859.
The band wheel described in Swiss Pat. No. 629,859 has proven to be particularly suitable. The wheel body 10 (reference numerals from the present drawings) has a disc-shaped part which is comprised of a honeycomb structure in which the cells run parallel to the rotational axis of the band wheel 3 and are open on both sides of the wheel 3. This honeycomb piece, which is made of a light metal or a plastic, is covered on both sides by thin circular discs and at its circumference by a sheet or film. This composite structure of the wheel body 10 (FIG. 2) includes the honeycomb part 12, the side discs 13 and the sheet or film 14 on the circumference.
Since one end of the insertion band 4 is attached to the band wheel 3 by the screw 6, the band 4 is pushed when the gripper head 5 moves into the warp shed (during the unwinding of the insertion band 4), and is pulled when the gripper head 5 is withdrawn from the warp shed (during the winding of the insertion band 4). In the pushing mode, the insertion band 4 is forced away from the circumference of the band wheel 3 during the acceleration phase. In the pulling mode, the insertion band 4 is forced away from the circumference during the deceleration phase. In order to prevent the insertion band 4 from separating from the circumference of the band wheel 3 under these circumstances, a guide element is provided.
In the illustrated embodiment, this guide element is in the form of a cable 18 of appropriate length which has its two ends 15 and 16 anchored to a lug 17 attached to the band wheel 3. The cable 18 is wrapped around the band wheel 3 and presses against the insertion band 4 from the outside. In this way, the band 4 is pressed against the circumference of the band wheel 3. Another guide 19 is provided for the insertion band 4 between the band wheel 3 and the warp shed.
The cable 18 is wrapped around the entire circumference of band wheel 3, and additionally passes over two rollers 20 and 21 which are braced against each other by a spring (not shown). This roller and spring arrangement ensures that the cable 18 presses against the insertion band 4 from the outside with a definite and adjustable initial force.
An arrangement of this type with a guide element in the form of a cable 18 of appropriate length, provided for the purpose of preventing the insertion band 4 from separating from band wheel 3, is described in U.S. Pat. No. 4,274,449. Rollers 20 and 21 (reference numerals from the present drawings) and their mutual arrangement and functioning are also described in that patent. Therefore, a more detailed description of rollers 20 and 21 is not deemed to be essential in the present application. Therefore, U.S. Pat. No. 4,274,449 is hereby incorporated by reference.
As also described in U.S. Pat. No. 4,274,449, the cable 18 passes twice around the circumference of the band wheel 3. In the first pass, the cable 18 (reference numerals from the present drawings) presses against the insertion band 4 and in the second pass the cable 18 runs in a guide groove. The transition between the two passes is made by the rollers 20 and 21. With reference to FIG. 1, the cable 18 runs in its first pass clockwise from the end 16 over the insertion band 4 to the roller 21 and then to roller 20. The cable 18 is then returned on the second pass in which the cable extends to the other end 15.
The arrangement of the cable 18 and the insertion band 4 on the band wheel 3 in accordance with the present invention can be seen from FIGS. 2 and 3. Also, the configuration of the band wheel 3 in the region where the cable ends 15 and 16 are anchored can be seen from FIGS. 4-6. FIGS. 2 and 3 are cross-sectional views along the line II-II of FIG. 1, with the sectional view of FIG. 2 corresponding to the rotational position of band wheel 3 indicated in FIG. 1. The sectional view of FIG. 3 corresponds to the rotational position following one full rotation of the band wheel 3 in the clockwise direction.
FIG. 4 is a cross-sectional view of the band wheel 3 absent the insertion band 4 and the cable 18; FIGS. 5 and 6 are cross-sectional views through the location indicated in FIG. 4 on band wheel 3, viewed respectively from opposite directions.
FIG. 2 corresponds to the rotational position of the band wheel 3 in which the gripper head 5 (FIG. 1) is fully and maximally withdrawn from the warp shed. In this rotational position of the band wheel 3, the insertion band 4 winds around the band wheel 3 about 1 and 1/4 times circumferentially (about 460°) from the anchor point of the band 4. Thereafter, the band 4 leaves tangentially from the band wheel 3 and runs in the guide 19. In order for the cable 18 to prevent any separation of the insertion band 4 from the circumference of the band wheel 3 during the entire unwinding and winding motion of the band 4, the cable 18 must wind around the band wheel 3 for a length corresponding to the instantaneous wound length of the insertion band 4. In the rotational position of FIGS. 1 and 2, this length is about 460°. With this arrangement, the cable 18 winds around the band wheel 3 in two layers in the first pass over the segment of the circumference on which the insertion band 4 is wound in two layers. This segment corresponds to the overlapped winding length, about 100°.
As can be seen from FIG. 2, the sheet or film 14 on the circumference of the band wheel 3 includes a support element 22. The support element 22 has a shoulder 23 for supporting the insertion band 4 and further has a guide groove 24 for the cable 18. The groove 24 has an inclined interior side 25 on the side nearest the shoulder 23, and a ridge 26 on its other side. The groove 24 is deeper than the radius of the cable 18 and the guide groove 24 serves as a base for the second pass.
Disregarding the fact that the two rollers 20 and 21 are a certain distance apart, and thus disregarding the length of cable 18 around and between the rollers 20 and 21, the length of the cable 18 pressing against the band wheel 3 is about twice the circumference of the band wheel 3. This length is apportioned to the two passes of the cable 18 depending upon the position of the gripper head 5 and thus the rotational position of the band wheel 3.
FIG. 3 corresponds to the rotational position of the band wheel 3 at which position the gripper head 5 (FIG. 1) is maximally extended into the warp shed and at which position the insertion band 4 is nearly completely unwound from the band wheel 3. Also in this position, the band wheel 3 has rotated about 450° clockwise from the position of FIGS. 1 and 2, and the end of the insertion band 4 which end is attached to the band wheel 3 by the screw 6 lies immediately counterclockwise of the roller 20 (FIG. 1).
In this position, the first pass of the cable 18, over the insertion band 4 resting on the shoulder 23, comprises only the short length up to the roller 21 (FIG. 1). In the second pass in the guide groove 24, the cable 18 is in a double layer over the entire circumference of the band wheel 3.
The guide groove 24 and the insertion band 4 are both configured so as to enable the cable 18 to wind around the band wheel 3 in the respective path in a double layer. In this connection, as mentioned, the guide groove 24 is deeper than the radius of the cable, and has the ridge 26 and the inclined side 25 to retain two layers of the cable 18.
With reference to FIGS. 2 and 3, the first layer or pass of the cable 18 runs at the bottom of the guide groove 24 and rests against the ridge 26. As shown in FIG. 3, the second layer or pass settles in on the inclined side 25, to the side of the first layer. Alternatively, the inclined side 25 may be dispensed with and the guide groove may be made deeper than the diameter of the cable 18. In this way, the groove 24 would be bounded on both sides by ridges similar to the ridge 26, and the two layers of the cable 18 would be directly above one another.
The insertion band 4 lies on the shoulder 23 from the screw 6 over 360° of the circumference of the band wheel 3, and the cable 18 lies over the band 4. After one complete circuit of the band wheel 3, the overlap region begins. In the overlap region, the insertion band 4, now in its second layer or pass, lies over the first layer of the cable 18 and is held down by the second layer of the cable 18 (FIG. 2). Since this configuration is relatively unstable, the configuration could lead to the second layer of insertion band 4 tilting or twisting and resting against its edge. Accordingly, the second layer is preferably supplied with two separating strips 27 attached to a portion of the band 4 near its edges and over the extent of the maximum overlap of the second layer on the first, i.e., over approximately a 100° angle in the region adjacent to the screw 6 (clockwise as seen in FIG. 1). These separating strips 27 are made of plastic and are attached to the insertion band 4 by gluing. As shown, the cross section of the strips 27 is rectangular and their height corresponds to the diameter of the cable 18.
According to FIGS. 4 to 6, the band wheel 3 is configured on its circumference which supports the insertion band 4 such that the overlapping of the band 4 is accommodated. Further, the band wheel 3 has a step 29 at a hole 28 which receives the attaching screw 6 (FIG. 1). The height of the step 29 corresponds to the diameter of the cable 18 plus the thickness of the insertion band 4. This height is accomplished by a basically spiral configuration of the circumference of the band wheel 3. Preferably the honeycomb part 12 is circular, and the shoulder 23 of the support element 22, which shoulder supports the insertion band 4, has a thickness which varies suitably along the circumference of the band wheel. In the region of the circumference clockwise from the hole 28 for a distance at least equal to the winding overlap length (about 100°), the shoulder 23 has a constant thickness. Following this region, the thickness increases continuously up to the location of the step 29. The step can be seen in FIG. 4 along with the support surface 30 of the shoulder 23.
The overlapping of the insertion band according to the present invention on the band wheel may be employed in connection with other known guiding arrangements for preventing the insertion band from separating from the circumference of the band wheel. These alternative guiding arrangements do not necessarily involve a cable cut to length.
If the guiding arrangement is in the form of an endless belt or cable, as described in U.S. Pat. No. 4,274,449, it is sufficient for the guiding arrangement to encircle the band wheel only once. In this way, in a region where the insertion band is in two layers, the guide runs over the external layer, and presses on the internal layer through the external layer. In a region where the insertion band is in only one layer, the band is held down directly by the belt or cable.
The principles, preferred embodiment and mode of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby. | The present invention relates to a weft insertion device for use on a band-gripper weaving machine. The device has a driven, rotationally oscillating band wheel having a flexible insertion band including a gripper head. The band executes an oscillating movement transversely to the warp shed as the band unwinds from the winds onto the circumference of the band wheel. The circumference of the band wheel is smaller than the maximum excursion of the gripper head. The insertion band is wound around the circumference of the band wheel to the extent of more than 360° when the gripper head is in the position in which the head is fully and maximally withdrawn from the warp shed. In this way, the diameter of the band wheel can be kept small. This small diameter permits operation at high rotational speeds and also renders the band wheel less expensive. This is particularly advantageous when the machine is wide. Further, the contribution to total machine width made by the band wheels is less than under the prior art, and additionally the height of the machine does not need to be increased with a corresponding increase in machine width. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to copending application, Ser. No. 744,363, filed on June 13, 1985, by Bruce Arthur Luxon and Malalur Venkat Murthy.
The present invention relates to reinforcing filament bundles in the form of elongated granules and to their use in dispersing fibers in thermoplastic resins during injection molding processes.
BACKGROUND OF THE INVENTION
Fiber filled plastic compounds suitable for injection molding have become widely used. The fibers impart many valuable characteristics to the injection molded articles, foremost of which are high dimensional stability, high modulus of elasticity, high resistance to distortion by heat, high tensile strength, unusually high flexural modulus and low shrinkage during curing. Glass-reinforced thermoplastic injection molding compounds and injection molding processes employing them are described in Bradt, U.S. Pat. No. 2,877,501. The technology of the Bradt patent has subsequently been extended. In addition to the styrene resins, styrene-acrylonitrile copolymer resins and styrene-butadiene copolymer resins described therein, numerous other injection-moldable thermoplastic resins, such as polycarbonate resins, acrylonitrile-butadiene-styrene terepolymer resins, poly (ethylene terephthalate) resins, polysulfone resins, polyphenylene ether resins, nylon resins, and the like, are effectively reinforced by glass fibers. Moreover, instead of glass fibers, subsequently developed commercial products are reinforced with filaments of carbon fibers, graphite fibers, aramid fibers, stainless steel filaments and others, as well as mixtures of any of the foregoing, many such products stemming directly from the technology disclosed in the above-mentioned U.S. Pat. No. 2,877,501. Such technology involves providing elongated granules, each of the granules containing a bundle of elongated reinforcing filaments extending generally parallel to each other longitudinally of the granule and a thermoplastic molding composition surrounding and permeating the bundle. In the process of injection molding, such granules are forced into a mold, wherein the filaments will be dispersed and produce molded articles with improved properties in comparison with the molded thermoplastic alone.
The above-mentioned U.S. Pat. No. 2,877,501, discloses pellets comprising 15-60 wt. % glass in thermoplastic resin, e.g., polystyrene. This corresponds to 8.1%-42.9% of filaments by volume and correspondingly 91.9-57.1% by volume of resin. Current processes for making such prior art filamentfilled granules require a compounding/pelletizing step, in which the thermoplastic material is mixed with filaments, usually chopped bundles of filaments, and usually in an extruder, then the extrudate is chopped into molding granules. Such equipment is not readily available to the molder, and a number of specialty compounders have established businesses in which fibers from one source, and thermoplastics from another source are formulated into granules in drums or truckloads for sale to molders. It would be desirable to by-pass such compounders and permit molders to feed mixtures of thermoplastics and fibers directly into the molding press hopper achieving fiber dispersion by shear forces at the screw, nozzle, check valve, runners, gates, etc. in the injection molding machine. It would also be desirable to use, in comparison with the prior art, much less resin in the pellets, e.g., 2.5-32.5% by volume (instead of 57.1-91.9%) and much higher filament loadings, e.g, 67.5-97.5% by volume (instead of 8.1-42.9% by volume). However, until the present invention, this has not been possible because the fiber or filament bundles separate during chopping and tumbling with the reduced volume fractions of resin. There is also a tendency for the resin to degrade if the temperature is raised to lower viscosity and enhance dispersion. Moreover, individual fibers can become airborne and cause problems in handling.
The above-mentioned patent application discloses improved elongated granules which solve such problems by substituting for the thermoplastic matrix separating and coating the fiber bundles, as in the prior art, a much thinner layer of an efficient thermoplastic adhesive, which acts as a binder. However, although the poly (C 2 -C 6 alkyl oxazoline) binder used in the above-mentioned application holds the fiber bundle together sufficiently to prevent broken bundles during chopping into elongated pellets and tumbling with the resin to be reinforced and then readily breaks down in the presence of molten resin and thereafter does not interfere with fiber dispersion, or degrade the resin properties, or constitute-an environmental hazard, one drawback has developed and this is a tendency to prematurely break apart or "bird's nest" when high speed aggressive blending equipment is used.
Because the molding process itself is used to disperse the fibers uniformly throughout the molded part and the melt-blending compounding/pelleting step is to be strictly avoided, it is obviously important to maintain fiber bundle integrity prior to the dispersion step.
The present invention has, as its principal object, the provision of a means to keep the bundles together during dryblending in high speed production machinery. As a result, when using electrically conductive fibers, such as nickel coated graphite fibers, superior electromagnetic shielding can be provided at vastly increased rates of production at equal load levels (compared with compounded pellets), providing better shielding at one-half the cost, and, in comparison with the use of conductive, e.g., silver, paint there is much less or no secondary finishing with equivalent or better shielding, far superior physical properties, and superior long-term reliability.
DESCRIPTION OF THE DRAWING
In the drawing,
FIG. 1 is a somewhat idealized isometric view, on an enlarged scale, of a molding granule of the prior art;
FIG. 2 is a somewhat idealized, fragmental crosssection of a molding granule of the prior art on a still further enlarged scale;
FIG. 3 is a somewhat idealized isometric view, on an enlarged scale, of a molding granule according to this invention, showing closer packing and no overcoat;
FIG. 4 is a somewhat idealized, fragmental cross-section of a molding granule of this invention on a still further enlarged scale;
FIG. 5a is a semi-schematic diagram showing a preferred way-of making the elongated molding pellets of this invention; and
FIG. 5b is a semi-schematic drawing illustrating the way in which the pellets of this invention are mixed and molded into shaped articles.
SUMMARY OF THE INVENTION
In accordance with the invention, there are provided injection molding compounds comprising elongated granules, each of the granules containing a bundle of elongated reinforcing filaments extending generally parallel to each other longitudinally of the granule and substantially uniformly dispersed throughout the granule in a thermally stable, film forming thermoplastic adhesive comprising
(a) a poly(C 2 -C 6 alkyoxazoline) in combination with
(b) a poly (vinylpyrrolidone), said adhesive substantially surrounding each filament.
Also contemplated by the invention are mixed injection molding compositions comprising:
(i) thermoplastic resin molding granules; and
(ii) elongated granules comprising 67.5-97.5% by volume of reinforcing filaments extending generally parallel to each other longitudinally of each of the granules and substantially uniformly dispersed throughout the granule in from 2.5 to 32.5% by volume of a thermally stable, film forming thermoplastic adhesive comprising
(a) a poly(C 2 -C 6 alkyoxazoline) in combination with
(b) a poly (vinylpyrrolidone), the amount of component (ii) in the composition being sufficient to provide 1-60% by weight of the filaments per 100% by weight of (i) plus (ii).
It is a further feature of the invention to provide a method of manufacturing an injection molding compound comprising the steps of continuously passing reinforcing filaments through one or more baths of a thermally stable, film forming thermoplastic adhesive in a solvent, e.g., water, to impregnate the filaments, passing the impregnated filaments through means such as a sized opening or over grooved rollers to remove any excess adhesive, passing the impregnated filaments into a heating zone first to evaporate the solvent and then to flux the thermoplastic adhesive, and withdrawing the treated filaments from the heating zone and thereafter chopping them into elongated granules, whereby there are produced granules comprising 67.5-97.5% by volume of reinforcing filaments extending generally parallel to each other longitudinally of the granule, substantially uniformly dispersed throughout said granule in from 2.5-32.5% by volume of the thermally stable, film forming thermoplastic adhesive combination as above defined which substantially surrounds each said filament.
In still another aspect, the present invention contemplates, as an improvement in the process of injection molding, the step of forcing into a mold an injection molding composition comprising a blend of:
(i) thermoplastic molding granules; and
(ii) an amount effective to provide reinforcement of elongated granules, each of the granules containing a bundle of reinforcing filaments extending generally parallel to each other longitudinally of the granule substantially uniformly dispersed in a thermally stable, film forming thermoplastic adhesive comprising
(a) a poly(C 2 -C 6 alkyoxazoline) in combination with
(b) a poly (vinylpyrrolidone), said adhesive substantially surrounding each said filament.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing, FIGS. 3 and 4, each filament contained in the injection molding granule is surrounded by and the bundle is impregnated by the thermally stable, film-forming thermoplastic adhesvie combination. The pellet itself may be of cylindrical or rectangular or any other cross-sectional configuration, but preferably is cylindrical. The length of the granules can vary, but for most uses, 1/8 inch-3/4 inch will be acceptable and 1/8 inch-1/4 inch will be preferred. The differences between the pellets of this invention and those of the prior art can be seen by comparison of FIG. 1 with FIG. 3 and FIG. 2 with FIG. 4, respectively. Unlike the prior art (FIGS. 1 and 2) the pellets of this invention have close-packed filaments and the thermoplastic adhesive jacket is substantially dispersed upon contact with hot molten thermoplastic in the present invention. On the other hand, the prior art pellets will not readily separate into reinforcing filaments because of interference by the relatively thick jacket of thermoplastic resin.
Instead of using a lot of resin to impregnate the fiber bundle and surround it, as is done in the prior art, it is essential to use an adhesive efficient for the purposes of the invention, and that is to bind a high proportion of filaments into each elongated granule and maintain them throughout the chopping process and any subsequent blending steps in high speed, high throughput machines. The adhesive preferably will be used also in an amount which is not substantially in excess of that which maintains the fiber bundle integrity during chopping. This amount will vary depending on the nature of the fibers, the number of fibers in the bundle, the fiber surface area, and the efficiency of the adhesive, but generally will vary from 2.5 to 32.5% and preferably from 5 to 15% by volume of the granule.
For uniform adhesive pick up on the fibers in the bundle it is preferred to use a small, but effective amount of a conventional surface active agent, which facilitates wetting and bonding to numerous different substrates. Anionic, cationic and non-ionic surfactants are suitable for this purpose, the only requirement being that they be miscible with any solvent system used for impregnation and compatible with the thermoplastic film forming adhesive combination. Preferred surfactants, especially when graphite, or metal coated carbon fiber substrates are used, comprise anionic surfactants especially sodium salts of alkyl sulfuric acids. Particularly useful is sodium hepadecyl sulfate, sold by Union Carbide Co., under the Trademark NIACET® No. 7.
Careful consideration should be given to selection of the film forming thermoplastic adhesive combination, subject to the above-mentioned parameters. Some adhesives are more efficient than others, and some, which are suggested for use as fiber sizings in the prior art will not work. For example, poly(vinyl acetate) and poly(vinyl alcohol), the former being suggested by Bradt in U.S. Pat. No. 2,877,501, as a sizing, do not work herein because, it is believed, thermosetting or cross linking occurs and this operates to prevent rapid melting and complete dispersion in the injection molding machine. While such materials are suitable for the resin rich compounded granules used in the Bradt patent, they are unsuitable herein.
Much preferred for use herein is a combination comprising poly (C 2 -C 6 alkyl oxazolines) and poly (vinylpyrrolidone). The former is somewhat structurally related to N,N-dimethylformamide (DMF) and have many of its miscibility properties. A readily available such polymer is poly(2-ethyl oxazoline), Dow Chemical Co. PEOx. This can also be made by techniques known to those skilled in this art. Poly(2-ethyl oxazoline) is thermoplastic, low viscosity, water-soluble adhesive. It can be used in the form of amber-colored and transparent pellets 3/16" long and 1/8" diameter. Typical molecular weights are 50,000 (low); 200,000 (medium) and 500,000 (high). Being water soluble, it is environmentally acceptable for deposition from aqueous media. It also wets the fibers well because of low viscosity. It is thermally stable up to 380° C. (680° F.) in air at 500,000 molecular weight. Poly(vinylpyrrolidone) is an item of commerce, being widely available from a number of sources, and varying in molecular weight, as desired. While the poly(oxazoline) appears to provide dispersibility to the elongated bundles, the poly(vinylpyrrolidone) is useful for high temperature resistance. Like the oxazoline, poly(vinylpyrrolidone) works well in water based impregnation media. Typical molecular weight ranges readily availabe can be used, for example 10,000; 24,000; 40,000; and 220,000. The higher molecular weight material tends to provide bundles which are more difficult to disperse. On the other hand, the lowest molecular weight causes some loss in heat resistance. However, within the foregoing parameters, the adhesive combination on fiber bundles does not fracture appreciably during chopping to minimize free filaments from flying about, which can be a safety hazard. When blended with pellets of a thermoplastic resin system, the adhesive combination will melt readily allowing complete dispersion of the fibers throughout the resin melt while in a molding machine. However, pellets bound with this thermoplastic adhesive combination are indefinitely stable with the resin pellets during blending, and don't break apart prematurely.
As a result of a number of trials, the invention as currently practiced provides optimum results when the following guidelines are adhered to:
The fiber type can vary, any fiber being known to be useful as a filler or reinforcement in a resin system can be used. Preferred fibers are carbon or graphite fibers, glass fibers, aramid fibers, stainless steel fibers, metal coated graphite fibers, or a mixture of any of the foregoing.
The preferred thermoplastic adhesive component (a) comprises poly(ethyloxazoline), having a molecular weight in the range of about 25,000 to about 1,000,000, preferably 50,000-500,000, most preferably about 50,000.
The preferred thermoplastic adhesive component (b) comprises poly(vinylpyrrolidone), having a molecular weight in the range of from about 10,000 to about 220,000, preferably from about 24,000 to about 40,000 and most preferably about 24,000.
It is preferred that the adhesive be deposited onto the filaments from a solvent system which can comprise any polar organic solvent, e.g., methanol, or mixture of such solvents, or water, alone, or in admixture. Acceptable bath concentrations for the thermoplastic adhesive can vary but is generally for component (a) it is in the range of 2.5-12% by weight, preferably 2.5-8%, and especially preferably 4-8% by weight and, for component (b), in the range of 1-8% by weight, preferably 1-6% by weight, and, especially preferably, 1-4% by weight.
If a surface active agent is used, this too can vary in type and amount, but generally if an anionic alkyl sulfate is used, such as sodium heptadecyl sulfate, bath concentrations can range from 0.0005-0.5% by weight, preferably from 0.0005 to 0.05%, and most preferably, 0.0005-0.005%, by weight.
The amount of non-filament material in the filamentcontaining granules of the invention will vary, but, in general, will range from 2.5 to 32.5% by volume with any fiber, preferably from 5 to 15% by volume.
The amount of component (b) will be from about 7.5 to about 75% by weight based on the combined weights of (a) and (b) preferably from about 15% to about 50%.
The length of the elongated granule will generally range from 1/8 to 1/4 inch, preferably from 1/8 to 3/4 inch. The diameters of each elongated granule can vary, depending primarily on the number of filaments and the thicknesses will vary from about one-forty eighth to about three-sixteenths inch in diameter. Preferably, the diameter will be in the range of from about one-thirty-second to about one-eighth inches.
Numerous thermoplastic resins can be employed with the elongated granules of the present invention. In general any resin that can be injection molded and that can benefit from a uniform dispersion of fibers can by used. For example polystyrene, styrene/acrylic acid copolymer, styrene/acrylonitrile copolymer, polycarbonate, poly (methyl methacrylate) poly(acrylonitrile/butadiene/styrene), polyphenylene ether, nylon, poly(1,4-butylene terephthalate), mixtures of any of the foregoing, and the like, can be used.
It is preferred to manufacture the injection molding composition of this invention by a continuous process. A suitable apparatus is shown in FIG. 5a. Typically, bundles of filaments, such as graphite fiber tows or metal coated graphite fiber tows, 3,000 to 12,000 filaments per bundle, glass yarns, 240 filaments to a strand, or stainless steel tow, 1159 filaments per bundle, are drawn from storage roller 2 and passed through one or more baths 4, containing the thermally stable, film forming thermoplastic adhesive in a solvent medium, e.g., water, to impregnate the filaments, then through means such as die 6, to control pick up. The impregnated filaments thereafter are passed into a heating zone, e.g., oven 8, to evaporate the solvent, e.g., water and then to flux the thermoplastic adhesive. The treated filaments 10 are withdrawn from the heated zone, transported to chopper 12 and cut into fiber pellets illustratively varying between 1/8-1/4" according to the requirements of the particular apparatus. The pellets are then stored in a suitable container 14 for subsequent use. Any surfactant conveniently is included in a single bath with the adhesive. It will be observed that this procedure results in the orientation of the reinforcing fibers along one axis of the granule.
To carry out the molding method of the present invention, a flow diagram in the general form illustrated in FIG. 5b is preferably employed. Fiber pellets 16 are mixed with resin pellets 18 to produce a blended mixture 20. This is added to conventional hopper 22 on molding press 24. When passing through cylinder 26, prior to being forced into mold 28 a uniform dispersion of the fibers is accomplished. Removal of molded article 30 provides a fiber reinforced item produced according to this invention.
It is understood that other plasticizers, mold lubricants, coloring agents, and the like, can be included, and that the amount of reinforcement in the components can be varied according to well understood techniques in this art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following are examples of the present invention but are not to be construed to limit the claims in any manner whatsoever. The electrical measurements (Shielding effectiveness (SE) values in decibels) are averages usually of four samples.
EXAMPLE 1
Using an apparatus of the type generally shown in FIG. 5a a bath comprising the following is formulated:
______________________________________Component % by weight______________________________________poly(ethyl oxazoline), MW 50,000 6.0poly(N-vinylpyrrolidone), MW 24,000 4.0sodium heptadecyl sulfate* 0.001%water 89.899______________________________________ * NIACET ® No. 7 surfactant
A tow of continuous graphite fibers (12,000 count) each of which has an electroplated nickel coating thereon is led through the bath. The graphite filaments each average about 7 microns in diameter. The nickel-coating thereon is approximately 0.5 microns in thickness. The nickel coated graphite tows are prepared by continuous electroplating in accordance with the prcedure described in European Patent Application No. 0088884 (published Sept. 21, 1983). After passing out of the coating bath the treated fibers are passed over grooved rollers to remove excess adhesive then passed through an oven at about 300° F. The impregnated filaments then are chopped to 1/4" lengths and there are produced elongated granules of approximately 1/16" in diameter of cylindrical shape and form. The non-filament material content is 9% by volume.
EXAMPLES 2-3
The procedure of Example 1 is repeated, adjusting the poly(vinylpyrrolidone) content in the bath to 2% and 6% by weight, respectively, and elongated granules according to this invention are produced.
EXAMPLES 4-6
Using the process generally shown in FIG. 5b, sufficient of the elongated pellets produced in Examples 1, 2 and 3, respectively, are blended with pellets of a thermoplastic molding resin composition comprising poly(bisphenol A carbonate) (Mobay Co. MERLON® 6560) to provide 5 weight percent of nickel-coated graphite filaments in the blend. The blended mixture is molded in an injection molding press into work pieces suitable for physical and electrical testing. The electromagnetic shielding effectiveness (SE) and EMI attenuation are measured to determine dispersion efficiency.
The Electro-Metrics Dual Chamber test fixture is used according to ASTM ES7-83 to measure the shielding effectiveness (SE) of the compositions of Examples 4-6 of this invention. The results are set forth in Table 1:
TABLE l______________________________________Shielding Effectiveness Poly(bisphenol-A Carbon-ate) Containing Nickel-Plated Graphite Filaments EXAMPLE Composition (parts by weight) 4 5 6______________________________________Poly(bisphenol A carbonate) 95 95 95Elongated film bonded 5 5 5bundles (Examples 1-3)Shielding Effectiveness,decibels @ 30 MHz 20 13 15 100 MHz 17 12 13 300 MHz 33 31 311000 MHz 12 10 11______________________________________ *Controls
These data demonstrate that the fibers are uniformly and efficiently dispersed.
EXMPLE 7
The procedure of Examples 4-6 is repeated substituting for the thermoplastic resin pellets, pellets comprising poly(acrylonitrile/butadiene/styrene) (Borg Warner CYCOLAC® KJB) resin and plaques suitable for measuring SE effect are molded.
EXAMPLE 8
The procedure of Example 4-6 is repeated but poly(2,6-dimethyl-1,4-phenylene ether)-high impact strength rubber modified polystyrene resin pellets (General Electric NORYL® N-190) are substituted, and plaques suitable for measuring SE are prepared.
EXAMPLES 9-11
The procedure of Example 1 is repeated, substituting for the nickel coated graphite tows, tows of uncoated graphite fibers (Example 9), glass fibers, 240 filaments/strand (Example 10), and stainless steel fiber tows comprising 1159 count filaments each measuring about 7 microns in diameter (Example 11). Elongated granules according to this invention are prepared, comprising about 85 to 95% by volume of the respective filaments.
EXAMPLES 12-14
The procedure of Examples 1-3 and 4-6 are repeated but poly(N-vinyl pyrrolidone), MW 40,000 is substituted for the 24,000 molecular weight PVP. Plaques for measuring SE properties and test pieces for strength testing are prepared.
The Shielding Effectiveness of the compositions molded from the mixtures of Examples 12, 13 and 14 are measured by ASTM ES7-83 as described above and the data are set forth in Table 2:
TABLE 2______________________________________Shielding Effectiveness of Polycarbonate ResinsContaining Nickel Coated Graphite Fibers EXAMPLEComposition (parts by weight) 12 13 14______________________________________Poly(bisphenol A carbonate) 95 95 95Nickel coated graphite 5 5 5elongated film bondedbundles (4%, 2%, 6% PVP)Shielding Effectiveness,decibels @ 30 MHz 16 18 17 l00 MHz 14 15 15 300 MHz 38 36 391000 MHz 11 11 11______________________________________
Again, significant shielding effectiveness is obtained after using the bundles bonded according to the present invention.
In making the elongated pellets of this invention, other fibers can be substituted, e.g., aramid fiber, e.g., KEVLAR® fiber, ceramic fiber, or combinations of any of the foregoing such fibers. Aramid fiber is particularly interesting because it is virtually impossible to chop and blend with thermoplastic resins because it frays and birdnests. When prepared in the form of coated bundles herein, aramid fiber chops very well and mixes easily.
The foregoing examples show that poly(vinylpyrrolidone) (PVP) alloyed with poly(ethyloxazoline) is very useful to provide elongated granules according to this invention. Experiments have shown that various molecular weights can be used. Experiments also have shown that PVP is useful to reduce tack at elevated temperatures, while at the same time aiding significantly in the preservation of bundle integrity. It has also been observed that toughness increases as the molecular weight of the PVP increases. This property is useful when compounding at high temperature, with rapid drying, or under aggressive handling conditions.
The foregoing patents and publications are incorporated herein by reference.
Many variations of the present invention will suggest themselves to those skilled in the art in light of the foregoing detailed description. All such obvious variations are within the full intended scope of the appended claims. | Elongated granules of reinforcing fibers extending generally parallel to each other longitudinally of the granule each of said fibers being substantially surrounded by a thermally stable, film forming thermoplastic adhesive comprising
(a) a poly(C 2 -C 6 alkyl oxazoline) in combination with
(b) a poly (vinylpyrrolidone), provide complete dispersion of the fibers in thermoplastics during an injection molding cycle, conserving physical properties and providing significantly better EMI shielding than prior art extruder compounded resin/fiber blends. | 2 |
This is a division of Ser. No. 07/627,637 , filed Dec. 14, 1990, U.S. Pat. No. 5,231,196.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to asymmetric calixarene derivatives and a process for the preparation of the same. Description of the Prior Art
It has been found by C. D. Gutsche et al. that the reaction of a phenol with formaldehyde under suitable conditions gives cyclic tetrameric to octameric compounds, i.e., calixarenes (see, for example, J. Org. Chem., 43, 4905 (1978 )) . The benzene units of the calixarene each have such a freedom of causing conformational changes that they generally rotate at relatively high rates around room temperatures (see C. D. Gutsche et al., J. Am. Chem. Soc., 104, 2652 (1982)) . Owing to this freedom, a calixarene is present as several conformational isomers. For example, a calix[4]arene is present as four conformational isomers, i.e., cone, partial cone, 1,2-alternate and 1,3-alternate. A calix[4]arene or a calix[5]arene generally takes a stable cone conformation owing to the rotation of the benzene units.
Meanwhile, it has been thought that a suitable derivative of a calixarene can possess an asymmetric structure. for example a calix[4]arene having at least three kinds of different benzene units, shown in FIG. 1, or at least one laterally unsymmetrical benzene unit, shown in FIG. 2, can possess an asymmetric strtucture. However, since such a calix[4]arene causes inversion owing to the rotation of its benzene units to give a racemization, the rotation of the benzene units must be hindered in order to obtain an optically active substance. It has been already known that the rotation of the benzene units of a calixarene can be hindered by converting a calixarene into a suitable derivative (see, for example, C. D. Gutsche et al., Tetrahedron, 39, 409 (1983)). However, when such a derivative is prepared by the process of the prior art, a mixture of various conformational isomers as described above is formed because of the hindrance to the rotation of the benzene units, and the isolation of a pair of optical isomers from the crude product is very difficult. Thus, neither a process for the effective preparation of a racemic modification of a calixarene derivative nor a process for the optical resolution thereof have been found as yet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 are typical illustrations of the structure of the calix(4)arene derivative according to the present invention;
FIG. 4 is an infrared absorption spectrum of the calixarene derivative prepared in Example 1;
FIG. 5 is a nuclear magnetic resonance spectrum thereof;
FIG. 6 is an infrared absorption spectrum of the calixarene derivative prepared in Example 2;
FIG. 7 is a nuclear magnetic resonance spectrum thereof;
FIG. 8 is a chromatogram of the optical resolution in Example 3;
FIG. 9 is circular dichroism spectra of the obtained optical isomers;
FIG. 10 is a chromatogram of the optical resolution in Example 4; and
FIG. 11 is circular dichroism spectra of the obtained optical isomers.
SUMMARY OF THE INVENTION
In order to solve the above problem, the inventors of the present invention have developed a process for the preparation of a calixarene derivative characterized by using an alkaline earth metal base such as barium hydroxide, calcium hydride or calcium hydroxide in the reaction of the hydroxyl groups of a compound represented by the general formula (2): ##STR2## (wherein n is an integer of 4 to 12, preferably 4 to 8;
m is an integer of 1 to n; and
R 11 to R 1m , and R 31 to R 3m each represent a hydrogen atom, a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 20 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having 4 to 20 carbon atoms, or an aralkyl group having 5 to 20 carbon atoms),
by which a calixarene derivative having a specific conformation called "cone" is selectively prepared by virtue of the template effect of the base, wherein the cone conformation being one characterized in that the hydroxyl groups or substituents therefor are all present on the same side of the ring structure. The present invention has been accomplished on the basis of this finding. FIGS. 1 to 3 are typical illustrations of the structure of the calixarene derivative according to the present invention, wherein □ represents a laterally symmetrical benzene unit of a calix 4 arene; Δ represents a laterally unsymmetrical benzene unit thereof and A, B, C and D are benzene units different from other. For example, when the process of the present invention is applied to a case as shown in FIG. 2 wherein a calixarene derivative is not present as a racemic modification because of the rapid rotation of the benzene units though it has a structure which can exhibit asymmetry, the derivative is selectively induced into "cone"-type conformation hindered in the rotation of the benzene units, thus giving a racemic modification of a calixarene derivative.
The calixarene derivative of the present invention is one having an asymmetric structure and represented by the general formula (1): ##STR3## (wherein n is an integer of 4 to 12, preferably 4 to 8;
m is an integer of 1 to n; and
R 11 to R 1m , R 21 to R 2m , R 31 to R 3m and R 41 to R 4m each represent a hydrogen atom, a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 20 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having 4 to 20 carbon atoms, or an aralkyl group having 5 to 20 carbon atoms, with the proviso that they must be selected so as to have enough bulkiness to hinder the rotation of the benzene units around the ring, though they are not particularly limited in structure, and although the bulkiness needed to hinder the rotation varies depending upon the value of n, the rotation can be hindered when, for example, R 11 to R 14 are each a n-propyloxy group in a case wherein n is 4).
Although a calix (4)arene derivative having at least three kinds of benzene units can take an asymmetric structure as described above, the asymmetry is lost when the benzene units are arranged as shown in FIG. 3. Accordingly, the development of a process for the preparation of such a calixarene derivative without losing the asymmetry has been sought.
As a result of studies, the inventors of the present invention have developed a process for the preparation of an asymmetric calixarene derivative hindered in the rotation of its benzene units which comprises replacing all or a part of the hydrogen atoms of the hydroxyl groups of a calixarene derivative represented by the general formula (2): ##STR4## (wherein n is an integer of 4 to 12, preferably 4 to 8;
m is an integer of 1 to n; and
R 21 to R 2m , and R 31 to R 3m each represents a hydrogen atom, a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 20 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having to 20 carbon atoms, or an aralkyl group having to 20 carbon atoms)
by a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 0 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having 4 to 20 carbon atoms, or an aralkyl group having 5 to 20 carbon atoms, characterized in that one kind of a conformational isomer is selectively prepared by conducting the reaction in the presence of an alkaline earth metal and that one to three bulky substituents are first introduced and the introduction of residual substituents is then conducted regioselectively. For example, when one bulky substituent B is first introduced into a calix(4)arene and two substituents A are then introduced thereinto, one of the substituents A is first introduced at a position diagonal to the substituent B owing to the steric effect of the substituent B and the other substituent A is then introduced at a position adjacent to the substituent B. Thus, a racemic modification as shown in the upper row in FIG. 1 is formed.
An asymmetric calixarene derivative represented by the above general formula (i) prepared by the above process can be optically resolved by bringing it into contact with an optically active polymer mainly constituted of a unit represented by the following general formula (3) ##STR5## (wherein n is an integer of 20 or above and R 1 , R 2 and R 3 may be the same or different from each other and each represent a substituted or unsubstituted aromatic group having 4 to 10 carbon atoms and which may contain a heteroatom),
and having a specific rotation of at least 50° (in terms of absolute value),
or a substance prepared by bonding an optically active group derived from an amino acid represented by the following general formula (4): ##STR6## (wherein R 1 and R 2 each represent a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 20 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having 4 to 20 carbon atoms, or an aralkyl group having 5 to 20 carbon atoms, with the proviso that R must be different from an ##STR7## to a carrier.
By the above optical resolution, an optically active calixarene derivative represented by the general formula (1): ##STR8## (wherein n is an integer of 4 to 12, preferably 4 to 8;
m is an integer of 1 to n; and
R 11 to R 1m , R 21 to R 2m , R 31 to R 3m and R 41 to R 4m each represent a hydrogen atom, a straight-chain or branched, saturated or unsaturated, acyclic or cyclic group having 1 to 20 carbon atoms which may contain a heteroatom, a substituted or unsubstituted aromatic group having 4 to 20 carbon atoms, or an aralkyl group having 5 to 20 carbon atoms, with the proviso that they must be selected so as to give a bulkiness enough to hinder the rotation of the benzene units around the ring, though they are not particularly limited in structure, and although the bulkiness enough to hinder the rotation varies depending upon the value of n, the rotation can be hindered when, for example, R 11 to R 14 are each a n-propyloxy group in a case wherein n is 4) can be prepared.
The compound of the invention can form an inclusion compound and therefore can be used for optical separation of another racemate. It has a corn-like structure. It has hydroxy groups which are alligned on the edge of its cylindrical structure and will eventually work to form a cationic coordination like crown ether compounds. It can include in its cylindrical structure an organic compound, like cyclodextrin. Moreover, it has many hydroxy groups and benzene rings which may easily have substituents thereon and therefore can be designed into derivatives providing intended physical properties. These possibilities will result in optical separation of many compounds and other applications.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will now be described in more detail by referring to the following Examples.
EXAMPLE 1
Synthesis of 4-methyl-5-isopropyl-11,17,23-tri-t-butyl-25,26,27,28-tetra-n-propyloxy-calix[4]arene
120 ml of a solution of 3.28 g (9.76 mmol) of 2,6-bis (bromomethyl) -3-methyl-4-isopropylphenol and 4.63 g (9.76 mmol) of 2,6-bis(2-hydroxy-5-t-butylphenylmethyl)-4-t-buthylphenol in distilled dioxane was dropped into 600 ml of distilled dioxane containing 10.0 ml (91.0 mmol) of titanium tetrachloride in high-degree dilution equipment over a period of 34 hours. After the completion of the dropping, the obtained mixture was cooled by allowing it to stand, followed by the addition of methanol. The resulting mixture was freed from the solvent by vacuum distillation and the obtained residue was dissolved in methylene chloride. The obtained solution was washed with water, dried over anhydrous sodium sulfate and filtered. 30 g of silica gel was added to the obtained filtrate and the obtained mixture was stirred to carry out absorption. The resulting mixture was extracted with methylene chloride by the use of a Soxhlet apparatus. The extract was freed from the solvent by vacuum distillation. The obtained residue (6.88 g) was purified by silica gel chromatography (benzene/hexane=1:1) to give a white solid (0.84 g, TLC: Rf=0.68, 0.52). This solid was recrystallized from toluene to give 575 mg (0.886 mmol) of 4-methyl-5-isopropyl-11,17,23-tri-t-butyl-25,26,27,28-tetrahydroxycalix[4]arene as a colorless prism.
Yield: 9%,
m.p: 265.5° to 266.0° C.,
TLC: Rf=0.68 (benzene/hexane=1:1).
The infrared absorption spectrum of the product is shown in FIG. 4 and the nuclear magnetic resonance spectrum thereof is shown in FIG. 5.
______________________________________elemental analysis C % H %______________________________________found 82.33 8.50calculated.sup.a) 81.44 8.70calculated.sup.b) 82.66 8.70______________________________________ .sup.a) calculated as (C.sub.11 H.sub.14 O).sub.4 .sup.b) calculated as a total of (C.sub.11 H.sub.14 O).sub.4 and toluene
0.35 g (0.539 mmol) of the product and 10.8 ml of dimethylformamide were placed in a nitrogen-purged flask, followed by the addition of 0.56 g (3.29 mmol) of barium oxide (purity: 90%) and 0.60 g (1.90 mmol) of barium hydroxide octahydrate. 2.91 ml (32.3 mmol) of propyl bromide was added into the flask. The obtained mixture was stirred at room temperature for 19 hours. 10 ml of a 5% aqueous solution of hydrochloric acid and 10 ml of water were added into the flask successively to precipitate a crystal. This crystal-was extracted with chloroform. The obtained chloroform layer was separated, washed with water, dried over anhydrous sodium sulfate, and filtered. The filtrate was freed from the solvent by distillation to give a colorless transparent oil. Methanol was added to the oil to precipitate a white crystal. This crystal was purified with a large-scale TLC sheet to give 186 mg (0.246 mmol) of 4-methyl-5-isopropyl-11,17,23-tri-t-butyl-25-hydroxy-26,27,28-tri-n-propyloxycalix[4]arene in a yield of 45%.
m.p.: 251.5° to 253.0° C.
The above product was reacted with n-propyl bromide in the presence of sodium hydroxide in a dimethylformamide/tetrahydrofuran mixture to give the title compound in a yield of 72%.
m.p.: 163 to 164° C.
______________________________________elemental analysis C % H %______________________________________found 82.31 9.94calculated 82.30 9.87______________________________________
IR (Nujol) ν C--O 1130, 1220 cm -1 , ν OH not observed ν C ═C 1490 cm -1 , δ C--H 880 cm -1
NMR (CDCl 3 , 30° C.)δ0.95-1.04(m, 15H, CH 3 in n-PrO and CH 3 in i-Pr), 1.01, 1.05, 1.06 (s each, 9H each, t-Bu), 1.12 (d, 3H, CH 3 in i-Pr), 1.89-2.06 (m, 8H, C-CH 2 -C in n-Pr), 2.12(s, 3H, 4-Me), 2.90(m, 1H, CH in i-Pr), 3.10, 3.11, 3.12, 3.37(d each, 1H each, Hendo in ArCH 2 Ar), 3.69-4.03 (m, 8H, OCH 2 ), 6.62, 6.68, 6.69, 6.73, 6.74, 7.26(broad, 7H, ArH).
EXAMPLE 2
Synthesis of 5,11,17,23-tetra-t-butyl-25-(2-pyridylmethoxy)-26,27-di-n-propyloxycalix[4]arene
253 mg (1.54 mmol) of α-chloromethylpyridine hydrochloride and 124 mg (3.08 mmol) of sodium hydride (60%) were added to 20 ml of toluene. The obtained mixture was stirred at room temperature for 30 minutes, followed by the addition of 500 mg (0.77 mmol) of p-t-butylcalix[4]arene. The obtained mixture was stirred in an oil bath kept at 70° C. for 20 hours, treated with methanol and distilled in a vacuum to remove the toluene. The residue was extracted with chloroform/water. The chloroform layer was separated, washed with water, dried over anhydrous sodium sulfate, and filtered. The filtrate was freed from the solvent by distillation and the residue was recrystallized from chloroform/methanol to give 635 mg of monopyridylmethoxycalix[4]arene as a white powder.
Yield: 59%,
m.p.: 274.8° to 275.8° C.
______________________________________elemental analysis C % H % N %______________________________________found 80.41 8.29 1.80calculated 81.15 8.31 1.89______________________________________
2 g (2.70 mmol) of the above product, 3.36 g (10.65 mmol) of barium hydroxide octahydrate and 1-68 g (10.96 mmol) of barium oxide were suspended in 40 ml of dimethylformamide, followed by the addition of 1.33 g (10.8 mmol) of n-propyl bromide. The obtained mixture was stirred in an oil bath kept at 70° C. for 7 hours and extracted with chloroform/water. The chloroform layer was separated, washed with water, dried over anhydrous sodium sulfate, and filtered. The filtrate was freed from the solvent by distillation and the residue was recrystallized from methanol to give 2 g of the title compound as a white powder.
Yield: 90%,
m.p.: 170.0° to 171.5° C.
The infrared absorption spectrum of the product is shown in FIG. 6 and the nuclear magnetic resonance spectrum thereof is shown in FIG. 7.
______________________________________elemental analysis C % H % N %______________________________________found 81.72 8.41 1.67calculated 82.01 8.48 1.71______________________________________
EXAMPLE 3
Optical Resolution of 5,11,17-tri-t-butyl-22-methyl -23-isopropyl-25,26,27,28-tetra-n-propyloxycalix[4]arene
The optical resolution was conducted by the use of Chiralpak OP (a product of Daicel Chemical Industries, Ltd.) connected to a high-performance liquid chromatograph, under the following conditions:
solvent: hexane/2-propanol/methanol=1/3/16,
flow rate: 0.4 ml/min,
temperature: room temperature,
detection: UV 254 nm.
The obtained chromatogram is shown in FIG. 8. The resolved optical isomers were separately recovered by the use of the same column as that used above. 35 mg of a nearly pure (+) isomer and 25 mg of a (-) isomer having an optical purity of 95% were obtained from 100 mg of the racemic modification. The angle of rotation [α] D of the (+) isomer was +255 (c=0.08, in chloroform). The circular dichroism spectra of the both isomers are shown in FIG. 9.
EXAMPLE 4
Optical Resolution of 5,11,17,23-tetra-t-butyl-25-(2-pyridylmethoxy)-26,27-di-n-propyloxycalix[4]arene
The above optical resolution was conducted by the use of Sumipax BOA-2000 (a product of Sumitomo Chemical, Co., Ltd.) connected to a high-performance liquid chromatograph, under the following conditions:
solvent: hexane/2-propanol=98/2,
flow rate: 2.0 ml/min,
temperature: room temperature,
detection: UV 254 nm.
The obtained chromatogram is shown in FIG. 10. The resolved optical isomers were separately recovered by the use of the same column as that used above. 50 mg of a nearly pure (+) isomer and 20 mg of a (-) isomer having an optical purity of 99.9% were obtained from 120 mg of the racemic modification. The angle of rotation [α] D of the (+) isomer was +12.5 (c=0.04, in hexane). The circular dichroism spectra of both optical isomers are shown in FIG. 11. | The present invention relates to an improvement in the process for preparing a calixarene derivative in which the rotation of its benzene units are hindered and which comprises replacing all or a part of the hydrogen atoms of the hydroxyl groups of a calixarene derivative represented by the general formula: ##STR1## and is characterized by conducting the reaction in the presence of an alkaline earth metal. According to the present invention, an asymmetric calixarene derivative having a "cone" conformation can be selectively prepared by virtue of the template effect of the metal. | 2 |
FIELD OF THE INVENTION
The present invention relates to an interactive tennis racket. Specifically, the present invention relates to the tennis racket with flexible joints and the strings tension mechanism.
The tennis racket of the present invention allows one to select the direction of the head angle and the strings tension for users preferences.
The tennis racket head is split and assembled with flexible spherical joints, pulleys and flexible balls. Such flexible assembly controls and minimizes the oscillation, shock impact, decreases the muscles stress, and improves the comfort for the player by a dampening effect during the period of such control and minimization.
The strings tension in the flexible head assembly results in less vibration and more sufficient impact of the tennis ball.
The frame of the head racket is assembled in the nest of the handle and creates the flexible joint that reduces the impact from the striking tennis ball.
The flexible handle assembly provides the gripping to control the oscillation, twisting torque from racket frame, and as a result minimizes wrist injures.
The strings tension mechanism allows the user to adjust the desired level of the string tension during tennis play.
The flexibility of the tennis racket facilitates less muscle stress and offers more enjoyment, and enables a technically oriented pattern of the tennis play.
BACKGROUND OF THE INVENTION
The optional criteria for the tennis racket is to maximize the performance while minimizing the risk of injury.
In general, tennis rackets employ a frame with strings, or a frame, a head, a handle, and strings. Such construction of the tennis racket affects the load to the hand, the arm, and the shoulder of the tennis player. The loads by the incoming tennis ball on the tennis racket results—vibration, shock, and twisting
These loads are determinates of the risk for injury.
The vibrations result from the strings and from the oscillation of the racket frame. These types of oscillations create an adequate level of resulting energy and require the muscle activation to withhold such reaction. The frame structure has influence on the amplitude of the vibration. Therefore, gripping the handle tighter decreases the oscillation of the energy, but transforms the energy to the forearm muscles and results in lessening the risk of injury.
When the tennis ball strikes the tennis racket, a shock develops that causes a reaction in the hand and the arm to the shock. To withstand and remove shock energy, the muscles have to be activated and act as the shock absorber. This reaction results in lessening of the risk of injury.
Another reaction is when the tennis ball strikes the center of the tennis racket, and this results in a twisting torque. The muscles react to control this condition and therefore result in lessening the risk of the wrist to injury.
SUMMARY OF THE INVENTION
It an object of the present invention to provide an interactive tennis racket, with personalized parameters; the head angle, the hardness of flexible balls, and the strings tension.
It is an object of the present invention to provide the tennis racket, with the selection of the angle of the head in respect to the handle, and can be selected by the user, as desired.
It is an object of the present invention to provide the tennis racket, in which the head is split, and assembled by spherical joints and flexible balls.
It is an object of the present invention to provide the spherical nest, to assemble the head and the handle.
It is an object of the present invention to provide the tennis racket with a flexible head assembly.
It is an object of the present invention to provide the tennis racket with a flexible handle assembly.
It is an object of the present invention to provide the tennis racket with the strings tension mechanism, where the strings are in the contact with a pulley, and in such, a pattern to allow better sliding of the strings in the tension process.
It is an object of the present invention to provide the tennis racket with the retractable handle to apply the torque during the strings tension process.
It is an object of the present invention to provide the means to apply the dial torque wrench to monitor the level of strings tension.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the tennis racket of the present invention.
FIG. 2 is a side view of the tennis racket of FIG. 1 .
FIG. 2A is an enlarged, sectional view of the tennis racket of FIG. 2 at 2 A, showing the flexible ball assembly of the present invention.
FIG. 2B is an enlarged, sectional view of the tennis racket of FIG. 2 at 2 B, showing the spherical joint assembly.
FIG. 3 is another side view of the tennis racket FIG. 1 , shown in the tilted position.
FIG. 4 is a front view of the tennis racket FIG. 1 , showing the bottom segment of the tennis racket head.
FIG. 5 is a front view of the tennis racket FIG. 1 , showing the top segment of the tennis racket head.
FIG. 6 is a sectional view of the tennis racket handle taken across section line 6 - 6 of FIG. 7 .
FIG. 7 is a front view of the tennis racket handle.
FIG. 8 is a bottom view of the handle of FIG. 7 .
FIG. 9 is a sectional view the handle of FIG. 7 taken across section line 9 - 9 of FIG. 7 .
FIG. 9A is a sectional view of FIG. 9 .
FIG. 10 is a sectional view of the handle of FIG. 7 taken across section line 10 - 10 of FIG. 2 .
FIG. 11 is a sectional view of the spherical nest of the tennis racket of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments of the present invention may be further understood with reference to the following description and related appended drawings.
Referring to the FIG. 1 , the tennis racket is provided. The tennis racket includes the head 1 , the handle 2 , the strings tension mechanism 3 , and the strings 4 .
The tennis racket in FIGS. 1-5 is split centrally. On one side is the bottom segment 6 and the other side is the top segment 7 .
As shown in FIG. 4 , the bottom segment 6 assembly has an extruded frame shape with inside opening 16 , 17 and 18 , the pulley 8 , the flexible balls 12 , the string guides, the strings 4 .
As shown in FIG. 5 , the top segment 7 has an extruded frame shape mirroring the bottom segment 6 . There is some elimination of friction, by free rotation of the pulley in the grove and the pattern of strings.
The typical spherical joint assembly is explained in FIG. 2B . The bottom segment 6 has an extruded outer clip 9 , and has an inner spherical surface 21 , an outer spherical surface 22 , the flange 23 , and the groove 29 . The pulley 8 is assembled with the clip 9 for the free rotation in the groove 29 , and has the groove 30 for the strings. The top segment 7 has an extruded an inner clip 14 , and has an inner slot 25 , an outer spherical surface 24 , and the flange 26 . The inner clip 14 is locking in the outer clip 9 within a locking space 27 , which results in a spring effect in the joint. In the top segment 7 , the inner clip 14 is the inner clip 14 is pressed to the bottom outer clip 9 , and with balls 15 results in the flexible frame assembly.
The typical assembly of flexible ball 15 with the bottom segment 6 , and top segment 7 is explained in FIG. 2A . The flexible ball 15 is placed in the bottom nest 12 , and the upper nest 13 is held in by the tension from the spring effect in the spherical joint, as explained above.
The tennis racket handle 2 of FIGS. 1-3 and FIG. 10 has an extruded housing 49 to accommodate the strings tension mechanism 3 .
As shown on in FIGS. 6-11 and FIG. 9A , an outer extrusion of the housing 49 forms the protruded cylindrical segment 35 , with an arrayal located on the cylindrical 33 at 66 and 38 degrees. As shown in FIG. 9A the protrusion has an inner slot 44 and the outer cylindrical surface 43 forms the flexible joint with the strip 40 . The strip 40 forms the segment with an inner 46 and an outer 47 cylindrical surface.
As shown on FIG. 6 , an inner extrusion of the housing 49 forms the nest 30 for the head and the cylindrical groove 36 as the guide for the tension mechanism 3 .
As shown on FIG. 1 and FIG. 11 , the housing 49 has the nest to form the spherical joint with the head 1 and the handle 2 of the tennis racket. The head 1 with an outside spherical surface 93 is turning at 90 degrees in the nest 30 so the extrusion 11 , 13 accommodates the grooves 31 and 32 . The locking position is performed by the tension from the spring disc 96 to the spherical extrusion 95 on the bottom segment 6 , and the top segment 7 of the tennis racket head 1 . The discs are located in the cavity 94 , and centrally rested on the screw shoulder 97 , and loaded by the set screw 98 .
In FIG. 1 and FIG. 10 , the string tension mechanism 3 is accommodated in the housing 49 of the tennis racket handle 2 . The strings tension mechanism 3 includes the main shaft 50 , the inner shaft 52 , the lower clamp 53 , the middle clamp 57 , the upper clamp 58 , the nut 56 , and the compression spring 55 , and the assembly pins 85 , 86 , 87 , 88 .
The main shaft 50 is in a cylindrical shape and has the spherical extrusion 80 for the guide in the groove 36 , has the cylindrical inner hole to fit the inner shaft 52 , and has the inner spherical surface 59 to fit with the middle clamp 57 . The main shaft 50 has the acme thread and the helical slot 72 for the coarse movement.
The inner shaft 52 has the outside spherical shape 70 to fit with the upper clamp 58 , and has the hole for the pin 87 to assemble with the middle clamp 57 . On the other side, the inner shaft 52 has the hole for the pin 77 to assemble with the lower clamp 53 , and the socket for the dial torque wrenches.
The lower clamp 53 , FIG. 10 has arrayal located spherical protrusions 74 , to fit the spring holder 54 into the cavity 75 and the retractable handle 73 . The handle 73 , with the outer spherical surface 82 and further mounted into the groove 76 by the pin 86 for the rotation with the inner shaft 52 . The lower clamp 53 has centrally located the hole to assembly with the inner shaft 52 by the pin 88 .
As shown in FIG. 10 , the middle clamp 57 has an outer spherical surface 77 , 78 to fit the main shaft and the upper clamp 58 and has centrally located the cavity 79 to assemble with the inner shaft by the pin 88 .
As shown in FIG. 10 , the upper clamp 58 has the pattern of the hole 71 to fit the strings 4 , the protruded sphere 80 to guide in the groove 36 , to assembly with the inner shaft 52 .
With respect to FIG. 1 and FIG. 10 , as the handle 73 rotates the inner shaft 52 , the pin 87 slides in the helical slot 72 , the nut groove 83 , and activates the main shaft 50 to rotate in the nut 56 . Further rotation of the inner shaft 52 causes an engagement the spherical protrusion 74 into the cavity 75 of the spring holder 54 , and creates the load on the compression spring 55 to the nut 56 , and to the spring holder 54 . The main shaft 50 rotates in the nest of the middle clamp 57 , which results in the upper clamp 58 sliding in the groove 36 of the handle housing 49 .
As shown in FIG. 1 , FIG. 2B and FIG. 10 , the strings 4 are arranged in the vertical, the horizontal, the cross pattern, and are mounted in the strings holes 71 of the upper clamp 58 . The strings 4 slide in the groove 30 of the pulley 8 in the guide 10 and they are under the tension as the result of the rotation of an inner shaft 52 . Applying the dial torque wrench indicates the desired level of the strings' 4 tension. Such an arrangement of the strings elements minimizes the friction and maximizes the life of the strings.
It should be understood that for foregoing description in only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to encompass all such alternatives, modifications and variances that fall within the scope of appended claims. | The tennis racket for interacting with the tennis ball has the flexible head, the flexible handle, and the string tension mechanism. The tennis racket head form with the handle the flexible spherical joint, with the inner adjustment of the tension, and the angle of the head. The tennis racket handle has flexible gripping to absorb the impact from the incoming tennis ball. The string tension mechanism is operated manually for the adjustment the tension. The structure flexibility of the tennis racket minimizes the injury, and offers more enjoyment of the play. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional No. 61/665,484 entitled “Radiation Shield Adapted to Fit a Medical MR Injector Syringe” filed Jun. 28, 2012, and to U.S. Provisional No. 61/656,743 entitled “Radiopharmaceutical Delivery and Tube Management System”, filed Jun. 7, 201, each of which is incorporated by reference herein in its entirety.
GOVERNMENT INTERESTS
Not applicable
PARTIES TO A JOINT RESEARCH AGREEMENT
Not applicable
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not applicable
BACKGROUND
Administration of radioactive pharmaceutical substances or drugs, generally termed radiopharmaceuticals, is often used in the medical field to provide information or imagery of internal body structures and/or functions including, but not limited to, bone, vasculature, organs and organ systems, and other tissue or as therapeutic agents to kill or inhibit the growth of targeted cells or tissue, such as cancer cells. Radiopharmaceutical agents used in imaging procedures and therapeutic procedures typically include highly radioactive nuclides of short half-lives and are hazardous to attending medical personnel. These agents are toxic and can have physical and/or chemical effects for attending medical personnel such as clinicians, imaging technicians, nurses, and pharmacists. Excessive radiation exposure is harmful to attending medical personnel due to their occupational repeated exposure to the radiopharmaceuticals. The constant and repeated exposure of medical personnel and patients to radiopharmaceuticals over an extended period of time is a significant problem in the nuclear medicine field.
Administration of optically sensitive substances is an additional concern in the medical field. These substances are often used for imaging purposes and if exposed to ambient light contamination can have reduced function or complete loss of function. It is a significant problem if these substances become contaminated from ambient light and it is of high importance to have these substances protected from exposure to ambient light in order to preserve their function before delivery to the patient.
SUMMARY OF THE INVENTION
Various embodiments are directed to syringe shields including a first shield panel having a syringe bore designed and configured to correspond to the shape of a syringe and a second shield panel having a syringe bore designed and configured to correspond to the shape of a syringe wherein reversible coupling of the first shield panel and the second shield panel provides a syringe bore configured to encase a syringe and provide a plunger access bore configured to allow access to a plunger associated with the syringe. In some embodiments, the first shield panel and the second shield panel may be hingedly attached.
In such embodiments, the first shield panel and the second shield panel may include or be composed of a radioactive emissions blocking material, and in certain embodiments, a syringe may be completely or nearly completely encased by the radioactive emissions blocking material when the first shield panel and the second shield panel are coupled. The radiation emissions blocking material is not limited and can include, but are not limited to, materials such as tungsten, tungsten alloys, molybdenum, molybdenum allows, lead, lead alloys, lead-lined wood, leaded glass, polymer composite materials, ceramic materials, borated polymers, and combinations thereof. In other embodiments, the first shield panel and the second shield panel may include or be composed of an optical blocking material, and in certain embodiments, a syringe may be completely or nearly completely encased by the optical blocking material when the first shield and the second shield panel are coupled. The optical blocking material is not limited and can include, but are not limited to, materials such as metals, metal alloys, wood, dark colored glass, non-clear polymer composite materials, ceramic materials, or any other material that may block ambient light contamination.
In some embodiments, the syringe bore may be sized to accommodate a syringe having a diameter sufficient to hold 0.5 ml, 1 ml, 3 ml, 5 ml 10 ml, 15 ml, 20 ml, 30 ml, 40 ml, 50 ml, 60 ml, and combinations thereof. In particular embodiments, the syringe shield may include an integrated cap, and in other embodiments, the syringe shield may include a removable cap. In some embodiments, the syringe shield may include a sleeve encasing the first shield panel, the second shield panel, or combinations thereof. In various embodiments, the sleeve is composed of a material selected from the group consisting of metals, metal alloys, polymeric materials, polymer composites material, and combinations thereof, and in certain embodiments, the sleeve may be composed of aluminum or polycarbonate. In particular embodiments, the sleeve may be integrally attached to each of the first shield panel and the second shield panel, and such sleeves may be composed of, for example, metals, metal alloys, polymeric materials, polymer composite materials, and combinations thereof or, in particular embodiments, aluminum or polycarbonate.
In some embodiments, the syringe shield may include a clamping means configured to connect the first shield panel and the second shield panel. In particular embodiments, each of the first shield panel and the second shield panel may include hinge extensions and the syringe shield further comprises a hinge pin received by the hinge extensions, and in some embodiments, each of the first shield panel and the second shield panel may include one or more connector plates. In some embodiments, the syringe shield may include a collar configured and arranged to reversibly connect to the first shield panel and the second shield panel and connect the syringe shield to a device or base plate. In some embodiments, the syringe shield may include a carrier handle, and in certain embodiments, the carrier handle may be configured to be reversibly attached to the first and second shield panels.
DESCRIPTION OF DRAWINGS
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.
FIG. 1 is a drawing showing a syringe sleeve with and without a pivot and a sleeve cover.
FIG. 2 is a drawing showing an embodiment of a syringe shield.
FIG. 3A is a drawing showing a second embodiment of a syringe shield having latched, clam shell syringe access.
FIG. 3B is a drawing showing a syringe shield with a forward enlarged portion and a carrier handle.
FIG. 4 is a drawing showing a collar syringe shield support.
FIG. 5 is a drawing showing a vertical shield support and cap.
FIG. 6 is a drawing showing a shield and support structure mounted on an injector system.
FIG. 7 is a drawing showing a syringe shield and a carrier handle.
DETAILED DESCRIPTION
Before the present compositions and methods are described, it is to be understood that they are not limited to the particular compositions, methodologies or protocols described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit their scope which will be limited only by the appended claims.
It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments disclosed, the preferred methods, devices, and materials are now described.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
“Substantially no” means that the subsequently described event may occur at most about less than 10% of the time or the subsequently described component may be at most about less than 10% of the total composition, in some embodiments, and in others, at most about less than 5%, and in still others at most about less than 1%.
For purposes of the description hereinafter, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the orientation of embodiments disclosed in the drawing figures. However, it is to be understood that embodiments may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
It is to be understood that the disclosed embodiments may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments.
Various embodiments are directed to a syringe shield that is configured to reduce or eliminate exposure of the operator, subject, or other injected organism to radioactive emissions from a radiopharmaceutical in a syringe and to reduce or eliminate ambient light contamination to optical components in a syringe. In other embodiments, shielding components may stabilize radiopharmaceuticals or optical tracers thermally and mechanically. For example, shielding components may be designed to reduce or eliminate exposure of an optical tracer to light which can quench fluorescence and cause the tracer to become heated or chemically modified over time reducing the optical output or chemical or enzymatic activity of the tracer.
In various embodiments, the syringe shield may include one or more shield panels, and in some embodiments the one or more shield panels may be encased by one or more interconnected sleeves to form the syringe shield. In some embodiments, the shield panels and sleeves may be integrated together such that each sleeve contains a shield panel that is fixedly attached to the sleeve. In other embodiments, the shield panels and sleeves may be separate parts that are designed to be combined around the syringe to create the syringe shield. For example, in some embodiments, two or more shield panels may be placed over a syringe and a hinged sleeve may be placed around the two or more shield panels and locked into place over the syringe. The shield may have any number of shield panels and sleeve components. For example, in some embodiments, the syringe shield may have 1, 2, 3, 4, 5, or 6 shield panels and 1, 2, 3, 4, 5, or 6 sleeve components to encase the shield panels.
In some embodiments, the shield panels contain radioactive emissions blocking material such as, for example, tungsten, tungsten alloys, molybdenum, molybdenum allows, lead, lead alloys, lead-lined wood, leaded glass, polymer composite materials, ceramic materials, borated polymers, and the like and combinations thereof. In certain embodiments, the one or more shield panels may be tungsten. In some embodiments, the sleeves encasing the panels may be composed of any material including metals, metal alloys, polymeric materials, polymer composite materials, and the like and combinations thereof. In particular embodiments, the sleeves may be aluminum or polycarbonate. In further embodiments, the sleeves and shield panels may be integrated together. The syringe shield may contain little or no magnetic materials and little or no electronics.
FIG. 1 is an example of a syringe shield having two shield panels 150 , 160 . Each shield panel 150 , 160 includes a syringe bore 180 designed and configured to correspond to the shape of a syringe. The syringe bore 180 may be configured to accommodate any syringe or type of syringe known in the art, and in some embodiments, the syringe bore may provide a universal fitting for syringes of various types and sizes. For example, the syringe shield may be intentionally larger than the syringes that will likely be used with the syringe shield. In other embodiments, the size of the syringe bore 180 may closely match the size of the syringe to be used with the syringe shield. For example, in particular embodiments, the syringe bore may be configured to accommodate syringes having similar flange sizes and body lengths but different body diameters. Therefore, a syringe having a diameter sufficient to allow the syringe to hold 10 ml, 15 ml, 20 ml, 30 ml, 40 ml, 50 ml, 60 ml, or 65 ml and a syringe having a diameter sufficient to allow the syringe to hold 1 ml, 3 ml, 5 ml or 10 ml can be securely held within the syringe bore. Alternatively, shield panel 170 may be inserted into bore 180 to provide the shielding material that closely fits the selected syringe. In such embodiments, 150 and 160 act as sleeves. An element 170 is placed (generally but not necessarily permanently) into each of 150 and 160 to act as the shield panel. FIG. 6 shows the assembled unit.
In some embodiments, the syringe shield may be tapered on a forward end to accommodate the shape of the tapered end of a common syringe, and in such embodiments, the syringe shield may include an additional smaller bore at the tapered end that may provide an access point to the syringe when the syringe is enclosed within the shield. In some embodiments, the forward end of the syringe shield may be domed such that the tapered end of the syringe is enclosed under the dome, but outer surfaces of the syringe do not physically contact the domed portion of the syringe shield. As with the tapered forward end, the domed forward end may include an additional bore to provide access to the syringe when the syringe is encased in the syringe shield.
The aft portion of the syringe shield may be designed to allow the syringe encased in the syringe shield to be accessed and contacted by a device for expelling the contents of the syringe such as a piston, rod, or plunger. In some embodiments, such as that depicted in FIG. 1 , the aft portion of the syringe shield may be open and continuous with the bore. Thus, any means for expelling the syringe can easily reach the syringe. In other embodiments, the aft portion of the syringe shield may be partially enclosed. For example, in some embodiments, the aft portion of each shield panel 150 , 160 may be enclosed with a center bore such that when the shield panels 150 , 160 are combined a circular center bore is provided that allows access to a piston or plunger to contact the syringe. The size of the circular center bore may vary among embodiments and may be sufficiently sized to allow access to the syringe while blocking at least a portion of the radiation from the syringe or to block ambient light contamination to optical components in the syringe.
In some embodiments, the shield panels 150 , 160 may be connected. For example, in some embodiments, the shield panels 150 , 160 may be hingedly attached to one another to produce a clam shell syringe shield. In other embodiments, the shield panels 150 , 160 may be individual devices that can be reversibly connected to one another during use. For example, as illustrated in FIG. 1 , each shield panel 150 , 160 may include one or more appendages 152 , 162 , one or more hinge extensions 153 , 163 , one or more connector plates 155 , and the like or combinations thereof.
In embodiments, such as those shown in FIG. 1 , the shield panels 150 , 160 may contact one another such that the hinge extensions 153 , 163 interconnect allowing a continuous bore to be created through the aligned hinge extensions 153 , 163 . A hinge pin (not shown) may be placed through the continuous bore facilitating a connection between the shield panels 150 , 160 . In some embodiments, the hinge pin may be permanently held within the continuous bore by, for example, providing a cap or flange on either end of the hinge pin after it has been placed in the continuous bore. In other embodiments, the hinge pin may be removable, and in certain embodiments, the hinge pin may include a handle to allow at least one end of the hinge pin to be easily grasped and manipulated.
The shield panels 150 , 160 of the example shield illustrated in FIG. 1 further include appendages 152 , 162 that align when the shield panels are brought into contact with one another. In some embodiments, one or both shield panels 150 , 160 may include a clasp (not shown) or other closure device that is fixedly attached to one of the shield panels 150 , 160 , and is capable of contacting and holding an appendage 152 , 162 of the other shield panel 150 , 160 to effect a reversible connection. In other embodiments, an appendage 152 on one shield panel 150 may be aligned with an appendage 162 on another shield 160 and a clamping device 120 be used to hold the aligned appendages 152 , 162 together facilitating a reversible connection. The clamping device 120 can be held in place using any means known in the art including, for example, a tension screw, a spring loaded ball detent, a hinge, various clamping mechanism, and the like or combinations thereof.
The shield panels 150 , 160 may further include one or more connector plates 155 . The connector plates 155 are, generally, a lateral extension or flange extending from one end of the shield panels. In some embodiments, the connector plate 155 may facilitate connection of the shield panels 150 , 160 , and in certain embodiments, the connector plate 155 may facilitate connection between the shield and a device. In some embodiments, the connector plate 155 may fit within a groove on a surface of the device that holds the shield in place on the device. In other embodiments, a magnet or other electromagnetic connection may be made between the device and the shield, and in still other embodiments, the connector plate 155 may include one or more orifices 156 through which a connector pin or screw may be passed that operably connects the shield to the device. Devices may be any devices that hold radiation or optically sensitive components or containers including radioactive or optically sensitive materials. In certain embodiments, the device may be a fluid delivery device or system, and in some embodiments, such fluid delivery devices or systems may be designed and configured to deliver radiopharmaceuticals or optically sensitive components.
The connector plate 155 may be separated from one another when the shield panels 150 , 160 are connected to form the shield, for example, connector plates may be on opposing sides of the shield. In other embodiments, the connector plates may contact one another at joints along the circumference of the shield to produce a continuous flange around a circumference of the shield, and in still other embodiments, the connector plates 155 may be interconnected when the shield panels 150 , 160 are aligned. For example, a first connector plate 155 may be configured to receive the second connector plate (not shown) when the shield panels are aligned such that orifices 156 on each connector plate 155 align to produce a continuous opening through which a connector pin, screw, or bolt can be passed. In such embodiments, the connector plate may provide both a reversible connection between shield panels 150 , 160 and a reversible connection to a device. In some embodiments, only one shield panel 150 contains a connector plate 155 , which may be used to connect the shield to a mounting support or device. The second shield plate 160 is connected to the first shield plate 150 , for example, through hinges 163 , 153 and through the connector plate 155 of shield panel 150 both panels 150 , 160 are connected to a mounting support or device.
In some embodiments, an upper or forward portion of the syringe shield may be open as illustrated in FIG. 1 . In other embodiments, the syringe shield may include an integrated cap that encloses around the forward end of the shield allowing for minimal emissions from the shielded syringe. In such embodiments, the cap may include a bore providing access to the nozzle of the syringe. In other embodiments, a removable cap may be attached to the shield after the shield panels are in connection with one another. The removable cap may be attached to the shield panels by any means, such as, for example a threaded assembly, a snap enclosure, a slide fit, a vacuum seal, and the like and combinations thereof. As in the integrated cap, the removable cap may include a bore to allow for tubing or other fluid path elements to the nozzle of the syringe. In some embodiments, the bore may include a shoulder to properly position the syringe within the forward portion of the syringe shield when being prepared for injection.
In particular embodiments, the syringe shield may include one or more sleeves that cover the shield panels to facilitate attachment of the shield panels and/or improve handling. For example, FIG. 2 shows another example of a syringe shield 20 having an upper housing sleeve 211 and a lower housing sleeve 212 . In some embodiments, the upper housing sleeve 211 and the lower housing sleeve 212 may encase a shield panel 22 containing a bore (not shown) capable of housing a syringe 21 . As illustrated in FIG. 2 , the syringe shield 20 may include various addition housing or sleeve sections. For example, the syringe shield may include one or more removable or hinged segments 208 that encase, for example, a plunger portion of the syringe 21 , a piston, a rod, or other means for expelling the contents of the syringe. In some embodiments, the upper housing sleeve 211 may be removeably attached to the lower housing sleeve 212 by any means including pressure fittings, snaps, screws, clamps, bolts, pins, and the like and combinations thereof, and in other embodiments, the upper housing sleeve 211 may be fixedly attached to the lower housing sleeve 212 by, for example, welding or gluing. In other embodiments, the upper housing sleeve 211 and the lower housing sleeve 212 may be connected by, for example, a hinge. In still other embodiments, the upper housing of the syringe shield 20 may include a hinged syringe access door 208 that allows access to part of the internal segments of the syringe shield 20 . For example, as illustrated in FIG. 2 a hinged access door 208 may allow access to the syringe 21 such that the user can more easily maneuver the syringe while inserting it into the syringe shield 22 . The upper housing sleeve 211 may be fixedly attached to the lower housing sleeve 212 , for example, the upper housing sleeve 211 and lower housing sleeve 212 may be hingedly attached to each other in a clam shell configuration.
In other embodiments, the syringe shield has shield panels which may be incorporated in the sleeves. As illustrated in FIG. 3A , in some embodiments, the syringe shield 30 may be designed to include a radioactive shield panel 311 in the upper housing sleeve 313 and a shield panel 312 in the lower housing sleeve 314 . As illustrated in FIG. 3A , shield panels 311 , 312 may be incorporated into the syringe housing such that the syringe 31 is completely or nearly completely encased by the radioactive emissions blocking material when the syringe shield sleeves are in the closed position, and the upper housing 313 or any part thereof can be hingedly attached to the lower housing 314 to allow access to the syringe 31 . In some embodiments, the syringe bore 315 may be configured and designed to accommodate a syringe 31 . Such a syringe bore may include a shoulder 318 positioned to contact a front portion of the syringe and syringe bore 315 to provide a means for accessing the outlet portion of the syringe.
An aft groove 319 associated with the plunger access bore 321 may also be provided to accommodate a flanged portion 320 of the syringe 31 . In certain embodiments, the plunger 322 of the syringe or another actuation means may fit within an enlarged portion 316 of the shield 30 that allows user access to the syringe 31 and plunger 322 . The enlarged portion of the housing may further accommodate the piston or other part of the actuation component that is configured to associate with the plunger 322 allowing the plunger to advance and retract. In some embodiments, the enlarged portion may include additional shield panels or extensions of the shield panels 311 , 312 . In other embodiments, the enlarged portion may not include additional shielding.
While FIG. 3A illustrates a syringe shield 30 having an aft enlarged portion, in certain embodiments, the syringe shield may include a forward enlarged portion 340 , as illustrated in FIG. 3B , to encase tubing or other extensions from the syringe. In some embodiments, as illustrated in FIG. 3B the syringe shield may include a forward enlarged portion 340 with an access bore 341 designed to encase a connector portion 342 of the syringe 31 and a portion of the tubing extending from the connector 342 of the syringe 31 to a delivery device. In other embodiments, the forward enlarged portion 340 may include a lateral access bore provided on a side of the forward enlarged portion 340 while the forward section of the forward enlarged portion 340 remains enclosed and shielded. Without wishing to be bound by theory, a lateral bore may allow for a reduction in shine from the forward end of the syringe thereby reducing light exposure or potential irradiation of the user or to reduce or eliminate ambient light contamination to optically sensitive components in a syringe. The forward enlarged portion 340 may be connected to the syringe shield 30 and form part of the syringe shield 30 . In some embodiments, the forward enlarged portion 340 may be separately attached to the syringe shield 30 and may include a separate hinged portion that allows access to the connector 342 and tubing section when the syringe 31 is encased in the syringe shield 30 . In certain embodiments, the forward extension 341 may include a lateral exit port 344 through which the tubing section may exit the syringe shield 30 . The forward section of the access bore 341 may be enclosed with a blocking material to reduce shine from the connector 342 and potential exposure of the user to radiation or to reduce or eliminate ambient light contamination to optically sensitive components in a syringe. FIG. 3B additionally shows a syringe shield 31 having a built in handle 346 which is further described below with FIG. 7 .
In some embodiments, a connection between the shield and a device may be facilitated by a locking mechanism that is integrated into the housing. For example, as illustrated in FIG. 2 , the syringe shield 20 of such embodiments may attach to a delivery injector body (not shown) using a syringe mount system which may include one or more flanges or grooves configured to associate with a syringe mount 206 . The syringe mount 206 of such embodiments may be in any configuration and may include, for example, buttons, pins, slides, grooves, and the like configured to associate with the syringe shield 20 to facilitate proper placement of the housing on or within the delivery injector body. In other embodiments, the syringe shield 20 may attach to a delivery injector body through a saddle mount which may be shaped to fit within a groove provided on the syringe shield 20 . In some embodiments, the saddle mount may include pressure fittings, grooves, pins, buttons, and the like that facilitate reversible attachment of the syringe shield 20 to the saddle mount. The saddle mount of such embodiments may be similar to a ski boot connector in which a first flange on the syringe shield 20 is inserted into a groove on the saddle mount and a second flange or groove is received by a hinged clamp that holds the second flange or groove in the mount. The hinged clamp may include one or more springs that are positioned to apply force to the second flange or groove holding it in place. The hinged clamp may be forced backward by a lateral flange on the syringe shield that contacts the hinged clamp when, for example, the syringe shield is pivoted in the saddle mount.
In various embodiments, the syringe mount may be associated with and attached to a framework underlying the housing rather than the housing itself. The framework will generally be composed of a rigid material that provides mechanical support for the syringe mount with a syringe shield mounted to the syringe mount and an actuation component mount. Without wishing to be bound by theory, the framework may substantially improve the accuracy and reproducibility of injections by reducing or eliminating flexion that can occur when the syringe mount and/or actuation component are attached to a housing composed of a more flexible material. In some embodiments, the framework may be composed of steel, aluminum, or another metal or metal alloy or high tensile strength polymer compositions and may be designed to fit within the housing and provide attachment sites for mechanical components of the device in addition to the syringe mount and actuation component.
In certain embodiments, the syringe mount may include a forward groove or ridge into which a corresponding ridge or groove on the syringe shield fits. The syringe mount may further include a rear binding that associates with a groove or ridge on the syringe shield. In some embodiments, the binding may include a housing attached to a delivery injector body that includes one or more springs positioned to urge a clamp forward against the groove or ridge of the syringe shield to lock the syringe shield in place when it has been pushed into position. Embodiments are not limited to any particular syringe holder or mount. For example, in some embodiments, the syringe holder may be a device configured to accept and hold a syringe or vial holding the radiopharmaceutical by removably attaching to the syringe or vial body or flanges associated with the syringe or vial. In other embodiments, the syringe holder or mount may be configured to accept and hold a secondary device housing a syringe or vial including a radiopharmaceutical.
In certain embodiments, the syringe shield may be attached to a delivery injector body using a collar syringe shield support, and the like or combinations thereof. For example, FIG. 4 is an example of a base plate 40 configured to connect with the syringe shield described above with reference to FIG. 1 . Such base plates 40 may be an integral part of a device onto which the syringe shield is designed to interact, or in some embodiments, such base plates 40 may be made as a separate component that can be attached to existing devices as an adapter. Thus, in some embodiments, the base plate 40 may include flanges, holes, clamps, appendages, and the like or other components and combinations thereof for attaching the base plate to the device.
The base plates 40 of such embodiments may generally include one or more orifices 402 , 404 positioned to allow actuation devices from the device to contact the syringe or a plunger, stopper, or piston associated with the syringe to expel the contents of the syringe. The base plate 40 may further include a means for attaching the syringe shield to the base plate. For example, in some embodiments, the one or more orifices 402 , 404 may include grooves or threads that correspond with grooves or threads on the syringe shield and allow the syringe shield to be screwed into the base plate. In other embodiments, holes may be provided near the orifices 402 , 404 that are configured to receive a pin or screw which is received by the orifices in a connector plate ( 155 and 156 in FIG. 1 ), and attach the syringe shield to the base plate 40 .
In some embodiments, the collar syringe shield support is designed to fit over and around the front of a delivery injector body to avoid modification to the injector and to provide free access of the syringes to the injector head for syringe mounting, while providing a relatively immovable base to which to attach the syringe shield. For example, FIG. 5 provides a two piece collar 501 , 502 that is designed and configured to encircle a portion of a device, and this collar assembly may be attached to the base plate of the collar syringe shield support by an attachment extension 503 . More specifically, the base plate may be received by an opening in the collar mount 501 and used to secure the base plate in place using screws, pins, or another attachment means. The collar mount 501 may include one or more attachment extensions 503 that include a means for attaching the collar to the base plate. As illustrated in FIG. 5 , the attachment means includes a groove 504 and a screw-plate 505 that is configured to fit over and connect with an appendage or flange on the base plate. Screws, pins, or another attachment means can be introduced through the screw-plate 505 into corresponding holes or orifices in the appendage or flange on the base plate to connect the collar syringe shield assembly to the base plate. In a particular embodiment, the syringe shield may be permanently or temporarily attached to a Medrad Spectris Solaris EP injector or similar fluid delivery systems to provide shielding for a drug containing syringe.
In some embodiments, the collar syringe shield assembly may be pivoted on the appendage or flange of the base plate to allow the position of the syringe to change during use without disassembling the collar/syringe shield assembly or removing the collar from the appendage or flange, as shown in FIG. 6 . FIG. 6 shows the components of FIG. 4 and FIG. 5 with a syringe shield of FIG. 1 and syringes mounted onto a device. In particular embodiments, the syringe shield can be selectively moved by the operator into a position 601 where the syringe shield is around a syringe, or be moved to a second position 602 for storage on the injector head where it is not surrounding or shielding the syringe. In some embodiments, a locking pin 603 may be provided that fits into holes in the collar syringe shield support, enabling the shield to be locked into position either around a syringe or in a second, storage position not surrounding a syringe. In other embodiments, the locking pin is spring loaded so that it is a part of the syringe shield and not removable such that the pin can be pulled out and spring into the hole when it is moved to the correct position, or the locking pin can be rotated 90 degrees to hold it in the disengaged position to facilitate easier movement between the deployed and stored position and then turned 90 degrees again to engage the hole.
Further embodiments include a carrier handle 730 designed to attach to the syringe shield to ease transport of the radiopharmaceutical and reduce exposure to the person carrying the syringe shield. For example, as illustrated in FIG. 7 , in some embodiments, a carrier handle 730 may include a tubing bore cover 731 configured and arranged to fit within the tubing bore 715 and/or a groove, flange, 732 or other attachment means associated with the tubing bore. The carrier handle may further include a plunger cover 734 configured and arranged to associate with the enlarged portion of the syringe housing 711 by, for example, contacting the housing within the enlarged portion of the housing 711 . In some embodiments, the tubing bore cover 731 and/or the plunger cover 734 may include a material capable of blocking radioactive emissions that is positioned to block emission that could otherwise escape through the tubing bore 715 and the plunger access point 716 . In particular embodiments, the carrier handle 730 may include a carrier body 735 that includes a grip portion 736 and the plunger cover 734 . The tubing bore cover 731 may be hingedly attached to the carrier body and may include a lever or button 737 that is configured to allow the tubing bore cover to be released from the tubing bore 715 or corresponding flanges and grooves 732 on the housing 711 when the lever or button is depressed.
In operation, the user may grasp the syringe shield 711 by positioning the plunger cover 734 within the plunger access point 716 or within the enlarged portion of the syringe shield 711 while the lever or button 737 is depressed. The tubing bore cover 731 may be positioned over the tubing bore 715 and the lever or button 737 can be released such that the tubing bore cover 731 is properly positioned within the tubing bore 715 and corresponding grooves 732 . The carrier handle 730 is thereby sufficiently connected to the syringe shield to allow the user to easily pick up and transport the syringe shield 711 without actually touching the housing itself. To remove the carrier handle 730 , the user can position the syringe shield 711 within a delivery injector body to allow the syringe shield 711 to connect to a syringe mount. The lever or button 737 may be depressed releasing the tubing access bore cover 731 from the tubing access bore 715 and corresponding groove 732 , and the user may rotate the carrier handle 730 such that the plunger cover 734 is removed from the plunger access point 716 and enlarged portion of the syringe shield 711 . Finally, the carrier handle 730 can be withdrawn from the syringe shield 711 while the syringe shield 711 remains mounted on a delivery injector body. Exposure to radioactive emissions from radiopharmaceutical minimalized during transport, and only occurs during loading of the syringe into the syringe shield 711 and installation of the tubing sections after the carrier handle 730 has been removed.
The carrier handle 730 and syringe shield 711 may be made from any material. For example, the carrier handle 730 and syringe shield 711 may be made from a metal, a polymeric material, or combinations thereof. In certain embodiments, the carrier handle 730 may be prepared from a rigid polymeric material such as a polycarbonate that may reduce the weight of the combined syringe shield 711 and the carrier handle 730 , while the syringe shield 711 may be prepared from a metal or other material that is capable of blocking radioactive emissions such as tungsten or lead. In still other embodiments, the syringe shield 711 may be made from a metal such as tungsten or lead that is covered in a polymeric material such as a polycarbonate or light weight metal such as aluminum. In still other embodiments, the syringe shield 711 may include a pigment or dye at eliminates exposure of optical tracers to light. For example, in embodiments in which an optical tracer is delivered using the delivery device, the syringe shield 711 may be prepared exclusively from an opaque or colored to absorb particular wavelengths of light to reduce decay of the optical tracer. In such embodiments, the syringe shield 711 may not include a metal or other material to block radioactive emissions, and the radioactive emissions blocking material 712 portion of the devices illustrated may be omitted and replaced with, for example, a polymeric material.
The systems that incorporate the syringe shield of the various embodiments may be configured to deliver any radiopharmaceutical known in the art, and the radiopharmaceutical may be delivered alone or in combination with another pharmaceutical composition. For example, in some embodiments, the system may be designed and configured to deliver 47 Ca—Ca 2 , 11 C-L-methyl-methionine, 14 C-glycocholic acid 14 C-para-amino benzoic acid (PABA), 14 C-urea, 14 C-d-xylose, 51 Cr-red blood cells, 51 Cr—Cr 3+ , 51 Cr-ethylenediaminetetraacetic acid (EDTA), 57 Co-cyanocobalamin (vitamin B12), 58 Co-cyanocobalamin (vitamin B12), 169 Er-colloid, 18 F-fluorodeoxyglucose (FDG), 18 F-fluoride, 18 F-fluorocholine, 68 Ga-dotatoc or dotatate, 3 H-water, 111 In-diethylenetriaminepenta-acetic acid (DTPA), 111 In-leukocytes, 111 In-platelets, 111 In-pentetreotide, 111 In-octreotide, 123 I-iodide, 123 I-o-iodohippurate, 123 I-m-iodobenzylguanidine (MIBG), 123 I-FP-CIT, 125 I-fibrinogen, 131 I-iodide, 131 I-iodide, 131 I-m-iodobenzylguanidine (MIBG), 59 Fe—Fe 2+ or Fe 3+ , 81 mKr-aqueous, 13 N-ammonia, 15 O-water, 32 P-phosphate, 82 Rb-chloride, 153 Sm-ethylenediaminotetramethylenephosphoric acid (EDTMP), 75 Se-elenorcholesterol, 75 Se-23-Seleno-25-homo-tauro-cholate (SeHCAT), 22 Na—Na+, 24 Na—Na+, 89 Sr-chloride, 99 mTc-pertechnetate, 99 mTc-human albumin, 99 mTc-human albumin macroaggregates or microspheres, 99 mTc-phosphonates and phosphate, 99 mTc-diethylenetriaminepenta-acetic acid (DTPA), 99 mTc-dimercaptosuccinic acid (V) (DMSA), 99 mTc-dimercaptosuccinic acid (III) (DMSA), 99 mTc-colloid, 99 mTc-hepatic iminodiacetic acid (HIDA), 99 mTc-denatured red blood cells, 99 mTc-red blood cells, 99 mTc-mercaptoacetyltriglycine (MAG3), 99 mTc-exametazime, 99 mTc-sestamibi (MIBI-methoxy isobutyl isonitrile), 99 mTc-sulesomab (IMMU-MN3 murine Fab′-SH antigranulocyte monoclonal antibody fragments), 99 mTc-human immunoglobulin, 99 mTc-tetrofosmin, 99 mTc-ethyl cysteinate dimer (ECD), 201 Tl-n+, 133 Xe in isotonic sodium chloride solution, 90 Y-silicate, and the like and combinations thereof. In certain embodiments, the system may be configured for delivery of radiopharmaceuticals for imaging myocardial or other cardiovascular conditions. In such embodiments, the system may be configured to deliver 18 F-fluorodeoxyglucose (FDG), 13 N-ammonia, 15 O-Water, 82 Rb-Chloride, 99 mTc-pertechnetate, 99 mTc-human albumin, 99 mTc-human albumin macroaggregates or microspheres, 99 mTc-diethylenetriaminepenta-acetic acid (DTPA), 99 mTc-denatured red blood cells, 99 mTc-red blood cells, 99 mTc-exametazime, 99 mTc-sestamibi (MIBI-methoxy isobutyl isonitrile), 99 mTc-tetrofosmin, 201 Tl—Tl + , and the like and combinations thereof.
Optical tracers used in various embodiments may be derived from any source. For example, in some embodiments, the optical tracer may be a fluorochrome, green fluorescent protein, red fluorescent protein, and luciferin or any other bioluminescent molecule isolated from, for example, ctenophores, coelenterases, mollusca, fish, ostracods, insects, bacteria, crustacea, annelids, and earthworms. In particular embodiments, the optical tracer may be isolated from fireflies, Mnemiopsis, Beroe ovata, Aequorea, Obelia, Pelagia, Renilla, Pholas Aristostomias, Pachystomias, Poricthys, Cypridina, Aristostomias, Pachystomias, Malacosteus, Gonadostomias, Gaussia, Watensia, Halisturia, Vampire squid, Glyphus, Mycotophids, Vinciguerria, Howella, Florenciella, Chaudiodus, Melanocostus, Sea Pens, Chiroteuthis, Eucleoteuthis, Onychoteuthis, Watasenia, cuttlefish, Sepiolina, Oplophorus, Acanthophyra, Sergestes, Gnathophausia, Argyropelecus, Yarella, Diaphus, Gonadostomias, Ptilosarcus , or Neoscopelus , and in certain embodiments, the optical tracer may be luciferin or coelentrazine.
In some embodiments, the system may be configured to administer a single radiopharmaceutical composition, and in other embodiments the system may be configured to deliver two or more different radiopharmaceuticals. In embodiments in which the system is configured to deliver multiple radiopharmaceuticals, the system may allow the operator to switch configurations depending on the intended procedure. The amount of radiopharmaceutical delivered by the system may vary among embodiments and based on the protocol being used. Generally, a doctor, technician, or other qualified personnel can determine an appropriate amount of the radiopharmaceutical to be delivered to a particular subject using metrics regarding the subject known in the art. Because of the flexibility of the system, any amount of radiopharmaceutical can be delivered.
Although various embodiments have been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the disclosure is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments. | A syringe shield useful for containing a syringe loaded with radioactive and/or light sensitive drugs is disclosed. The syringe shield may reduce a healthcare provider's exposure to radiation and/or may reduce or eliminate ambient light contamination to optically sensitive components in the syringe. | 0 |
This application is a continuation-in-part of application Ser. No. 123,813, filed Jan. 10, 1980 now abandoned.
BACKGROUND OF THE INVENTION
In many homes presently under construction, the buyer desires that a fireplace be constructed in one wall or an opening formed in a wall wherein a wood or other type burner may be installed. This being the case, usually one wall is constructed of brickwork and when a builder is called upon to form an opening in a wall, a mason is required to erect the one wall. If the opening in the wall is to be arch-shaped, several problems are presented, one being that it is quite time consuming and costly to engage a mason to form the archway since following the placement of the bricks and after the mortar has hardened, the mason must now come along with a masonry saw to cut the bricks individually to form the curvature of the arch.
When the opening in the wall is to be of square configuration, the mason must carefully align the bricks at the opening in order not to destroy the appearance of the fireplace opening. Again, this perfect alignment of the bricks at the opening in the wall can be quite time consuming and of course, this adds to the overall costs in the building of a home.
With the above in mind, it is one object of the invention to provide a pre-cast form either of square or arch-shaped in configuration and to use the same to cover the sides of the opening formed in the wall whereby the cutting off of the bricks so as to form an arch shape is eliminated. Likewise, the necessity of perfectly aligning the bricks for a square opening in the wall is obviated.
Another object of the invention is to pre-cast a form of metal which will either be square or arch-shaped in configuration and which will have on one face thereof a brick or stone design.
Another object of the invention is to pre-cast a brick or stone simulation for either a square or arch-shaped structure which is to be used to cover the sides of a like formed opening in either a brick or stone wall.
Another object of the invention is to laminate a formica or like non-combustible material to the one face of a pre-cast form, the non-combustible sheet having formed thereon the appearance of a brick or stone structure and to incorporate the pre-cast form into a brick or stone wall structure.
These and other objects and aspects of the invention will be more clearly understood from the following description of the embodiments of the invention shown by way of example only in the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of the pre-cast form as applied to an opening formed in a brick wall with parts broken away;
FIG. 2 is a front elevation of the pre-cast form shown in FIG. 1;
FIG. 3 is a side elevation of the pre-cast form shown in FIG. 1;
FIG. 4 is a side elevation of the pre-cast form with the simulated bricks along the side of the form;
FIG. 5 is a section taken on line 5--5 of FIG. 2 looking in the direction of the arrows;
FIG. 6 is a top plan view of the pre-cast arch;
FIG. 7 is a sectional view showing the sides of the simulated brickwork;
FIG. 8 is a view showing the back of the pre-cast arch structure;
FIG. 9 is a section taken on lines 9--9 of FIG. 9, looking in the direction of the arrows;
FIG. 10 is a top plan view of the arch showing the first full course of bricks applied over the upper portion of the arch;
FIG. 11 is a cross section taken on line 11--11 of FIG. 5 looking in the direction of the arrows;
FIG. 12 is a front elevation of a pre-cast form for a square or rectangular opening formed in a wall;
FIG. 13 is a section taken on lines 13--13 of FIG. 12 looking in the direction of the arrows; and
FIG. 14 is a section taken on line 14--14 of FIG. 12 looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Shown in FIGS. 1 to 11 inclusive of the drawings is one modification of the invention whereas shown in FIGS. 12 to 14 of the drawings is another modification of the invention.
Referring now particularly to FIGS. 1 to 11 of the drawings, like reference numerals are employed to designate like parts throughout the several views, numeral 10 designates in general the pre-cast form of the present invention. The form may be made of metal or other suitable material and is provided on the facing with either brick or stone imitation 11 which simulates a brick or stone facing which is to be employed in forming a facade for an arch opening in either a brick or stone wall. As shown more particularly in FIG. 2 of the drawings, the facade is to be employed in an installation where the opening in a wall is of arch configuration and the pre-cast form is of arcuate configuration.
As shown in FIG. 1 of the drawings, the pre-cast form 12 is adapted to be mounted in an opening left in a wall where it is desired to present an arch-shaped opening and the form 12 is placed in the opening in the wall. The form 12 is provided with a flange 13 which extends along the outer periphery of the form and is adapted to overlie the brickwork 14 of the wall 15 of the arch when installed. As can be seen more clearly in FIG. 1 of the drawings, a mason in constructing the wall need not perfectly align the brick or stone defining the opening of the arch since the edges of the pre-cast form will overlie the ends of the brick such as shown in FIG. 1 of the drawings. Thus, considerable saving in costs in the formation of an arch-shaped opening is occasioned. This is an important feature of the invention since much time and effort must be spent by a mason if the brick or stone surrounding the opening are to be in perfect alignment to thus form the arch opening. As it is, the mason need only to lay the courses of brick or stone work in such manner that the ends of the brick or stone will extend under the outer edges of the form.
The form shown in FIGS. 1 to 11 of the drawings is composed of two half sections, 16 and 17, although the form may be formed in one piece. If formed of two half sections, the sections may be joined as by a plate 18 which may be secured in any manner to the aforementioned half sections. When the mortar is poured in the formation of the uppermost course of brick or stone, the plate is embedded in the mortar and serves to retain the half section in proper position within the opening in the wall.
Provided at the lower portions of the half sections 16 and 17 are plate members 21 which are formed integral with or otherwise secured to the half sections 16 and 17. The plate members 21 are adapted to extend under the lowermost course of brick or stone when the wall is being erected in order to secure the form to the opening formed in the wall either for the formation of an arch shaped opening or a square or rectangular opening for a fireplace or arch formation.
As shown more particularly in FIGS. 4, 5 and 11 of the drawings, the wall 22 of the form slants inwardly and is provided with a flange 13 which is adapted to overlie the ends of the brick or stone defining the opening in the wall. The inward slanting of the form adds to the aesthetic appearance of the installation. Also, the flange 23, which extends inwardly of the form may be employed in securing the form to the housing or casing of a burner unit mounted in the fireplace opening.
The structure shown in FIGS. 12 to 14 inclusive is adapted to be mounted in a wall opening in the same manner as previously described with respect to the other modification of the invention. The flange 23' is employed for securing the form to a housing or casing surrounding a stove (not shown) mounted within the fireplace opening.
The pre-cast form 12' is placed in the opening in the wall and is provided with a flange 13' which extends about the top and sides of the form and is adapted to overlie the brick wall which defines the opening for the fireplace. With the flange 13' extending over the bricks which define the opening for the fireplace, the mason need not carefully align the ends of the bricks at the juncture of the wall. The form may be made in half sections or may be integral. If made in two half sections, the same may be joined to one another as by a plate member 19'. Plates 21' are secured to the sides of the form at the lowermost portion thereof and are adapted to extend under the lowermost row of bricks so as to secure the form to the brick wall.
While my invention has been disclosed herein in connection with certain embodiments and certain structural details, it is clear that changes, modifications or equivalents can be used by those skilled in the art. Accordingly, such changes within the principles of my invention are intended to be included within the scope of the appended claims. In these claims it is my intent to claim the entire invention disclosed herein, except as I am limited by the prior art. | Wall structure having an opening and comprised of masonry and pre-cast facade wherein the facade is anchored into the masonry and the facade closely conforms to and overlies the masonry portion forming the opening whereby the solid elements of said portion need not be individually configured and dispensed to necessarily provide an esthetic alignment of end pieces thereof as is requisite in conventional masonry structures. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to storing, retrieving and organizing items in a database, such as an electronic catalog, using part number formulas. More particularly, the invention relates to relating sections of part number formulas to particular aspects of different configurations of an item and storing, retrieving and organizing the different configurations as variations on a single item.
2. Description of the Related Art
Searchable electronic catalogs are commonly used in support of various electronic commerce and purchasing functions. These catalogs typically have a user interface for selectively retrieving and displaying records as well as a system for electronically purchasing any items that are selected. Some items that may be cataloged are available in a variety of different configurations and each configuration will often have a unique part number. For example, a particular type of pen may be available with different colors and points. A garment may be available in different sizes, fabrics and colors. A power supply may be available with different input and output voltages, current capabilities, and housings. If all the configurations of an item are each listed as separate items, then the catalog can become cumbersome. Finding and selecting items and managing the catalog can be more difficult. On the other hand, if the different configurations are ignored, then details about the item and complete part numbers may be unavailable for each configuration.
Pens and shirts represent simple examples of products with a variety of available configurations. In some product domains, there may be thousands or even millions of different possible configurations. A lighting fixture, for example, may be offered with choices of lamps, starting circuits, lamp wattages, ballasts, input voltages, housings, lenses, mounting brackets, finishes, fuses and certifications. When represented as thousands of different items, one for each configuration, such complicated configurable items become almost impossible to search, load, extract and add to an electronic catalog shopping cart because of the very large number of combinations that must be handled. Sifting through the thousands of possibilities can be very time consuming and confusing for a purchaser.
In relational databases, such items have been handled by coding long sequences of conditional branch instructions, typically in the form of “if, then” statements. The hard-coded configurations, while usable, can only be changed by an expert in the conditional logic system using a map of the “if, then” sequence for the particular product. In addition, the hard-coded configurations are difficult to translate across platforms to populate catalogs that operate using different software or architectures. Updates and translations are particularly important because the options in such configurable products often are changed. For the example of a particular pen, an additional color choice may be added at any time. For the lighting fixture, mentioned above, it would be common for an option in lamp wattage to be added or taken away as the available lamps change. As a result, neither a long list of thousands of separate items nor complex hard-coded configuration logic is satisfactory for a category that is easy to use, reconfigure, update, and transport across platforms.
BRIEF SUMMARY OF THE INVENTION
An improvement for composing and cataloging item configuration data is disclosed. One embodiment of the invention includes identifying a base item, identifying a part number for the base item, breaking the part number into sections, each section corresponding to an attribute of the base item, and determining which of the part number sections relate to configurable attributes of the base item. The embodiment further includes listing a plurality of selectable part number section values for the configurable attributes, listing descriptive information for each of the selectable part number section values, linking the descriptive information to the corresponding selectable part number section value, generating a part number formula to define the configurable sections and associate configurable sections to the corresponding list of values, and generating a description formula to define a configurable description and associate descriptive information with corresponding configurable selectable part number values. The embodiment further includes adding the base item part number, values list, descriptive information list, part number formula and description formula to an electronic catalog.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The appended claims set forth the features of the invention with particularity. The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements and in which:
FIG. 1 is a block diagram representation of an electronic catalog system suitable for use in implementing the present invention;
FIG. 2 is a representative example of a computer system suitable for implementing the present invention;
FIG. 3 is a representative display of search results for an electronic catalog system in which items are displayed in a basic form;
FIG. 4 is a representative display of the configurable details of a selected item;
FIG. 5 is a representative display of the item of FIG. 4 in which the ink color of the item can be selected in accordance with the present invention;
FIG. 6 is a representative display of the item of FIG. 4 in which the configurable aspects of the item have been selected in accordance with the present invention;
FIG. 7 is a flow diagram of adding a configurable item to an electronic catalog in accordance with the present invention; and
FIG. 8 is a flow diagram of selecting a configurable item from an electronic catalog in accordance with the present invention
DETAILED DESCRIPTION OF THE INVENTION
I
FIG. 1 is a functional block diagram representation of an electronic catalog and automated purchase requisition system. An application server 12 is connected to interact with a database 14 in the form of an electronic catalog which resides in a computer memory storage device at the server or at another device. The catalog can be integrated with the server, co-located with the server or connected using a local or wide area network connection. Users of the system have workstations or clients 18 that are connected to the application server 12 through a local or wide area network such as the Internet or an intranet. The client includes a browser 20 such as a common Internet web browser or dedicated software through which the workstation communicates with the server 12 to render a search display 22 . Commands entered into the web browser software can cause information to be extracted from the database 14 and displayed at the workstation 18 in the search display or in some other display. While the invention will be described in terms of browsers communicating using typical web interfaces such as HTTP (Hyper Text Transfer Protocol) and Java instructions, the present invention does not rely on any particular platform or interface. The invention can use web-type browser software or software that has been developed specifically for the purposes of the present invention with unique code, interfaces and display technologies. The invention can be implemented on a single machine or with any kind of distributed processing environment from mainframes with dumb terminals to wireless servers with mobile radio PDAs (Personal Digital Assistant).
The database 14 is an electronic catalog of items, such as products or services. The database 14 can be constructed using a uniform catalog schema so that each product has a single database record that includes all of its different suppliers. However, multiple catalogs, one or more for each supplier, or an aggregated catalog, an aggregate of product information from multiple suppliers, can also be used. In the aggregated catalog, the same item may be listed several times in inconsistent ways.
In one embodiment of the invention, the server 12 uses servlets 16 to operate a search engine 24 that accesses one or more electronic catalogs 14 . The search engine is a common and useful application of the present invention, however the present invention can be used whenever records are retrieved from the catalog. It can be used to generate a catalog to be published whether to a marketplace, a purchaser or a seller. It can also be used for any direct product purchase and for any other use of catalog records, such as system administration, management and quality control.
In the search engine example, the application server 12 queries the database 14 through the search engine and directs the results to the workstation 18 . The type or format of the catalog is irrelevant as long as the catalog will respond appropriately to a query from the search engine 24 . For example, the catalog may reside within a relational database or may reside within an object-oriented database. The catalog can be stored on a disk drive, a tape drive, RAM, or any other computer data storage devices. The application server 12 may reside in a computer attached directly to the storage device, or alternatively may be connected to the storage device 16 through a network. In one embodiment, the servlets are based on Java APIs (Application Program Interface) and JavaScript/HTML (Hyper Text Markup Language) Interface Generation. These use JDBC (Java Database Connectivity) to communicate through the search engine to a separate data store where the catalog resides. The JDBC protocol allows the search engine to communicate with a catalog based on a variety of different commonly used databases including those available from Oracle Corp., Microsoft Corp., and SAP AG.
The search engine 24 is also connected to a rules store 26 through similar Java or HTTP-type protocols. The rules store contains rules that are used to configure, modify or present data that has been requested by the user. As an alternative to the rules store, the rules can be incorporated into the catalog. In one embodiment, the catalog is maintained and loaded in the form of XML (Extensible Markup Language) statements and these statements can include values for attributes of catalog items or rules about how to determine values of catalog items. Other types of markup languages, such as SGML (Standard Generalized Markup Language) and HTML (Hyper Text Markup Language) can be used as can other types of database formats.
II
A computer system 200 representing an example of a system upon which features of the present invention may be implemented is shown in FIG. 2 . The workstation, search engine, servers, and databases of FIG. 1 will typically be configured similar to what is shown in FIG. 2 . Each of these components can be provided using its own computer system or several different components can be combined. For example, the search engine, server, rules, and catalog can all be provided using a single computer system. The computer system can be deployed on a single platform as shown, or different components can be provided on separate platforms so that the bus 201 connects several different platforms together containing different portions or aspects of the mass storage 207 and other system 210 components. The computer system can also be implemented in one or more small portable platforms such as laptops and PDAs. The computer system 200 includes a bus or other communication means 201 for communicating information, and a processing means such as a microprocessor 202 coupled with the bus 201 for processing information. The computer system 200 further includes a main memory 204 , such as a random access memory (RAM) or other dynamic data storage device, coupled to the bus 201 for storing information and instructions to be executed by the processor 202 . The main memory also may be used for storing temporary variables or other intermediate information during execution of instructions by the processor.
The computer system may also include a nonvolatile memory 206 , such as a read only memory (ROM) or other static data storage device coupled to the bus for storing static information and instructions for the processor. A mass memory 207 such as a magnetic disk or optical disc and its corresponding drive may also be coupled to the bus of the computer system for storing information and instructions such as the various databases.
The computer system can also be coupled via the bus to a display device or monitor 221 , such as a cathode ray tube (CRT) or Liquid Crystal Display (LCD), for displaying information to a user. For example, graphical and textual indications of installation status, operations status and other information may be presented to the user on the display device. Typically, an alphanumeric input device 222 , such as a keyboard with alphanumeric, function and other keys, may be coupled to the bus for communicating information and command selections to the processor. A cursor control input device 223 , such as a mouse, a trackball, or cursor direction keys can be coupled to the bus for communicating direction information and command selections to the processor and to control cursor movement on the display 221 .
A communication device 225 is also coupled to the bus 201 . The communication device 225 may include a modem, a network interface card, or other well known interface devices, such as those used for coupling to Ethernet, token ring, or other types of physical attachment for purposes of providing a communication link to support a local or wide area network (LAN or WAN), for example. In this manner, the computer system may also be coupled to a number of clients or servers via a conventional network infrastructure, including an intranet or the Internet, for example. Source Content and the databases can be made available to the computer system in this way.
It is to be appreciated that a lesser or more equipped computer system than the example described above may be preferred for certain implementations. Therefore, the configuration of the exemplary computer system 200 will vary from implementation to implementation depending upon numerous factors, such as price constraints, performance requirements, technological improvements, or other circumstances.
III
The search engine 24 is activated by the application server 12 in response to inputs from the workstation's web browser. The search engine follows an algorithm, for example the algorithm described in U.S. Pat. No. 6,032,145, the disclosure of which is incorporated fully by reference herein, to search through the catalog for any items related to the query. The algorithm in the above-mentioned patent applies a cascading sequence of progressively broader searches in order to locate records in the catalog. This provides a significantly greater probability that a desired item will be found. However, any other type of search algorithm can be used. A proximity query, for example, is offered in some well known commercial databases, such as those from Oracle Corp.
In the present application, the search can be a broad search based on any characteristic of an item generally, for example, a search for a Bic brand pen. Alternatively, the search can be very specific for a single item, such as Bic part number SCSM11. In either case, the user inputs a search string to the web browser guided by the search display 22 as shown in FIG. 2 . The search string can be free-form or subject to specific structural rules. The particular format of the search algorithm and the input string is not important to the present invention. The search string may comprise search terms in any order. For example, the search string can include the name of an item, a part number for an item, or any descriptive attribute of the item. The search engine can be designed to handle misspellings, word fragments, or any other string that may lead a user to find the desired product within the database 14 .
An example of a search display 22 is shown in FIG. 3 . This display already includes the results of the search, in this case a list of pens from Bic Corp. The display, in this example, has a single text box 300 for search strings located in the upper-left corner of the display. The example search string in box 300 is “bic pen” which represents a combination of sought for values from the fields of manufacturer name, classification, and description. Alternatively, there may be separate text boxes for different parts of the search strings. The single box can be simpler to use. The display has several other areas of information, as shown in FIG. 3 . The search results or list of identified items is shown in a display list 302 . The display list 302 includes the category, the manufacturer name, the manufacturer part number, a description, a supplier part number and a price. For each of these fields, values are shown for each item or record, including supplier part number and price.
A compilation of each unique category of product, compiled from the list of the identified items, is shown in a category display area 304 . If several different categories of products were found during the search, then each category will be displayed along with a corresponding CATEGORY radio button 306 . The user can narrow the list by selecting one of the categories. For example, FIG. 3 shows that two different categories of items were found: pens and pen refills. Since there are 29 matching items (only the first 10 are shown), the selection of the PENS category radio button 306 will narrow the list to include only pens and not pen refills. A new display will be generated in which the display list includes only items in the pens category and not in the pen refills category. If the desired item from the catalog is not immediately visible in the display, the user has the option of paging through the remaining items in the list by clicking on a NEXT button 308 . If the desired item is found, no further searching is required.
A further alternative is to select only items having a particular manufacturer. The search display also includes a MANUFACTURER (Mfr Name) button 310 . This can be used to invoke a screen containing a list of all manufacturers of the products shown in the display list 302 . Selecting one of the manufacturers will cause the server 12 to narrow the display list 302 to include only items from the selected manufacturer. The user can also use information in the display to submit a new query to further limit the results. For example a query for “bic pen red fine” will return a shorter list of items.
One way to generate the display of FIG. 3 is for the user to enter a query into a browser or dedicated catalog application. The search query is sent over a network, such as the Internet or an intranet, by the client 18 from the browser 20 to the application server 12 using, e.g. HTTP. The application server 12 , upon receiving the query parses the HTML packet as appropriate for the search engine 24 . It also determines the identity of the user based on embedded ID codes, the packet source or some other approach. The search engine can perform any one or more types of queries using the search string to find a match for the search string within the database 14 . Typically, the search string within the HTML packet is compared to the catalog text that is identified as attribute values of each item. If no record is identified in response to the query, then the application server builds a results display by compiling the information into an HTML package that can be displayed within the browser to show the user that no records have been found. This display is sent back over the network using, e.g. HTTP to the workstation browser where it is displayed as a web page or a window to the user in the search display 22 . The user can then try another query, try another catalog etc.
If a record is identified, then the search engine can retrieve the values of the attributes for the identified records from the catalog. As discussed above, FIG. 3 shows an example of some catalog records with attributes and values displayed. The attributes as displayed are category, manufacturer name, manufacturer part number, Description, Supplier Part number, and Price. These attributes have been selected as examples, but many other attributes can be included in the catalog. In addition to the global attributes, such as the ones shown, that apply to all types of items, the catalog is likely to have local attributes that apply only to certain kinds of items. Local attributes can be such things as ink color, voltage, fuel capacity etc. The items each have values for each attribute as shown in the display list 302 . For example, category has values of pens and pen refills. Manufacturer part number is shown with values of SGSF, REMBID, SCSM11, etc. These values are stored and maintained in the catalog from which they have been retrieved.
IV
In the case of the first listed pen, the displayed manufacturer part number SGSF represents only a portion of the complete manufacturer part number. The complete number includes two further sections, one for color and one for the fineness of the point. A complete number might be SGSF-RED FINE. Another part number might be SGSF-GRN MEDM. As mentioned above, it is entirely possible to list every variation in color and point fineness as a separate item. This can result in many more items in the catalog however. If the pens are available in four alternative colors and three alternative finenesses, that would result in twelve different possible pen configurations. The twelve listings, if available for each of the 29 different matching items in the display of FIG. 3 , also make it harder for a user to find a product. The twelve different possible combinations for the SGSF pen are listed below in Table 1. These combinations are provided as examples only. The actual Bic product upon which this example is based may or may not be available in all of these configurations. The product may also be discontinued at present.
TABLE 1
Mfr Name
Mfr Part No.
Description
Point
Ink Color
Price
Bic
SGSF-FINE BLK
Ballpoint Pen Soft-Feel w/clip
Fine Point
Black
0.55
Bic
SGSF-FINE BLU
Ballpoint Pen Soft-Feel w/clip
Fine Point
Blue
0.60
Bic
SGSF-FINE GRN
Ballpoint Pen Soft-Feel w/clip
Fine Point
Green
0.55
Bic
SGSF-FINE RED
Ballpoint Pen Soft-Feel w/clip
Fine Point
Red
0.55
Bic
SGSF-MEDM BLK
Ballpoint Pen Soft-Feel w/clip
Medium Point
Black
0.55
Bic
SGSF-MEDM BLU
Ballpoint Pen Soft-Feel w/clip
Medium Point
Blue
0.60
Bic
SGSF-MEDM GRN
Ballpoint Pen Soft-Feel w/clip
Medium Point
Green
0.55
Bic
SGSF-MEDM RED
Ballpoint Pen Soft-Feel w/clip
Medium Point
Red
0.55
Bic
SGSF-BOLD BLK
Ballpoint Pen Soft-Feel w/clip
Bold Point
Black
0.78
Bic
SGSF-BOLD BLU
Ballpoint Pen Soft-Feel w/clip
Bold Point
Blue
0.83
Bic
SGSF-BOLD GRN
Ballpoint Pen Soft-Feel w/clip
Bold Point
Green
0.78
Bic
SGSF-BOLD RED
Ballpoint Pen Soft-Feel w/clip
Bold Point
Red
0.78
Many other products are also available in a variety of different configurations. Consider an example of clothing. A particular men's shirt might be available in a range of collar sizes, sleeve lengths, colors and fabrics. When all possible combinations of the four different parameters are listed in a catalog, the number of items can make it difficult to find any other items . Typical US men's shirt sizes offer nine collar sizes, from 14 to 18 with half sizes, and six sleeve lengths, from 30-35. If five colors and three fabrics are available, then the one style of shirt may include 810 items. Similar examples may be found with power supplies and voltage controllers or with modular furniture sets, for example.
So that all the variations can be offered in a single concise listing, the pen or the shirt or the power supply can be listed just once as a single configurable item. The variations in color, size, capacity, voltage, housings etc. can be displayed if the user wants to investigate those possibilities. This allows the listings of items responsive to a search to be made much more concise, such as the one shown in FIG. 3 . An alternative concise listing for the pen of Table 1, is provided below in Table 2. In Table 2, the different point finenesses and ink colors are shown as options on a single item. The part number detail has been reduced to just the generic or common portion of the part number. The portion in Table 1 that describes the options is not shown, however, it can be if desired.
TABLE 2
Mfr Name
Mfr Part No.
Description
Point Options
Ink Color Options
Prices
Bic
SGSF-
Ballpoint Pen
Fine Point, Medium
Black, Green, Blue,
0.55, 0.60,
Soft-Feel w/clip
Point, Bold Point
Red
0.78, 0.83
In one embodiment, the decision as to how many different items to show at this first highest level tier is based on part numbers. The example pen of Tables 1 and 2 lends itself very well to being organized around the manufacturer's own part number. However, the manufacturer's or supplier's part numbers need not serve as a guide. A fine point pen can be regarded as a different item than a medium point pen or it can be regarded as a variation on the same pen. Similarly, a shirt with the same design but a different fabric may be regarded as a different shirt just as a short sleeve version of a shirt may be regarded as a different shirt from a long sleeve shirt. It is entirely possible that different manufacturers associate products and part numbers differently. While one manufacturer may treat fine point and medium point pens as the same item, another may treat them as different items. In the described embodiment, manufacturer part numbers are used as a guide, regardless of any inconsistencies among manufacturers. As an alternative, supplier part numbers or any other part number source can be used. In another embodiment, an organized structure can be created just for the catalog so that competing items from different manufacturers are treated the same way, notwithstanding the manufacturer's part numbers. This external structure can be imposed to replace any manufacturer or supplier part number scheme with a separate catalog or reference number.
As can be seen from the pen example above, the part number can be parsed fairly easily and a meaning to each component of the part number can be attached. The part number of one pen was SGSF-RED-FINE. The part number has three sections. The first SGSF identifies the structure of the pen and can be associated with descriptive attributes such as pen, ballpoint, soft-feel, with clip. The second section identifies the ink color of the pen as red and the third section identifies the ballpoint as being fine. To catalog this item, the cataloger can rather easily create a matrix such as the one shown in Table 3. Using this table, a part number can be built up for any of the 12 different possible alternative configurations that can be offered based on the SGSF base item. Table 3 shows the designator for each part number section, the order in which it appears in the part number, the structure of the part number section and all possible alternative values. The structure is shown as the number of alphabetic characters and the connecting symbol in this case a hyphen or a space. Some part numbers have no connectors and use numbers, letters and other symbols usually in some consistent pattern.
TABLE 3
Base Section
Color Section
Point Section
4 alpha, hyphen
3 alpha, space
4 alpha
SGSF
BLK
FINE
BLU
MEDM
GRN
BOLD
RED
From Table 3, the cataloger can identify a base item, the Bic SGSF pen. The base item can be configured with ink color and point selections. The base item can be set as having no color or fineness or a particular attribute value can be selected as the base value. For example, the base item can be defined as the SGSF-BLK MEDM pen. The last two attributes, color and point are configurable for the base item, i.e. they can be changed, while the first attribute corresponding to the first section of the part number, SGSF, is not configurable and can not be changed.
Table 3 also provides a part number formula in the second row from which all the configurations can be derived. In this case, a part number formula can be defined as SGSF-Ink Color_CODE Point Fineness_CODE. The structure and format for the Ink Color_CODE is provided above as three alphabetic characters. Using this formula and the values provided in the table, a part number can be generated. Ink Color_CODE, as can be seen above, can have values of BLK, BLU, GRN, and RED, while Point Fineness_CODE can have values of FINE, MEDM, and BOLD. The part number can then be used for ordering, inventory, and fulfillment purposes. Using the formula and values, the part number matrix in Table 3 can be rendered in a text form, such as XML, as shown below.
As described above, pens are found in the catalog based on a search for the attributes of the pen that is desired, such as “bic pen.” In order to allow all of the characteristics of the pens to be searched, the description values for each of the variations can be made searchable. In the structure of the catalog described herein, this means that descriptive terms for each variation are added to data records that are accessible to the search engine, for example through a search index. In particular, the pen of Table 1 will have at least three sets of descriptive terms, one set for each part number section.
Items can be viewed as having two tiers of attributes. The first tier of descriptive terms can be called global attributes. These are qualities that are shared by every item in the catalog, such as manufacturer, supplier, price, quantity per package, delivery time, availability, etc. The global attributes can typically be associated with the base section of the part number. The pen will also have attributes that are unique to pens or unique to pens and a few other types of items that are like pens, such as ink color and fineness. The local attributes will often depend, in part, upon the other sections of the part number, the sections corresponding to the configurable aspects of the item. These descriptive terms can be rendered in an options matrix as shown in Table 4. Table 4 provides the codes for each part number section with the corresponding description and price adjustment for each option. It also indicates whether the descriptions will be made available to the search index. Typically, this determines whether the descriptions will be compiled into the catalog's search index when the catalog is being compiled. In one embodiment all the part number matrices are maintained as XML documents. When the XML is loaded into the catalog, the loader looks for flags to indicate which items are to be added to the search index and which items are not.
TABLE 4
Color Section
Description
Description
Part No.
(ink color)
Searchable
Price Adjustment
BLK
black
yes
0
BLU
blue
yes
0
GRN
green
yes
0.05
RED
red
yes
0
Point Section
Description
Description
Part No.
(point)
Searchable
Price Adjustment
FINE
fine point
yes
0
MEDM
medium point
yes
0
BOLD
bold point
yes
0.23
In addition to the part number formula described above, a description formula can be defined from Table 4 as pen, ballpoint, soft-feel, with clip, Ink Color_DESC, Point Fineness_DESC. The last two descriptive terms are taken from the table depending upon which selections have been made. Table 4 shows that Ink Color_DESC can have values of black, blue, green, and red. Point Fineness_DESC can have values of fine point, medium point, and bold point. These values can be linked to the Ink Color_CODE and Point Fineness_CODE as shown in Table 4 using, for example a mark-up language. As result, the description formula can provide a description of any configured item based on the base item, SGSF or SGSF-BLK-MEDM.
The matrix need not be limited to single word descriptions or even to single descriptions. Different sets of descriptions can be defined and selected based on a user identification. For example, a highly technical user may desire a more detailed set of descriptions than another user. Using two sets of descriptions, and checking the user preferences or authorization, the appropriate set of descriptions can be selected for display to the user. Another example of multiple descriptions sets is to accommodate different languages. While the same pens may be sold under the same part numbers in different countries, purchasers may prefer descriptions in different languages. Accordingly, a second set of color descriptions can be added to the matrix, for example, negro, azul, verde, rojo. By indicating a language preference, the user can be provided with descriptions in the appropriate language to the extent that the descriptions are available. This allows for multilingual catalogs with very little repetition in subject matter. It also allows the catalog to easily be modified in all languages at the same time
Table 4 also has a price column for each configurable option. These options are expressed in terms of amounts that are to be added to the base item price. However, they can be expressed in any other way that allows the differences in price between different configurations to be determined. Percent increases and multipliers can be used as price factors for example. The price column provides enough information to define a price formula. The price formula can be+Ink Color_PRICE+Point Fineness_PRICE. So for example, the green fine point pen costs 5 cents more than the base item, the black medium point pen. The green, bold point pen costs 28 cents more. The price factors can also be expressed as text and linked to the appropriate configurable options using a mark-up language as discussed above. In the example above, the mathematical operators are plus signs. Subtraction can be accomplished by price codes preceded by a minus sign. The formula may also include other mathematical functions such as subtraction, multiplication and division. While the mathematical operators (plus signs) are defined by the price formula in the example above, they can instead be a part of the price values in the matrix. In that case, the formula is used to refer to the appropriate values and determine the ordering while the mathematical function to be applied comes from the matrix.
The price formula and matrix approach can be used for a wide variety of different price adjustments. Any attribute value with a price impact can be linked to a price adjustment. These attributes can include precision grades, tolerances, warranty levels, shipping alternatives, rush delivery options, installation alternatives, and more. One common factor that influences product pricing is the purchased quantity. Many vendors offer volume discounts. Such discounts can also be accommodated using the matrix approach described above. Cable may have one price if purchased by the meter and another price if purchased by the tens of meters or the kilometer. Pens, as discussed above may be sold independently, in boxes of 12 or in cases of 24 boxes. This can be expressed in a matrix as well or be made part of the matrix shown in Table 4. The shipping or package units may be a part of the part number or it may be a separate descriptive element. In either event, the quantity or shipping unit choices can be added to the matrix and the price formula. It can then be configured in the same way as the ink color as shown, for example, in FIG. 4 . An example of a matrix for packing units is shown in Table 5. The price formula can be rewritten as+Ink Color PRICE+Point Fineness PRICE+Package Units PRICE. Similar changes can be made to the part number and description formulas.
TABLE 5
Package Units.
Description
Price Adjustment
EA
each
0
BX
box of 12
10
CS
case of 24 boxes (288)
100
RC
box of 12 (recycled)
−40
Volume discounts do not require unique packaging such as boxes and cases or 50 m reels and 500 m reels. In terms of the matrix and the pricing formula, a box of 24 and a quantity of 24 can be treated in the same way. The buyer can be informed whether 12 individual units or a box will be shipped using the description.
In addition, the matrix and formulas are not limited to any type of actual part number. Additional descriptors can be attached to the part number using the same principles discussed above. For the pens example, the manufacturer's part number may include the package units. After configuration, the part number can look like SGSF-RED BOLD BX. It is also possible that the package unit is not a part of the manufacturer's part number at all. In either event, the part number formula can be structured to configure a unique product identifier that is understandable to the supplier. The part number formula can also render an expression such as Box SGSF-RED BOLD. Alternatively, the part number may be SGSF-MEDM. The ink color, which must also be specified can be treated in the same way as a part number section but not added to the part number. The green, medium point pen can be ordered using the part number and color as SGSF-MEDM, green, case. In this case, the ink color codes and ink color descriptive information can be the same.
Similarly, shirts often use a part number to identify a style and perhaps a color but not the size. For these items, the size must be specified in order to uniquely identify the product but the size is not a part of the part number, it is an additional element. These additional elements, whether they relate to size, color, power ratings or any other aspect of the item can be treated in the same way as described above using the type of matrix shown. The matrix will still be able to construct an item number that uniquely identifies an item including any constraints or selections that are not part of the part number using the same principles applied above. A shirt may be identified, for example, using a part number formula, such as A721-RED XL.
In the embodiments described above in which the search engine searches the descriptive terms of each item to find a match, the description values from the table for these local attributes can be provided to the search engine. If this is done, then the search for “bic pen red” will find and display, the SGSF pen. On the other hand, a search for “bic pen purple” or “bic pen extrafine”, will not find the SGSF pen. Each matrix within the part number in the example above, for example, the ink color matrix and the point fineness matrix, relates to a particular attribute of the pen. The search engine access for each matrix and therefore each attribute can be specified independently for each matrix using, for example, metadata statements linked to the descriptive terms.
V
As can be seen from FIG. 3 , not all of the information regarding the SGSF pen, or probably any of the other pens is displayed. The displayed information is also not enough to allow the product to be ordered because the color and point need to be specified. While it is possible for the user's selection to be inferred based on a customer profile or previous behavior, the present invention allows the user to see the options and make a choice.
Upon selecting the “View Cart” button 312 or the SGSF pen item, more details of the SGSF pen can be displayed. This is shown in FIG. 4 , an example of a web browser display 402 according to one embodiment of the invention. FIG. 4 provides the user with a summary of information about the selected product, in this case, the SGSF pen. An item type legend 404 informs the user that the item is configurable. A description section 406 provides the category, description, Manufacturer part number, price, units of measure and saleable quantity for the selected item. A frame 408 for an illustration of the item, such as a photo is also provided, when one is available in the catalog. Using this display, the user can configure the selected item and automatically build the part number.
The display 402 provides two drop-down menus or pick lists 410 , 412 for configuring the point size and color of the pen, respectively. The windows are placed next to the corresponding header 414 , 416 for the respective configurable item. They are identified with instructions in the windows to “select a point” and “select a color.” A selection cost window 418 provides any additional costs associated with any selection after the selection has been made. In this example, the user selects a color by typing the name of the desired color in the window 412 with the words “select a color”. Alternatively, the arrow next to the window can be selected to produce a pick list 420 as shown in FIG. 5 .
In FIG. 5 , the display is unchanged except that the ink color can be configured. The color choices in the pick list are the same as those in Tables 1 and 2. The pick list can be generated from a table or matrix in the electronic catalog or from a list of choices defined in a mark-up language and tied to the Ink Color attribute From the displayed pick list, the user can select the desired color. This color is plugged into the part number formula, description formula and pricing formula.
The point can be selected in the same way as the ink color. After making the selections, the browser display can indicate both choices as shown in FIG. 6 . FIG. 6 also shows that, with both choices made, the manufacturer part number and selection cost can also be assembled, computed and displayed using, for example, the formulas described above. The part number for the configured item is shown as SGSF-GRN FINE. The description for the configured item is shown as Pen, Ballpoint, Soft-Feel, with clip, Green, Fine Point. The selection cost is shown as 0.05. In the illustrated embodiment, the selection cost window is used to show the additional cost of a particular selected configurable attribute, in this case 5 cents for green ink. Alternatively, it can be used to show the actual price or discounted price for the item. In either case, a matrix, table or text file can be used. The price formula mentioned above can be used to calculate the eventual price.
Having configured the item, the user can then select the “Add to Cart” button to purchase the configured item. FIGS. 4 , 5 , and 6 show a particular way to configure the item using a graphical user interface that is presently in common use. Other existing or future types of displays and selection interface tools, whether graphical or not, can also be adapted to accomplish the same functions as the interface described. The selection of a particular interface will depend on the application of the present invention and the desires of the developer. The illustrated example allows the user to know which choices are available, enter a choice and see the results.
The following XML document shows an implementation of the principles of the invention to render the SGSF pen of Table 1 as a configurable catalog item in XML. The same principles can be applied to render any other items regardless of the number of configurable features. The text below can be rendered into the browser display screens using Java applets or any one of a variety of other tools.
<CATALOG xml:lang=“en-US”>
<DATA>
<ITEM>
<OWNER>
<NAME>Ballpoint Pen Soft-Feel w/clip</NAME>
<KEY>Pens</KEY>
</OWNER>
<KEYVALUE>
<KEY>Description</KEY>
<VALUE>This is a configurable item.</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Mfr Part Num</KEY>
<VALUE>SGSF-BLK MED</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Long Description</KEY>
<VALUE>pen, ballpoint, soft-feel, with clip</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Price</KEY>
<VALUE>0.55</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Mfr Name</KEY>
<VALUE>Bic Corp.</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Sup Part Num</KEY>
<VALUE>NIGS32</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Sup Name</KEY>
<VALUE>Office Supply House</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>UOM</KEY>
<VALUE>EA</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Saleable Quantity</KEY>
<VALUE>Each</VALUE>
</KEYVALUE>
</ITEM>
<MATRIX MATRIXID=“14054a3dc1”>
<MATRIXATTRIBUTE key=“pens”>
<KEYVALUE>
<KEY>SEARCHABLE</KEY>
<VALUE>true</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>CODE</KEY>
<VALUE>pens</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>DESCRIPTION</KEY>
<VALUE>ballpoint pens</VALUE>
</KEYVALUE>
</MATRIXATTRIBUTE>
<MATRIXATTRIBUTE key=“Ink Color”>
<KEYVALUE>
<KEY>SEARCHABLE</KEY>
<VALUE>true</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>CODE</KEY>
<VALUE>BLK</VALUE>
<VALUE>GRN</VALUE>
<VALUE>BLU</VALUE>
<VALUE>RED</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>DESCRIPTION</KEY>
<VALUE>Black</VALUE>
<VALUE>Green</VALUE>
<VALUE>Blue</VALUE>
<VALUE>Red</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>PRICE</KEY>
<VALUE>0</VALUE>
<VALUE>0</VALUE>
<VALUE>0.05</VALUE>
<VALUE>0</VALUE>
</KEYVALUE>
</MATRIXATTRIBUTE>
<MATRIXATTRIBUTE key=“Point Fineness”>
<KEYVALUE>
<KEY>SEARCHABLE</KEY>
<VALUE>true</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>CODE</KEY>
<VALUE>FINE</VALUE>
<VALUE>MEDM</VALUE>
<VALUE>BOLD</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>DESCRIPTION</KEY>
<VALUE><Fine Point></VALUE>
<VALUE><Medium Point></VALUE>
<VALUE>Bold Point</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>PRICE</KEY>
<VALUE>0</VALUE>
<VALUE>0</VALUE>
<VALUE>0.23</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Price Formula</KEY>
<VALUE>Ink Color_PRICE_+Point Fineness_PRICE_</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Part Number Formula</KEY>
<VALUE>pens_CODE_-Ink Color_CODE_Point Fineness_CODE_-</VALUE>
</KEYVALUE>
<KEYVALUE>
<KEY>Description Formula</KEY>
<VALUE>pens_DESC_,Ink Color_DESC_, Point Fineness_DESC_,</VALUE>
</KEYVALUE>
</MATRIX>
</DATA>
</CATALOG>
While the SGSF pen has only two possible configurable features, ink color and point fineness, the same principles can be applied to more complex configurable products as well. The XML document above can be loaded into a catalog in order to preserve the matrix structure of the configurable options. The matrix can be represented in a variety of different ways. In one embodiment, the matrix structure is represented by the XML document and rendered in the catalog as indexed tables. An example of suitable tables is provided, for example, by Tables 4 and 5, above.
Alternatively, the XML document above can be loaded into a catalog that is unable to preserve the matrix structure of the configurable options. To do this, the one pen with its configurable options can first be expanded into the twelve different possibilities as shown in Table 1. The different possible configurations can all be rendered in a new XML document as separate items and then loaded into the catalog. Even though, the catalog does not support the matrix format of the configurable part, the matrix format still provides a tremendous advantage in administration, management, and updating the item.
VI
Table 6 shows a base item number or part number for a particular high intensity discharge industrial lighting fixture. The characteristic defined by each section of the part number is provided and the number of different alternatives for each characteristic. In some cases, the alternative is to either have the feature or not, e.g. special finish or standard finish. In other cases, there are many different options from which to choose. Lamp Wattage can range, for example from 50 to 400 Watts for the fixture. With all of the choices provided, the lighting fixture can be configured in approximately 368 million ways. The matrix required to fully describe the lighting fixture and all its configurations is significantly smaller than what would be required to separately describe all 368 million different item configurations.
TABLE 6
Base Item No.
Description
No. of Options
V
Base Section
1
S
Lamp Type
3
0
Starter Circuit
4
15
Lamp Wattage
8
H
Ballast Circuit
2
12
Voltage/Frequency
8
0
Ballast Housing Style
6
TGL
Optical Assembly
26
P2
Mounting Style
16
T
Finish
2
E1
Packaging
6
F
Fusing
2
N
NEMA Lamp Wattage Decal
2
C
CSA Certification
2
The present invention can be adapted to accommodate excluded combinations. Suppose, for example that the SGSF pen was available in medium and fine point with green ink but not in a bold point with green ink. Instead of adding complex conditional logic or some other type of coding, this constraint on green ink can be accommodated by rendering the SGSF pen as two different catalog items. The first item is the SGSF pen in black, red or blue ink, available with three different point finenesses. The second pen is the SGSF green pen, available in only two point finenesses, medium and fine.
In the example industrial lighting fixture above, there are some excluded combinations. This reduces the total number of possibilities to approximately 46 million. The three lamp types are high pressure sodium (HPS), metal halide (MH) and mercury vapor (MV) and the eight available lamp wattages are 50, 70, 100, 150, 175, 200, 250, and 400. The six ballast housings come in three types each available with or without stainless steel inserts. The ballast housings, however, are constrained in the amount of heat and power they can support as shown in Table 7.
TABLE 7
Ballast Housing
Code
Style Description
Available Lamps
0
Standard
HPS up to 150 W
MH, MV up to 250 W
R
Refractor Globe
HPS up to 150 W
MH, MV up to 250 W
L
Large
HPS 200 W-400 W
MH, MV 400 W only
S
Standard w/SS Inserts
HPS up to 150 W
MH, MV up to 250 W
I
Refractor Globe w/SS Inserts
HPS up to 150 W
MH, MV up to 250 W
M
Large w/SS Inserts
HPS 200 W-400 W
MH, MV 400 W only
As with the pen, the constraints in the housings shown in Table 7 can be accommodated by dividing the lighting fixture into two different items. One item can be configured with the 0, R, S and I ballast housings and with HPS lamp types up to 250W and MH and MV lamp types up to 250W. The other item has only the L and M ballast housings and it can be configured with an HPS type lamp in 200W, 250W and 400W or with an MH or MV lamp at 400W. Rendering the single item as two different items with only certain of the options available allows a very simple matrix to be used for all variations of the product. It avoids complex branch instructions or conditional logic which might otherwise be used. At the same time, the item is still greatly simplified over listing all of the configurations separately. The writing pen and lighting fixture example illustrate how the principles of the present invention can be applied to a wide range of products and services that offer a great variety of configurable or selectable options.
VII
FIG. 7 shows a more concise process flow for adding items to an electronic catalog using the part number matrix discussed above. Initially the item that is to be added to the catalog is selected and all of the corresponding information, such as manufacturer part number, price, size, supplier, description, illustration, and any other information is collected and identified 702 . The number that is to be used in the item number matrix, such as manufacturer part number, supplier catalog number, or a new unique catalog number is identified. The number is then parsed into sections 704 . Each section of the number is then associated with the corresponding item attributes 706 . For example, the section of the part number that defines the ink color is associated with the ink color attribute. This can be done in the context of defining a list of possible section values 708 . This list contains all the possible values that the particular section of the part number can have depending on the configuration of the product that is selected, as shown in Table 4 and the XML example above. The corresponding descriptions are then associated with the item number section values 710 , as can also be seen in Table 4. Then the descriptions can be associated with the attributes 712 . The associations can be done using key values as illustrated in the XML document example above. The precise order of these operations is not important to the invention. At this point, the information will be collected and the related values will be associated. Table 4 is an example of a format for the information.
Once the information is collected and related, the item can be added to the catalog. The item will be added as a configurable item. This can be indicated to the catalog by a flag such as the description key shown in the XML document above. The item need not be truly configurable, in that it has interchangeable parts etc. The invention can be applied to any group of items that have enough common characteristics that they can be readily accessed and displayed as a single configurable item. Pens of different colors may share no common components even if the design is the same. Shirts in different sizes normally share no common components except labeling and perhaps buttons. On the other hand, a set of power supplies may share many common components in their various configurations.
The item can be added to the catalog by first adding the base section of the item number to the catalog with the corresponding descriptive information that is common to all configurations of the item, i.e. the base description 714 . The corresponding item number section values can then be added to the catalog 716 . These are accompanied by the descriptions for each item number section. These can be added only with respect to the corresponding attributes for the item as they exist in the catalog 718 . For example, the various colors, black, blue, green and red are added to the ink color attribute for the SGSF item pen.
The descriptions can be added in at least two different ways. In one embodiment, the descriptions for the particular configuration are only available in association with the particular configuration. This can be done when the configurable attribute is not likely to be the subject of a search. If, for example, a pen were available with different cap colors the descriptions of the cap colors might be excluded from the search engine. In this embodiment, a search for “bic pen red” would find the SGSF pen discussed above because the red ink color is available to the search engine. If silver is an available cap color, a search for “bic pen silver” would not find the SGSF pen because the cap color descriptions are not available to the search engine.
In another embodiment, all the descriptive information for all of the different configurations is added to a long description attribute, or some other appropriate attribute for the base item 720 . The long description and normally all of the descriptions for each of the attributes are loaded into a search engine in the catalog. After the catalog is loaded, this will allow even the simple search to find the SGSF pen because “red” is a part of the description. In a third embodiment, the descriptive information for all of the configurations is added to both a configuration-specific description and to the base item description. In the XML document above, there is a matrix for each configurable attribute. Each matrix has a searchable key that can be set to true or false. When the key is set to true, the descriptions in that matrix are loaded into a search index to be available to the search engine, when the key is set to false, the descriptions are not loaded and not available. This provides the greatest amount of flexibility. To finish the catalog, any price definitions or other details are associated with the corresponding item number section values 722 .
The use of the catalog, whether to purchase an item, conduct research, or manage the catalog is shown as a flow chart in FIG. 8 . To begin, an item is selected 802 . This can be done with a search, a direct query, working through taxonomical lists or in any other way. The base item number section for the selected item is then identified 804 . If the process is being performed by a user, the user need not be aware of the base item number or of any of its sections, however, the number is generally needed to link the configurations to a single item and for any type of purchasing or management operations. The description of the configurable item is then identified 806 and can be reviewed. The descriptive information for each of the possible configurations is then presented and selected 808 as shown, for example, in FIG. 5 . At this point, the configuration of the item has been selected. If there is more than one aspect of the item that can be configured, for example, ink color and point fineness, then all of the selections are made.
Once the configuration is selected, the values for the corresponding item number sections for the selected configuration can be identified 810 . The descriptive information can be assembled into an item description for the selected configuration. This is done using the base description and the selected descriptive information 812 . It can also be done using a description formula and inserting the appropriate description values from the part number matrix into the formula. Similarly, the item number for the selected configuration can be assembled from the base item number and the corresponding values for the item number sections 814 . A part number formula can be used by inserting the appropriate part number values from the part number matrix into the formula.
If the catalog item offers additional options that are not properly a part of the item number, such as size or voltage mentioned above, then these further options can be handled the same way as the other configurable attributes. The choices of possible option values can be shown and then selected by the user 816 . Each option will typically have a code, such as S, M, or L, associated with it. The appropriate code can then be selected and associated with the assembled item number 818 .
VIII
The catalog of the present invention is particularly well suited to transport data to other catalogs that operate on independent, incompatible platforms. The matrix structure of the catalog items, as mentioned above, is particularly useful for catalog administration, correction, and updating. When one of the options changes, the item can be updated with a very simple change. For example, if a purple pen were added to the ink color choices for the example SGSF pen mentioned above, the administrator can simple add purple with its code to the ink color list. Three more versions of the pen are then made a part of the catalog, a purple fine, purple medium and purple bold point pen. If green were discontinued, the administrator can simple delete the green option from the available ink colors and all green variations are removed from the catalog. The convenience of this, as compared to administering all the different configurations independently, can be understood more fully by reference to the industrial lighting fixture of Tables 6 and 7. Changing a voltage supply, a ballast item or a housing may affect thousands or millions of different configurations of the lamp. It is much easier to manage the change by changing the one configurable option.
Many catalogs, however, do not support configurable items. The present invention allows these catalogs to be administered using a part number matrix nevertheless. In one embodiment, the configurable items are structured as XML documents, such as the one provided above. This document can be expanded to generate each of the different configurations of the item. In other words, the single configurable item can be converted into multiple items, one for each configuration. Returning to the pen example, the matrix of pens with four colors and three points becomes twelve pens: SGSF-BLK FINE, SGSF-BLK MEDM, SGSF-BLK BOLD, SGSF-BLU FINE, SGSF-BLU MEDM, SGSF-BLU BOLD, SGSF-GRN FINE, SGSF-GRN MEDM, SGSF-GRN BOLD, SGSF-RED FINE, SGSF-RED MEDM, SGSF-RED BOLD, as shown in Table 1. Each of the twelve pen items will contain duplicate information for all of the common information, such as the description tied to the SGSF section of the part number. The part number, description, and price formulas can all be used to generate the twelve items.
The result of the expansion process is a list containing many more items but in which each item is separately listed in a format that can be used on a wider variety of different computing and communications platforms. XML, for example, can be converted to an appropriate proprietary data format and used in many enterprise, inventory and purchasing systems, such as those offered by Oracle Corp., Ariba Inc., and SAP AG. Many such systems include translators or converters to take XML data into the proprietary platform as well as to convert proprietary format data into XML. Once the items are converted from XML, or another easily converted format, into the proprietary format, they can be loaded by the proprietary platform into the system's own catalog or inventory system. The workings of the various different platforms and their respective catalogs vary from one system to the next.
The catalog can therefore easily be expanded and loaded into the proprietary platform's system. Changes can be handled almost as easily. After the catalog with the configurable items has been modified, the modified portions, or the entire catalog, can again be expanded into single items. The single items can be loaded into the proprietary system. The modified items can be written over the older unmodified items using tools within the proprietary platform. Deleted items can be handled by reloading the entire catalog. Other actions can be supported depending upon the various tools made available on the proprietary platform. Using this approach, the catalog can be maintained in one place in one way and published to a great many different systems.
IX
It should be noted that, while the steps described herein may be performed under the control of a programmed processor, such as the processor 202 , in alternative embodiments, the steps may be fully or partially implemented by any programmable or hard coded logic, such as Field Programmable Gate Arrays (FPGAs), TTL logic, or Application Specific Integrated Circuits (ASICs), for example. Additionally, the method of the present invention may be performed by any combination of programmed general purpose computer components or custom hardware components. Therefore, nothing disclosed herein should be construed as limiting the present invention to a particular embodiment wherein the recited steps are performed by a specific combination of hardware components.
In the present description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. In other instances, well-known structures and devices are shown in block diagram form. The specific detail may be supplied by one of average skill in the art as appropriate for any particular implementation.
The present invention includes various steps, which may be performed by hardware components or may be embodied in machine-executable instructions, such as software or firmware instructions. The machine-executable instructions may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, the steps may be performed by a combination of hardware and software.
The present invention may be provided as a computer program product that may include a machine-readable medium having stored instructions thereon, which may be used to program a computer (or other machine) to perform a process according to the present invention. The machine-readable medium may include, but is not limited to, floppy diskettes, optical disks, CD-ROMs, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, magnet or optical cards, flash memory, or any other type of medium suitable for storing electronic instructions. Moreover, the present invention may also be downloaded as a computer program product, wherein the program may be transferred from a remote computer to a requesting computer by way of data signals embodied in a carrier wave or other machine-readable propagation medium via a communication link (e.g., a modem or network connection).
Importantly, while embodiments of the present invention are described with reference to externally supplied attributes of office supplies, the method and apparatus described herein are equally applicable to externally supplied attributes for any other types of electronic catalogs and of any other types of items including documents, and data files. In addition, while the invention has been described in terms of an electronic catalog, other types of ordered information stored in an electronic form can benefit from the present invention.
Although this disclosure describes illustrative embodiments of the invention in detail, it is to be understood that the invention is not limited to the precise embodiments described. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. Various adaptations, modifications and alterations may be practiced within the scope of the invention defined by the appended claims. | An improvement for composing and cataloging item configuration data is disclosed. One embodiment of the invention includes identifying a base item, identifying a part number for the base item, breaking the part number into sections, each section corresponding to an attribute of the base item, and determining which of the part number sections relate to configurable attributes of the base item. The embodiment further includes listing a plurality of selectable part number section values for the configurable attributes, listing descriptive information for each of the selectable part number section values, linking the descriptive information to the corresponding selectable part number section value, generating a part number formula to define the configurable sections and associate configurable sections to the corresponding list of values, and generating a description formula to define a configurable description and associate descriptive information with corresponding configurable selectable part number values. The embodiment further includes adding the base item part number, values list, descriptive information list, part number formula and description formula to an electronic catalog. | 8 |
BACKGROUND OF INVENTION
The present invention refers to an equipment assembly meant to promote the hanging, locking and sealing of a submarine oil-well tubing.
It is the scope of the present invention to provide a set of pieces of equipment for the support, locking and sealing of the tubing of a submarine oil-well, the two last functions being performed by a double hydraulic packer (for production), besides establishing a method for the use of the referred set.
To make the oil produced by an oil-well flow it is necessary to perform several operations from the beginning of the drilling until its effective production. Several pipings are installed in the well, by operations the experts call pipe running (in-hole running).
These pipes carry out the lining of the well, in this case called "casing", or serve to lead the oil to the set of equipments existing on the sea bed, where the wellhead and the Christmas-tree are located.
Simply speaking, the purpose of the wellhead is to support the load of the several hangers where the well casing and the production tubing are fixed on and also provides means of sealing the well to prevent leaks, and also as a support for the set of valves, seals and control devices that enable the connection of the well with the piping which takes the oil to the storage- or processing place. This last set is called Christmas-tree by the specialists. In the case of submarine producing oil-wells the experts denominate these sets as "Submarine wellhead" and "Wet Christmas-tree".
The operations of preparing an oil-well for production are called "completion" by the technical people. Among the completion operations one is highlighted for presenting a large amount of failures, causing large losses to the operations, which is the placing of the tubing hanger. The tubing hanger basically has the functions of supporting the tubing, to lock the tubing against axial movements and, finally, to provide the sealing at the casing hanger where it is sustained.
The large amount of failures on the tubing hangers is due to their locking and their sealing being performed by elements with relatively small dimensions as compared to the size of the referred tubing hanger which makes this latter easily subjected to damages. This is worsened by the fact that very often debris from the sea bed settle on the surface of the casing hanger, where the tubing hanger will be supported in order to be locked and sealed, making the success of these operations more difficult. The settlement of debris is unavoidable because it results from the turbulence caused by placing the pieces of equipment on the wellhead, which stirs the debris in the vicinity of the well.
Another factor to be taken into consideration is the complexity of the tubing hanger hydraulic running tool, which needs for its operation the use of a complex piece of equipment the specialists call "completion riser". The hydraulic running tool will need up to four hydraulic functions to place the tubing hanger, which means a piece of equipment of difficult maintenance due to its high number of components.
The above-mentioned problems cause large loss of time and, as a consequence, rising of costs due to the high number of steps needed to perform the operation of placing the tubing hanger, not mentioning the cost of unforeseen extra operations to correct failures that may occur.
It is clearly seen that the current art, besides not providing the needed safety for the tubing hanger placing operation, frequently leads to an increase in the final costs of the operations due to the necessity of not scheduled operations for correction of problems.
SUMMARY OF THE INVENTION
It is the scope of the present invention to provide an equipment set to support the tubing of a submarine oil-well; also provide a method for its use, in order to eliminate the necessity of locking and sealing the tubing hanger on its seat on the casing hanger.
The tubing hanger seats on a sleeve that seats itself on the casing hanger. The locking and sealing is done by a double hydraulic packer seated on the casing, slightly below the wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described based on the drawings attached to it, as follows:
FIG. 1 shows a frontal view of a cross section of a tubing hanger according to the prior art, already seated on the casing hanger.
FIG. 2 shows a cross section of a tubing hanger used in the present invention and the double hydraulic packer used for locking and sealing the tubing.
FIG. 3 shows a cross section of a wellhead with the casing hanger already placed.
FIG. 4 shows a frontal elevation of the tubing hanger already placed according to the method of the present invention.
FIG. 5 shows an elevation with partial cross section of the running tool of the tubing hanger.
FIG. 6 shows a cross section of the tool take along the 6--6 of FIG. 5.
FIG. 7 shows another cross section of the tool take along the line 7--7 in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Before the beginning of the description of the invention, reference is made to FIG. 1, where the tubing hanger 1 can be seen, designed in accordance with the prior art, seated on the casing hanger 4, this one now seated on the wellhead housing 2.
The tubing hanger 1 is supported and locked on the casing hanger 4 by means of grips 5, in order to prevent axial movements of the tubing, and the sealing between the two parts is done by a packing unit 3.
As can easily be seen in FIG. 1, either the packing unit 3 or the locking grips have rather reduced dimensions, if compared to the size of the tubing hanger 1. As no other points for locking and sealing exist than the referred, one concludes that locking and sealing of the tubing hanger 1 are precarious. A slight fault on the alignment or the presence of debris on the surface of the casing hanger 4 where the tubing hanger is seated is enough to endanger the operation, worsened by the inherent difficulties of an operation performed remotely from the surface.
In FIG. 2 a set of pieces of equipment 10 can be seen which shall be denominated tubing hanging set according to the concept of the present invention. The referred tubing hanging set 10 basically consists of a tubing hanger 11, tubular extensions 20 and 22 and a double hydraulic packer 16.
The tubing hanger 11, opposed to the previous technique, is simply seated on the upper internal portion of a connecting sleeve 13. The lower external portion 60 of the connecting sleeve 13 on its turn seats on the upper internal part of the casing hanger 12, as seen in FIG. 4. It is important to point out that this casing hanger 12 is of the same type as those used by the prior art and does not need any change for utilization of the tubing hanging set 10, which is the subject of the present invention.
The locking and fixing of the tubing hanging set 10 is done by the grips 17 of the double hydraulic packer 16, and the sealing of the tubing hanging set 10 by means of the packing unit 18 of the double hydraulic packer 16. On FIG. 4 the tubing hanging set 10 duly seated can be better seen.
As the position of the casing hanger 12 regarding the top of the high pressure wellhead housing 46 varies according to the manufacturer, the connecting sleeve 13 must have its dimension "H" designed properly to ensure that the top of the tubing 11 keeps a certain distance "L" in respect to the top of the high pressure wellhead housing 46, suitable for installation of the wet Christmas-tree which will afterwards be installed on this high pressure wellhead housing 46.
It can be well seen that the connection sleeve 13 is one of the main features of the present invention, simultaneously playing two roles since besides promoting the connection between tubing hanger 11 and casing hanger 12, it makes possible to set easily the position the top of the tubing hanger 11 in respect to the high pressure wellhead housing 46 top. It is sufficient for this purpose that the connecting sleeve 13 have its dimensions designed so as to ensure that the final assembly of the set will be done as desired, viz., that for each high pressure wellhead housing 46 supporting any casing hanger 12 it will be always possible to seat the top of the tubing hanger 11 as required by the Christmas-tree to be installed. The only requirement is that connecting sleeve 13 have its dimensions properly established.
The tubing hanger 11 has a passageway 15 for connection with the extension 20, which in turn is connected to the tubing 14 and a passageway 25, having inside thereof a valve for blocking the flow coming from the annulus between the tubing 14 and the casing 19 below the double hydraulic packer. The juncture from passageway 25 to the referred annulus is expected by the extension 22, which is connected by means of the sleeve 23 to the short tubing 21 of the double hydraulic packer 16, as shown on FIGS. 2 and 4.
The tubing hanger 11 has also passageways for hydraulic lines, not shown in the drawings, which lead to the subsurface safety valve, added to other technical details needed for the operations which are also found in the hangers designed according to the prior art and not mentioned in this report, since they are largely known by the specialists and do not pertain to the scope of the present invention, although they have to be considered at time of design and fabrication.
As already mentioned, the double hydraulic packer 16 is one responsible one for locking and sealing of the tubing hanging set 10 and, for this purpose is provided with grips 17 for locking and at least one sealing unit 18. The double hydraulic packer is a well known equipment, used, for instance, for completion of wells in multi-production zones. In the present invention, as already seen, it is used in a different function.
The placement of the tubing hanging set 10, object of the present invention, is done by means of a tool 27, shown in FIG. 5, and which is a feature of the present invention.
The tool 27 comprises a lengthened body with an enlarged part 28 of cylindrical shape, usually called re-entry mandrel by the skilled in the art. As shown in FIG. 5, the eccentricily of the tubular elements that make up the tool 27 are located in the re-entry mandrel 28.
Below the re-entry mandrel 28 there are two tubular elements 29 and 31 used for direct connection with the tubing hanger 11. The tubular connection elements 29 and 31 are provided at their lower ends with coupling terminals 30 and 32, respectively, which are provided with elastomeric sealing rings confined inside suitable grooves.
Such coupling terminals, as will be explained in detail together with the operation description, fit into passageways 15 and 25 on tubing hanger 11, their upper parts entering in such a way that this coupling remains secure and lead tight.
The tubular extension 33 above the re-entry mandrel 28 is a cylindrical pipe vertically aligned which has on its upper end a connector 34 for connection to the lowering string for the tool 27. Also, the connector 34 is provided with fittings for connection of hydraulic lines 36 for installation and operation control.
The tubular extension 33 is a hollow cylinder with a certain wall thickness. As shown in FIGS. 6 and 7, several longitudinal borings are made in its wall for passageways of the hydraulic control lines. Thus, FIG. 5 shows that on the upper tubular extension 33, at an intermediate height, there are holes provided with filters 37 which allow the communication between the inside of the tool and the external region.
FIGS. 6 and 7 disclose sections made at two levels of the hollow tubular extension 33 (section 6--6 and section 7--7) to show these holes which are, for example, holes 40 and 41 defining passageways for subsurface safety valve control and operation lines, the tubular holes 38 and 39 meant for the passageway of the locking and unlocking control pipes for the connections to be made. The holes 43 are meant for lines that give access to the annulus in the casing 19.
Before continuing the description steps, it have to be clear that the quantity and disposal of the different passageway holes for remote control and operation lines are given only to exemplify the possibility of their use in the present invention, not and the invention is in any way limited because of them. Furthermore it is necessary to add that none of the locations or quantities of elements is final, being only representative of one real possibility.
On the lower part of the tubing hanger installation tool 27, can be seen an extension 44 which is dimensioned to its introduction into the upper part of the tubing hanger 11 and has a cam 45, that fits into the notch 26 on the top of the tubing hanger 11 when coupling tool 27 to tubing hanger 11, enabling torque to be applied for orientation of the tubing hanger 11.
Another characteristic of the tool 27 is the fact that its tubular extension 33 may be sheared by a special shear valve, of the submarine blow out preventor, in case of any emergency.
A large advantage that is presented by the present invention is the fact that the running string 35 of the tool 27 is nothing else than the proper drilling string, viz. that tool 27 replaces a complex equipment called "completion risers", which are used on tubing hangers for placing operations designed according to the prior art.
The method for installing the tubing hanging set 10 consists in, before running the assembly, coupling the bottom part of tool 27 to the tubing hanger and locking this bottom part of tool 27 by pressing its extension element 44 against the top of the tubing hanger 11, fitting its cam 45 into the notch 26 existing on the top of tubing hanger 11, so as the assembly can rotate to couple in an exact positioning.
At this point, the tubular connection elements 29 and 31 shall be duly fitted in the passageways 15 and 25 of the tubing hanger 11 and properly sealed by means of the sealing rings of the fitting terminals 30 and 32, respectively.
The double hydraulic packer 16 will be run coupled to the bottom part of the tubing 14, and connected at the upper part to the tubular extensions 20 and 22, that connect to passageways 15 and 25 respectively.
The assembly described above, together with the hydraulic lines and necessary cables already connected via connector 34, runs to the wellhead housing 46 where it is inserted until the tubing hanger 11 seats on the connecting sleeve 13, which was previously seated on the casing hanger 12.
The double hydraulic packer 16 is then hydraulically fixed by means of pressure applied on tubing 14, promoting in this way sealing and locking of the whole assembly in a more safety way than the manner of the prior art.
Thus, functionally speaking, the tubing hanging set 10, of the present invention, comprises all components from the tubing hanger 11 to the double hydraulic packer 16, leaving to the tubing hanger 11 only the function of supporting the tubing weight, while the double hydraulic packer 16 responds for locking and sealing the assembly.
Once more it must be clear that the described devices are presented in a general manner and the construction details should not in any way must be considered as restricting the invention, since they serve only to give notice to the skilled in the art how the different parts are combined to achieve the desired result.
The installation tool for the assembly, which is also a feature of the present invention, may not be limited by specific construction details, but considered as a whole assembly and as a conception of practical use. Incidental modifications should be considered as included in the scope of present disclosure and its basic concept and with the scope of the claim. | A tubing hanging set for hanging, locking and sealing a submarine oil well includes a tubing hanger which is seated on an upper internal surface of a connection sleeve which in turn is seated on an internal surface of a casing hanger. The tubing hanger is provided with passageways extending therethrough and tubular extensions are connected in the passageways and to tubing passing through a double hydraulic packer. The lower end of one of the tubes passing through the packer extends into a oil producing zone and the other tube passing through the packer is in communication with an annular chamber between the other tubing and the casing. An installation tool is also provided which can be detachably connected to the tubing hanger for carrying out a method of installation of the tubing hanging set in a wellhead housing. | 4 |
FIELD OF THE INVENTION
[0001] The subject matter of the present disclosure relates generally to a heat pump system that uses magneto caloric materials to exchange heat with a circulating heat transfer fluid.
BACKGROUND OF THE INVENTION
[0002] Conventional refrigeration technology typically utilizes a heat pump that relies on compression and expansion of a fluid refrigerant to receive and reject heat in a cyclic manner so as to effect a desired temperature change or i.e. transfer heat energy from one location to another. This cycle can be used to provide e.g., for the receiving of heat from a refrigeration compartment and the rejecting of such heat to the environment or a location that is external to the compartment. Other applications include air conditioning of residential or commercial structures. A variety of different fluid refrigerants have been developed that can be used with the heat pump in such systems.
[0003] While improvements have been made to such heat pump systems that rely on the compression of fluid refrigerant, at best such can still only operate at about 45 percent or less of the maximum theoretical Carnot cycle efficiency. Also, some fluid refrigerants have been discontinued due to environmental concerns. The range of ambient temperatures over which certain refrigerant-based systems can operate may be impractical for certain locations. Other challenges with heat pumps that use a fluid refrigerant exist as well.
[0004] Magneto caloric materials (MCMs)—i.e. materials that exhibit the magneto caloric effect—provide a potential alternative to fluid refrigerants for heat pump applications. In general, the magnetic moments of an MCM will become more ordered under an increasing, externally applied magnetic field and cause the MCM to generate heat. Conversely, decreasing the externally applied magnetic field will allow the magnetic moments of the MCM to become more disordered and allow the MCM to absorb heat. Some MCMs exhibit the opposite behavior—i.e. generating heat when the magnetic field is removed (which are sometimes referred to as para-magneto caloric material but both types are referred to collectively herein as magneto caloric material or MCM). The theoretical Carnot cycle efficiency of a refrigeration cycle based on an MCM can be significantly higher than for a comparable refrigeration cycle based on a fluid refrigerant. As such, a heat pump system that can effectively use an MCM would be useful.
[0005] Challenges exist to the practical and cost competitive use of an MCM, however. In addition to the development of suitable MCMs, equipment that can attractively utilize an MCM is still needed. Provision should be made for the transfer or heat to and from the MCM, preferably in a continuous manner so that the equipment does not operate in a start and stop fashion that can be inefficient. Currently proposed equipment may require relatively large and expensive magnets, may be impractical for use in e.g., appliance refrigeration, and may not otherwise operate with enough efficiency to justify capital cost.
[0006] Additionally, as stated above, the ambient conditions under which a heat pump may be needed can vary substantially. For example, for a refrigerator appliance placed in a garage or located in a non-air conditioned space, ambient temperatures can range from below freezing to over 90° F. Some MCMs are capable of accepting and generating heat only within a much narrower temperature range than presented by such ambient conditions.
[0007] Accordingly, a heat pump system that can address certain challenges such as those identified above would be useful. Such a heat pump system that can also be used in e.g., a refrigerator appliance would also be useful.
BRIEF DESCRIPTION OF THE INVENTION
[0008] The present invention provides a heat pump system having magneto caloric material positioned in a continuously rotating regenerator. The magneto caloric material is staged so that as the regenerator is rotated, a portion of the material is cycled in and out of a magnetic field in a continuous manner. A heat transfer fluid is circulated through the magneto caloric material simultaneously along at least two paths to provide for the transfer of heat both to and from the material in a cyclic manner. The magneto caloric material may include zones having different temperature ranges of responsiveness to the magnetic field. An appliance using a heat pump system based on magneto caloric material is also provided. The heat pump may also be used in other applications for heating, cooling, or both. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0009] In one exemplary embodiment, the present invention provides a heat pump system that includes a regenerator housing defining a circumferential direction and rotatable about an axial direction, the axial direction extending between a first end and a second end of the regenerator housing. The regenerator housing includes a plurality of chambers with each chamber extending longitudinally along the axial direction between a pair of openings. The plurality of chambers are arranged proximate to each other along the circumferential direction. A plurality of stages are provide with each stage comprising magneto caloric material positioned within one of the plurality of chambers and extending along the axial direction.
[0010] This exemplary embodiment further includes a pair of valves with a first valve attached to the first end of the regenerator housing and a second valve attached to the second end of the regenerator housing. The first valve and second valve each include a plurality of apertures spaced apart from each other along the circumferential direction with each aperture positioned adjacent to one of the pair of openings of one of the plurality of chambers. A magnetic element is positioned proximate to the regenerator housing and extends along the axial direction. The magnetic element creates a magnetic field and is positioned so that a subset of the plurality of stages are moved in and out of the magnetic field as the regenerator housing is rotated about the axial direction.
[0011] This exemplary system also includes a pair of seals with a first seal positioned adjacent to the first valve and a second seal adjacent to the second valve such that the regenerator housing and the pair of valves are rotatable relative to the pair of seals. The first seal and the second seal each include a pair of ports positioned in an opposing manner relative to each other and also positioned so that each port can selectively align with at least one of the pair of openings of the plurality of chambers as the regenerator housing is rotated about the axial direction.
[0012] In still another exemplary embodiment, the present invention provides a refrigerator appliance that includes a compartment for the storage of food items; a first heat exchanger for the removal of heat from the compartment; a second heat exchanger for the delivery of heat removed by the first heat exchanger to a location external of the compartment; a pump for circulating a heat transfer fluid between the first heat exchanger and the second heat exchanger; and a heat pump in fluid communication with the pump. The heat pump is also in fluid communication with the first heat exchanger through a first inlet port and a first outlet port and is in fluid communication with the second heat exchanger by a second inlet port and a second outlet port.
[0013] For this exemplary embodiment, the heat pump further includes a regenerator housing defining a circumferential direction and rotatable about an axial direction, the axial direction extending between a first end and a second end of the regenerator housing. The regenerator housing includes a plurality of chambers with each chamber extending longitudinally along the axial direction between a pair of openings. The plurality of chambers are arranged proximate to each other along the circumferential direction.
[0014] A plurality of stages are provided with each stage including magneto caloric material positioned within one of the plurality of chambers and extending along the axial direction. A pair of valves includes a first valve attached to the first end of the regenerator housing and a second valve attached to the second end of the regenerator housing. The first valve and second valve each include a plurality of apertures spaced apart from each other along the circumferential direction with each aperture positioned adjacent to one of the pair of openings of one of the plurality of chambers. A magnetic element is positioned proximate to the regenerator housing and extends along the axial direction. The magnetic element creates a magnetic field. The magnetic element is positioned so that a subset of the plurality of stages are moved within the magnetic field as the regenerator housing is rotated about the axial direction.
[0015] A pair of seals are provided with a first seal positioned adjacent to the first valve and a second seal positioned adjacent to the second valve such that the regenerator housing and the pair of valves are rotatable relative to the pair of seals. The first seal includes the first inlet port and the first outlet port. The second seal includes the second inlet port and a second outlet port. The first inlet port and the first outlet port are positioned in an opposing manner about the first seal and second inlet port and the second outlet port are positioned in an opposing manner about the second seal. The first inlet port and the second outlet port are positioned for fluid communication with the pair of openings of at least one chamber at a time as the regenerator housing is rotated about the axial direction so that heat transfer fluid from the first heat exchanger may receive heat from the stage of magneto caloric material located in the at least one chamber. The second inlet port and the first outlet port are positioned for fluid communication with the pair of openings of at least one other chamber at a time as the regenerator housing is rotated about the axial direction so that heat transfer fluid from the second heat exchanger may deliver heat to the magneto caloric material in the at least one other chamber.
[0016] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0018] FIG. 1 provides an exemplary embodiment of a refrigerator appliance of the present invention.
[0019] FIG. 2 is a schematic illustration of an exemplary heat pump system of the present invention positioned in an exemplary refrigerator with a machinery compartment and a refrigerated compartment.
[0020] FIG. 3 provides a perspective view of an exemplary heat pump of the present invention.
[0021] FIG. 4 is an exploded view of the exemplary heat pump of FIG. 3 .
[0022] FIG. 5 is a cross-sectional view of the exemplary heat pump of FIG. 3 .
[0023] FIG. 6 is perspective view of the exemplary heat pump of FIG. 3 . Seals located at the ends of a regenerator housing have been removed for purposes of further explanation of this exemplary embodiment of the invention as set forth below.
[0024] FIG. 7 is a schematic representation of various steps in the use of a stage of the heat pump of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0025] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0026] Referring now to FIG. 1 , an exemplary embodiment of an appliance refrigerator 10 is depicted as an upright refrigerator having a cabinet or casing 12 that defines a number of internal storage compartments or chilled chambers. In particular, refrigerator appliance 10 includes upper fresh-food compartments 14 having doors 16 and lower freezer compartment 18 having upper drawer 20 and lower drawer 22 . The drawers 20 , 22 are “pull-out” type drawers in that they can be manually moved into and out of the freezer compartment 18 on suitable slide mechanisms. Refrigerator 10 is provided by way of example only. Other configurations for a refrigerator appliance may be used as well including appliances with only freezer compartments, only chilled compartments, or other combinations thereof different from that shown in FIG. 1 . In addition, the heat pump and heat pump system of the present invention is not limited to appliances and may be used in other applications as well such as e.g., air-conditioning, electronics cooling devices, and others. Thus, it should be understood that while the use of a heat pump to provide cooling within a refrigerator is provided by way of example herein, the present invention may also be used to provide for heating applications as well.
[0027] FIG. 2 is a schematic view of another exemplary embodiment of a refrigerator appliance 10 including a refrigeration compartment 30 and a machinery compartment 40 . In particular, machinery compartment 30 includes a heat pump system 52 having a first heat exchanger 32 positioned in the refrigeration compartment 30 for the removal of heat therefrom. A heat transfer fluid such as e.g., an aqueous solution, flowing within first heat exchanger 32 receives heat from the refrigeration compartment 30 thereby cooling its contents. A fan 38 may be used to provide for a flow of air across first heat exchanger 32 to improve the rate of heat transfer from the refrigeration compartment 30 .
[0028] The heat transfer fluid flows out of first heat exchanger 32 by line 44 to heat pump 100 . As will be further described herein, the heat transfer fluid receives additional heat from magneto caloric material (MCM) in heat pump 100 and carries this heat by line 48 to pump 42 and then to second heat exchanger 34 . Heat is released to the environment, machinery compartment 40 , and/or other location external to refrigeration compartment 30 using second heat exchanger 34 . A fan 36 may be used to create a flow of air across second heat exchanger 34 and thereby improve the rate of heat transfer to the environment. Pump 42 connected into line 48 causes the heat transfer fluid to recirculate in heat pump system 52 . Motor 28 is in mechanical communication with heat pump 100 as will further described.
[0029] From second heat exchanger 34 the heat transfer fluid returns by line 50 to heat pump 100 where, as will be further described below, the heat transfer fluid loses heat to the MCM in heat pump 100 . The now colder heat transfer fluid flows by line 46 to first heat exchanger 32 to receive heat from refrigeration compartment 30 and repeat the cycle as just described.
[0030] Heat pump system 52 is provided by way of example only. Other configurations of heat pump system 52 may be used as well. For example, lines 44 , 46 , 48 , and 50 provide fluid communication between the various components of the heat pump system 52 but other heat transfer fluid recirculation loops with different lines and connections may also be employed. For example, pump 42 can also be positioned at other locations or on other lines in system 52 . Still other configurations of heat pump system 52 may be used as well.
[0031] FIGS. 3 , 4 , 5 , and 6 depict various views of an exemplary heat pump 100 of the present invention. Heat pump 100 includes a regenerator housing 102 that extends longitudinally along an axial direction between a first end 118 and a second end 120 . The axial direction is defined by axis A-A about which regenerator housing 102 rotates. A radial direction R is defined by a radius extending orthogonally from the axis of rotation A-A ( FIG. 5 ). A circumferential direction is indicated by arrows C.
[0032] Regenerator housing 102 defines a plurality of chambers 104 that extend longitudinally along the axial direction defined by axis A-A. Chambers 104 are positioned proximate or adjacent to each other along circumferential direction C. Each chamber 104 includes a pair of openings 106 and 108 positioned at opposing ends 118 and 120 of regenerator housing 102 .
[0033] Heat pump 100 also includes a plurality of stages 112 that include MCM. Each stage 112 is located in one of the chambers 104 and extends along the axial direction. For the exemplary embodiment shown in the figures, heat pump 100 includes eight stages 112 positioned adjacent to each other along the circumferential direction as shown and extending longitudinally along the axial direction. As will be understood by one of skill in the art using the teachings disclosed herein, a different number of stages 112 other than eight may be used as well.
[0034] A pair of valves 114 and 116 are attached to regenerator housing 102 and rotate therewith along circumferential direction C. More particularly, a first valve 114 is attached to first end 118 and a second valve 116 is attached to second end 120 . Each valve 114 and 116 includes a plurality of apertures 122 and 124 , respectively. For this exemplary embodiment, apertures 122 and 124 are configured as circumferentially-extending slots that are spaced apart along circumferential direction C. Each aperture 122 is positioned adjacent to a respective opening 106 of a chamber 104 . Each aperture 124 is positioned adjacent to a respective opening 108 of a chamber 104 . Accordingly, a heat transfer fluid may flow into a chamber 104 through a respective aperture 122 and opening 106 so as to flow through the MCM in a respective stage 112 and then exit through opening 108 and aperture 124 . A reverse path can be used for flow of the heat transfer fluid in the opposite direction through the stage 112 of a given chamber 104 .
[0035] Regenerator housing 102 defines a cavity 128 that is positioned radially inward of the plurality of chambers 104 and extends along the axial direction between first end 118 and second end 120 . A magnetic element 126 is positioned within cavity 128 and, for this exemplary embodiment, extends along the axial direction between first end 118 and second end 120 . Magnetic element 126 provides a magnetic field that is directed radially outward as indicated by arrows M in FIG. 5 .
[0036] The positioning and configuration of magnetic element 126 is such that only a subset of the plurality of stages 112 is within magnetic field M at any one time. For example, as shown in FIG. 5 , stages 112 a and 112 e are partially within the magnetic field while stages 112 b, 112 c, and 112 d are fully within the magnetic field M created by magnetic element 126 . Conversely, the magnetic element 126 is configured and positioned so that stages 112 f, 112 g, and 112 h are completely or substantially out of the magnetic field created by magnetic element 126 . However, as regenerator housing 102 is continuously rotated along the circumferential direction as shown by arrow W, the subset of stages 112 within the magnetic field will continuously change as some stages 112 will enter magnetic field M and others will exit.
[0037] A pair of seals 136 and 138 is provided with the seals positioned in an opposing manner at the first end 118 and second end 120 of regenerator housing 102 . First seal 136 has a first inlet port 140 and a first outlet port 142 and is positioned adjacent to first valve 114 . As shown, ports 140 and 142 are positioned 180 degrees apart about the circumferential direction C of first seal 114 . However, other configurations may be used. For example, ports 140 and 142 may be positioned within a range of about 170 degrees to about 190 degrees about the circumferential direction C as well. First valve 114 and regenerator housing 102 are rotatable relative to first seal 136 . Ports 140 and 142 are connected with lines 44 and 46 ( FIG. 1 ), respectively. As such, the rotation of regenerator housing 102 about axis A-A sequentially places lines 44 and 46 in fluid communication with at least two stages 112 of MCM at any one time as will be further described.
[0038] Second seal 138 has a second inlet port 144 and a second outlet port 146 and is positioned adjacent to second valve 116 . As shown, ports 144 and 146 are positioned 180 degrees apart about the circumferential direction C of second seal 116 . However, other configurations may be used. For example, ports 144 and 146 may be positioned within a range of about 170 degrees to about 190 degrees about the circumferential direction C as well. Second valve 116 and regenerator housing 102 are rotatable relative to second seal 138 . Ports 144 and 146 are connected with lines 50 and 48 ( FIG. 1 ), respectively. As such, the rotation of regenerator housing 102 about axis A-A sequentially places lines 48 and 50 in fluid communication with at least two stages 112 of MCM at any one time as will be further described. Notably, at any one time during rotation of regenerator housing 102 , lines 46 and 50 will each be in fluid communication with at least one stage 112 while lines 44 and 48 will also be in fluid communication with at least one other stage 112 located about 180 degrees away along the circumferential direction.
[0039] FIG. 7 illustrates an exemplary method of the present invention using a schematic representation of stage 112 of MCM in regenerator housing 102 as it rotates in the direction of arrow W between positions 1 through 8 as shown in FIG. 6 . During step 200 , stage 112 is fully within magnetic field M, which causes the magnetic moments of the material to orient and the MCM to heat as part of the magneto caloric effect. Ordering of the magnetic field is created and maintained as stage 112 is rotated sequentially through positions 2 , 3 , and then 4 ( FIG. 6 ) as regenerator housing 102 is rotated in the direction of arrow W. During the time at positions 2 , 3 , and 4 , the heat transfer fluid dwells in the MCM of stage 112 and, therefore, is heated. More specifically, the heat transfer fluid does not flow through stage 112 because the openings 106 , 108 , 122 , and 124 corresponding to stage 112 in positions 2 , 3 , and 4 are not aligned with any of the ports 140 , 142 , 144 , or 146 .
[0040] In step 202 , as regenerator housing 102 continues to rotate in the direction of arrow W, stage 112 will eventually reach position 5 . As shown in FIGS. 3 and 6 , at position 5 the heat transfer fluid can flow through the material as first inlet port 140 is now aligned with an opening 122 in first valve 114 and an opening 106 at the first end 118 of stage 112 while second outlet port 146 is aligned with an opening 124 in second valve 116 at the second end 120 of stage 112 . As indicated by arrow Q H-OUT , heat transfer fluid in stage 112 , now heated by the MCM, can travel out of regenerator housing 102 and along line 48 to the second heat exchanger 34 . At the same time, and as indicated by arrow Q H-IN , heat transfer fluid from first heat exchanger 32 flows into stage 112 from line 44 when stage 112 is at position 5 . Because heat transfer fluid from the first heat exchanger 32 is relatively cooler than the MCM in stage 112 , the MCM will lose heat to the heat transfer fluid.
[0041] Referring again to FIG. 7 and step 204 , as regenerator housing 102 continues to rotate in the direction of arrow W, stage 112 is moved sequentially through positions 6 , 7 , and 8 where stage 112 is completely or substantially out of magnetic field M. The absence or lessening of the magnetic field is such that the magnetic moments of the material become disordered and the MCM absorbs heat as part of the magneto caloric effect. During the time in positions 6 , 7 , and 8 , the heat transfer fluid dwells in the MCM of stage 112 and, therefore, is cooled by losing heat to the MCM as the magnetic moments disorder. More specifically, the heat transfer fluid does not flow through stage 112 because the openings 106 , 108 , 122 , and 124 corresponding to stage 112 when in positions 6 , 7 , and 8 are not aligned with any of the ports 140 , 142 , 144 , or 146 .
[0042] Referring to step 206 of FIG. 7 , as regenerator housing 102 continues to rotate in the direction of arrow W, stage 112 will eventually reach position 1 . As shown in FIGS. 3 and 6 , at position 1 the heat transfer fluid in stage 112 can flow through the material as second inlet port 144 is now aligned with an opening 124 in second valve 116 and an opening 108 at the second end 120 while first outlet port 142 is aligned with an opening 122 in first valve 114 and opening 106 at first end 118 . As indicated by arrow Q C-OUT , heat transfer fluid in stage 112 , now cooled by the MCM, can travel out of regenerator housing 102 and along line 46 to the first heat exchanger 32 . At the same time, and as indicated by arrow Q C-IN , heat transfer fluid from second heat exchanger 34 flows into stage 112 from line 50 when stage 112 is at position 5 . Because heat transfer fluid from the second heat exchanger 34 is relatively warmer than the MCM in stage 112 at position 5 , the MCM will lose some of its heat to the heat transfer fluid. The heat transfer fluid now travels along line 46 to the first heat exchanger 32 to receive heat and cool the refrigeration compartment 30 .
[0043] As regenerator housing 102 is rotated continuously, the above described process of placing stage 112 in and out of magnetic field M is repeated. Additionally, the size of magnetic field M and regenerator housing 102 are such that a subset of the plurality of stages 112 is within the magnetic field at any given time during rotation. Similarly, a subset of the plurality of stages 112 are outside (or substantially outside) of the magnetic field at any given time during rotation. Additionally, at any given time, there are at least two stages 112 through which the heat transfer fluid is flowing while the other stages remain in a dwell mode. More specifically, while one stage 112 is losing heat through the flow of heat transfer fluid at position 5 , another stage 112 is receiving heat from the flowing heat transfer fluid at position 1 , while all remaining stages 112 are in dwell mode. As such, the system can be operated continuously to provide a continuous recirculation of heat transfer fluid in heat pump system 52 as stages 112 are each sequentially rotated through positions 1 through 8 .
[0044] As will be understood by one of skill in the art using the teachings disclosed herein, the number of stages for housing 102 , the number of ports in valve 114 and 116 , and/or other parameters can be varied to provide different configurations of heat pump 100 while still providing for continuous operation. For example, each valve could be provided within two inlet ports and two outlet ports so that heat transfer fluid flows through at least four stages 112 at any particular point in time. Alternatively, regenerator housing 102 , valves 122 and 124 , and/or seals 136 and 138 could be constructed so that e.g., at least two stages are in fluid communication with an inlet port and outlet port at any one time. Other configurations may be used as well.
[0045] As stated, stage 112 includes MCM extending along the axial direction of flow. The MCM may be constructed from a single magneto caloric material or may include multiple different magneto caloric materials. By way of example, appliance 10 may be used in an application where the ambient temperature changes over a substantial range. However, a specific magneto caloric material may exhibit the magneto caloric effect over only a much narrower temperature range. As such, it may be desirable to use a variety of magneto caloric materials within a given stage to accommodate the wide range of ambient temperatures over which appliance 10 and/or heat pump 100 may be used.
[0046] Accordingly, as shown in FIG. 7 , each stage 112 can be provided with zones 152 , 154 , 156 , 158 , 160 , and 162 of different magneto caloric materials. Each such zone includes an MCM that exhibits the magneto caloric effect at a different temperature or a different temperature range than an adjacent zone along the axial direction of stage 112 . For example, zone 152 may exhibit the magnet caloric effect at a temperature less than the temperature at which zone 154 exhibits the magnet caloric effect, which may be less than such temperature for zone 156 , and so on. Other configurations may be used as well. By configuring the appropriate number sequence of zones of MCM, heat pump 100 can be operated over a substantial range of ambient temperatures.
[0047] Referring now to FIGS. 4 , 5 , and 6 , magnetic element 126 is constructed in the shape of an arc from a plurality of magnets 130 arranged in a Halbach array for this exemplary embodiment. More specifically, magnets 130 are arranged so that magnetic element 126 provides a magnetic field M located radially outward of magnetic element 126 and towards regenerator housing 102 while minimal or no magnetic field is located radially-inward towards the axis of rotation A-A. Magnetic field M may be aligned in a curve or arc shape. A variety of other configurations may be used as well for magnetic element 126 and/or its resulting magnetic field. For example, magnetic element 126 could be constructed from a first plurality of magnets positioned in cavity 128 in a Halbach array that directs the field outwardly while a second plurality of magnetics is positioned radially outward of regenerator housing 102 and arranged to provide a magnetic field that is located radially inward to the regenerator housing 102 . In still another embodiment, magnetic element 128 could be constructed from a plurality of magnets positioned radially outward of regenerator housing 102 and arranged to provide a magnetic field that is located radially inward towards the regenerator housing 102 . Other configurations of magnetic element 128 may be provided as well. For example, coils instead of magnets may be used to create the magnetic field desired.
[0048] For this exemplary embodiment, the arc created by magnetic element 128 provides a magnetic field extending circumferentially about 180 degrees. In still another embodiment, the arc created by magnetic element 128 provides a magnetic field extending circumferentially in a range of about 170 degrees to about 190 degrees.
[0049] A motor 28 is in mechanical communication with regenerator housing 102 and provides for rotation of housing 102 about axis A-A. By way of example, motor 28 may be connected directly with housing 102 by a shaft or indirectly through a gear box. Other configurations may be used as well.
[0050] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. | A heat pump system having magneto caloric material positioned in a continuously rotating regenerator is provided. The magneto caloric material is staged so that as the regenerator is rotated, a portion of the material is cycled in and out of a magnetic field in a continuous manner. A heat transfer fluid is circulated through the magneto caloric material simultaneously along at least two paths to provide for the transfer of heat both to and from the material in a cyclic manner. The magneto caloric material may include zones having different temperature ranges of responsiveness to the magnetic field. An appliance using a heat pump system based on magneto caloric material is also provided. | 5 |
This is a division, of application Ser. No. 376,751, filed on Jul. 7, 1989 now U.S. Ser. No. 5,086,979.
FIELD OF THE INVENTION
The invention relates to airblast type fuel nozzles for small gas turbine engines and, in particular, such airblast fuel nozzles having high efficiency inner air swirlers to aid cold fuel ignition performance.
BACKGROUND OF THE INVENTION
FIGS. 1 and 2 illustrate a small airblast fuel nozzle used in the past in small gas turbine engines of, for example, 1000-2000 horsepower. These airblast fuel nozzles include a first nozzle body 10 having a flange 10a by which the nozzle is mounted to the combustor wall 12 and an upstream threaded inlet fitting 14 connected to a fuel conduit. A second nozzle body 16 is attached by welding and the like on the front tubular extension 15 of the first nozzle body. Attached on the downstream end of the second nozzle body is nozzle tip 17 having outer air shroud 18 therearound.
Fuel enters the nozzle through fitting 14 and passes through filter 20 past flow restrictor orifice 22 into chamber 24. Fuel from chamber 24 flows through drilled circumferentially spaced passages 26 to annular chamber 28 and through a transverse slot (not shown) to discharge orifice 30 in the air swirl chamber 32 for atomization by swirling air exiting therefrom.
Swirl air for chamber 32 enters circumferentially spaced air inlet passages 34 which as shown extend in radially and forwardly inclined directions relative to axis A. The air inlet passages intersect the swirl chamber 32 in a tangential manner as shown in FIG. 2. The purpose of air inlet passages 34 is to impart sufficient swirl to air as it enters chamber 32 and flows therealong to effect sufficient atomization of fuel at discharge orifice 30 to ignite same in the presence of a spark ignition.
Outer air passing inside shroud 18 is also swirled by swirl vanes 36 to aid fuel atomization as the previously atomized fuel exits from discharge lip 40 for injection into the combustor.
In these small gas turbine engines low stagnation air pressure; e.g., 1-1-1/2 inches of water, is available from the compressor section of the engine at cold ignition for entering air inlet passage 34 and swirling along swirl chamber 32. At these low air pressure values, there has been a problem with achieving cold ignition on a consistent basis; i.e., the engines have been difficult to start.
What is needed is a solution to the problem of inconsistent and difficult cold ignition of such small gas turbines having only low stagnation air pressure available from the compressor at cold ignition.
SUMMARY OF THE INVENTION
An object of the invention is to provide a solution to the aforesaid problem wherein an airblast fuel nozzle is provided capable of effecting sufficient fuel atomization by air swirl enhancement at the aforesaid low compressor stagnation air pressure available in small gas turbine engines to provide improved cold ignition characteristics.
The invention relates to the discovery that the low cold ignition stagnation air pressure in combination with a low efficiency inlet air passages restrict the amount of inner cylindrical air swirl strength that can be generated in the inner air swirl chamber of such airblast fuel nozzles.
In particular, low efficiency of inner air swirling is severely limited by the small inner diameter of the inner cylindrical air swirl chamber. For example, the small airblast fuel nozzles of the type shown typically have an inner cylindrical air swirl chamber with a maximum inner diameter of 0.12 inch as a result of the need to maintain the wall thickness of the nozzle body therearound at a sufficient thickness to provide required structural strength.
The small diameter of the inner air swirl chamber exerts an adverse effect on the amount of swirl strength capable of generation since the degree of swirl strength decreases as the distance "X" (FIG. 2) between the centerline of air inlet passages and the centerline of the inner cylindrical air swirl chamber decreases. The small inner diameter of the inner cylindrical air swirl chamber is thus inherently self limiting since it cannot be increased and still maintain the same nozzle body envelope (outer dimension and profile of the nozzle body) designed for the particular gas turbine engine.
The present invention provides the aforementioned solution within the constraints imposed by such small airblast fuel nozzles and the small gas turbine engines in which they are used (low cold ignition stagnation air pressure) so that the improved airblast fuel nozzles of this invention can be substituted for those of the type shown in FIGS. 1 and 2; i.e., the improved nozzle characteristics are provided in substantially the same nozzle body envelope without substantially altering the inner diameter of the cylindrical inner air swirl chamber.
In particular, the invention contemplates a novel high efficiency design for the air inlet passages conducting and imparting swirl to inner air entering the inner cylindrical air swirl chamber to achieve sufficient inner air swirling to provide enhanced cold ignition at low ignition air pressure.
The invention also contemplates such small airblast fuel nozzles having high efficiency inner air inlet passages from the standpoint that significantly higher stagnation air pressure is available for swirl promotion at the entrance of the passages into the inner cylindrical air swirl chamber wherein of the original 1-1-1/2 inch water of stagnation air pressure available greater than 0.70 inch water, and preferably greater 0.90 inch water, is still present as the air enters the inner cylindrical air swirl chamber. This compares to only about 0.30 inch water available in the prior art nozzle design of FIGS. 1-2.
The invention also contemplates an improved method of igniting a gas turbine engine having such an initial air stagnation pressure (i.e., about 1-11/2 inches of water).
The invention achieves the above objects and advantages by providing multiple circumferentially spaced air inlet slots with a novel slot configuration that attempts to maximize the value of the "X" dimension referred to above while at the same time attempting to minimize adverse air pressure losses through the slots to the inner cylindrical air swirl chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view through a prior art airblast fuel nozzle for a small gas turbine engine.
FIG. 2 is a sectional view taken along lines 2--2 of FIG. 1.
FIG. 3 is a longitudinal sectional view through an airblast fuel nozzle of the invention for the same gas turbine engine.
FIG. 4 is a sectional view of the second nozzle body of the fuel nozzle of FIG. 3.
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 4.
FIG. 6 is an elevation taken in the direction of arrow 6 in FIG. 5.
FIG. 7 is a sectional view taken along lines 7--7 of FIG. 4.
FIG. 8 is a sectional view taken along lines 8--8 of FIG. 7.
FIG. 9 is a sectional view of the fuel system swirler slots.
FIG. 10 is a sectional view similar to FIG. 7 for a second embodiment of the invention.
FIGS. 11A-F and 12A-F are pressure profile diagrams for nozzles of the invention measured at different axial locations along the nozzle central axis.
FIG. 13A-F are similar to FIGS. 11A-F and 12A-F but for the prior art nozzle.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 3-9, a first embodiment of the airblast fuel nozzle 50 is shown as including a first nozzle body 52 having an annular circular (in plan) flange 52a by which the nozzle is mounted to the combustor wall 12 (FIG. 1) and a threaded inlet fitting 54 connected to a fuel conduit (not shown) in usual fashion.
A second nozzle body 56 is attached by welding, brazing and the like on the front downstream tubular extension 55 of first nozzle body 54. Attached on the downstream end of the second nozzle body is nozzle tip 57 having outer air shroud 58 therearound. Nozzle body 56 has a cylindrical outer profile or shape.
Fuel enters the fuel nozzle through fitting 54 and passes through fuel filter 60 and cylindrical flow restrictor orifice 62 into cylindrical chamber 64. Fuel filter 60 is supported on collar 61 which is held against internal shoulder 63 in position by snap-ring 65. Fuel from chamber 64 flows through drilled circumferentially spaced cylindrical fuel passages 66 to annular fuel chamber 68 and through annular chamber 70 past fuel swirl passages 72 for discharge past annular fuel discharge lip 74 on nozzle tip 57. Swirling inner air discharges past annular inner air discharge lip 76 from cylindrical inner air swirl chamber 80 which receives air through a plurality of circumferentially spaced air inlet passages 82 which extend in radially and forwardly inclined directions relative to axis A. Outer air passing inside shroud 58 is swirled by swirl vanes 84 for discharge past outer air discharge lip 86 after passing through swirl chamber 87.
The second nozzle body 56 has an outer radius that is equal to or greater than two times the inner radius of inner air swirl chamber 80.
As is known, air entering inner air passages 82 and entering chamber 88 of outer air shroud 58 is provided by the compressor (not shown) of the gas turbine engine in which combustor 12 is disposed.
The inner air and outer air discharged past respective discharge lips 76 and 86 atomizes the fuel discharging past discharge lip 74.
As mentioned hereinabove, in small gas turbine engines outputting 1000-2000 horsepower, the compressor provides relatively low stagnation air pressure at cold ignition for inner air entering inlet passages 82 and outer air entering shroud 58. At these low stagnation air pressure values, there has been difficulty in achieving cold ignition on a consistent basis and as a result the engines have been difficult to start.
In accordance with the invention, the efficiency of inner air inlet passages 82 has been dramatically improved to provide a higher proportion of stagnation air pressure or at least about 70% of the stagnation air pressure and preferably greater than at least about 90% of the stagnation air pressure, for the inner air entering inner air swirl chamber 80 for swirl promotion therein and to provide a geometry that enhances the degree of swirl strength capable of generation in chamber 80. As an exemplary illustration, for 1 to 1-1/2 inch water of cold ignition stagnation air pressure available at the entrance to inner air inlet passages 82, the improved efficiency passages 82 provide a measured air pressure greater than 0.70 inch water and preferably greater than 0.90 inch water at the juncture of passage 82 and inner air swirl chamber 80; i.e., where the inner air flows enter the chamber 80 after having passed through passages 82. These values compare to only about 0.30 inch water measured stagnation air pressure available at the same juncture for the prior art airblast fuel nozzle of FIGS. 1-2.
The geometry of the improved inner air inlet passages 82 increases the aforementioned distance "X" between centerline of each inner air inlet passage 82 and the centerline of the inner air said chamber 80 to increase swirl strength capable of generation in chamber 80 and to improve location of the maximum swirl of inner air close to the wall W defining inner air swirl chamber 80.
Referring to FIGS. 7 and 8, the shape of inner air inlet passages 82 in accordance with one embodiment of the invention is shown. Each inner air inlet passage 82 includes an inner tapered section 82a converging toward and into intersection with inner air swirl chamber 80 and an outer tapered section 82b converging toward and intersecting with the inner section 82a.
In particular, inner section 82a comprises a first wall 90 that is tangent to inner air swirl chamber 80 at its juncture with wall W forming chamber 80, and a second wall 92 spaced and disposed angularly from first wall 90 in the counterclockwise direction relative to FIG. 7. Walls 90,92 thus define a selected included angle A1 therebetween. Second wall 92 intersects wall W in a non-tangent relation and, if projected across the chamber 80, constitutes a chordal line through the cylindrical air swirl chamber 80 of the second nozzle body 56. Together, converging walls 90,92 define an outlet 95 into chamber 80 through which inner air flow enters into chamber 80 from each passage 82 and an inlet 97 at their diverging radially remote ends. It is apparent that as a result of the convergence of walls 90,92, inlet 97 has a greater cross-sectional effective air flow area than outlet 95. As shown in FIG. 8, each inner section 82a has a generally rectangular profile with rounded corners.
Tangent wall 90 extends a radial distance D1 while non-tangent wall 92 extends a radial distance D2 toward the outer circumference of nozzle body 56.
Outer section 82b of each passage 82 comprises a first wall 100 that intersects first wall 90. As is apparent, first wall 100 is substantially parallel to second wall 92 and, if projected across the nozzle body 56, would also constitute a chordal line therethrough. First wall 100 intersects first wall 90 at a point R1.
Outer section 82b also includes second wall 102 that is angularly disposed relative to first wall 100 and intersects second wall 92 at a point R2. Distance D2 is less than distance D1.
Walls 100,102 converge toward the inner section 82a and define an outlet coincident with inlet 97 of the inner section. Walls 100,102 define an inlet 105 in the outer circumference of nozzle body 56 to receive compressor discharge air. The inlet 105 of outer section 82b is greater in cross-sectional effective air flow area than its outlet into the inner section 82a.
The ratio of the air flow area of the inlet end of the outer section 82b to the outlet end of the inner section 82a is equal to or greater than 2.5, preferably 2.75.
Walls 100,102 are angularly displaced relative to the respective walls 90,92 in the same counterclockwise direction relative to FIG. 7. The included angle A2 defined between walls 100,102 is greater than included angle Al defined between walls 90,92.
Each outer section 82b has a generally rectangular profile with rounded corners like that illustrated in FIG. 8.
It is apparent that inner air inlet passages 82 define hooked cross type pattern of passages in nozzle body 56 when viewed as shown in FIG. 7 and that longitudinal axis L1 of inner section 82a and longitudinal axis L2 of outer section 82b intersect to form an obtuse angle when so viewed.
FIGS. 11 a-f illustrate measured pressure profiles at various radial distances from the longitudinal central axis of inner air swirl chamber 80 of the fuel nozzle 50 of FIGS. 3-9 at different axial locations (designated with the vertical "0" axis position line) relative to inner air inlet passages 82. Note that the axial location of measurement moves toward air inlet passages 82 as one proceeds from FIG. 11F through FIG. 11A. Only one half of the chamber 80 is shown since the pressure profile is generally symmetrical around the longitudinal central axis. Air entering inner air inlet passages 82 was supplied at 1.0 inch water stagnation air pressure.
It is apparent that the air inlet passages 82 are effective to provide a measured maximum air pressure in chamber 80 that is greater than 0.9 inch water, FIG. 11(e), and a maximum air pressure that is closely adjacent wall W forming chamber 80 having radius of 0.24 inches in FIGS. 11(a)-(f). The pressure profile shown in FIGS. 11(a)-(f) was determined on a fuel nozzle scaled up in dimensions by about four (4) times (hence the radius of 0.24) to enable a pressure probe to be inserted in the air swirl chamber 80 without adversely disrupting the aerodynamics of the highly swirling air flow in the chamber. The same aerodynamics exhibited by the upscaled fuel nozzle (e.g., as shown in FIGS. 11(a)-(f)) would be exhibited upon down scaling of the fuel nozzle to actual size for use in the aforementioned small gas turbine engines of 1000-2000 horsepower; e.g., to provide a maximum inner diameter of the air swirl chamber 80 of about 0.12 inch.
FIG. 10 illustrates a second embodiment of the invention where the inner air inlet passages have a slightly different configuration. The features of the second embodiment of FIG. 10 are similar to those of the first embodiment of FIGS. 3-9 and like features are represented by like reference numerals primed.
The primary difference between second embodiment of FIG. 10 and the first embodiment relate to the number of inner air inlet passages 82' and the dimensions of walls 90',92',100',102'.
In particular, it is apparent that there are six passages 82'. Also, there are six circumferentially space fuel passages 66' extending axially through nozzle body 56'.
It is also apparent that the first point of intersection R1' of first wall 90' of inner section 82a' and first wall 100' of outer section 82b' and the point of intersection R2 of second wall 92' and second wall 102' are different in that the distance D1' of the first point of intersection is less than distance D2' of the second point of intersection. Included angle A1 is less than included angle A2.
The second embodiment of FIG. 10 can be viewed as having inner section 82a', outer section 82b' and an intermediate section 82c' therebetween. Inner section 82a' converges toward and into intersection with chamber 80'. Intermediate section 82c' has a constant cross-sectional air flow area. Outer section 82b' converges toward and into intersection with the intermediate section. Air flows from outer section 82b' through intermediate section 82c' and then into inner section 82a' for discharge into inner air swirl chamber 80'.
FIGS. 12a-f illustrate measured pressure profiles at various radial distances from the central axis of inner air swirl chamber 80' of the second embodiment at different axial locations (see vertical "O" axis position line) relative to inner air inlet passages 82'. Only one-half of chamber 80' is shown since the pressure profile is generally symmetrical around the longitudinal central axis. Air entering inner air inlet passages 82' was supplied at 1.0 inch water stagnation air pressure. The fuel nozzle was scaled up by about four times for testing for the reasons given hereinabove.
It is apparent that the air inlet passages 82' are effective to provide a measured maximum air pressure in chamber 80' that is greater than 0.9 inch water, FIG. 12(e), and a maximum air pressure that is closely adjacent wall W' forming chamber 80' having radius 0.24 inches in FIGS. 12(a)-(f).
Similar pressure profiles for the prior art fuel nozzle of FIGS. 1 and 2 (upscaled in dimension by about four times) are shown in FIGS. 13(a)-(f). The dramatic improvement of the first and second embodiments of the invention in improving air swirl in the inner air swirl chamber as compared to the prior art fuel nozzle is evident. Not only is the maximum air pressure in the inner air swirl chamber at least twice as great as that of the prior art fuel nozzle but also the maximum air swirl (maximum pressure) is closer to the wall defining the inner air swirl chamber.
As mentioned above, these improvements are achievable in substantially the same inner nozzle body envelope without substantially altering the inner diameter of the inner air swirl chamber.
While there have been described in the foregoing specification the preferred modes for practicing the invention, it is our intent to cover in the appended claims all modifications thereof as fall within the spirit and scope of the invention as set forth in the appended claims. | The small airblast fuel nozzle improves cold ignition of small gas turbine engines of the type having a stagnation air pressure of only 1-11/2 inches of water available from the compressor for cold ignition. The fuel nozzle includes an inner air swirling system comprising a longitudinal cylindrical inner air swirl chamber and multiple air inlet slots spaced circumferentially on the nozzle body to supply air to the chamber. The air inlet slots each include an inner tapered section converging toward and into intersection with the chamber and an outer tapered section converging from the exterior of the nozzle body toward and into intersection with the inner section. The inner section and outer section are canted with respect to one another and in the same direction from one slot to the next so that the inner air slots collectively form a hooked cross type pattern when viewed in plan. The inner air swirl system is effective to provide much enhanced air swirling in the inner chamber with a high efficiency or use of the small available stagnation air pressure available at the nozzle exterior for improved cold ignition. | 5 |
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