description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
FIELD OF THE INVENTION
The present invention relates to shoes, and more specifically to shoes that can convert from one functional type to another functional type.
BACKGROUND OF THE INVENTION
This invention relates to shoes and more particularly to shoes that are used to cover, as a minimum, the soles of the feet while ambulating. Shoes come in a variety of functionalities, designs, sizes, shapes, colors, and materials of construction. Shoes, for the simplicity of this application, include flip-flops, dress shoes, sneakers, boots, sandals, beach shoes, moccasins, wooden shoes, high heels, sock shoes, tap shoes, toe shoes, boat shoes and any other structure intended to be placed on or around a foot, hoof, paw or flipper. Shoes are the coverings for feet which generally come in contact with the surfaces on which a person walks, runs, ambulates, scampers or moves from one place to another on. Shoes may have heels or raised areas on their soles towards the front, middle or rear.
Known shoes generally comprise a first area on the upper surface which is softer and more flexible than the lower surface (sole). Shoes may be constructed of leathers, plastics, woods, plants, papers, foams, fabrics, canvass, fibers, hairs, skins, rubbers, glass, metal, cloth, gels, water, and similar materials and/or combinations thereof. Shoes may be of solid construction or may contain spaces of air, water, gels, foam, fiber, liquids or similar materials or may contain combinations thereof.
Despite the fact that shoes have been produced for centuries, there still exists the need for better, more cost-saving, novel, and new improved types to satisfy an ever-changing world.
Thus, there remains a need for an improved, new, innovative, novel shoe type, the subject of this patent submission.
SUMMARY OF THE INVENTION
The present invention includes shoes that have a means to be changed from one type to another type and describes the method by which the change can be effected. According to one exemplary embodiment, the invention provides a shoe comprising an upper portion and a lower portion (sole) such that one type shoe can be transformed into another type shoe with another upper portion but with the same lower portion (sole).
In another exemplary embodiment of the invention, a shoe is presented with full upper portion and a lower portion (sole) that can be transformed into another type of shoe by detaching the full upper portion and inverting the upper portion which instantly becomes another partial upper portion but with the same lower portion (sole).
The invention also provides a method of transforming one type of shoe presentation to another type of shoe presentation. Another embodiment of the method according to the present invention includes a method of transforming one color of an upper portion into another color of the upper portion. Yet another embodiment of the method according to the present invention includes a method of transforming one design of an upper portion into another design of the upper portion.
DESCRIPTION OF THE FIGURES
The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description that follows taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side view of a portion of one embodiment of the present invention in which the upper surface shown is presented as a full design;
FIG. 2 is an illustration of the embodiment of FIG. 1 with partial design upper surface but with an exaggerated view of the upper-lower attachment means for illustration purposes;
FIG. 3 is an illustration of an upper portion of the embodiment detached from the lower portion of the present invention in which one surface is a full design and the opposite surface is a partial design;
FIG. 4 is an illustration of an upper portion of the embodiment detached from the lower portion of the present invention in which one surface is a full design and the opposite surface is a full design;
FIG. 5 is an illustration of a lower portion of yet another exemplary embodiment in which the second half of the upper-lower attachment means is illustrated;
FIG. 6 is an illustration of the embodiment with a full design upper portion on the top and a partial design upper portion on the bottom nestled in the recess cavity of the lower portion;
DETAILED DESCRIPTION OF THE INVENTION
This invention will now be described with reference to specific embodiments selected for illustration in the figures. It will be appreciated that the spirit and scope of this invention is not limited to the embodiments selected for illustration. Instead, the scope of this invention is defined separately in the appended claims. Also, it will be appreciated that the drawings are not rendered to any particular proportion or scale.
The present invention includes shoes and different types, functionalities, colors or presentations.
FIG. 1 shows such a shoe embodiment of the present invention, generally designated by the numeral “ 10 ”. The shoe embodiment 10 has an upper surface 100 that is of a full design and includes an open area 110 for the insertion of a foot into the upper surface. More specifically, shoe embodiment 10 illustrates the upper surface 100 attached to the lower surface (sole) 120 by an upper-lower surface attachment means 130 . The shoe embodiment 10 has the general appearance of a shoe as depicted in FIG. 1 however, said appearance and functionality may be changed by activating the upper-lower surface attachment means 130 causing the upper surface 100 to detach from the lower surface (sole) 120 and allowing the upper surface 100 to be turned inside out and re-attached to the lower surface (sole) 120 to give another appearance and functionality.
Generally, the upper surface 100 may be constructed of leather, plastics, wood, plants, paper, foam, fabric, canvass, fiber, hair, skin, rubber, glass, metal, cloth, gels, water, and similar materials and/or combinations thereof; however, softer materials such as leather, plastics, fabric, canvass, skin, rubber, and similar materials may be preferred. Generally the upper-lower attachment means 130 may be constructed of leather, plastics, wood, plants, paper, foam, fabric, canvass, fiber, hair, skin, rubber, glass, metal, cloth, gels, water, and similar materials and/or combinations thereof; however, plastics, metal, fabric, rubber, and similar materials may be preferred. Generally, the lower surface (sole) 120 may be constructed of leather, plastics, wood, plants, paper, foam, fabric, canvass, fiber, hair, skin, rubber, glass, metal, cloth, gels, water, and similar materials and/or combinations thereof; however, harder materials such as leather, plastics, wood, rubber, and similar materials may be preferred.
In an exemplary shoe embodiment, generally designated by the numeral “ 20 ” In FIG. 2 , there is shown the upper-lower attachment means 130 connecting the upper surface 100 with the lower surface (sole) 120 . Shown also are open area 110 for the placement of a foot and also toe opening 140 for the exposure of toes. The upper-lower attachment means 130 is preferably a zipper structure that is continuous around the horizontal outer circumference or perimeter of the shoe 20 upper-lower attachment means 130 .
FIG. 3 shows an embodiment, generally designated by the numeral “ 30 ,” of a structure the upper surface 100 consisting of two segments, the exposed segment 180 and the hidden segment 190 . In this presentation, the exposed segment 180 is a full segment and the hidden segment 190 is a partial segment. Shown also is the first-half member 160 of the upper-lower attachment means which when joined to a second-half member of the upper-lower attachment means will hold the upper surface to a lower surface (sole).
FIG. 4 shows yet another exemplary embodiment of the present invention, generally designated by the numeral “ 40 ,” which is essentially similar to the presentation in FIG. 3 . Shown is an upper surface 100 structure consisting of two segments, the exposed segment 180 and a similar hidden segment 200 . In this presentation, the exposed segment 180 is a full segment and the similar hidden segment 200 is also a full segment. Shown also is the first-half member 160 of the upper-lower attachment means which when joined to a second-half member of the upper-lower attachment means will hold the upper surface to a lower surface (sole).
FIG. 5 shows yet another embodiment, generally designated by the numeral “ 50 ,” wherein the lower surface (sole) 120 has attached to it the second-half member 170 of the upper-lower attachment means which when joined to a first-half member of the upper-lower attachment means by use of an upper-lower attachment connecting device 210 will hold the upper surface to the lower surface (sole).
FIG. 6 shows another version of the embodiment that is generally designated by the numeral “ 60 .” Embodiment 60 is an exploded view of a transformational shoe consisting of: an upper surface 100 , the upper surface 100 consisting of an exposed full segment 180 and a hidden partial segment 190 ; a lower surface (sole) 120 ; and an upper-lower attachment means consisting of a first-half member 160 of the upper-lower attachment means attached to the upper surface 100 and a second-half member 170 of the upper-lower attachment means attached to the lower surface (sole) 120 having attached thereon an upper-lower attachment connecting device 210 which when used will join a first-half member 160 of the upper-lower attachment means to a second-half member 170 of the upper-lower attachment means.
The invention also includes a method of forming a transformational shoe. The method comprises the steps of fabricating an upper surface, a lower surface and an upper-lower attachment means. The upper surface consists of an exposed segment and a hidden segment. The fabricated segments are attached to each other by bonding, gluing, sewing, melting or other means of attachment. After the segments are attached, the first-half of an upper-lower attachment means (such as the first-half of a zipper) is attached to the perimeter of the area where the segments are joined together. The lower surface (sole) is fabricated and the second-half of the upper-lower attachment means (such as the second-half of a zipper) is attached around its perimeter. The upper surface and lower surface (sole) structures are then attached by joining the two halves of the upper-lower attachment means (such as zipping together the two halves of the zipper).
Accordingly, while illustrated and described herein with reference to certain specific embodiments, the present invention is not intended to be limited to the embodiments and details shown. Rather, the appended claims are intended to include embodiments and modifications that may be made to these embodiments and details, which are nevertheless within the true spirit and scope of the present invention.
REFERENCES CITED
U.S. Patents
7,117,614
Oct. 10, 2006
Tonkel
7,032,327
Apr. 25, 2006
Tartaglia et al
6,905,127
Jun. 14, 2005
Lester
6,805,363
Oct. 19, 2004
Hernandez
6,634,656
Oct. 21, 2003
Gervason
6,631,570
Oct. 14, 2003
Walker
5,924,902
Jul. 20, 1999
Burns et al
5,848,484
Dec. 15, 1998
Dupree et al
5,737,853
Apr. 14, 1998
Smejkal
5,675,916
Oct. 14, 1997
Lewis
5,381,610
Jan. 17, 1995
Hanson
5,293,701
Mar. 15, 1994
Sullivan
5,087,385
Jan. 28, 1992
Halford
4,998,329
Mar. 12, 1991
Boros
4,928,982
May 29, 1990
Logan
4,839,948
Jun. 20, 1989
Boros
4,450,033
May 29, 1984
Connelly
4,363,177
Dec. 14, 1982
Boros
4,114,295
Sep. 19, 1978
Schaefer
3,955,293
May 11, 1976
Benedict | A transformational shoe construction comprising an upper surface, lower surface (sole) and an upper-lower attachment means; said upper surface consisting of an exposed segment and a hidden segment with the upper surface joined to a lower surface (sole) by an upper-lower attachment means; said upper surface detachable from said lower surface (sole) and said upper surface capable of being turned inside-out to cause the exposed segment to become the hidden segment and the hidden segment to become the exposed segment. | 0 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to the conversion of mixed alkylaromatic feedstreams and more particularly to the conversion of a feedstock comprising benzene, xylene and, optionally, ethylbenzene, to hydrocarbon components comprising primarily toluene by employing a metal-loaded mordenite zeolite catalyst.
BACKGROUND OF THE INVENTION
Processes for the disproportionation of toluene to produce benzene are well-known in industrial applications. Recently, however, the economic desirability of producing benzene has come under question. The effects of recent legislation, including the Clean Air Act, limit benzene levels in gasoline pools, which, in turn, may reduce the economic incentive to produce benzene. Consequently, these effects may cause an excessive amount of benzene in the market which may result in a decrease in the price of benzene.
In preparation for the regulations concerning a reformulated gasoline pool, including dropping the aromatic levels and removing benzene and xylene, a catalytic process using a mordenite catalyst has been developed to convert benzene and C 8 aromatics, such as xylene and ethylbenzene, to toluene. The toluene can be added to the gasoline pool for octane boost. This process involves transfer of the alkyl group between xylene(s) and benzene, producing toluene as a major product and other alkylated hydrocarbons (C9+).
The conversion of a mixed alkylaromatic feed comprising benzene, xylene(s) and, optionally, ethylbenzene to form toluene may be practiced in accordance with the following reaction: ##STR1##
As carried out in the instant invention, reaction (1) employs a metal-loaded mordenite zeolite catalyst. Ethylbenzene may be employed as an optional feedstock component.
Mordenite is one of a number of molecular sieve catalysts useful in the conversion of alkylaromatic compounds. Mordenite is a crystalline aluminosilicate zeolite exhibiting a network of silicon and aluminum atoms interlinked by oxygen atoms within the crystalline structure. For a general description of mordenite catalysts, reference is made to Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition, 1981, under the heading "Molecular Sieves", Vol 15, pages 638-643.
Mordenite as found in nature, or as synthesized to replicate the naturally occurring zeolite, typically exhibits a relatively low silica to alumina mole ratio of about 10 or less. Also known are "aluminum-deficient" mordenite catalysts exhibiting silica to alumina ratios between 10 and 100, which may be prepared by direct synthesis as disclosed in U.S. Pat. No. 3,436,174 to Sand or by acid extraction of a more conventionally prepared mordenite as disclosed in U.S. Pat. No. 3,480,539 to Voorhies, et. al. Both the typical and the aluminum deficient mordenites are known to be useful in toluene disproportionation reactions.
It is also a common practice to promote (or load) an aluminum deficient mordenite catalyst with a catalytically active metallic component. For example, U.S. Pat. No. 3,476,821 to Brandenburg et al. discloses disproportionation reactions employing mordenite catalysts having silica/alumina ratios within the range of 10-100 and preferably within the range of about 20-60. The mordenites are modified by the inclusion of a sulfided metal selected from the Group VIII metals. The metal may be included in the mordenite by well known ion exchange or impregnation techniques. The metal promoters substantially increase activity and catalyst life, as indicated by runs extending over several hours or days.
Other patents, such as U.S. Pat. No. 4,956,511 to Butler, U.S. Pat. No. 4,761,514 to Menard, U.S. Pat. No. 3,562,345 to Mitsthe and U.S. Pat. No. 3,677,973 to Mitsthe et al., disclose the use of molecular sieves such as mordenite catalysts in the disproportionation of toluene, and each of the entire disclosures of the above-referenced patents are incorporated herein by reference.
While metal-promoted mordenite catalysts may typically be used in toluene disproportionation processes, it has become desirable to employ these catalysts in a reverse toluene disproportionation process, i.e., toluene synthesis. Given the facts that (1) gasoline specifications will limit benzene levels and (2) toluene could be effectively used as a substitute for benzene, a benzene surplus may result causing the economic value of toluene to rise. It has therefore become desirable to develop a process for the conversion of surplus benzene and xylenes to toluene.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a process for the conversion of aromatic hydrocarbons including benzene to hydrocarbon components comprising primarily toluene.
According to one aspect of the invention, a catalyst reaction zone is established having a metal-loaded mordenite zeolite catalyst. A mixed feedstock of aromatic hydrocarbons, including benzene, is introduced into the reaction zone at a rate sufficient to produce a liquid hourly space velocity (LHSV) of approximately 2 hr -1 . Hydrogen is introduced as a cofeed into the reaction zone to provide a reductive environment. The feedstock is then contacted with the metal-loaded mordenite catalyst and the conversion of the aromatic hydrocarbon components is conducted under temperature and pressure conditions sufficient to effect the conversion of the feedstock to hydrocarbon components containing .primarily toluene. Finally, the conversion product containing primarily toluene is recovered from the reaction zone.
The metal-loaded mordenite may include nickel, gallium, zinc, palladium, copper, chromium or such combinations as nickel and gallium, and nickel and zinc. To effect a conversion, the temperature of the reaction zone is maintained within the range of 250° to 450° C. The pressure of the reaction zone is operated at a pressure within the range of 500 to 700 psig.
BRIEF DESCRIPTION OF THE FIGURES
Further aspects of the invention and their advantages will be discerned when one refers to the following detailed description as taken in conjunction with the drawings, in which:
FIG. 1 is a graph illustrating the relationship between the conversion of benzene, xylenes and ethylbenzene and selectively to toluene as a function of catalyst age over a nickel/mordenite catalyst (Catalyst I);
FIG. 2 is a graph illustrating the relationship between the temperature of the reactor bed as a function of the catalyst age, also over a nickel/mordenite catalyst (Catalyst I);
FIG. 3 is a graph depicting the relationship of the conversion of benzene, xylenes and ethylbenzene and the selectivity to toluene as a function of catalyst age over a nickel/mordenite catalyst (Catalyst I);
FIG. 4 is a graph depicting the relationship of the conversion of benzene, xylenes and ethylbenzene and the selectivity to toluene as a function of catalyst age over a second nickel/mordenite catalyst (Catalyst II);
FIGS. 5 and 6 are graphs depicting the relationship of the conversion of benzene, xylenes and ethylbenzene, and selectivity to toluene as a function of catalyst age over two types nickel/zinc/mordenite catalyst (Catalyst III and IV);
FIG. 7 is a graph depicting the relationship of the conversion of benzene, xylenes and ethylbenzene, and selectivity to toluene as a function of catalyst age over a gallium/mordenite catalyst (Catalyst VI); and
FIG. 8 is a graph depicting the relationship of the conversion of benzene, xylenes and ethylbenzene, and selectivity to toluene as a function of catalyst age over a zinc/dealuminated mordenite catalyst (Catalyst VIII).
DETAILED DESCRIPTION OF THE INVENTION
The process of toluene synthesis, according to the present invention, involves a novel application of a metal-promoted mordenite zeolite catalyst in the conversion of aromatic hydrocarbons including benzene to produce hydrocarbon components comprising primarily toluene. The metal-promoted mordenite catalysts employed in the present invention are modified by the inclusion of nickel, gallium and zinc, and combinations of nickel and gallium, and nickel and zinc. The invention may also be carried out using metal-promoted mordenite catalysts modified by the inclusion of palladium, copper or chromium.
Eight metal-promoted mordenite catalysts (Catalysts I-VIII, described infra) were tested for the conversion of the aromatic compounds. Catalyst I was modified by the inclusion of nickel in the amount of approximately 1.4 weight percent. As used in the claimed process, nickel can be incorporated into the mordenite by any suitable technique including well known impregnation and exchange procedures. A nickel mordenite catalyst suitable for use as Catalyst I may be obtained from Universal Oil Products (UOP) of Des Plaines, Ill. Catalysts II-VIII included synthesized mordenite powder samples ion-exchanged with ammonium ions, followed by the incorporation (also by ion-exchange) of nickel, zinc and gallium (as subsequently described) into the mordenite zeolite. The zinc-dealuminated mordenite of Catalyst VIII was prepared by first dealuminating (by acid extraction) and then ion-exchanging the mordenite zeolite. All mordenite samples were then extruded with 20% alumina as a binder and calcined at 530° C. These techniques used for preparing the mordenite samples are well known in the art.
The mordenite catalyst employed in the present invention is preferably a moderately to highly aluminum deficient mordenite catalyst having a silica to alumina mole ratio within the range of 10 to 60. Catalysts I-VII had a silica to alumina mole ratio (SAR) of approximately 18. Catalyst VIII had an SAR of approximately 59. Aluminum deficient mordenite catalysts and processes for preparing same are well known in the art.
The eight catalysts tested for the conversion of aromatic hydrocarbons, including benzene, xylene and ethylbenzene, are described below in TABLE 1.
TABLE 1______________________________________Mordenite Catalysts.Catalyst Designation Description______________________________________I Ni/Mordenite (Ni = 1.4%) Commercial CatalystII Ni(0.5%)/Mordenite Prepared by ion-exchange(SAR = 18) method.III Ni(0.3%)/Zn(0.3%)/Mor- Prepared in the lab by simulta-denite (SAR = 18) neous ion-exchange method.IV Ni(1.4%)/Zn(0.5%)/Mor- Prepared in the lab by simulta-denite (SAR = 18) neous ion-exchange method.V Zn(0.5%)/Mordenite Prepared in the lab by ion-(SAR = 17) exchange method.VI Ga(0.5%)/Mordenite Prepared in the lab by ion-(SAR = 18) exchange method.VII Ni(0.4%)/Ga(0.4%)/Mor- Prepared in the lab by ion-denite (SAR = 18) exchange method.VIII Zn(0.5%)/Deal-Mordenite Prepared by acid dealumina-(SAR = 59) tion followed by ion-exchange method.______________________________________
The experimental work described as follows is provided to illustrate the invention in accordance with the principles of the invention, but is not to be construed as limiting the invention.
In preparation for the disclosed process, a known volume of approximately 15 ml. of precalcined metal-promoted mordenite catalyst was loaded into a microreactor. Hydrogen was introduced as a cofeed into the reaction zone to establish a reductive environment, as the catalyst dried in the reactor at temperatures between 200° and 250° C. While the reverse disproportionation reaction (1) does not involve chemical consumption of hydrogen, the use of a hydrogen cofeed is generally considered to prolong the useful life of the catalyst. Such use of hydrogen as a preflush gas is well known in the art. Next, a premixed feed of aromatic hydrocarbons, including benzene, xylene(s) and ethylbenzene, was introduced in a down-flow mode at approximately 250° C., at a desired rate to give a feedstock liquid hourly space velocity (LHSV) of approximately 2 hr -1 . Hydrogen was again used as a cofeed, preferably adjusted to give a hydrogen/feed mole ratio of between 3 and 4. The reactor temperature was gradually increased from about 250° up to temperatures between 300° and 450° C., preferably within the range of 300°-400° C. Pressures were within the range of 500 to 700 psig.
Both the liquid and gas effluent samples were analyzed to calculate percent conversion of the aromatics and selectivities to the conversion products. The percent conversion of each of the aromatic hydrocarbons and the percent selectivity to toluene were calculated using the following equations:
% Conversion of X=[(Wt% X.sub.F -Wt% X.sub.E)/Wt% X.sub.F ]×100
% Selectivity of X=[(Wt% X.sub.E -Wt% X.sub.F)/% Conversion of the aromatics]×100
where, in each of the above equations,
Wt% X F =Weight percent of X in feed; and
Wt% X E =Weight percent of X in effluent.
Catalyst I, as described supra, was used as a reference catalyst to determine the optimal feedstock mixture of benzene, xylene(s) and ethylbenzene (including whether ethylbenzene was required in the feedstock). The following four feed mixtures were used:
FEED 1: Benzene 49.3 wt %, Xylenes 44.5 wt %, EB 5.8 wt %,
FEED 2: Benzene 53.2 wt %, Xylenes 34.8 wt %, EB 4.8 wt %,
FEED 3: Benzene 39.8 wt %, Xylenes 22.3 wt %, EB 3.2 wt %,
FEED 4: Benzene 39.8 wt %, Xylenes 52.9 wt %, EB 0.7 wt %.
Catalyst I was also used to provide a general idea of the manner in which the reactor bed temperature affected conversion activity and selectivity to toluene. Turning to the drawings, FIG. 1 depicts conversion activity and selectivity to toluene for each of the four feed mixtures. FIG. 2 depicts the corresponding reactor bed temperatures for each of the mixtures 1-4 described supra. FIGS. 1 and 2, when viewed together, illustrate the effect of feed content and reactor bed temperature on the conversion of aromatics and the selectivity to toluene over Catalyst I.
Due to the occurrence of concomitant reactions, a greater percentage of a component was sometimes observed in the product effluent than in the feedstock mixture, resulting in a negative percent conversion. Specifically, this was observed in feed mixtures 2-4, with respect to ethylbenzene conversion. As depicted, ethylbenzene conversion in feed mixture 1 approximated 40-65%. However, as the ethylbenzene concentration was lowered in feed mixture 2, a negative conversion was observed at temperatures below around 350° C. (Refer to FIG. 2 to observe the reactor bed temperatures corresponding to each feed mixture.) Ethylbenzene conversion in feed mixtures 3 and 4 exhibited much greater negative values, up to 500% (not illustrated). Consequently, from FIG. 1 it can be observed that ethylbenzene conversion was apparently dependent on its concentration in the feed mixture.
The concentration of benzene in each of the feed mixtures 1-4 ranged within 39-55 weight percent. Generally (except for feed mixture 1), benzene conversion increased with an increase in temperature. The concentration of total xylenes ranged between 22-53 weight percent for all feed mixtures. In each case, total xylene conversion also increased with an increase in temperature. (See FIGS. 1 and 2.) Unlike ethylbenzene, the concentration of benzene and total xylenes did not appear to affect their respective conversion activities.
After completing the conversion selectivity and reactor bed temperature tests employing Catalyst I, each of the Catalysts I-VIII, were tested using a feedstock mixture having a benzene:xylene:ethylbenzene ratio of approximately 5:4:1. In the case of the zinc dealuminated mordenite catalyst (Catalyst VIII), a ratio of 5:4:0.5 was used due to the presence of a small amount of heavy aromatics (C9+) in the feed.
Listed below are test results for each of the Catalysts I through VIII.
TABLE 2______________________________________Conversion Activities and Selectivities overMordenite Catalysts.______________________________________CATALYST I - Ni/Mordenite (Ni = 1.4%) (See FIGS. 1, 2, 3.)Temperature (°C.) 248 287 301 328 342 344Conversion Weight %Benzene Conv. 20.5 25.3 25.2 32.0 31.0 36.3Total Xylenes Conv. 13.6 28.1 51.5 62.4 64.8 69.2Ethylbenzene Conv. 19.0 28.2 40.1 46.5 49.2 60.1Selectivity, Weight %:Toluene 5.6 33.1 58.8 68.7 72.3 51.1CATALYST II - Ni(0.5%)/Mordenite (See FIG. 4.)Temperature °C. 253 300.2 348.2Conversion, Weight %Benzene Conv. 13.5 14.0 31.1Total Xylenes Conv. 19.2 29.2 60.2Ethylbenzene Conv. 22.3 22.7 40.3Selectivity, Weight %Toluene 78.0 67.7 71.5CATALYST III - Ni(0.3%)/Zn(0.3%)/Mordenite (See FIG. 5.)Temperature °C. 250 298 296.8 298Conversion, Weight %Benzene Conv. 14.6 14.6 12.4 9.4Total Xylenes Conv. 17.4 37.1 34.8 22.8Ethylbenzene Conv. 23.6 26.9 25.4 18.6Selectivity, Weight %Toluene 83.7 75.8 72.6 75.1CATALYST IV - Ni(1.4%)/Zn(0.5%)/Mordenite (See FIG. 6.)Temperature °C. 250 288 303 317 332 340Conversion, Weight %Benzene Conv. 8.5 14.0 19.4 24.8 30.8 31.2Total Xylenes Conv. 4.7 21.9 35.1 48.4 57.6 61.9Ethylbenzene Conv. 7.1 21.9 30.3 35.2 41.2 43.8Selectivity, Weight %Toluene 14.6 41.9 47.3 59.9 61.7 66.3CATALYST V - Zn(0.5%)/Mordenite (Not graphicallydepicted.)Temperature °C. 297 297 245 390Conversion, Weight %Benzene Conv. -1.9 -0.5 2.9 6.2Total Xylenes Conv. 3.4 3.1 8.1 14.4Ethylbenzene Conv. 4.3 3.9 8.2 13.6Selectivity, Weight %Toluene 6.5 39.9 41.0 59.6CATALYST VI - Ga(0.5%)/Mordenite (See FIG. 7.)Temperature °C. 247 284 346 346Conversion, Weight %Benzene Conv. 9.3 10.6 16.0 17.4Total Xylenes Conv. 6.7 17.4 36.8 37.4Ethylbenzene 7.5 16.5 26.2 27.4Selectivity, Weight %Toluene 38.2 50.9 74.8 69.8CATALYST VII - Ni(0.4%)/Ga(0.4%)/Mordenite(Not graphically depicted.)Temperature °C. 252 299 348Conversion, Weight %Benzene Conversion 5.4 23.4 23.1Total Xylenes Conv. 34.1 26.1 57.2Ethylbenzene Conv. 28.1 19.2 39.6Selectivity, Weight %Toluene 73.1 64.0 75.7CATALYST VIII - Zn(0.5%)/Dealuminated Mordenite(See FIG. 8.)Temperature °C. 250 293 243 392 442Conversion, Weight %Benzene Conv. 10.0 15.0 26.4 36.7 47.9Total Xylenes Conv. 24.0 28.9 54.4 63.1 67.1Ethylbenzene Conv. -18.9 14.0 29.4 40.0 56.2Selectivity, Weight %Toluene 68.6 79.8 79.3 76.3 60.3______________________________________
Turning again to the drawings, FIGS. 1-8 graphically illustrate the results of experimental work for those Catalysts I-IV, VI and VIII as described in TABLE 2. All tested catalysts were found to be active for the conversion of benzene, xylenes, and ethylbenzene. FIGS. 3-8 specifically depict conversion activities and selectivities over various combinations of metal-promoted mordenite catalysts (nickel, zinc and gallium and combinations of zinc and nickel and of gallium and nickel).
Catalysts I and II represent the nickel-promoted mordenite catalysts. Catalyst I, a conmercially available catalyst having a nickel content of approximately 1.4 weight percent, exhibited the most favorable conversion activity as compared to all other tested catalysts, with good toluene selectivity. Depending on specific economic factors with respect to the feed mixture components and conversion products, Catalyst I can be considered one of the most effective catalysts to be used in the claimed process. Catalyst II, having a nickel content of approximately 0.5 weight percent, showed good conversion activity with higher toluene selectivity than that observed for Catalyst I, 68.1% versus 58.8%. While toluene selectivity was better for Catalyst II, the overall numbers indicate that Catalyst I outperformed Catalyst II.
As previously described, Catalyst III through VIii represented the mordenite promoted with zinc or gallium, with and without the inclusion of nickel. Catalysts III, IV and VII, included nickel and zinc or gallium, while Catalysts V, VI and VIII included only zinc or gallium. Catalysts III and IV included a combination of nickel and zinc and tested the effect of inclusion of zinc in the catalyst system. Catalyst III had nickel and zinc contents of approximately 0.3 weight percent each. As compared to Catalyst II, Catalyst III showed higher activity for xylenes and ethylbenzene conversion with slightly better selectivity to toluene than Catalyst II, which did not include zinc. These results for Catalyst III suggest that the inclusion of zinc in a nickel/mordenite catalyst system enhances the activity for xylenes and ethylbenzene conversion and improves selectivity to toluene. Increasing the amount of both nickel and zinc, however, as represented by Catalyst IV having a nickel content of 1.4 weight percent and a zinc content of 0.5 weight percent, did not affect conversion activity, but did appreciably decrease toluene selectivity. While Catalyst VII, having nickel and gallium contents of 0.4 weight percent showed good conversion activity, overall conversion activity was each poorer than the nickel/mordenite or nickel/zinc/mordenite catalysts.
Catalysts V, VI, and VIII did not include nickel. Catalyst V, having a zinc content of approximately 0.5 weight percent, showed very poor performance. Catalyst VI, having a gallium content of approximately 0.5 weight percent, and Catalyst VIII, a dealuminated mordenite having a zinc content of approximately 0.5 weight percent, showed conversion activities better than those recorded for Catalyst V, but lower than those catalysts having some nickel content. Accordingly, these results suggest the desirability of a nickel-promoted mordenite catalyst, alone or in combination with other metals.
Generally, it was observed that conversion and selectivity maintained favorable levels at temperatures around 300° C. While in some instances, conversion activity and selectivity to toluene values were higher at temperatures greater than 300° C., it is well known that lower temperatures prolong the life of the catalyst. Accordingly, appreciable increases in conversion/selectivity due to increases in temperature are often offset by shortened catalyst life. Summary results listing conversion activities for benzene, xylenes, ethylbenzene and selectivity to toluene at a temperature around 300° C. are summarized in TABLE 3.
TABLE 3______________________________________Summary Results for Conversion Activities ofBenzene, Xylenes and Ethylbenzene (EB) and TolueneSelectivities. % Conversion (%) Selec- To- tivity Repre- tal to sented Temp., Xy- Ben- tol- inCatalyst °C. lenes EB zene uene FIG.______________________________________I Ni(1.4%)/ 301 51.5 40.1 25.2 58.8 1,2,3Mordenite(SAR = 18)II Ni(0.5%)/ 300 29.22 22.70 14.01 68.1 4Mordenite(SAR = 18)III Ni(0.3%)/Zn 298 37.06 26.87 14.62 73.79 5(0.3%)/Mord(SAR = 18)IV Ni(1.4%)/Zn 303 35.2 30.3 19.45 47.25 6(0.5%)/Mord(SAR = 18)V Zn(0.5%)/ 297 3.3 3.9 -0.5 39.93 --Mord(SAR = 17)VI Ga(0.5%)/ 284 17.4 16.5 10.62 50.9 7Mord(SAR = 18)VII Ni(0.4%)/Ga 299 26.10 19.2 23.40 63.98 --(0.4%)/Mord(SAR = 18)VIII Zn/Dealumi- 293 28.9 14.0 15.1 79.0 8nated Mord(SAR = 59)______________________________________
In summary, and as can be seen in TABLE 3, Catalyst I exhibited the most favorable conversions of benzene, xylene(s) and ethylbenzene with good toluene selectivity. Catalysts II-IV also exhibited good conversion percentages, with high percent selectivity to toluene. Depending on the economic forces shaping the benzene/toluene markets, each of Catalysts I-IV could be used in an efficient process for the conversion of mixed alkylaromatic feedstock mixtures, including benzene, xylenes and ethylbenzene, to hydrocarbons components comprising primarily toluene. While the results depicted in TABLE 3 were recorded for temperatures of approximately 300° C., higher temperatures (refer to Table 2) may be appropriate as a function of the catalyst employed in the conversion reaction.
While the invention has been described with reference to particular embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention or from the scope of the appended claims. | In accordance with the the present invention, there is provided a process for the conversion of aromatic hydrocarbons including benzene to hydrocarbon components comprising primarily toluene. According to the invention, a catalyst reaction zone is established having a metal-loaded mordenite catalyst. A mixed feedstock of aromatic hydrocarbons, including benzene, xylene(s) and, optionally, ethylbenzene is introduced into the reaction zone and hydrogen is used as a cofeed to provide a reductive environment. The feedstock is contacted with the metal-loaded mordenite catalyst and the conversion of the aromatic hydrocarbon components is conducted under temperature and pressure conditions sufficient to effect the conversion of the feedstock to hydrocarbon components containing primarily toluene. Finally, the conversion product containing primarily toluene is recovered from the reaction zone. | 1 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention is related in general to a power amplifier, and more particularly, to a switching amplifier that can efficiently and linearly amplify an input signal having first and second polarities for obtaining a low-distortion output signal.
(2) Description of the Related Art
Amplifiers are electronic devices which are used for increasing the power of a signal, and are generally categorized into various classes. The popular amplifiers include class A, class B and class D amplifiers.
Reference is made to the exemplary U.S. Patents that disclose various types of amplifiers: U.S. Pat. Nos. 7,952,426; 7,816,985; 7,400,191; 7,286,008; 6,922,101; 6,794,932; 6,563,377; 6,356,151; 5,949,282; 5,805,020; 5,160,896; 5,115,205; 5,014,016; 4,531,096 and 3,629,616.
In general, class A amplifiers produce a linearly amplified replica of an input signal, but are inefficient in terms of power usage because the amplifying elements are always biased and conducting, even if there is no input.
Class B amplifiers only amplify half of the input wave cycle, thus creating a large amount of distortion, but their efficiency is greatly improved and is much better than class A. A practical circuit using class B elements is the push-pull stage, such as the very simplified complementary pair arrangement. Complementary or quasi-complementary devices are each used for amplifying the opposite halves of the input signal, which is then recombined at the output. This arrangement gives excellent efficiency, but can suffer from the drawback that there is a small mismatch in the cross-over region—at the “joins” between the two halves of the signal, as one output device has to take over supplying power exactly as the other finishes. This is called crossover distortion.
In a class D amplifier an input signal is converted to a sequence of higher voltage output pulses. The averaged-over-time power values of these pulses are directly proportional to the instantaneous amplitude of the input signal. The frequency of the output pulses is typically ten or more times the highest frequency in the input signal to be amplified. The output pulses contain inaccurate spectral components (that is, the pulse frequency and its harmonics) which must be removed by a low-pass passive filter. The resulting filtered signal is then a linearly amplified replica of the input.
The main advantage of a class D amplifier is power efficiency. Because the output pulses have fixed amplitude, the switching elements are switched either completely on or completely off, rather than operated in linear mode.
However, one significant challenge for a driver circuit in class D amplifiers is keeping dead times as short as possible. “Dead time” is the period during a switching transition when both output MOSFETs are driven into Cut-Off Mode and both are “off”. Dead times need to be as short as possible to maintain an accurate low-distortion output signal, but dead times that are too short cause the MOSFET that is switching on to start conducting before the MOSFET that is switching off has stopped conducting. The MOSFETs effectively short the output power supply through themselves, a condition known as “shoot-through”. Driver failures that allow shoot-through result in excessive losses and sometimes catastrophic failure of the MOSFETs.
Therefore, the main disadvantage of a class D amplifier is having the “dead time” problem to cause the distortion of the output signal.
In summary, class A amplifiers produce a linearly amplified replica of an input signal, but are inefficient in terms of power usage. The push-pull class B amplifiers provide excellent efficiency (compared to class A amplifiers), but introduce crossover distortion. Class D amplifiers are most efficient compared to class A and class B amplifiers, but there is one significant problem for MOSFET driver circuits in class D amplifiers: the “dead time” that cause the distortion of the output signal.
Accordingly, in light of current state of the art and the drawbacks to current amplifiers mentioned above. A need exits for a switching amplifier that would continue to be highly efficient, that would efficiently and linearly amplify an input signal for generating low-distortion output signals.
SUMMARY OF THE INVENTION
The present invention discloses a switching amplifier that produces a linearly amplified replica of an input signal, is highly efficient, and does not have the “dead time” problem related to class D amplifiers.
One aspect of the present invention provides a method of obtaining an output signal, wherein the output signal is a linearly amplified replica of an input signal having first and second polarities, comprising the steps of: receiving the input signal; pulse modulating the input signal for generating a pulse modulated signal; switching a pulsed current according to the pulse modulated signal; conducting said pulsed current positively or negatively to a filter according to the polarity of the input signal; filtering said pulsed current positively or negatively conducted to the filter for outputting the output signal by the filter.
Yet another aspect of the present invention provides a method of obtaining one or more than one slave output signals that are linearly amplified replicas of the input signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present general inventive concept will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
FIG. 1 is an exemplary block and circuit diagram illustrating a first embodiment of a switching amplifier in accordance with present invention, wherein the pulsed current supply unit using an inductor.
FIG. 2 are exemplary waveform diagrams illustrating the various waveforms at input and output points of a switching control unit of various figures in accordance with the present invention.
FIG. 3 is an exemplary block and circuit diagram illustrating an embodiment of the amplifier control unit integrating an input signal and a negative feedback signal in FIGS. 1, 4 and 5 in accordance with the present invention.
FIG. 4 is an exemplary block and circuit diagram illustrating a second embodiment of a switching amplifier in accordance with present invention, wherein the pulsed current supply unit using a flyback transformer comprising an output winding.
FIG. 5 is an exemplary block and circuit diagram illustrating a third embodiment of a switching amplifier in accordance with present invention, wherein the pulsed current supply unit using a flyback transformer comprising two output windings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized.
FIG. 1 is an exemplary block and circuit diagram illustrating a first embodiment of a switching amplifier 100 in accordance with present invention, wherein the pulsed current supply unit 102 using an inductor 102 F.
As illustrated in FIG. 1 , the switching amplifier 100 of the present invention for amplifying an input signal 106 having positive and negative polarities is comprised of: a pulsed current supply unit 102 comprising a plurality of switches for switching a pulsed current from a direct current (DC) voltage 109 ; a switching power transmitting unit 104 comprising a plurality of switches and coupled to the pulsed current supply unit 102 for conducting the pulsed current from the pulsed current supply unit 102 positively or negatively to a filter unit 107 ; an amplifier control unit 105 for receiving the input signal 106 and coupled to the switches of the pulsed current supply unit 102 and the switching power transmitting unit 104 to control their switching according to the input signal 106 ; the filter unit 107 to obtain an output signal 108 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 104 and outputting the output signal 108 .
The switching amplifier 100 according to present invention, wherein the pulsed current supply unit 102 comprises: an inductance means 102 F; a first switching unit comprising two switches 102 A, 102 B coupled to the inductance means for switching a current from a direct current (DC) voltage 109 to the inductance means 102 F; a second switching unit comprising a switch 102 C and two diode 102 D, 102 E coupled between the inductance means 102 F and the direct current (DC) voltage 109 for switching a current from the inductance means 102 F to the direct current (DC) voltage 109 .
The switching amplifier 100 according to present invention, wherein the switching power transmitting unit 104 comprises: a diode 104 A for preventing a current flow from the filter unit 107 to the pulsed current supply unit 102 ; switches 104 B, 104 C, 104 D, and 104 E for transmitting a current from the switching power transmitting unit 104 to the filter unit 107 positively or negatively.
The switching amplifier 100 according to present invention, wherein the filter unit 107 is a low pass filter
In this non-limiting exemplary embodiment, the input signal 106 is an analog signal. And it should be noted that it is obvious for a corresponding embodiment of a switching amplifier in accordance with this invention for an input signal which is a discrete time signal.
As further illustrated in FIG. 1 , the amplifier control unit 105 comprises an input unit 105 A for receiving the input signal 106 and having an analog to digital converter for converting the input signal 106 to a discrete time input signal x [n]
x={x[n]}, 0<n<∞;
a pulse modulation unit 105 B for getting a pulse modulated signal from pulse modulating the discrete time input signal x[n]; and a switching control unit 105 C coupled to the switches 102 A, 102 B, and 102 C of the pulsed current supply unit 102 , the switches 104 B, 104 C, 104 D and 104 E of the switching power transmitting unit 104 to control their switching according to the pulse modulated signal from the pulse modulation unit 105 B.
In this non-limiting exemplary embodiment 100 , the amplifier control unit 105 is a digital signal processing circuit. And it is obvious for a corresponding embodiment of an analog signal processing circuit for the amplifier control unit 105 in accordance with this invention by using an input unit for receiving an analog input signal and a pulse modulator for pulse modulating said analog input signal.
FIG. 2 are exemplary waveform diagrams illustrating the various waveforms at input and output points of switching control units in the circuits of various figures in accordance with the present invention.
As illustrated in FIG. 2 , a non-limiting exemplary waveform for the pulse modulated signal from the pulse modulation unit 105 B is illustrated in FIG. 2(A) , since the input signal 106 has first and second polarities; therefore, the pulse modulated signal also has first and second polarities. According to the pulse modulated signal illustrated in FIG. 2(A) , a non-limiting exemplary waveform of switching control signals from the switching control unit 105 C to the switches 102 A and 102 B for controlling their switching are illustrated in FIG. 2(B) ; a non-limiting exemplary waveform of switching control signal from the switching control unit 105 C to the switch 102 C for controlling its switching is illustrated in FIG. 2(C) . Also according to the pulse modulated signal illustrated in FIG. 2(A) , non-limiting exemplary waveforms of switching control signals from the switching control unit 105 C to the switches 104 B, 104 D and 104 C, 104 E are illustrated in FIG. 2(D) and FIG. 2(E) , respectively.
Accordingly, as illustrated in FIG. 1 and FIG. 2 , when the input signal 106 is zero, the switches 104 B, 104 C, 104 D, 104 E of the switching power transmitting unit 104 are all switched off. The switches 102 A, 1028 and 102 C switch on and off alternately to charge and discharge the inductor 102 F to regulate current of the inductor 102 F: when the switches 102 A, 102 B switch on and 102 C switches off, the inductor 102 F is charging energy from the direct current (DC) voltage 109 ; and when the switches 102 A, 102 B switch off and 102 C switches on, the energy contained in the inductor 102 F is discharged back to the direct current (DC) voltage 109 . Therefore, at steady state, for approximately equal charging and discharging time, the energy flow in and out of the inductor 102 F are equal during each switching, therefore, this switching keeps the energy stored in the inductor 102 F constant. For the inductance of the inductor 102 F is large enough and the switching frequency of the switches 102 A, 1028 and 102 C is fast enough, the current flow through the inductor 102 F keeps approximately constant since its variation is small enough.
When the input signal 106 is not zero, as illustrated in FIG. 1 and FIG. 2(A) ˜ 2 (E), the switches 102 A, 102 B, 102 C and the switching power transmitting unit 104 switch alternately to keep the energy stored in the inductor 102 F constant, therefore when the switching power transmitting unit 104 is switched on, the current from the inductor 102 F to the filter 107 keeps constant.
As illustrated in FIG. 1 and FIG. 2(A), 2(D), 2(E) the switches 104 B˜ 104 E switch for conducting the current from the inductor 102 F to the filter unit 107 . For the polarity of the pulse modulated signal FIG. 2(A) is positive, the switches 104 B, 104 D switch on to conduct the current from the inductor 102 F to the filter unit 107 positively; otherwise, for the polarity of the pulse modulated signal FIG. 2(A) is negative, the switches 104 C and 104 E switch on to conduct the current from the inductor 102 F to the filter unit 107 negatively.
As further illustrated in FIG. 1 , the filter unit 107 is a low pass filter to obtain the output signal 108 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 104 and outputting the output signal 108 .
As further illustrated in FIG. 1 and FIG. 2 , the level of the output signal 108 can be adjusted by control the current level of the inductor 102 F. Based on the current level feedback signal 110 representing a current flow through the inductor 102 F, the switching control unit 105 C can adjust the current flow through the inductor 102 F by changing the duty ratio between the charging and discharging periods of the inductor 102 F according to the current level feedback signal 110 .
As further illustrated in FIG. 1 , the switching amplifier 100 further comprises a negative feedback signal generator 111 to generate a negative feedback signal corresponding to the output signal 112 , wherein the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 .
FIG. 3 is an exemplary block and circuit diagram illustrating an embodiment of the amplifier control unit 105 integrating the input signal 106 and a negative feedback signal 112 in FIG. 1 in accordance with the present invention.
As illustrated in FIG. 3 and FIG. 1 , the input unit 105 A has an analog to digital converter 301 and further comprises a linear digital transformer 302 and a negative feedback controller 303 . Wherein the analog to digital converter 301 receives the input signal 106 and converts the input signal 106 to a discrete time input signal:
x={x[n]}, 0<n<∞;
The linear digital transformer 302 transforms the discrete time input signal x[n] by multiplying a gain G to the discrete time input signal (the default value of the gain G is 1):
X[n]={G×x[n ]}), 0< n<∞
to get a compensated discrete time signal X[n] and sends the compensated discrete time signal X[n] to pulse modulation unit 105 B.
Accordingly, for the switching amplifier 100 further comprises the negative feedback signal generator 111 to generate the negative feedback signal corresponding to the output signal 112 and the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 , the pulse modulation unit 105 B receives the compensated discrete time signal X[n].
As further illustrated in FIG. 3 , the negative feedback controller 303 receives the discrete time input signal from the analog to digital converter 301 and compares it to the negative feedback signal 112 , therefore to adjust the gain G of the linear digital transformer 302 according to the comparison. For example, if the negative feedback signal 112 corresponding to the output signal 108 shows that the output signal 108 is below a required level, then the negative feedback controller 303 will increase the gain G of the linear digital transformer 302 to increase the output signal 108 , wherein said required level is obtained according to the discrete time input signal.
In this non-limiting exemplary embodiment 100 , the amplifier control unit 105 is a digital signal processing circuit. And it is obvious for a corresponding embodiment of an analog signal processing circuit for the amplifier control unit 105 in accordance with this invention by using an analog input unit for receiving an analog input signal, a programmable gain amplifier for amplifying the an analog input signal and a pulse modulator for pulse modulating said amplified analog signal.
FIG. 4 is an exemplary block and circuit diagram illustrating a second embodiment of a switching amplifier 400 in accordance with present invention.
As illustrated in FIG. 4 , the switching amplifier 400 of the present invention for amplifying an input signal 106 having positive and negative polarities is comprised of: a pulsed current supply unit comprising a plurality of switches 402 for switching a pulsed current from a direct current (DC) voltage 109 ; a switching power transmitting unit 404 comprising a plurality of switches and coupled to the pulsed current supply unit for conducting the pulsed current positively or negatively to a filter unit 407 ; an amplifier control unit 105 for receiving the input signal 106 and coupled to the switches 402 of the pulsed current supply unit and the switching power transmitting unit 404 to control their switching according to the input signal 106 ; the filter unit 407 to obtain an output signal 408 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 404 and outputting the output signal 408 .
The switching amplifier 400 of the present invention, wherein its pulsed current supply unit comprises: a flyback transformer 401 ; a first switching unit 402 A coupled to the flyback transformer 401 for switching a current from a direct current (DC) voltage 109 to the flyback transformer 401 ; a second switching unit 402 B coupled between the flyback transformer 401 and the direct current (DC) voltage 109 for switching a current from the flyback transformer 401 to the direct current (DC) voltage 109 ; wherein the pulsed current supply unit outputs a pulsed current when the switches of the first switching unit 402 A and the second switching unit 402 B are all switched off. A diode means 402 C is for preventing a current flow from the direct current (DC) voltage 109 to the secondary winding 401 B.
The switching amplifier 400 of the present invention, wherein the flyback transformer 401 comprises: a primary winding 401 A coupled to the first switching unit 402 A for charging energy to the flyback transformer from the direct current (DC) voltage 109 ; a secondary winding 401 B coupled to the second switching unit 402 B for discharging energy stored in the flyback transformer 401 to the direct current (DC) voltage 109 ; an output winding unit comprising an output winding 401 C for discharging energy stored in the flyback transformer to the output signal 408 .
The switching amplifier 400 of the present invention, wherein the switching power transmitting unit 404 comprises: a diode means unit 404 A for preventing a current flow from the filter unit 407 to the pulsed current supply unit; a plurality of switches 404 B, 404 C, 404 D, 404 E for transmitting a current from the pulsed current supply unit to the filter unit 407 positively or negatively.
FIG. 2 are exemplary waveform diagrams illustrating the various waveforms at input and output points of switching control units in the circuits of various figures in accordance with the present invention.
As illustrated in FIG. 2 , a non-limiting exemplary waveform for the pulse modulated signal from the pulse modulation unit 105 B is illustrated in FIG. 2(A) , since the input signal 106 has first and second polarities; therefore, the pulse modulated signal also has first and second polarities. According to the pulse modulated signal illustrated in FIG. 2(A) , a non-limiting exemplary waveform of switching control signals from the switching control unit 105 C to the switch 402 A for controlling its switching is illustrated in FIG. 2(B) ; a non-limiting exemplary waveform of switching control signal from the switching control unit 105 C to the switch 402 B for controlling its switching is illustrated in FIG. 2(C) . Also according to the pulse modulated signal illustrated in FIG. 2(A) , non-limiting exemplary waveforms of switching control signals from the switching control unit 105 C to the switches 404 B, 404 D and 404 C, 404 E are illustrated in FIG. 2(D) and FIG. 2(E) , respectively.
Accordingly, as illustrated in FIG. 4 and FIG. 2 , when the input signal 106 is zero, the switches 404 B, 404 C, 404 D, 404 E of the switching power transmitting unit 404 are all switched off. The switches 402 A and 402 B switch on and off alternately to charge and discharge the flyback transformer 401 to regulate current of the flyback transformer 401 : when the switch 402 A switches on and 402 B switches off, the flyback transformer 401 is charging energy from the direct current (DC) voltage 109 ; and when the switch 402 A switches off and 402 B switches on, the energy contained in the flyback transformer 401 is discharged back to the direct current (DC) voltage 109 . Therefore, at steady state, for approximately equal charging and discharging time, the energy flow in and out of the flyback transformer 401 are equal during each switching, therefore, this switching keeps the energy stored in the flyback transformer 401 constant. For the inductance of the primary winding 401 A is large enough and the switching frequency of the switches 402 A and 402 B is fast enough, the current flow through the flyback transformer 401 keeps approximately constant since its variation is small enough.
When the input signal 106 is not zero, as illustrated in FIG. 4 and FIG. 2(A) ˜ 2 (E), the switches 402 A, 402 B and the switching power transmitting unit 404 switch alternatively to keep the energy stored in the flyback transformer 401 constant, therefore when the switching power transmitting unit 404 is switched on, the current from the flyback transformer 401 to the filter 407 keeps constant.
As illustrated in FIG. 4 and FIG. 2(A), 2(D), 2(E) the switches 404 B˜ 404 E switch for conducting the current from the flyback transformer 401 to the filter unit 407 . For the polarity of the pulse modulated signal FIG. 2(A) is positive, the switches 404 B, 404 D switch on for conducting the current from the flyback transformer 401 to the filter unit 407 positively; otherwise, for the polarity of the pulse modulated signal FIG. 2(A) is negative, the switches 404 C and 404 E switch on for conducting the current from the flyback transformer 401 to the filter unit 407 negatively.
As further illustrated in FIG. 4 , the filter unit 407 is a low pass filter to obtain the output signal 408 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 404 and outputting the output signal 408 .
As further illustrated in FIG. 4 and FIG. 2 , the level of the output signal 408 can be adjusted by control the current level of the flyback transformer 401 . Based on the current level feedback signal 410 representing a current flow through the flyback transformer 401 , the switching control unit 105 C can adjust the current flow through the flyback transformer 401 by changing the duty ratio between the charging and discharging periods of the flyback transformer 401 according to the current level feedback signal 410 .
As further illustrated in FIG. 4 , the switching amplifier 400 further comprises a negative feedback signal generator 111 to generate a negative feedback signal corresponding to the output signal 112 , wherein the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 .
FIG. 3 is an exemplary block and circuit diagram illustrating an embodiment of the amplifier control unit 105 integrating the input signal 106 and a negative feedback signal 112 in FIG. 4 in accordance with the present invention.
As illustrated in FIG. 3 and FIG. 4 , the input unit 105 A has an analog to digital converter 301 and further comprises a linear digital transformer 302 and a negative feedback controller 303 . Wherein the analog to digital converter 301 receives the input signal 106 and converts the input signal 106 to a discrete time input signal:
x={x[n]}), 0<n<∞;
The linear digital transformer 302 transforms the discrete time input signal x[n] by multiplying a gain G to the discrete time input signal (the default value of the gain G is 1):
X[n]={G×x[n ]}), 0 <n<∞
to get a compensated discrete time signal X[n] and sends the compensated discrete time signal X[n] to pulse modulation unit 105 B.
Accordingly, for the switching amplifier 400 further comprises the negative feedback signal generator 111 to generate the negative feedback signal corresponding to the output signal 112 and the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 , the pulse modulation unit 105 B receives the compensated discrete time signal X[n].
As further illustrated in FIG. 3 , the negative feedback controller 303 receives the discrete time input signal from the analog to digital converter 301 and compares it to the negative feedback signal 112 , therefore to adjust the gain G of the linear digital transformer 302 according to the comparison. For example, if the negative feedback signal 112 corresponding to the output signal 508 shows that the output signal 508 is below a required level, then the negative feedback controller 303 will increase the gain G of the linear digital transformer 302 to increase the output signal 508 , wherein said required level is obtained according to the discrete time input signal.
In this non-limiting exemplary embodiment 400 , the amplifier control unit 105 is a digital signal processing circuit. And it is obvious for a corresponding embodiment of an analog signal processing circuit for the amplifier control unit 105 in accordance with this invention by using an analog input unit for receiving an analog input signal, a programmable gain amplifier for amplifying the an analog input signal and a pulse modulator for pulse modulating said amplified analog signal.
The switching amplifier 400 according to the present invention further comprising: a rectifying and smoothing unit comprising a full bridge rectifier 415 and a capacitor 413 to rectify and smooth an alternating current (AC) voltage 416 and to provide the direct current (DC) voltage 109 .
The switching amplifier 400 according to the present invention further comprising: isolator circuits 417 , 418 coupled between the switches 402 A, 402 B of the pulsed current supply unit and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 400 according to the present invention further comprising: isolator circuits 419 , 420 coupled between the switching power transmitting unit 404 and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 400 according to the present invention further comprising: isolator circuits 421 coupled between the negative feedback signal generator 111 and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 400 according to the present invention further comprising: the flyback transformer further comprising one or more than one slave output winding units that each slave winding unit comprises a slave output winding 401 D; one or more than one switching power transmitting units 422 and their corresponding filters 425 coupled to the slave output winding units of the flyback transformer 401 for getting or more than one slave output signals 423 corresponding to the input signal.
The switching amplifier 400 according to the present invention further comprising: isolator circuits coupled between the switching power transmitting units 422 and the amplifier control unit 105 to provide electric isolation between the switching power transmitting units 422 and the amplifier control unit 105 .
FIG. 5 is an exemplary block and circuit diagram illustrating a second embodiment of a switching amplifier 500 in accordance with present invention.
As illustrated in FIG. 5 , the switching amplifier 500 of the present invention for amplifying an input signal 106 comprising positive and negative polarities is comprised of: a pulsed current supply unit comprising a plurality of switches 502 for switching a pulsed current from a direct current (DC) voltage 109 ; a switching power transmitting unit 504 comprising a plurality of switches and coupled to the pulsed current supply unit for conducting the pulsed current positively or negatively to a filter unit 507 ; an amplifier control unit 105 for receiving the input signal 106 and coupled to the switches 502 of the pulsed current supply unit and the switching power transmitting unit 504 to control their switching according to the input signal 106 ; the filter unit 507 to obtain an output signal 508 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 504 and outputting the output signal 508 .
The switching amplifier 500 of the present invention, wherein its pulsed current supply unit comprises: a flyback transformer 501 ; a first switching unit 502 A coupled to the flyback transformer 501 for switching a current from a direct current (DC) voltage 109 to the flyback transformer 501 ; a second switching unit 502 B coupled between the flyback transformer 501 and the direct current (DC) voltage 109 for switching a current from the flyback transformer 501 to the direct current (DC) voltage 109 ; wherein the pulsed current supply unit outputs a pulsed current when the switches of the first switching unit 502 A and the second switching unit 502 B are all switched off. A diode means 502 C is for preventing a current flow from the direct current (DC) voltage 109 to the secondary winding 501 B.
The switching amplifier 500 of the present invention, wherein the flyback transformer 501 comprises: a primary winding 501 A coupled to the first switching unit 502 A for charging energy to the flyback transformer from the direct current (DC) voltage 109 ; a secondary winding 501 B coupled to the second switching unit 502 B for discharging energy stored in the flyback transformer 501 to the direct current (DC) voltage 109 ; an output winding unit comprising two output windings 501 C, 501 D for discharging energy stored in the flyback transformer to the output signal 508 .
The switching amplifier 500 of the present invention, wherein the switching power transmitting unit 504 comprises: a diode means unit comprising two diodes 504 A, 504 B for preventing a current flow from the filter unit 507 to the pulsed current supply unit; a plurality of switches 504 C, 504 D for transmitting a current from the pulsed current supply unit to the filter unit 507 positively or negatively.
FIG. 2 are exemplary waveform diagrams illustrating the various waveforms at input and output points of switching control units in the circuits of various figures in accordance with the present invention.
As illustrated in FIG. 2 , a non-limiting exemplary waveform for the pulse modulated signal from the pulse modulation unit 105 B is illustrated in FIG. 2(A) , since the input signal 106 has first and second polarities; therefore, the pulse modulated signal also has first and second polarities. According to the pulse modulated signal illustrated in FIG. 2(A) , a non-limiting exemplary waveform of switching control signals from the switching control unit 105 C to the switch 502 A for controlling its switching is illustrated in FIG. 2(B) ; a non-limiting exemplary waveform of switching control signal from the switching control unit 105 C to the switch 502 B for controlling its switching is illustrated in FIG. 2(C) . Also according to the pulse modulated signal illustrated in FIG. 2(A) , non-limiting exemplary waveforms of switching control signals from the switching control unit 105 C to the switches 504 C and 504 D are illustrated in FIG. 2(D) and FIG. 2(E) , respectively.
Accordingly, as illustrated in FIG. 5 and FIG. 2 , when the input signal 106 is zero, the switches 504 C, 504 D of the switching power transmitting unit 504 are all switched off. The switches 502 A and 502 B switch on and off alternately to charge and discharge the flyback transformer 501 to regulate current of the flyback transformer 501 : when the switch 502 A switches on and 502 B switches off, the flyback transformer 501 is charging energy from the direct current (DC) voltage 109 ; and when the switch 502 A switches off and 502 B switches on, the energy contained in the flyback transformer 501 is discharged back to the direct current (DC) voltage 109 . Therefore, at steady state, for approximately equal charging and discharging time, the energy flow in and out of the flyback transformer 501 are equal during each switching, therefore, this switching keeps the energy stored in the flyback transformer 501 constant. For the inductance of the primary winding 501 A is large enough and the switching frequency of the switches 502 A and 502 B is fast enough, the current flow through the flyback transformer 501 keeps approximately constant since its variation is small enough.
When the input signal 106 is not zero, as illustrated in FIG. 5 and FIG. 2(A) ˜ 2 (E), the switches 502 A, 502 B and the switching power transmitting unit 504 switch alternately to keep the energy stored in the flyback transformer 501 constant, therefore when the switching power transmitting unit 504 is switched on, the current from the flyback transformer 501 to the filter 507 keeps constant.
As illustrated in FIG. 5 and FIG. 2(A), 2(D), 2(E) the switches 504 C, 504 D switch for conducting the current from the flyback transformer 501 to the filter unit 507 . For the polarity of the pulse modulated signal FIG. 2(A) is positive, the switch 504 C switches on for conducting the current from the flyback transformer 501 to the filter unit 507 positively; otherwise, for the polarity of the pulse modulated signal FIG. 2(A) is negative, the switch 504 D switches on for conducting the current from the flyback transformer 501 to the filter unit 507 negatively.
As further illustrated in FIG. 5 , the filter unit 507 is a low pass filter to obtain the output signal 508 corresponding to the input signal 106 by filtering the output of the switching power transmitting unit 504 and outputting the output signal 508 .
As further illustrated in FIG. 5 and FIG. 2 , the level of the output signal 508 can be adjusted by control the current level of the flyback transformer 501 . Based on the current level feedback signal 510 representing a current flow through the flyback transformer 501 , the switching control unit 105 C can adjust the current flow through the flyback transformer 501 by changing the duty ratio between the charging and discharging periods of the flyback transformer 501 according to the current level feedback signal 510 .
As further illustrated in FIG. 5 , the switching amplifier 500 further comprises a negative feedback signal generator 111 to generate a negative feedback signal corresponding to the output signal 112 , wherein the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 .
FIG. 3 is an exemplary block and circuit diagram illustrating an embodiment of the amplifier control unit 105 integrating the input signal 106 and a negative feedback signal 112 in FIG. 5 in accordance with the present invention.
As illustrated in FIG. 3 and FIG. 5 , the input unit 105 A has an analog to digital converter 301 and further comprises a linear digital transformer 302 and a negative feedback controller 303 . Wherein the analog to digital converter 301 receives the input signal 106 and converts the input signal 106 to a discrete time input signal:
x={x[n]}, 0<n<∞;
The linear digital transformer 302 transforms the discrete time input signal x[n] by multiplying a gain G to the discrete time input signal (the default value of the gain G is 1):
X[n]={G×x[n ]}), 0< n<∞
to get a compensated discrete time signal X[n] and sends the compensated discrete time signal X[n] to pulse modulation unit 105 B.
Accordingly, for the switching amplifier 500 further comprises the negative feedback signal generator 111 to generate the negative feedback signal corresponding to the output signal 112 and the amplifier control unit 105 integrates the input signal 106 and the negative feedback signal 112 , the pulse modulation unit 105 B receives the compensated discrete time signal X[n].
As further illustrated in FIG. 3 , the negative feedback controller 303 receives the discrete time input signal from the analog to digital converter 301 and compares it to the negative feedback signal 112 , therefore to adjust the gain G of the linear digital transformer 302 according to the comparison. For example, if the negative feedback signal 112 corresponding to the output signal 508 shows that the output signal 508 is below a required level, then the negative feedback controller 303 will increase the gain G of the linear digital transformer 302 to increase the output signal 508 , wherein said required level is obtained according to the discrete time input signal.
In this non-limiting exemplary embodiment 500 , the amplifier control unit 105 is a digital signal processing circuit. And it is obvious for a corresponding embodiment of an analog signal processing circuit for the amplifier control unit 105 in accordance with this invention by using an analog input unit for receiving an analog input signal, a programmable gain amplifier for amplifying the an analog input signal and a pulse modulator for pulse modulating said amplified analog signal.
The switching amplifier 500 according to the present invention further comprising: a rectifying and smoothing unit comprising a full bridge rectifier 515 and a capacitor 513 to rectify and smooth an alternating current (AC) voltage 516 and to provide the direct current (DC) voltage 109 .
The switching amplifier 500 according to the present invention further comprising: isolator circuits 517 , 518 coupled between the switches 502 A, 502 B of the pulsed current supply unit and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 500 according to the present invention further comprising: isolator circuits 519 , 520 coupled between the switching power transmitting unit 504 and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 500 according to the present invention further comprising: isolator circuits 521 coupled between the negative feedback signal generator 111 and the amplifier control unit 105 to provide electric isolation between them.
The switching amplifier 500 according to the present invention further comprising: the flyback transformer further comprising one or more than one slave output winding units that each slave winding unit comprises two slave output windings 501 E, 501 F; one or more than one switching power transmitting units 522 and their corresponding filters 525 coupled to the slave output winding units of the flyback transformer 501 for getting or more than one slave output signals 523 corresponding to the input signal.
The switching amplifier 500 according to the present invention further comprising: isolator circuits coupled between the switching power transmitting units 522 and the amplifier control unit 105 to provide electric isolation between the switching power transmitting units 522 and the amplifier control unit 105 .
From the switching amplifiers 100 , 400 and 500 in accordance with the present invention, one aspect of the present invention provides a switching amplifier that is highly efficient and without the “dead time” problem related to the class D amplifiers. Accordingly, the switches of the switching amplifiers 100 , 400 and 500 are never short the direct current (DC) voltage through themselves.
From the switching amplifiers 100 , 400 and 500 in accordance with the present invention, another aspect of the present invention provides a switching amplifier that its output signal is completely off when there is no input signal, as illustrated in FIG. 2 .
From the switching amplifiers 100 , 400 and 500 in accordance with the present invention, yet another aspect of the present invention provides a switching amplifier comprised of an act of comparing an input signal with an output feedback signal for detection and correction of overall system signal processes therefore is substantially immune to DC current source supply and load perturbations, as illustrated in FIGS. 1, 4 and 5 .
It is to be understood that the above described embodiments are merely illustrative 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. | A switching amplifying method or a switching amplifier for obtaining one or more than one linearly amplified replicas of an input signal, is highly efficient, and does not have the disadvantage of “dead time” problem related to the class D amplifiers. Said switching amplifying method comprises the steps of: receiving the input signal; pulse modulating the input signal for generating a pulse modulated signal; switching a pulsed current from a direct current (DC) voltage according to the pulse modulated signal; conducting said pulsed current positively or negatively to a filter according to the polarity of the input signal; filtering said pulsed current positively or negatively conducted to the filter for outputting an output signal by the filter. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
A portable device for both trimming vegetation and for concomitantly collecting the resultant clippings.
2. Description of the Prior Art
Most commercial portable hedge and shrub trimmers are not furnished with an integral clippings collector. Such appurtenances are common however in the case of lawn mowers such as the well known rotary power mowers. In this case a simple catch bag is provided behind the mower, with the grass clippings simply being flung, thrown or pushed into the bag.
The advantages of providing an integral clippings collector in conjunction with a portable hedge and shrub trimmer are numerous, and the prior art has suggested several configurations of feasible clippings collectors.
Among the pertinent prior art in this field may be mentioned U.S. Pat. Nos. 3,916,521; 3,795,050; 3,552,013; 3,073,025; 2,747,276; 2,281,189; and 1,833,246; and British Pat. Nos. 632,539 and 618,339. These prior art patents generally provide bulky and heavy configurations, albeit portability is contemplated. Generally there is nothing to prevent clippings from falling back out of the devices if they are tipped forwards. In this case, the clippings will fly out of the device due to brush action and will be widely scattered and dispersed. Generally these prior art devices are not amenable to cutting the sides of hedges or shrubs, and they are heavy in weight which necessitates the provision of straps etc. for mounting the device on the person of the operator, rather than being truly lightweight enough to be completely portable.
SUMMARY OF THE INVENTION
Purposes of the Invention
It is an object of the present invention to provide an improved combination hedge trimmer and clippings collector.
Another object is to prevent severed vegetation from being dispersed onto the ground, or onto hedges or shrubs or the like, when being cut with a hedge trimmer.
A further object is to provide a lightweight portable hedge trimmer and clippings collector.
An additional object is to provide an improved hedge trimmer with integral clippings collector.
Still another object is to provide a hedge trimmer and clippings collector in which the jamming or clogging of the device due to accumulation of clippings is effectively prevented.
Still a further object is to provide a hedge trimmer and clippings collector which may be operated at an angle to the horizontal plane without having collected clippings fall out of the device or back onto the hedge trimmer blades.
Still an additional object is to provide a hedge trimmer and clippings collector which may be tipped forwards, or inclined rearwards, or employed in a sideways vertical orientation to cut the sides of hedges, shrubs or the like, without having accumulated clippings fall out of the clippings collector section of the device.
An object is to provide a hedge trimmer and clippings collector in which clippings are immediately and permanently removed and separated from the hedge trimmer portion of the device.
An object of the invention is to provide an improved device for the trimming or cutting of leaves, twigs, vines, excessive growth, branches, blades or shoots from hedges, shrubs; grass and/or weeds growth such as in parks, lawns, farms or cemeteries; or from trees, bushes and the like vegetation.
These and other objects and advantages of the present invention will become evident from the description which follows.
Brief Description of the Invention
Within the context of the present invention, the term hedge trimmer will be understood to encompass and include a mechanical device provided with a plurality of juxtaposed blades, for the trimming or cutting of leaves, twigs, vines, branches, shoots, or any form of excessive growth of vegetation, from hedges, shrubs, bushes, trees, or from grass and/or weeds growth, such as in parks, lawns, farms, cemeteries, or about and around private homes and other dwellings.
In the present invention, a combination hedge trimmer and clippings collector is provided which includes a generally linear, i.e. straight, slightly curved, arcuate or C-shaped, hedge trimmer portion. The hedge trimmer portion in any case consists essentially of a plurality of juxtaposed blades together with means to reciprocate the blades. Although reciprocation per se of the blades is the usual practice in hedge trimmer specification and design, within the context of the present invention reciprocation will be understood to encompass and include not only conventional opposed shearing movement of adjacent blades relative to each other, but also a chain saw type of motion of the blades, i.e., in a continuous looped path. In any event, the blades are movable relative to stationary vegetation so that at least a portion of the vegetation may be severed from connection to ground. In most instances, gaps between the teeth or blades of the hedge trimmer grab and pull branches or other vegetation into cutting grooves. Typically the blade is a single or double edged toothed blade of alloy steel which provides thousands of cuts per minute. The blade or blades are driven in most instances by an electric motor which receives power from ordinary house current (cord-type) or from rechargeable batteries (cordless type).
The present device further includes a generally cylindrical brush which is of any generally cylindrical configuration, e.g. a plurality of parallel liner, spiral or circular rows of tufts of bristles which extend outwards from an inner attachment to a rigid support such as a metal pipe or cylinder. In any case the brush is rotatable about its central axis so that the tufts describe circular paths and a cylindrical sweeping action is attained. The central axis of the brush means is oriented substantially parallel to the hedge trimmer.
In accordance with the present invention, a baffle of specific orientation relative to the balance of the elements in the device is provided. One edge of the baffle is juxtaposed with the hedge trimmer, and the baffle is disposed about a portion of the circular path of motion of the terminal ends of the brush means, so that these terminal ends of the tufts of the brush means are contiguous with the baffle during a portion of the rotation of the brush means.
An enclosure is provided about and extending from the terminus of the baffle, such terminus being spaced away from the hedge trimmer portion of the device. Thus the severed portion of the vegetation is directed by the brush means to a disposition first adjacent to, and then contiguous with, the aforementioned baffle. Thereafter, the severed portion of the vegetation is discharged by the brush means from juxtaposition with the baffle and into the enclosure, wherein the successive clippings, i.e. severed portions of the vegetation, are accumulated.
The device is completed in its broadest embodiment by the provision of suitable means to periodically remove accumulated severed portions of the vegetation from the enclosure, as well as by the provision of suitable means to manipulate the hedge trimmer so that the plurality of juxtaposed blades are brought in contact with further portions of stationary vegetation to be severed from connection to ground.
The brush means generally will consist of a plurality of juxtaposed tufts, each of such tufts consisting of a plurality of contiguous linear bristles, fibers or strands, with the tufts extending radially outwards from the central axis of the brush means as mentioned supra. However, the brush means may alternatively consist of any type of cylindrical brush configuration, e.g. one in which the individual tufts or bristles are mounted on a plurality of parallel linear slats or holders which are spaced apart and oriented so as to define a cylindrical configuration, with the slats being attached by rods or the like to a central shaft or axle which in turn is rotated by suitable driving means.
The hedge trimmer in a preferred embodiment will consist of at least two rows of blades, with the blades in each row being spaced apart from each other, and with the two rows of blades being contiguous. Reciprocating motion of one row of blades relative to the next in this case provides the cutting action. In most instances the hedge trimmer will be of straight line form, however other configurations such as a slightly bowed, curved or arcuate linear hedge trimmer may be employed, in which case the vegetation being trimmed or cut would be urged inwards into the blades or teeth area, the center of the hedge trimmer in this case being rearwards of the path of cutting action.
Any suitable means to rotate the brush means about its central axis may be provided, however typically such rotation means includes a motor and a shaft, with the motor rotating the shaft and the shaft extending from the motor to connection with the central axis of the brush means. The shaft will usually be a rigid member of straight line form, and in this case the shaft will be coaxial with the central axis of the brush means. However, alternatively the drive shaft may be a flexible linear shaft within an annular casing, with the flexible linear shaft being curved to accommodate for the relative dispositions of the motor and brush means.
The enclosure may be of any suitable configuration to accommodate the terminal dimension of the baffle and the path of travel of the severed portions of vegetation, however preferably the enclosure is of generally rectangular parallelpiped form. Typically the enclosure is provided with a movable panel, which when shut allows for the accumulation of clippings, i.e. severed portions of vegetation, and which when open permits the dumping of accumulated clippings of severed portions of vegetation into a trash bin or can or for other suitable disposal of the clippings, which clippings in some instances of home gardening will be added to a compost heap or pile. The movable panel may be slidably adjustable in grooves to alternate open and shut position, however in a preferred embodiment the movable panel is adjustable to alternate open and shut positions by the provision of suitable means to manually pivot the movable panel about one edge thereof.
A unique configuration of means to pivot the movable panel about one edge thereof contemplated in the present invention entails the provision of an angular handle, which handle is mounted on the enclosure with the inner portion of the handle being partially rotatable about its central axis. The handle extends from within the enclosure to external means for manipulation of the handle. A lever is also provided, which lever extends laterally from the end of the handle within the enclosure. Finally, a rod is provided. One end of the rod is pivotally attached to the outer end of the lever, and the other end of the rod is pivotally attached to the movable panel, so that partial rotation of the handle causes the lever to displace the rod, the rod thereby pivoting the movable panel about its edge.
The aforementioned handle will preferably be right angled, with the inner portion of the handle being perpendicular to and extending through a planar wall of the enclosure and with the outer portion of the handle being parallel to the wall of the enclosure and provided with staggered serrations, bumps or ridges for easy manipulation by the user.
In a preferred embodiment, and in order to stabilize the movable panel in the closed position while still permitting easy manipulation of the movable panel to the opened position as a temporary expedient for periodic disposal of accumulated clippings, suitable spring means are provided external to the enclosure and in conjunction with the handle, to bias the handle away from the enclosure. At least one roller and detent means within the enclosure are provided in conjunction with the spring means. The roller extends laterally from the handle and is in contact with the detent means. The detent means extends about at least a portion of the handle and is attached to the inner wall of the enclosure, so that the handle is maintained in a fixed position, with the movable panel in shut position, by the roller mating with the detent means, except during periodic dumping of accumulated clippings, at which time the handle is concomitantly manually depressed into the enclosure and then is partially rotated, so as to pivot the movable panel about its edge.
The movable panel is preferably rectangular so as to conform to the preferred rectangular parallelepiped configuration of the enclosure, and in this regard the movable panel may be and extend over all or a portion of a wall or walls of the enclosure. As will appear infra, this wall may be either a top wall, a side wall or a rear wall of the enclosure. Any of these configurations and orientations of discharge movable panel will work satisfactorily. The top discharge offers the least chance of damaging the movable panel, which is comparable to a door, when emptying the clippings into a trash can or the like. The rear discharge is the most convenient, but is also the most susceptible to damage. The side discharge is also highly susceptible to damage. Thus the main and most feasible orientation of the movable panel is as a top discharge door.
A portion of the enclosure is preferably foraminous, i.e., all or a portion of one or more walls of the enclosure may be provided with perforations or an integral wire mesh screen or the like, so that air may escape from within the enclosure as the quantity of severed vegetation portions or clipping increases within the enclosure. Thus air pressure within the enclosure which could inhibit the action and movement of the brush means is prevented.
The baffle is preferably slightly arcuate so as to conform to the circular path of motion of the ends of the tufts or bristles of the brush means, however a flat planar baffle may alternatively be provided for reasons of simplicity, lower cost and ease of assembly. However in most instances arcuate, i.e. curved, bowed or otherwise configured baffle will be provided so as to conform to the cylindrical configuration of the brush means and thereby to rapidly and completely direct clippings to the enclosure without the accumulation of clippings at the interface between the brush means and the baffle or at the terminal end of the baffle.
In most instances, the means to reciprocate the cutter blades of the hedge trimmer, and the means to rotate the brush means about its central axis, extend from a common power generation means such as the electric motor or the like mentioned supra. However, it is evident that it is also feasible, and may prove desirable in some instances, to provide a separate individual drive means for the reciprocation of the blades, and a separate individual drive means for rotation of the brush means.
The present combination hedge trimmer and clippings collector provides several salient advantages. One salient advantage is that the clippings are caught and collected in situ, so that the clippings are not scattered about adjacent to the hedge or shrub. Thus the clippings, which if left ungathered would soon age and wither to an unsightly brown color, are collected before they fall into the hedge or shrub or onto the ground, and the necessity of tedious raking around the hedge or shrub, or the shaking of the hedge or shrub to dislodge clippings, is obviated. Another desirable attribute of the present integral clippings collector is that the branches and/or stems, and leaves, when cut, cannot fall back into the cutting blades or associated mechanism, and hence the likelihood of the apparatus clogging or jamming due to a bulky accumulation of severed vegetation is eliminated. The present device is lightweight and is truly portable, and may be operated at an angle to the horizontal plane without having collected clippings fall out of the device or back onto the hedge trimmer blades. Thus the present hedge trimmer and clippings collector, during operation, may be tippd forwards, or inclined rearwards, or employed in a sideways vertical orientation to cut the sides of hedges, shrubs or the like, without having accumulated clippings fall out of the clippings collector enclosure section of the device, since the clippings are immediately and permanently removed and separated from the hedge trimmer portion of the device. Finally, the present device is of low cost and is relatively simple and easy to fabricate, assemble and market, since the present device does not entail the provision of complex or costly parts, structure and appurtenances.
The invention accordingly consists in the features of construction, combination of elements and arrangement of parts which will be exemplified in the device hereinafter described and of which the scope of application will be indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings in which are shown several of the various possible embodiments of the invention:
FIG. 1 is an overall perspective view of one embodiment of the device;
FIG. 2 is a sectional elevation view of a portion of the device, taken substantially along the line 2--2 of FIG. 1;
FIG. 3 is a sectional elevation view of the device taken substantially along the line 3--3 of FIG. 1;
FIG. 4 is a perspective view of the handle and appurtenances thereto;
FIG. 5 is a sectional elevation view taken substantially along the line 5--5 of FIG. 4;
FIG. 6 is a bottom plan view taken substantially along the line 6--6 of FIG. 5;
FIG. 7 is a perspective view of the handle similar to FIG. 4 but showing movement, i.e. rotation, of the handle so as to open the movable panel by a pivoting of the movable panel about one edge thereof;
FIG. 8 is a perspective view of an alternative embodiment of the present device;
FIG. 9 is a sectional elevation view showing an alternative embodiment in which the movable panel opens from the rear wall of the device; and
FIG. 10 is a plan view showing an alternative embodiment in which the movable panel opens from a side wall of the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1, 2 and 3, the device is generally characterized by the provision of a hedge trimmer section 20, a clippings collector enclosure section 22, and a motor 24 to provide motive power for the device. The hedge trimmer section 20, as best shown in FIGS. 2 and 3, is provided with two rows 26 and 28 of reciprocating blades or teeth, mounted respectively in juxtaposition, so as to exert a cutting or shearing action, on stationary straight linear frame 30 and movable straight linear frame 32, which frame 32 is reciprocated by connection 34 and gearing, not shown, to motor 24. The upper stationary frame 30 is attached via bolting such as 36 (FIG. 3) to stationary parts of the framework of the device, in this case to a stationary baffle 38 furnished in accordance with the present invention. It will be evident that both frames 30 and 32 may be reciprocated in successive cyclic opposite directions by motor 24, if so desired.
The device is grasped by knobbed or knurled handles 40 and 42. Forwards manual manipulative movement of the device, as indicated by the arrow 44, across and through vegetation 46 while the hedge trimmer blades 26 and 28 are reciprocating causes the severing of portions 48 of vegetation to take place, so that the severed portions 48 are no longer connected to ground. The severed portions or clippings 48 ultimately join a body of accumulated clippings 50 in the enclosure section 22 of the device as will appear infra.
The clippings 48 are initially swept upwards and away from the teeth or blades 26 by virtue of the provision of a generally cylindrical brush means 52, best seen in FIG. 3 as composed of a plurality of tufts or bristles 54 in clumps which radially extend outwards from a central annular longitudinal mounting 56 which in turn is driven by a central axle or shaft 58. The shaft 58 extends to motor 24, as best seen in FIG. 2, so that the motor 24 provides motive power for both rotation of the bristles 54 and reciprocating movement of teeth or blades 28.
The direction of rotation of the bristles 54 is indicated by arrows 60 (FIG. 3). This counterclockwise rotation of the bristles 54 serves to sweep the clippings 48 upwards and rearwards above baffle 38, and thereafter the momentum of the clippings 48 causes them to lodge with the accumulated clippings 50. As best seen in FIG. 3, the baffle 38 is slightly arcuate in this embodiment of the invention, so as to accommodate for the circular path of travel of the terminal ends of the bristles 54.
Thus the clippings 50 lodge and accumuate on the lower wall or floor 62 of the enclosure 22, which as shown is a rectangular parallelepiped container extending rearwards from a curved front panel section 64 which is provided as a guard means to prevent inadvertnet extension of limbs such as a hand or an arm of the user into the moving parts of the device, which could cause injury to the person. The floor 62 of the container 22 also extends rearwards from a stiffening panel 66 which depends from the terminal end of baffle 38 so as to provide structural rigidity to the baffle 38. The box-like configuration of section 22 is preferably obtained by the provision of upper and lower opposed halves, sections 68 and 70, which are joined at a flanged interface 72 by bolts such as bolt 74 (FIG. 3). As shown in FIG. 2, bolting 76 secures connector beam 34 to the framework of the hedge trimmer and clippings collector so that motor 24 is permanently attached to the device. Electric power to drive the motor 24, which in this embodiment of the invention is an electric motor, is furnished by cord 78 which extends to a terminal plug 80 which is inserted into a socket or other electrical outlet, not shown.
A wire mesh screen 82 is mounted in and forms part of the rear wall of upper container portion 68 so as to permit the egress of air from the interior of the device. Air pressure buildup within the enclosure, both from accumulation of clippings 50 and from the rotary motion of the bristles 54 of the brush means 52, is thus effectively prevented. Such air pressure buildup could act as an impediment to free rotary motion of the bristles 54 and thus as a drag and extra burden on the motor 24, as well as impeding free flow and motion of the cuttings or clippings 48 towards the rear of the enclosure.
Referring now to the handle 40, and as best seen in FIGS. 3-7, in this embodiment of the invention, structure is provided to restrain a movable top panel 84 in a closed position during operation of the device to cut vegetation as shown in FIG. 3, while allowing for periodic pivotal displacement of the panel 84, as shown in phantom outline in FIG. 3, and also as shown in FIG. 7, to permit opening of the enclosure or container 22 so that accumulated clippings 50 may be removed from the device by inverting or tipping the unit thereby dumping the clippings 50 for suitable disposal as described supra.
The handle 40 is mounted in front section 86 of top portion 68 of the enclosure 22 in such a manner as to permit restrained partial rotation of the dependent front portion 88 of the handle 40, which portion 88 extends at a right angle to the horizontal portion of handle 40 which is grasped by the hand of the user, and as shown in FIG. 3, portion 88 extends vertically downwards through section 86 and into the interior of the enclosure. A spring 90 circumscribes the portion 88 immediately external to section 86, and the spring 90 is maintained under compression by the provision of an upper circular ring 92 about portion 88, which ring 92 is restrained from moving away from section 86 by pin 94. Upwards motion of the entire handle assemblage away from the interior of the enclosure 22 is prevented by the provision of a lower pin 96 (FIGS. 5 and 6) which extends laterally through portion 88 to terminal rollers or roller bearings 98. Since the spring 90 is under compression, rollers 98 are urged upwards against circular plate 100 which is fastened to the underside of section 86 by bolts 102 and which is provided with detents 104 and 106. Thus the handle section or portion 88 is urged upwards by the spring 90 so that the rollers 98 tend to remain seated in detents 104 and 106, and the handle is restrained from any motion, in particular from partial rotational movement, unless and until downwards force is exerted against the handle 40 and/or concomitantly twisting force is exerted by the hand of the user. This is only done when dumping of accumulated clippings 50 is to take place, by the pivoting of panel 84 about one edge defined by hinge 108, as shown in FIG. 7 and in phantom outline in FIG. 3. The pivotal motion of panel 84 at this time is indicated by arrow 109 (FIG. 3) and the concomitant partial rotational motion of handle 40 and especially section 88 is indicated by arrows 110 (FIG. 7).
In order to accomplish these motions, a lever 111 depends laterally from the lower and inner terminus of the handle portion 88. The lever 110 is secured to handle portion 88 by an inner sleeve 112 which extends upward concentrically within and contiguous to the lower part of portion 88 and which is secured in place by virtue of the pins 94 and 96 extending through opposed holes in both elements 88 and 112, see especially FIG. 5. A rod 114 is swiveledly or pivotally attached at one end to the outer end of the lever 111, and the other end of the rod 114 is swiveledly or pivotally attached to a fitting 116 which is secued to the lower surface of the movable panel 84. Thus the coaction of the handle portion 88, lever 111 and rod 114 serves to pivot panel 84 about hinge 108 when handle 40 is grasped and manipulatively partially rotated from the position shown in FIG. 4 to that of FIG. 7, as indicated by arrows 110. When this happens, the rollers 98 leave the detents 104 and 106 and assume positions juxtaposed with bolts 102. It will be understood as mentioned supra that during normal operating periods of the device, i.e. unless accumulated clippings 50 are being dumped, the handle 40 is in the position shown in FIG. 4 and the detents 104 and 106 serve to restrain the handle 40 against inadvertent or accidental rotation and thus accidental opening of the enclosure via pivoting of panel 84 about hinge 108 is effectively prevented, which is important since the device as discussed supra is intended to be used in a variety of dispositions, e.g. inclined forwards, backwards or sideways, in which case accidental opening of the enclosure and premature spillage of the accumulated clippings 50 onto the ground or onto the vegetation being trimmed or cut is effectively prevented.
FIG. 8 shows an alternative configuration of the hedge trimmer and clippings collector in which the means to rotate the brush means is a flexible linear shaft within an annular casing 118, which element 118, and also the flexible shaft disposed coaxially inside elements 118, are curved to accommodate mechanical power transfer from an upper outlet 120 of motor 24 to a side inlet 122 of the brush means portion of the device. FIG. 8 also shows an alternative configuration of the enclosure or container for clippings collection, namely an entirely foraminous cloth or wire screen or mesh rear section 124 provided with a back horizontal zipper means 126 which is periodically manipulated by sliding end slider 128 laterally so as to open the zippered section 124, so that accumulated clippings may be removed from the device. The rear section 124 in this embodiment is supported by an internal or external rigid framework, ribs, or webs composed of rigid linear stiffening or beam members, not shown.
FIG. 9 shows an alternative configuration in which the movable panel is disposed at the rear of the device as a rear wall. The foraminous screen 82 in this case is disposed in the top horizontal wall 68 of the device. FIG. 10 shows another alternative embodiment in which the movable panel is disposed as part of a side wall of the device. The disposition of the various appurtenances to acommodate for these configurations of FIGS. 9 and 10 is clearly evident.
It thus will be seen that there is provided a device which achieves the various objects of the invention and which is well adapted to meet the conditions of practical use.
As various possible embodiments might be made of the above invention, and as various changes might be made in the embodiments above set forth, it is to be understood that all matter herein described or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. Thus, it will be understood by those skilled in the art that although preferred and alternative embodiments have been shown and described in accordance with the Patent Statutes, the invention is not limited thereto or thereby. | A portable device for trimming hedges, shrubs and trees, cutting grass etc. in which an integral clippings collector is provided. The device features a hedge trimmer consisting of reciprocating blades, a generally cylindrical rotatable brush juxtaposed with the hedge trimmer, and a baffle so disposed in relation to the hedge trimmer and brush that severed portions of the vegetation are directed to an enclosure in which the severed portions are collected. In a preferred embodiment the enclosure may be periodically emptied of accumulated vegetation by pivoting a panel portion of the enclosure about one edge thereof. | 0 |
[0001] This application is a continuation of U.S. patent application Ser. No. 14/996,711, filed 15 Jan. 2016, which is a continuation of U.S. patent application Ser. No. 13/643,688, filed 16 Nov. 2012, which is a national stage application of PCT/SE2012/051140, filed 23 Oct. 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61/550,646, filed 24 Oct. 2011, the disclosures of each of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The embodiments of the present invention relates to a decoder and an encoder and methods thereof for managing reference pictures to be used for decoding an encoded representation of a picture of a video sequence.
BACKGROUND
[0003] High Efficiency Video Coding (HEVC) is a new video coding standard currently being developed in Joint Collaborative Team—Video Coding (JCT-VC). JCT-VC is a collaborative project between Moving Picture Experts Group (MPEG) and International Telecommunication Union—Telecommunication Standardization Sector (ITU-T). Currently, an HEVC Model (HM) is defined that includes a number of new tools and is considerably more efficient than H.264/Advanced Video Coding (AVC).
[0004] A picture in HEVC is partitioned into one or more slices, where each slice is an independently decodable segment of the picture. This means that if a slice is missing, for instance got lost during transmission, the other slices of that picture can still be decoded correctly. In order to make slices independent, they do not depend on each other. No bitstream element of another slice of the same picture is required for decoding any element of a particular slice.
[0005] Each slice contains a slice header which independently provides all required data for the slice to be independently decodable. One example of a data element present in the slice header is the slice address, which is used for the decoder to know the spatial location of the slice. Another example is the Buffer Description also referred to as Reference Picture Set which contains information of which reference pictures to be used when decoding a picture. However, these are only examples of data elements in the slice header.
[0006] HEVC has mechanisms for handling reference pictures. The reference pictures are previously decoded pictures to be used for decoding of a current picture. A decoded picture buffer (DPB) contains pictures decoded by the decoder. A reference picture in HEVC is a picture in the decoded picture buffer (DPB) that is available for reference by being marked “used for reference”. There may also be pictures in the DPB that are marked “unused for reference”, these pictures are not available for reference and are not reference pictures.
[0007] HEVC uses absolute signaling of reference pictures. The absolute signaling is realized by signaling what reference pictures to keep at the decoder. The signalling is done in a Buffer Description also referred to as Reference Picture Set (RPS), for each picture explicitly or by using a reference to a Sequence Parameter Set (SPS). The RPS also contains an indication of which pictures can be used for reference by the current picture. Reference pictures indicated to be used by the current picture are included in reference picture lists in the decoder. The reference picture lists are then used in the decoding process of the current slice of the current picture.
[0008] Each reference picture in the RPS is either identified as a short-term picture or as a long-term picture. The information if it is a short-term or a long-term reference picture is signaled in the RPS by sending two separate sets, one with all short-term reference pictures and one with all long-term reference pictures. An alternative design would be to send a single list and for each element indicate with a flag if it is a long-term reference picture or a short-term reference picture.
[0009] Picture Order Count (POC) is used in HEVC to define the output order (or display order) of pictures and also to identify reference pictures. Syntax elements used to derive the POC is signaled for each reference picture in the RPS. For short-term reference pictures the values of POC in the RPS must be identical to the values of POC signaled in the slice header of the reference picture to which the values of the POC in the RPS are referring. For long-term reference pictures there are two options; either the values of POC in the RPS are identical to the values of POC signaled in the slice header of the reference picture to which the values of the POC in the RPS are referring or the values of POC in the RPS are a shorter representation of to the values of POC signaled in the slice header (a.k.a. the least significant bits of the picture order count value or the POC_LSB) of the reference picture to which the values of the POC in the RPS are referring such that the reference pictures are uniquely identifiable. The latter is only allowed when there is only one picture in the DPB with a specific POC_LSB. For long-term reference pictures the term “corresponds to” is used to denote the identification of a reference picture using any of the two above mentioned options.
[0010] When buffer descriptions were originally proposed for inclusion in HEVC, the proposal included a marking process performed so that reference pictures that are in the DPB but not included in the RPS are marked as “unused for reference” prior to decoding of the current picture. The output process is also performed prior to the decoding of the current picture.
SUMMARY
[0011] An object of the embodiments is to achieve an improved reference picture handling. That is achieved by taking into account whether the reference pictures in the decoded picture buffer are long-term reference pictures or short-term reference pictures when determining how they should be marked when the information of the reference picture set is received. The reference pictures are marked as “used for short-term reference” or “used for long-term reference” in the Decoded Picture Buffer (DPB) depending on whether they are included as short-term pictures or long-term pictures in the RPS of a current picture.
[0012] According to a first aspect according to embodiments, a method performed by a decoder for managing reference pictures to be used for decoding an encoded representation of a picture of a video sequence is provided. In the method, a reference picture set received from an encoder is decoded, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer. A POC value indicated in the reference picture set is decoded and it is determined if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture. If the POC value indicated in the reference picture set corresponds to a long-term reference picture:
[0013] if there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping the long-term reference picture in a decoded picture buffer as a long-term reference picture,
[0014] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, marking the short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer,
[0015] if the POC value indicated in the reference picture set corresponds to a short-term reference picture:
[0016] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping the short-term reference picture in the decoded picture buffer as a short-term reference picture.
[0017] According to a second aspect according to embodiments, a decoder for managing reference pictures to be used for decoding an encoded representation of a picture of a video sequence is provided. The decoder is configured to decode a reference picture set received from an encoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer and to decode a POC value indicated in the reference picture set. The decoder comprises a processor configured to determine if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture. Further, the processor is configured, when there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a long-term reference picture, to keep the long-term reference picture in a decoded picture buffer as a long-term reference picture, the processor is further configured, when there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a long-term reference picture, to mark the short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer. The processor is further configured, when there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a short-term reference picture, to keep the short-term reference picture in the decoded picture buffer as a short-term reference picture.
[0018] According to a third aspect according to embodiments, a method performed by an encoder for managing reference pictures to be used for encoding an encoded representation of a picture of a video sequence is provided. In the method, a POC value is assigned wherein the POC value is selected such that a decoder can perform the following steps:
decoding a reference picture set received from an encoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer: decoding a Picture Order Count, POC, value indicated in the reference picture set and determining if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture,
[0022] if the POC value indicated in the reference picture set corresponds to a long-term reference picture:
[0023] if there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping the long-term reference picture in a decoded picture buffer as a long-term reference picture,
[0024] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, marking the short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer,
[0025] if the POC value indicated in the reference picture set corresponds to a short-term reference picture:
[0026] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping the short-term reference picture in the decoded picture buffer as a short-term reference picture and
including the assigned POC value in a reference picture set to be sent to a decoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer of the decoder.
[0028] According to a fourth aspect according to embodiments, an encoder for managing reference pictures to be used for encoding an encoded representation of a picture of a video sequence is provided. The encoder comprises a processor for assigning a POC value wherein the POC value is selected such that a decoder can perform the following steps
decoding a reference picture set received from an encoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer: decoding a POC value indicated in the reference picture set and determining if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture,
[0032] if the POC value indicated in the reference picture set corresponds to a long-term reference picture:
[0033] if there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping ( 206 ) the long-term reference picture in a decoded picture buffer as a long-term reference picture,
[0034] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, marking ( 207 ) the short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer,
[0035] if the POC value indicated in the reference picture set corresponds to a short-term reference picture:
[0036] if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, keeping ( 208 ) the short-term reference picture in the decoded picture buffer as a short-term reference picture.
[0037] and the processor is further configured to include the assigned POC value in a reference picture set to be sent to a decoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer of the decoder.
[0038] An advantage with the embodiments is that the taking into account whether the reference pictures in the decoded picture buffer are long-term reference pictures or short-term reference when performing the picture marking process improves possibilities for detecting erroneous bitstream which is thus useful for example for error detection in error prone networks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 illustrates schematically reference picture handling according to embodiments of the present invention.
[0040] FIG. 2 is a flowchart illustrating the method in a decoder according to an embodiment of the present invention.
[0041] FIG. 3 illustrates an encoder in the context of the embodiments of the present invention.
[0042] FIG. 4 illustrates a decoder according to the embodiments of the present invention.
[0043] FIG. 5 is a flowchart illustrating the method in an encoder according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0044] With reference to FIG. 1 , the encoder 300 informs the decoder 400 about which reference pictures to use for decoding of a particular picture by including the POCs of the reference pictures in the reference picture set (RPS) 101 . The RPS is sent for each picture either in the slice header for the particular picture or in other control information. The decoder 400 stores decoded pictures in a decoded picture buffer (DPB) 103 and marks the pictures of the DPB as either used for reference or as not used for reference. In HEVC, the marking is performed before decoding of a current picture.
[0045] The reference pictures are included in the RPS 101 either as short-term (st) reference pictures or long-term (It) reference pictures and according to the embodiments there is a restriction that pictures that once have been included in the RPS as long-term pictures can not later be included as, or be converted to, short-term pictures in the DPB. Thus, the reference pictures are marked as “used for short-term reference” or “used for long-term reference” in the Decoded Picture Buffer (DPB) depending on whether they are included as short-term pictures or long-term pictures in the RPS of a current picture.
[0046] The POCs of the respective pictures in the DPB marked as used for reference are inserted into reference picture lists 105 a , 105 b e.g. denoted RefPicSetLtCurr, RefPicSetLtFoll, RefPicSetStCurrBefore, RefPicSetStCurrAfter or RefPicSetStFoll. The POCs of the long-term reference pictures are inserted in RefPicSetLtCurr or RefPicSetLtFoll and the POCs of the short-term reference pictures are inserted in RefPicSetStCurrBefore, RefPicSetStCurrAfter or RefPicSetStFoll.
[0047] From the POCs of the reference pictures in those lists 105 a , 105 b , the decoder 400 constructs the final reference picture lists 107 which contains the POCs of the reference pictures that should be used by the decoder for decoding. This procedure according to the embodiments is illustrated by the following example.
[0048] In addition, it should be noted that although the embodiments are explained in the context of the decoder, the embodiments also apply to the encoder, since the encoder mimics the decoder behavior to ensure that decoded pictures are created exactly as they should. The encoder decides which POC values to assign to each picture it encodes and it decides which old pictures that it wants to keep as reference pictures and which pictures that should be short-term and which that should be long-term. While saying that, the encoder is bound to old decisions, if a picture is marked as long-term earlier, it can not be re-marked as short-term, pictures that are marked unused for reference can not be used for reference in any future picture and so on.
[0049] In the encoder the following steps are performed which is illustrated in the flowchart of FIG. 5 :
[0050] 501 . The encoder selects the POC for the current picture. Thus, the encoder selects what POC value to signal to the decoder to identify the current picture. The encoder may select any POC value as long at is does not make the bitstream conflict with any bitstream requirement such as POC shall represent output order. That implies that the POC value must be assigned by the encoder such that the decoder can behave according to the embodiments of the present invention. In addition to the POC, the encoder also sends RPS syntax to the decoder to control what reference pictures to use and which ones should be short-term and which should be long-term.
[0051] 502 . The encoder encodes an RPS including the POCs of all short-term reference pictures and long-term reference pictures that are used by the current picture or may be used by pictures following the current picture.
[0052] 503 . The picture is encoded using the reference pictures indicated by the RPS.
[0053] Accordingly an encoder for managing reference pictures to be used for encoding an encoded representation of a picture of a video sequence is provided. The encoder comprises a processor for assigning a POC value such that a decoder can perform the following steps
decoding 201 a reference picture set received from an encoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer:
decoding 202 a Picture Order Count, POC, value indicated in the reference picture set and determining 203 if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture,
[0057] if the POC value indicated in the reference picture set corresponds to a long-term reference picture:
keeping 206 a long-term reference picture in a decoded picture buffer as a long-term reference picture if there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, marking 207 a short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set,
[0060] if the POC value indicated in the reference picture set corresponds to a short-term reference picture:
keeping 208 a short-term reference picture in the decoded picture buffer as a short-term reference picture if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set, and the processor is further configured to include the assigned POC value in a reference picture set to be sent to a decoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer of the decoder.
[0062] In the decoder the following steps are performed according to embodiments of the present invention:
[0063] 1. Turning now to the flowchart of FIG. 2 , the decoder receives a current picture and the RPS for that picture e.g. in the slice header and decodes the RPS 201 of the current picture before decoding the picture. It is preferred that the long-term reference pictures in the DPB are handled before the short-term reference pictures to mark the reference pictures in the DPB in order to avoid that one reference picture is included in the reference picture list as both a short-term and a long-term reference picture.
[0064] 2. The POC of each reference picture of the RPS is decoded 202 and the following steps are performed:
[0065] a) If the POC of the reference picture is included in the RPS as a long-term reference picture 203 with POC y and there is a reference picture with that POC y in the DPB marked as “used for long-term reference” 205 that picture is kept 206 in the DPB marked as “used for long-term reference”.
[0066] b) If POC of the reference picture is in included in the RPS as a long-term reference picture 203 and there is a picture with that POC in the DPB marked as “used for short-term reference” 205 that picture is kept in the DPB but remarked as “used for long-term reference” 207 . According to an embodiment, step 206 (keeping a long-term reference picture in a decoded picture buffer as a long-term reference picture if there is a long-term reference picture in the decoded picture buffer with a POC value equal to the POC value indicated in the reference picture set) is performed before step 207 (marking a short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer if there is a short-term reference picture in the decoded picture buffer with a POC value equal to the POC value indicated in the reference picture set). I.e. step 206 is performed and if the condition of step 206 is not fulfilled, step 207 is performed.
[0000]
I.e. if( there is a long-term reference picture picX in the DPB
with pic_order_cnt_lsb equal to PocLtCurr[ i ] )
RefPicSetLtCurr[ i ] = picX
else if( there is a short-term reference picture picY in the DPB
with pic_order_cnt_lsb equal to PocLtCurr[ i ] )
RefPicSetLtCurr[ i ] = picY
[0067] Wherein the pic_order_cnt_lsb is the POC value and PocLtCurr[i] is a list of long-term reference pictures in the RPS and the RefPicSetLtCurr[i] is a reference picture list containing long-term reference pictures.
[0068] c) Otherwise, if the POC of the reference picture is included in the RPS as a short-term reference picture 203 and if there is a picture with that POC in the DPB marked as “used for short-term reference” that picture is kept 208 in the DPB marked as “used for short-term reference”.
[0000]
I.e., for( i = 0; i < NumPocStCurrBefore; i++ )
if( there is a short-term reference picture picX in the DPB
with PicOrderCntVal equal to PocStCurrBefore[ i ])
RefPicSetStCurrBefore[ i ] = picX
else
RefPicSetStCurrBefore[ i ] = “no reference picture”
[0069] Wherein the PicOrderCntVal is the POC value and PocStCurrBefore[i] is a list of long-term reference pictures in the RPS and the RefPicSetStCurrBefore[i] is a reference picture list containing short-term reference pictures.
[0070] All reference pictures included in RefPicSetStCurrBefore, RefPicSetStCurrAfter and RefPicSetStFoll are already marked as “used for short-term reference”.
[0071] 3. All pictures in the DPB that are not included the RPS are marked as “unused for reference”. I.e. all reference pictures in the decoded picture buffer that are not included in RefPicSetLtCurr, RefPicSetLtFoll, RefPicSetStCurrBefore, RefPicSetStCurrAfter or RefPicSetStFoll are marked as “unused for reference”.
[0072] 4. A reference picture list is created at the decoder which contains the reference pictures from the RefPicSetLtCurr, RefPicSetLtFoll, RefPicSetStCurrBefore, RefPicSetStCurrAfter or RefPicSetStFoll. The current picture is decoded using the reference pictures of the reference picture list.
[0073] Another way to formulate the steps performed in the decoder according to the embodiments is:
[0074] 1. The decoder decodes the RPS of the current picture (before decoding the picture)
[0075] 2. If there is a long-term reference picture signaled in the RPS with POC=X and there is no picture in the DPB marked as “used for long-term reference” with POC=X and there is a picture with POC=X in the DPB marked “used for short-term reference” that picture is marked as “used for long-term reference”.
[0076] 3. All POCs of the pictures in the DPB that are not included the RPS are marked as “unused for reference”.
[0077] 4. The current picture is decoded.
[0078] 5. The current picture is marked as “used for short-term reference”, Hence each decoded picture is marked as a short-term reference picture immediately after it is decoded. If the decoded picture should be a long-term reference picture, it should be marked as a long-term reference picture in the very next picture. The picture will then never actually be used as short-term since marking (in this case marking to long-term) takes place before actual picture decoding of the next picture.
[0079] The POCs of the pictures that are in the RPS but have no corresponding picture in the DPB marked as “used for short-term reference” or “used for long-term reference” may be inferred as lost pictures depending on other syntax elements i.e. the used_by_curr_pic flag.
[0080] As illustrated in the flowchart of FIG. 2 , a method performed by a decoder for managing reference pictures to be used for decoding an encoded representation of a picture of a video sequence bitstream is provided according to an embodiment.
[0081] A reference picture set received from an encoder is decoded 201 , wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer. A POC value indicated in the reference picture set is decoded 202 and it is determined 203 if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture. If the POC value indicated in the reference picture set corresponds to a long-term reference picture, 203 a long-term reference picture is kept 206 in a decoded picture buffer as a long-term reference picture if there is a long-term reference picture in the decoded picture buffer 205 with a POC value corresponding to the POC value indicated in the reference picture set.
[0082] If the POC value indicated in the reference picture set corresponds to a long-term reference picture 203 , a short-term reference picture is marked 207 in the decoded picture buffer as a long-term reference picture and kept in the decoded picture buffer if there is a short-term reference picture in the decoded picture buffer 205 with a POC value corresponding to the POC value indicated in the reference picture set,
[0083] If the POC value indicated in the reference picture set corresponds to a short-term reference picture, 203 a short-term reference picture is kept 208 in the decoded picture buffer as a short-term reference picture if there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set.
[0084] Long-term reference pictures and short-term reference pictures are the same kind of pictures with the only difference that they are marked differently in the DPB; “used for long-term reference” and “used for short-term reference”, correspondingly. The reason to have this marking is
[0085] 1) to be able to signal them more efficiently (short-term pictures can be encoded with variable length codes while long-term ref pictures can be encoded with fixed length codes).
[0086] 2) to handle them differently in the decoding process (e.g. motion vectors from short-term pictures may be scaled in motion vector scaling while motion vectors from long-term pictures are not).
[0087] There does not have to be a distinct difference in POC steps between short-term and long-term, i.e. can be as close to the current picture as 1 POC step away. However one alternative is to determine that long term pictures must have negative DiffPOC compared to the current picture i.e. precede it in output order.
[0088] The methods according to the embodiments can be implemented by a computer program product encoded with computer program code means which, when loaded and executed by a processor, cause performance of the method according to the embodiments.
[0089] A computer readable storage medium encoded with instructions which, when loaded and executed by a processor, cause performance of the method according to the embodiments is also provided.
[0090] In one alternative there is a restriction that reference pictures that have been in the DPB for more than a specific period of time, which preferably is expressed in POC-steps, must be signaled as long-term pictures in the Buffer Descriptions.
[0091] In one alternative there is a restriction that reference pictures that have been displayed (outputted) can not be included as short-term reference pictures in a Buffer Description of a current picture if their DiffPOC( ) compared to the current picture is positive.
[0092] In one alternative there is a syntax element, e.g. a flag or an id, sent for each picture e.g. in the slice header to indicate if the current picture can be used as a long term picture or not. Preferably there is a restriction that a picture A can only indicate that it may be used for long-term reference if there is no long-term reference picture in the DPB with the same POC when A is decoded. In another alternative, the reference picture list construction allows for two pictures with the same POC, where one picture is a long-term picture and the other picture is a short term picture. It is preferred that short-term pictures come before long-term pictures in the reference picture list.
[0093] The embodiments of the invention may be applied to any suitable video codec comprising the encoder and/or the decoder according to the embodiments.
[0094] As mentioned above, the mechanisms described above are done both in the encoder as well as in the decoder. The encoder and the decoder, respectively, comprises a processor configured to perform the functions according to the above described embodiments. Further the encoder and the decoder, respectively comprises a memory for storing e.g. RPS, decoded pictures, and other picture information such as reference pictures in reference picture lists. The memory may also comprise instructions to be executed on the processor such that the processor can perform the steps according to the embodiments.
[0095] FIG. 3 schematically illustrates an encoder in the context of the embodiments of the present invention.
[0096] Accordingly an encoder, comprising one or more processors and e.g. one or more memories, is configured to carry out the methods according to the embodiments is provided.
[0097] FIG. 3 is a schematic diagram showing some components of the encoder 300 . The encoder comprises a processor 302 . The processor 302 could be any combination of one or more of a suitable central processing unit (CPU), multiprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC) etc., capable of executing software instructions contained in a computer program stored in one or more memories 301 .
[0098] Thus an encoder 300 configured to encode a representation of a current picture of a video sequence of multiple pictures using reference pictures is illustrated in FIG. 3 . The encoder comprises a processor 302 configured to assign a POC value for the current picture, wherein the POC value is assigned such that the decoder can perform the method according to the embodiments of the present invention. The processor 302 is configured to include the assigned POC value in a reference picture set to be sent to a decoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer of the decoder. Hence, the encoder is configured to encode an RPS including all short-term reference pictures and long-term reference pictures that are used by the current picture or may be used by pictures following the current picture and to encode the current picture using all or a subset of the reference pictures included in the RPS.
[0099] FIG. 4 schematically illustrates a decoder according to an embodiment of the present invention.
[0100] Accordingly a decoder, comprising one or more processors and e.g. one or more memories, is configured to carry out the methods according to the embodiments is provided.
[0101] FIG. 4 is a schematic diagram showing some components of the decoder 400 . The decoder comprises a processor 402 . The processor 402 could be any combination of one or more of a suitable central processing unit (CPU), multiprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC) etc., capable of executing software instructions contained in a computer program stored in one or more memories 401 .
[0102] A decoder 400 for managing reference pictures to be used for decoding an encoded representation of a picture of a video sequence is provided according to one embodiment. The decoder is configured to decode a reference picture set received from an encoder, wherein the reference picture set comprises information of the reference pictures to be kept in a decoded picture buffer and to decode a POC value indicated in the reference picture set. The decoder comprises a processor 402 configured to determine if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture. The processor 402 is configured to keep a long-term reference picture in a decoded picture buffer as a long-term reference picture when there is a long-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a long-term reference picture. The processor 402 is further configured to mark a short-term reference picture in the decoded picture buffer as a long-term reference picture and keeping it in decoded picture buffer when there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a long-term reference picture. In addition, the processor 402 is further configured to keep a short-term reference picture in the decoded picture buffer as a short-term reference picture when there is a short-term reference picture in the decoded picture buffer with a POC value corresponding to the POC value indicated in the reference picture set and when the POC value indicated in the reference picture set corresponds to a short-term reference picture.
[0103] According to an embodiment the processor is configured to determine if the POC value indicated in the reference picture set corresponds to a short-term reference picture or a long-term reference picture by determining if the POC value indicated in the reference picture set is included in one of the lists PocLtCurr or PocLtFoll in which case the POC value corresponds to a long-term reference picture or if the POC value indicated in the reference picture set is included in one of the lists PocStCurrBefore, PocStCurrAfter or PocStFoll in which case the POC value corresponds to a short-term reference picture.
[0104] Moreover, the long-term reference pictures in the reference picture set may be handled before the short-term reference pictures to mark the reference pictures in the decoded picture buffer.
[0105] The encoder may be an HEVC encoder and the decoder may be an HEVC decoder, but the embodiments are not limited to HEVC. The encoder and the decoder, respectively may be implemented in a mobile device or in any type of video camera and/or display. | An object of the embodiments is to achieve an improved reference picture handling. That is achieved by taking into account whether the reference pictures in the decoded picture buffer are long-term reference pictures or short-term reference pictures when determining how they should be marked when the information of the reference picture set is received. The reference pictures are marked as “used for short-term reference” or “used for long-term reference” in the Decoded Picture Buffer (DPB) depending on whether they are included as short-term pictures or long-term pictures in the RPS of a current picture. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/003,150, filed on Jan. 7, 2011, which is a 35 U.S.C. §371 national stage application of PCT/US2009/052709 filed Aug. 4, 2009, which claims the benefit of U.S. Provisional Patent Application No. 61/086,029 filed Aug. 4, 2008, all of which are incorporated herein by reference in their entireties for all purposes.
BACKGROUND
[0002] Deepwater accumulators provide a supply of pressurized working fluid for the control and operation of subsea equipment, such as through hydraulic actuators and motors. Typical subsea equipment may include, but is not limited to, blowout preventers (BOPs) that shut off the well bore to secure an oil or gas well from accidental discharges to the environment, gate valves for the control of flow of oil or gas to the surface or to other subsea locations, or hydraulically actuated connectors and similar devices.
[0003] Accumulators are typically divided vessels with a gas section and a hydraulic fluid section that operate on a common principle. The principle is to precharge the gas section with pressurized gas to a pressure at or slightly below the anticipated minimum pressure required to operate the subsea equipment. Hydraulic fluid can be added to the accumulator in the separate hydraulic fluid section, increasing the pressure of the pressurized gas and the hydraulic fluid. The hydraulic fluid introduced into the accumulator is therefore stored at a pressure at least as high as the precharge pressure and is available for doing hydraulic work.
[0004] Accumulators generally come in three styles—the bladder type having a balloon type bladder to separate the gas from the fluid, the piston type having a piston sliding up and down a seal bore to separate the fluid from the gas, and the float type with a float providing a partial separation of the fluid from the gas and for closing a valve when the float approaches the bottom to prevent the escape of the charging gas. A fourth type of accumulator is pressure compensated for depth and adds the nitrogen precharge pressure plus the ambient seawater pressure to the working fluid.
[0005] The precharge gas can be said to act as a spring that is compressed when the gas section is at its lowest volume/greatest pressure and released when the gas section is at its greatest volume/lowest pressure. Accumulators are typically precharged in the absence of hydrostatic pressure and the precharge pressure is limited by the pressure containment and structural design limits of the accumulator vessel under surface ambient conditions. Yet, as accumulators are used in deeper water, the efficiency of conventional accumulators decreases as application of hydrostatic pressure causes the gas to compress, leaving a progressively smaller volume of gas to charge the hydraulic fluid. The gas section must consequently be designed such that the gas still provides enough power to operate the subsea equipment under hydrostatic pressure even as the hydraulic fluid approaches discharge and the gas section is at its greatest volume/lowest pressure.
[0006] For example, accumulators at the surface typically provide 3000 psi working fluid maximum pressure. In 1000 feet of seawater the ambient pressure is approximately 465 psi. For an accumulator to provide a 3000 psi differential at 1000 ft. depth, it must actually be precharged to 3000 psi plus 465 psi, or 3465 psi.
[0007] At slightly over 4000 ft. water depth, the ambient pressure is almost 2000 psi, so the precharge would be required to be 3000 psi plus 2000 psi, or 5000 psi. This would mean that the precharge would equal the working pressure of the accumulator and any fluid introduced for storage may cause the pressure to exceed the working pressure and accumulator failure.
[0008] At progressively greater hydrostatic operating pressures, the accumulator thus has greater pressure containment requirements at non-operational (no ambient hydrostatic pressure) conditions.
[0009] The accumulator design must also take into account human error contingencies. For example, removal of the external ambient hydrostatic pressure without evacuating the fluid section of the accumulator to reestablish the original gas section precharge pressure may result in failure due to gas section pressures exceeding the original precharge pressures.
[0010] As shown in FIGS. 1 and 2 , accumulators may be included, for example, as part of a subsea BOP stack assembly 10 assembled onto a wellhead assembly 11 on the sea floor 12 . The BOP stack assembly 10 is connected in line between the wellhead assembly 11 and a floating rig 14 through a subsea riser 16 . The BOP stack assembly 10 provides emergency fluid pressure control of fluid in the wellbore 13 should a sudden pressure surge escape the wellbore 13 . The BOP stack assembly thus prevents damage to the floating rig 14 and the subsea riser 16 from fluid pressure exceeding design capacities.
[0011] The BOP stack assembly 10 includes a BOP lower riser package 18 that connects the riser 16 to a BOP package 20 . The BOP package 20 includes a frame 22 , BOPs 23 , and accumulators 24 that may be used to provide back up hydraulic fluid pressure for actuating the BOPs 23 . The accumulators 24 are incorporated into the BOP package 20 to maximize the available space and leave maintenance routes clear for working on the components of the subsea BOP package 20 . However, the space available for other BOP package components such as remote operated vehicle (ROV) panels and mounted controls equipment has become harder to establish due to the increasing number and size of the accumulators 24 required to be considered for operation in deeper water depths. Depending on the depth of the wellhead assembly 11 and the design of the BOPs 23 , numerous accumulators 24 must be included on the frame 22 , taking up valuable space on the frame 22 and adding weight to the subsea BOP stack assembly 10 . The accumulators 24 are also typically installed in series where the failure of any one accumulator 24 prevents the additional accumulators 24 from functioning.
[0012] The inefficiency of precharging accumulators under non-operational conditions requires large aggregate accumulator volumes that increase the size and weight of the subsea equipment. Yet, offshore rigs are moving further and further offshore to drill in deeper and deeper water. Because of the ever increasing envelop of operation, traditional accumulators have become unmanageable with regards to quantity and location. In some instances, it has even been suggested that in order to accommodate the increasing demands of the conventional accumulator system, a separate subsea skid may have to be run in conjunction with the subsea BOP stack in order to provide the required volume necessary at the limits of the water depth capability of the subsea BOP stack. With rig operators increasingly putting a premium on minimizing size and weight of the drilling equipment to reduce drilling costs, the size and weight of all drilling equipment must be optimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more detailed description of the embodiments, reference will now be made to the following accompanying drawings:
[0014] FIG. 1 is a schematic of a subsea BOP stack assembly connecting a wellhead assembly to a floating rig through a subsea riser;
[0015] FIG. 2 is a perspective view of a BOP package of the BOP stack assembly of FIG. 1 ;
[0016] FIG. 3 a cross-section view of an accumulator in accordance with one embodiment of the claimed subject matter; and
[0017] FIG. 4 is a cross-section view of an accumulator in accordance with one embodiment of the claimed subject matter.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
[0019] In FIG. 3 , an accumulator 300 includes an accumulator body 301 with a hydraulic fluid portion 304 and a charge fluid portion 309 . The hydraulic fluid portion 304 partially forms a hydraulic fluid chamber 305 and the charge fluid portion 309 partially forms a precharge gas chamber 310 . An end cap 330 having a hydraulic fluid port 335 seals off an end of the hydraulic fluid portion 304 at one end of the accumulator 300 . Another end cap 340 having a hydrostatic pressure port 345 seals off an end of the charge fluid portion 309 at the other end of the accumulator 300 .
[0020] A hydraulic piston 315 is slidably and sealingly mounted in the hydraulic fluid portion 304 . The hydraulic fluid chamber 305 is defined in the hydraulic fluid portion 304 between the hydraulic piston 315 and the end cap 330 . A charge piston 320 is slidably and sealingly mounted in the charge fluid portion 309 . The precharge gas chamber 310 is defined in the charge fluid portion 309 between the charge piston 320 and the hydraulic piston 315 .
[0021] At the surface before installation on the sea floor, a precharge gas, such as nitrogen, is provided into the precharge gas chamber 310 and pressurized according to a predetermined depth at which the accumulator will operate and the pressure needed to operate the subsea equipment, such as the rams of the BOPs. A precharge pressure port (not shown) may be, for example, in the side of the accumulator body 301 or in the charge piston 320 . During pressurization of the precharge gas chamber 310 , the hydraulic piston 315 moves towards the end cap 330 . After placement on the seafloor, hydraulic fluid is pumped into the hydraulic fluid chamber 305 , which moves the hydraulic piston 315 towards the opposing end of the hydraulic fluid portion 304 until contacting a shoulder 316 . The hydraulic fluid may be any suitable hydraulic fluid and may also include performance enhancing additives such as a lubricant. The accumulator 300 is then ready to provide pressurized hydraulic fluid to operate the rams of the BOPs.
[0022] In normal operation, the force of the precharge gas acting against the hydraulic piston 315 is sufficient to operate the subsea equipment with the hydraulic fluid stored in the hydraulic fluid chamber 305 . However, in case additional force is needed, the accumulator 300 further includes a valve 350 , which communicates ambient hydrostatic pressure through the port 345 when open. That hydrostatic pressure acts against the charge piston 320 and increases the pressure within the precharge gas chamber 310 . The increased pressure of the precharge gas in turn acts against the hydraulic piston 315 to increase the pressure of the hydraulic fluid. As hydraulic fluid is forced out of the hydraulic fluid chamber 305 by movement of the hydraulic piston 315 , the charge piston 320 will move in the same direction with hydrostatic pressure continuing to act against the charge piston 320 . Because hydrostatic pressure acts against the charge piston 320 , the effective increase in pressure of the hydraulic fluid is increased proportional to the difference in piston diameters, giving a multiplier effect to the hydrostatic pressure upon the hydraulic piston 315 . The hydrostatic pressure provides a boost in the force acting on the subsea equipments, such as hydraulic rams of a blowout preventer, which may be useful in an emergency situation. As the hydraulic rams close and the hydraulic fluid exits the accumulator 300 , seawater will flow into the accumulator to apply the constant hydrostatic pressure. Thus, the force applied by the hydraulic rams remains constant between the fully opened and fully closed positions.
[0023] Referring now to FIG. 4 , another accumulator 400 is shown that shares many of the same components as the accumulator 300 shown in FIG. 3 . In the accumulator of FIG. 4 however the hydraulic piston 315 is extended to form a piston body 401 that includes a hydraulic diameter portion 402 and a charge diameter portion 403 . The hydraulic diameter portion 402 slidably and sealingly engages the inside of the hydraulic fluid portion 304 of the accumulator body 301 , and the charge diameter portion 403 slidably and sealingly engages the inside of the charge fluid portion 309 of the accumulator body 301 . Although shown as a solid piston body, those having ordinary skill in the art will appreciate that the piston body 401 may be a single hollow piece or any assembly of cylinders that results in a mechanical connection between the hydraulic diameter portion 402 and the charge diameter portion 403 .
[0024] The hydraulic fluid chamber 305 is partially defined by the hydraulic fluid portion 402 of the piston body 401 and the end cap 330 . A buffer chamber 405 is defined as the annular space between the outer diameter of the piston body 401 and the inner diameter of the charge fluid portion 309 of the accumulator body 301 . At the surface before installation on the sea floor, the precharge gas is provided into the precharge gas chamber 310 defined between the charge piston 320 and the charge diameter portion 403 of the piston body 401 and pressurized according to a predetermined operating depth and pressure. As shown, the charge diameter portion 403 of the piston body 401 is larger than the hydraulic diameter portion 402 . Thus, the necessary precharge pressure may be reduced proportional to the difference in effective piston area of the two portions of the piston body 401 .
[0025] The pressure in the precharge gas chamber 310 at the surface causes the piston body 401 to move towards end cap 330 , which reduces the size of the buffer chamber 405 . Fluid, such as air, contained in the buffer chamber 405 may be vented through port 410 . If port 410 is closed after the piston body 401 has travelled fully towards the end cap 330 , the buffer chamber 405 will have a vacuum when the hydraulic fluid chamber 305 is filled with hydraulic fluid at the sea floor. By having a vacuum, none of the pressure in the precharge gas chamber 310 is counterbalanced by the buffer chamber 405 . If air in the buffer chamber 405 is not vented, actuation of the piston body 401 will compress the air in the buffer chamber 405 , thereby providing a pressure counterbalance to the precharge gas pressure.
[0026] In normal operation, the force of the precharge gas acting against the hydraulic piston 315 is sufficient to operate the subsea equipment with the hydraulic fluid stored in the hydraulic fluid chamber 305 . However, in case additional force is needed, the accumulator 300 further includes a valve 350 , which communicates ambient hydrostatic pressure through the port 345 when open. That hydrostatic pressure acts against the charge piston 320 and increases the pressure within the precharge gas chamber 310 . The increased pressure of the precharge gas in turn acts against the charge diameter portion 403 of the piston body 401 to increase the pressure of the hydraulic fluid. As hydraulic fluid is forced out of the hydraulic fluid chamber 305 by movement of the hydraulic diameter portion 402 of the piston body 401 , the piston body 401 will move in the same direction with hydrostatic pressure continuing to act against the charge diameter portion 403 of the piston body 401 . Because hydrostatic pressure acts against charge diameter portion of the piston body 401 via the charge piston 320 , the effective increase in pressure of the hydraulic fluid is increased proportional to the difference in piston diameters, giving a multiplier effect to the hydrostatic pressure upon the hydraulic diameter portion 402 of the piston body 401 . The hydrostatic pressure provides a boost in the force acting on the subsea equipment, such as hydraulic rams of a blowout preventer, which may be useful in an emergency situation. As the hydraulic rams close and the hydraulic fluid exits the accumulator 300 , seawater will flow into the accumulator to apply the constant hydrostatic pressure. Thus, the force applied by the hydraulic rams remains constant between the fully opened and fully closed positions.
[0027] While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | An accumulator for hydraulically actuating subsea equipment includes a hydraulic fluid chamber and a gas chamber. The hydraulic fluid chamber is in fluid communication with the subsea equipment and comprises a hydraulic piston slidably received, at least partially, within the hydraulic chamber. The gas chamber comprises a charge piston slidably received within the gas chamber, the charge piston dividing the gas chamber into a first portion and a second portion. The first portion of the gas chamber is configured to receive ambient hydrostatic pressure therein, and the second portion of the gas chamber is configured to receive precharge gas therein. | 4 |
This application is a Continuation-in-Part of U.S. patent application Ser. No. 08/029,247 filed Mar. 10, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a noise suppression apparatus used in radio wave communication and the like, and more particularly to a noise suppression apparatus used for a receiver.
2. Description of the Prior Art
Recently, the noise suppression using digital signal procession technology has been variously developed.
FIG. 20 is a circuit block diagram showing a conventional noise suppression apparatus. In FIG. 20, a reference numeral 20 represents a filter control section, and a reference numeral 52 represents a band pass filter group (abbreviated as BPF group). And a reference numeral 53 represents an adder. The filter control section 51 controls filter factors of the band pass filter group 52 in accordance with the noise level of sound input signal. The band pass filter group 52 includes a group of band pass filters, which separates the sound input signal into a plurality of bands. The characteristics of each band pass filter in this band pass filter group 52 is determined in accordance with the control signal of the filter control section 51. The adder 53 adds output signals fed from these band pass filters of the band pass filter group 52 and produces a noiseless sound signal.
An operation of this conventional noise suppression apparatus is explained below.
An input signal, for example a radio broadcasting sound signal containing-noise, is inputted, into the filter control section 51. The filter control section 51 judges what kind of noise components this input signal contains, and supplies the band pass filter group 52 the filter factors which cut these noise components. The band pass filter group 52 separates the input signal into a plurality of adequate band levels. Each band pass filter in the band pass filter group 52 responds to the filter factor supplied from the filter control section 51 to pass only the sound component of the input signal, and feeds it to the adder 53. The adder 53 adds the output signals of these band pass filters, so as to produce a noiseless sound signal.
In accordance with such a conventional noise suppression apparatus no significant improvement is expected in the articulation, though some increase of the S/N ratio is found. Furthermore, it is recognized that a particular noise sound remains even after the noise suppression is finished by this apparatus.
Moreover, the input signal may contain multipath noises. In order to suppress these multipath noises, there is known a method using a plurality of antennas. In this method, an antenna direction to receive radio waves is different from each other, so that the receiver can select the optimum antenna which is receiving the least multipath noise.
However, in the case where the multipath noise has once received by the receiver, this multipath noise was not removed by the signal processing. Because, the waveform of the radio wave is already distorted when received in the receiver.
SUMMARY OF THE INVENTION
Accordingly, the present invention has a purpose, in view of above-described problems or disadvantages, to provide a noise suppression apparatus capable of remarkably increasing S/N ratio as the static characteristics, suppressing multipath noises, distorting no sound signal, and being manufactured at low cost.
In order to accomplish above purposes, a first aspect of the present invention provides a noise suppression apparatus comprising: a receiving means for selectively receiving a radio wave signal to be received and transforming it through a signal transformer into an electric signal H(k); a field information detecting means for detecting electric field information of said radio wave signal received by said receiving means; a noise data generating means for generating a noise pattern W(k) on the basis of said electric field information detected by said field information detecting means; a noise cancel means for canceling a noise component of said signal received by said receiving means on the basis of said noise pattern W(k) generated by said noise data generating means, said noise cancel means including a cancel factor setting means for setting a cancel factor to the signal H(k) outputted from said receiving means, and said noise cancel means including a clamping factor setting means for generating a clamping factor, used for controlling said cancel factor in a noise canceling operation, so as to suppress adverse affection of noise removal, said noise cancel means obtaining a power spectrum |X(k)| 2 on the basis of the output signal H(k) of said signal transformer, and executing the noise canceling operation in accordance with the following equation:
S(k)=H(k)*(1-α·|W(k)|/|X(k).vertline.)
wherein, (1-α·|W(k)|/|X(K)|).gtoreq.β, 0.5≦α≦0.9, and 0.4≦β≦0.6.
Furthermore, a second aspect of the present invention provides a noise suppression apparatus comprising: a receiving means for receiving a radio wave signal an A/D converter for converting said radio wave signal from an analog signal into a digital signal; a signal transformer for transforming said digital signal into an appropriate signal form H(k); a field information detecting means for detecting electric field information of the radio wave signal; a noise data generating means for generating a noise pattern W(k) on the basis of the electric field information; a noise cancel means for receiving the signal H(k) outputted from said signal transformer and the noise pattern W(k) generated by said noise data generating means to cancel a noise component of said received radio wave signal on the basis of said noise pattern W(k); said noise cancel means obtaining a power spectrum |X(k)| 2 on the basis of the signal H(k) outputted from said signal transformer, and executing a noise cancel processing in accordance with the following equation:
S(k)=H(k)*(1-α·|W(k)|/|X(k).vertline.)
wherein, (1-α·|W(k)|/|X(k)|).gtoreq.β, 0.5≦α≦0.9, and 0.4≦β≦0.6;
an inverse signal transformer for receiving an output of said noise cancel means and executing an inverse processing of said signal transformer; and a D/A converter for converting an output of said inverse signal transformer into a noiseless analogue signal.
Still further, a third aspect of the present invention provides a noise suppression apparatus comprising: a tuner which selectively receives a radio wave signal to be received and transforms it into an electric signal H(k); a field information detector which detects electric field information of the radio wave signal received by the tuner; a noise data generator which generates a noise pattern W(k) on the basis of the electric field information detected by the field information detector; a noise canceler which removes a noise component from said received radio wave signal, said noise canceler obtaining a power spectrum |X(k)| 2 on the basis of the signal H(k) fed from said tuner and obtaining a noise canceling signal in accordance with the following equation:
S(k)=H(k)*(1-α·|W(k)|/|X(k).vertline.)
wherein, (1-α·|W(k)|/|X(k)|).gtoreq.β, 0.5≦α≦0.9, and 0.4≦β≦0.6; and an amplifier which outputs a noiseless signal outputted from the noise canceler.
Moreover, it is preferable that said coefficients α and β are set within optimum ranges of 0.5≦α≦0.9, and 0.2≦β≦0.8, respectively, in a case where said noise data generator further generates a multipath noise pattern on the basis of a multipath signal so as to cancel multipath noise. The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description which is to be read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing the present invention;
FIG. 2 is a circuit block diagram showing a first embodiment of the present invention;
FIG. 3 is a detailed circuit diagram showing the first embodiment of the present invention;
FIG. 4 is a circuit diagram for a digital signal processing in the first embodiment of the present invention;
FIGS. 5(a) to 5(c) are graphs showing noise patterns used in the first embodiment of the present invention;
FIG. 6 is a view showing how a noise pattern is obtained in the first embodiment of the present invention;
FIG. 7 is a graph showing a relationship between the input electric field strength and the output voltage of the tuner in accordance with the first embodiment of the present invention;
FIG. 8 is a signal flowchart showing an operation of the first embodiment of the present invention;
FIG. 9 is a flowchart showing an operation of the first embodiment of the present invention;
FIG. 10 is a graph showing an improvement of S/N ratio in accordance with the present invention;
FIG. 11 is a circuit diagram showing a second embodiment of the present invention;
FIG. 12 is a circuit diagram showing a third embodiment of the present invention;
FIGS. 13(a) and 13(b) are views showing multipath signals;
FIGS. 14(a), 14(b), and 14(c) are graphs showing examples of multipath signals;
FIGS. 15(a) and 15(b) show a system specification of the embodiment of the present invention;
FIG. 16 is a circuit block diagram showing a hardware of the embodiment of the present invention;
FIG. 17 is a memory layout of the embodiment of the present invention;
FIG. 18 is a data memory map of the present invention;
FIG. 19 is a circuit block diagram showing digital components of the embodiment of the present invention; and
FIG. 20 is a circuit diagram showing a conventional noise suppression apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, with reference to accompanying drawings, preferred embodiments of the present invention will be explained in detail.
First Embodiment
FIG. 1 is a schematic diagram showing the concept of the present invention. In FIG. 1, a reference numeral 1 represents a tuner, which serves as a receiving means in the present invention. This tuner 1 detects a radio wave to be received and transforms it into an electric signal. AM and FM tuners are known as this type of receiver.
The tuner 1 is normally connected with an antenna 1a to improve its sensitivity. A reference numeral 2 represents a field information detecting means, which detects electric field condition at the place where the radio wave is received and at the frequency thereof.
This field information detecting means 2 chooses an intermediate-frequency signal (e.g. 10.7 MHz in case of FM broadcasting, and 450 kHz in case of AM broadcasting) from the tuner 1. By analyzing the components of this intermediate-frequency signal--such as a stereo pilot signal, the field information detecting means 2 detects the strength of the electric field and the influence of the multipath to the received signal. The detecting result of the field information detecting means 2 is transmitted to a noise suppression control means 3. The strength of the electric field can be measured by detecting a direct-current component (signal level) of the intermediate-frequency signal. On the other hand, the influence of the multipath can be measured by detecting an amplitude (AM level) of the intermediate-frequency signal. The noise suppression control means 3 receives the signal from the tuner 1 and removes the noise component of this input signal. In more detail, the noise suppression control means 3 includes a noise cancel means 4 and a noise data generating means 6. A reference numeral 5 represents an amplifier serving as an output means in the present invention, which feeds the output of the noise suppression control means 3 to a speaker or the like.
FIG. 2 is a detailed circuit diagram showing the present embodiment. As shown in FIG. 2, the noise data generating means 6 includes a noise pattern memory 6A. This noise pattern memory 6A memorizes a plurality of noise patterns (e.g. weak electric field noises A1, A2, A3, - - - , Ak, - - - , An) which are determined so as to correspond to various antenna input levels (X1, X2, X3, - - - , Xk, - - - , Xn), respectively. Here, the noise patterns need not be always memorized in the noise pattern memory 6A.
The noise data generating means 6 can analyze a generating source of noise on the basis of various components of the output from the tuner 1 and produce or synthesize a noise corresponding to, for example, the strength of the electric field.
Though various factors are considered as the source of noise generation, the noise data generating means 8 in this embodiment synthesizes the noise data on the basis of the noise change with respect to the change of the electric field strength. Namely, one of sources of noise generation is the IC used in the receiver 1. Which circuit causes the noise depends on the strength of the electric field in the noise generation by this IC. Therefore, it is possible to make a plurality of noise patterns in accordance with various strengths of the electric field.
In this embodiment, the noise patterns are calculated in advance with respect to various strengths of the electric field. These noise patterns are memorized in the noise pattern memory 6A, and are read out from this noise pattern memory 6A in the noise suppression operation. By the way, it is possible to produce these noise patterns from the calculation using the parameter of the electric field strength or the multipath. The noise suppression utilizing the multipath will be described later.
As shown in FIG. 2, the antenna input level (Xk) is directly inputted from the tuner i to the noise data generating means 6. This antenna input level (Xk) functions as the field information detecting means 2 in the present invention. In other words, no special circuit is required for providing this field information detecting means 2 in the present invention.
The noise data generating means 6 selects an optimum noise pattern Ak in accordance with the antenna input level Xk, and outputs thus selected noise pattern Ak as a noise cancel data (Ak) to the noise cancel means 4.
Next, with reference to FIG. 3, the noise cancel means 4 used in this embodiment is explained in detail. As shown in FIG. 3, the noise cancel means 4 includes a cancel factor setting means 4a, a clamping factor setting means 4b, a masking control means 4c, and a subtraction means 4d. The cancel factor setting means 4a sets a cancel factor to each frequency band of the input signal. The clamping factor setting means 4b generates a clamping factor, which is used to control the cancel factor in the canceling operation of noise so as to suppress adverse affection of the noise removal. The masking control means 4c functions to judge whether or not the clamping factor should be set by the clamping factor setting means 4b. In the subtraction operation of the noise, the masking control means 4c detects noise levels of upper and lower frequencies adjacent to the frequency of the noise to be subtracted. If the noise component of the adjacent frequency is extraordinarily large (larger than a predetermined large value), the masking control means 4c prevents the clamping factor from being set.
The cancel factor setting means 4a, the clamping factor setting means 4b, and the masking control means 4c constitute a noise suppression parameter setting means 40. The subtraction means 4d receives signals from the noise suppression parameter Setting means 40 and subtracts the noise component from the input signal fed from the tuner 1.
FIG. 4 is a circuit diagram used for a digital signal processing (abbreviated by DSP) in the first embodiment of the present invention. In FIG. 4, a reference numeral 41 represents an A/D converter, which transforms an analogue signal into a digital signal. A reference numeral 42 represents a fast hartley transformer (abbreviated by FHT), which transforms the digital signal (e.g. audio signal) inputted through one A/D 41 into an appropriate signal whose noise pattern is easy to process. An output of the fast hartley transformer 42 is calculated by the following equation (1). ##EQU1##
A reference numeral 44 represents an inverse fast hartley transformer (abbreviated by IFHT), which carries out an inverse processing of the fast hartley transformer 42. A reference numeral 45 represents a D/A converter, which performs the opposite function of the A/D converter 41.
A reference numeral 43 represents an average circuit, which obtains an average of signals representing electric field strengths inputted through the other A/D 41. A noise calculation circuit 48 receives the averaged electric field signal from the average circuit 43 and synthesizes a noise signal on the basis of thus obtained average electric field signal and the noise data memorized in the noise pattern memory 6A. The synthesized noise is fed into the noise cancel means 4, in which the output of the fast hartley transformer 42 is processed by use of this synthesized noise so as to remove the noise components thereof. Then, the (audio) signal is fed to the IFHT 44 and the D/A 45 and outputted as a noiseless audio signal.
That is, the digital signal processing (DSP) section is constituted by the FHT 42, the noise cancel means 4, the IFHT 44, the average circuit 43, the noise calculation circuit 46, and the noise pattern memory 6A.
Next, an operation of the first embodiment described in the foregoing description will be discussed below.
First of all, the tuner 1 receives a radio wave signal to be received and transforms it into an electric signal. Subsequently, the field information detecting means 2 detects an electric field strength of the signal to be received on the basis of an intermediate-frequency component of the signal received by the tuner 1. Furthermore, the field information detecting means 2 detects the multipath condition at the frequency of the signal to be received. Next, these signals are transmitted to the noise suppression control means 3, in which the noise suppression operation is carried out in the following manner.
The noise pattern is produced on the basis of the information supplied from the field information detecting means 2. In this first embodiment, several noise patterns, some of which are shown in FIG. 5, are calculated in advance and memorized in the noise pattern memory 6A. In the production of noise patterns, some of these pre-memorized noise patterns are read out from the noise pattern memory 6A. FIG. 5(a) shows a noise pattern in the case where the input level of the radio wave signal is 10 dB, and FIG. 5(b) shows a noise pattern in the case where the input level of the radio wave signal is 20 dB. Furthermore, FIG. 5(c) shows a noise pattern in the case where the input level of the radio wave signal is 60 dB.
The following explanation supposes to use only three noise patterns shown in FIGS. 5(a) to 5(c). How this embodiment synthesizes the noise patten corresponding to each of electric field strengths by using only three noise patterns will be explained below, with reference to FIG. 6.
In FIG. 6, X-axis, Y-axis, and Z-axis represent an electric field strength, a frequency, and a noise level, respectively. The noise level W dn decreases as the electric field strength dn increases. Here, let the electric field strengths di and dj have noise patterns W di (k) and W dj (k), which are functions of frequency k as shown in FIG. 6. Now, if the electric field strength dn has a value between di and dj, its noise pattern W dn (k) is obtained by linearly obtaining approximation on the basis of two noise patterns W di (k) and W dj (k). As the input electric field strength has a good linear relationship with the signal level inputted from the tuner 1, this linear approximation can be easily realized. FIG. 7 is a graph showing a relationship between the input electric field strength and the output voltage of the tuner 1.
Therefore, the noise pattern memory 6A memorizes predetermined number of noise patterns (A1, A2, A3, - - - , Ak, - - - , An) corresponding to several electric field strengths, so as to obtain a good approximation with these pre-memorized noise patterns (A1, A2, A3, - - - , Ak, - - - , An). It is possible to make additional noise patterns defined by the parameter of multipath signal. Such a modification will be described in detail in the third embodiment.
Next, the noise pattern (i.e. the noise cancel data) produced in the noise pattern generating means 6 is supplied to the noise cancel means 4 so as to subtract the noise component from the output of the tuner 1. However, it should be noted that there is a particular noise sound remaining in the case where the noise pattern is directly subtracted from the output of the tuner 1. In order to prevent this kind of particular noise from generating, the clamping factor setting means 4b sets an upper limit to the subtraction of noise in the case where the original signal is not so large even if the noise pattern is fairly large. (Namely, a value of α is controlled in the equation 4)
The subtraction of noise pattern is carried out in each frequency band of a plurality of predetermined frequency bands in this embodiment. Here, the inventors of the present invention found the remarkable fact. Under the condition that a signal having a certain frequency component is fairly large while signals having upper and lower frequency components adjacent to this certain frequency are fairly small, these small signals can be completely removed as noises without giving any adverse affection to the sound quality of the music.
Accordingly, the masking control means 4c of this embodiment controls the cancel factor used in the subtraction operation of the noise pattern, on the basis of the comparison with noise levels of upper and lower frequencies adjacent to the frequency of the noise to be subtracted. Finally, the signal, whose noise is subtracted in this manner, is outputted from the amplifier 5.
An operation of this embodiment is expressed in the signal flowchart of FIG. 8. An analogue input signal Xt is transformed into a digital signal Xi through the A/D converter 41. The FHT 42 transforms this digital signal Xi into a signal H(k) through the fast hartley transformation. On the other hand, the noise generating means 6 generates a noise pattern W(k) in accordance with an electric field d. The noise cancel means 4 receives these signals H(k) and W(k) and generates a noiseless signal S(k). This signal S(k) is inversely transformed into a digital signal Yi in the IFHT 44 and, then, is transformed into an perceivable analogue signal Yt through the D/A converter 45.
The noise cancel processing in the noise cancel means 4 is explained in more detail with reference to the flowchart of FIG. 9. First of all, in a step S1, the noise cancel means 4 obtains a power spectrum |X(k)| 2 on the basis of the output signal H(k) of the FHT 42. In this embodiment, the calculation of the power spectrum |X(k)| 2 is carried out in accordance with the following equation (2).
|X(k)|.sup.2 =1/2·{H.sup.2 (k)+H.sup.2 (N-k)}(2)
Secondly, in a step S2, a square root of thus obtained power spectrum |X(k)| 2 is obtained in accordance with the following equation (3).
√x=-0.1985987·x.sup.2 +0.8803385·x+0.3175231(3)
Thirdly, the noise cancel processing is executed in a step S3. The calculation of the noise cancel processing is carried out in accordance with the following equation (4).
S(k)=H(k)*(1-α·|W(k)|/|X(k).vertline.) (4)
S(N-k)=H(N-k)*(1-α·|W(k)|/|X(k).vertline.)
Wherein, (1-α·|W(k)|/|X(k)|).gtoreq.β
α: 0.5 (in case of a weak electric field) 0.9 (in case of a strong electric field)
β: 0.4˜0.6
With these equations, the speedy processing can be realized so as to be practically used.
In the above equation (4), two coefficients α and β are independent from each other. The coefficient α relates to an improvement of S/N ratio. The other coefficient β relates to a deterioration of sound quality. The smaller the coefficient β becomes, the more the sound quality is deteriorated.
Although above equation (4) specifically determines values for these coefficients α and β, these numerical values merely show the best or optimum values applied exclusively to FM radios. If this invention is embodied in other apparatus such as a portable phone, above set values for these coefficients α and β will be newly obtained. In other words, the best or optimum values for these coefficients α and β should be determined by taking account of the fact as to what kind of apparatus the present invention is applied to.
If the values of these coefficients α and β excurse out of above range, processing noise sound may arise or a satisfactory S/N ratio will not be obtained.
Furthermore, in a case where the signal processing is stereo type wherein L- and R-signals are independently processed, above coefficient β can be set to smaller values.
Moreover, if the noise pattern is modified, above set values for the coefficients α and β will be correspondingly varied.
Yet further, if the loud-speaker has poor reproduction capability and, therefore, does not strictly require sound quality, the value of the coefficient β will be set to a wider range, e.g. 0.2˜0.8.
FIG. 10 shows the result of the noise suppression. FIG. 10 shows the improvement of S/N ratio with respect to the input electric field level. A dotted line represents the result of the conventional noise suppression apparatus, while a solid line represents the result of the present invention. As apparent from FIG. 10, the noise suppression apparatus in accordance with the present invention can bring 5˜6 dB improvement of the S/N ratio in the whole range of the electric field.
Second Embodiment
A second embodiment of the present invention will be explained below. In this second embodiment, a signal judging means 30 is provided in addition to the components of the first embodiment, as shown in FIG. 11. The same components as the first embodiment are suffixed by the same reference numerals.
In FIG. 11, the signal judging means 30 receives an output signal from the tuner 1 and judges a kind of signal to be received on the basis of this output signal from the tuner 1. For example, it is possible to classify the sound signal into several categories of a human speech sound, a piano sound, and a drum sound by analyzing the spectrum of the signal and the like. In this embodiment, the signal judging means 30 judges as to whether the received signal is a human speech sound (i.e. a conversation mode) or a music sound (i.e. a music mode).
If the signal judging means 30 judges the received signal is the music mode, the subtraction means 4d of the noise cancel means 4 is commanded not to subtract more than 60% of the signal component. That is, the clamping factor setting means 4b uniformly generates a clamping factor of 60% to every frequency component. However, it is needless to say that the value of this clamping factor can be differentiated finely in accordance with the frequency component.
In case of the conversation mode, the clamping factor setting means 4d generates no clamping factor.
In accordance with this embodiment, the signal judging means 30 judges as to whether the content of the broadcasting is news or music. Accordingly, the clamping factor can be accurately set to cancel noises on the basis of the kind of the received signal. Thus, the noise suppression can be performed without deteriorating sound quality.
Third Embodiment
Next, a third embodiment of the present invention will be explained with reference to the drawings. FIG. 12 shows a circuit block diagram of the third embodiment. The same components as those of the previous embodiments are suffixed by the same reference numerals. This embodiment has a purpose to realize the removal of the multipath noise, which was conventionally impossible, by using the DSP technology. The basic constitution of this third embodiment is similar to that of the first embodiment.
As shown in FIG. 12, the noise data generating means 6 include a multipath noise generating means 8B. This multipath noise generating means 6B basically receives a multipath signal M of the field information detecting means 2 (i.e. an output Yk from the FM tuner 1) and generates a multipath noise data K kk so as to cancel the multipath noise in the noise cancel means 4.
How the field information detecting means 2 detects the presence of the multipath noise will be explained below. Compared with AM signals, the characteristic feature of FM signals is that the frequency of the FM signal varies in response to the sound signal while its amplitude is maintained at a constant value.
After the radio wave signal is received and tuned, an FM signal is outputted from the intermediate-frequency amplifier. The amplitude of this FM signal does not vary under the condition of no presence of multipath, even in the range where the limiter of the intermediate-frequency amplifier does not work yet. However, if the multipath occurs, a distortion of the modulated sound signal is added to the amplitude of this FM signal. Therefore, the amplitude of the FM signal outputted from the intermediate-frequency amplifier varies under the presence of multipath. (Refer to FIG. 13(a))
Accordingly, the multipath signal M can be obtained by detecting and amplifying the distortion amount caused by the multipath.
Furthermore, in addition to the amplitude change, the multipath distortion is found in the frequency component when the multipath is generated. That is, the frequency component is also influenced by the multipath component. (Refer to FIG. 13(b)).
Therefore, this multipath component can be also used as the multipath signal M.
In this embodiment, the field information detecting means 2 supplies this multipath signal M (i.e. the output signal Yk of the FM tuner 1) to the multipath noise data generating means 6B. The multipath noise data generating means 6B constitutes the matrix of the multipath signal (Y1, Y2, - - - , Yk, - - - Yn) and the antenna input signal (X1, X2, X3, - - - , Xk, - - -, Xn). That is, the multipath noise pattern K kk is selected from this matrix on the basis of the multipath signal M (i.e. the output signal Yk of the FM tuner 1) and the antenna input signal Xk. It is needless to say that the multipath noise data generating means 6B can be constituted by using only the multipath signal (Y1, Y2, - - - , Yk, - - - , Yn).
FIG. 14(a) to 14(c) show several noise patterns of the multipath noise. FIG. 14(a) shows a large multipath noise signal, and FIG. 14(b) shows an intermediate multipath noise signal. And, FIG. 14(c) shows a small multipath noise signal.
The multipath noise pattern K kk is fed from the multipath noise data generating means 6B to a noise data mixer 6C, in which the multipath noise pattern K kk is added with the noise pattern A k . Thus added noise pattern (i.e. noise cancel data) A k +K kk is supplied to the noise cancel means 4, in which this noise pattern A k +K kk is subtracted from the output signal of the FM tuner 1. In this embodiment, the stereo processing is carried out for canceling right and left noises.
Returning to the specific values of the coefficients in the equation (4), the best or optimum value for the coefficient β, having been set in the first embodiment, can be more widely selected in this embodiment. For example, a setting of 0.2≦β≦0.8 will be preferable.
In accordance with this third embodiment, the field information detecting means 2 outputs the multipath signal and the noise data generating means 6 includes the multipath noise data generating means 6B. With these means, an adequate noise suppression can be performed against the multipath noise without deteriorating the sound quality.
Though the field information detecting means 2 detects only the electric field strength and the multipath condition, it is also possible to detect a signal level of a signal adjacent to the signal to be received, influence by other channels or peripheral devices. By transmitting these signals to the noise data generating means, the noise pattern can be controlled.
FIG. 15(a) shows a system specification used in this embodiment of the present invention, and FIG. 15(b) shows a relationship between the frame length and the frame period. FIG. 18 shows a block diagram of the hardware, and FIG. 17 shows a memory layout. FIG. 18 shows a data memory map, and FIG. 19 shows a circuit block diagram of the digital components.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiments are therefore illustrative and not restrictive, since the scope of the invention is defined by the appending claims rather than by the description preceding them, and all changes that fall within meets and bounds of the claims, or equivalence of such meets and bounds are therefore intended to embraced by the claims. | A noise suppression apparatus includes a tuner 1 which selectively receives a radio wave signal and transforms it into an electric signal H(k) , a field information detector 2 which detects electric field information of the radio wave signal received by the tuner 1, a noise data generator 6 which generates a noise pattern W(k) on the basis of the electric field information detected by the field information detector 2, a noise canceler 4 which removes an noise component from the signal outputted from the tuner 1, and an amplifier 7 which outputs a noiseless signal outputted from the noise canceler 4. The noise canceler 4 obtains a power spectrum |X(k)| 2 on the basis of the signal H(k) fed from the tuner 1. Thereafter, the noise canceler 4 obtains a noise cancel signal S(k) on the basis of the values of the signal H(k), the noise pattern W(k), and the power spectrum |X(k)| 2 . The calculation for obtaining the noise cancel signal S(k) is carried out in accordance with the following equation:
S(k)=H(k)*(1-α·|W(k)|/|X(k).vertl
ine.)
wherein, (1-α·|W(k)|/|X(k)|).gtoreq.β, 0.5≦α≦0.9, and 0.4≦β≦0.6. | 7 |
This invention was made with support from a grant ordered by the National Institute of Health. The Government has certain rights in the invention.
This application is a continuation-in-part of U.S. patent application Ser. No. 08/030,612, filed Mar. 11, 1993, now abandoned, which was a continuation in part of and U.S. patent application Ser. No. 08/029,759, filed Mar. 11, 1993, now abandoned.
FIELD OF THE INVENTION
The present invention relates to 2-debenzoyl-taxol and methods for preparing same, 2-debenzoyl-2-acyl taxol analogues thereof, and methods for making same.
BACKGROUND OF THE INVENTION
The anti-cancer drug taxol 1 has shown excellent clinical activity against ovarian cancer and breast cancer and has also shown good activity against non-small cell lung cancer in preliminary studies. See "Taxol: A Unique Antineoplastic Agent With Significant Activity in an Advanced Ovarian Epithelial Neoplasms, " Ann. Intern. Med., 111, 273-279 (1989), and "Phase II Trial of Taxol, an Active Drug in the Treatment of Metastatic Breast Cancer," J. Natl. Cancer Inst., 83, 1797-1805 (1991). Taxol was first isolated and its structure reported by Wani, et al, in "Plant Anti-Tumor Agents. VI. The Isolation and Structure of Taxol. A Novel Anti-Leukemic and Anti-Tumor Agent From Taxus Brevifolia," J. Am. Chem. Soc., 1971, 93, 2325. Taxol is found in the stem bark of the western yew, Taxus brevifolia, as well as in T. baccata and T. cuspidata. All references cited herein are incorporated by reference as if reproduced in full below. ##STR2##
The preparation of analogues of taxol is an important endeavor, especially in view of taxol's clinical activity and its limited supply. The preparation of analogues might result in the synthesis of compounds with greater potency than taxol (thus reducing the need for the drug), compounds with superior bioavailability, or compounds which are easier to synthesize than taxol from readily available sources. Indeed, the synthesis of the taxol analogue taxotere 2, which differs from taxol only in the nature of the N-acyl substituent and in the absence of the 10-acetyl group, indicates the usefulness of this approach, since taxotere is reported to be approximately twice as active as taxol in some assays. See "Chemical Studies of 10-deacetyl Baccatin III. Hemisynthesis of Taxol Derivatives." Tetrahedron, 42, 4451-4460 (1986), and "Studies With RP56976 (taxotere): A Semi-Synthetic Analogue of Taxol." J. Natl. Cancer Inst., 83, 288-291 (1991). ##STR3##
Numerous analogues of taxol having modifications of the C-13 side chain have been prepared. See U.S. Pat. No. 5,059,699. Many of the derivatives bearing modifications on the C-13 side chain have demonstrated anti-cancer activity. See for example: "The Chemistry of Taxol," Pharmac. Ther., 52, 1-34 (1991) and references therein, "Synthesis and Evaluation of some water-soluble prodrugs and derivatives of taxol with anti-tumor activity, J. Med. Chem., 35, 145-151 (1992), "Biologically Active Taxol Analogues with Deleted A-Ring Side Chain Substituents and Variable C-2' Configurations," J. Med. Chem., 34, 1176-1184 (1991), "Relationships Between the Structure of Taxol Analogues and Their Antimitotic Activity" J. Med. Chem., 34, 992-998 (1991).
Factors that contribute to the paucity of taxol congeners relative to their importance as anti-cancer agents include: the large size and complexity of these compounds, the presence of multiple reactive sites, and the presence of many stereospecific sites, which makes synthesis of even close analogues difficult. The large number of possible reaction mechanisms for even the simplest reactions leads to unpredictability of new reactions.
Although taxol has exhibited promising antineoplastic activity, there is a need for compounds which have even greater antineoplastic activity. It is believed that, by altering certain portions of the taxol structure, compounds with improved antineoplastic activity can be produced. Nevertheless, the aforementioned synthetic difficulties have prevented or at least slowed the development of more than only a few compounds, such as taxotere, which have similar or greater activity than taxol. Since it is believed that the tetracyclic taxane nucleus contributes to the antineoplastic activity of compounds incorporating same, it is desired to alter the ring substituents in order to develop derivatives of taxol and taxol analogues. Based on the previously noted studies, it is anticipated that such derivatives will have antineoplastic activity. Nevertheless, the complexity of taxol and its analogues makes it difficult to selectively alter certain substituents on the molecule. In particular, it has been previously impossible to selectively deacylate the C-2 position of taxol, and to produce taxol analogues modified at the C-2 position. Thus, there is a need for C-2 debenzoylated taxol analogues and congeners modified at the C-2 position, having antineoplastic activity, and intermediates thereof. There is also a need for methods for producing same and for using same to treat cancer. Since taxol and taxol analogues have low water solubility, there is a need to produce taxol analogues modified at the C-2 position having improved water solubility to aid in administration to cancer patients.
OBJECTS OF THE INVENTION
Thus, it is a primary object of this invention to produce taxol analogues which have a modified substituent at the C-2 position.
It is a further object of the present invention to provide taxol analogues having antineoplastic activity.
It is another object of this invention to produce taxol analogues that have improved in vivo activities for use as anti-cancer agents.
It is another object of the present invention to produce taxol analogues that have increased water solubility as compared with taxol.
It is yet another object of the present invention to make intermediates which are useful for producing taxol analogues having a modified substituent at the C-2 position. It is a further object to use taxol analogues which have a modified substituent at the C-2 position to treat cancer.
It is another object of this invention to provide methods for preparing derivatives of taxol and taxol analogues which have a modified substituent at the C-2 position.
SUMMARY OF THE INVENTION
The present application describes 2-debenzoyl taxol analogues, 2-debenzoyl-2-acyl taxol analogues, as well as procedures for preparing these compounds, and intermediates which can be utilized in preparing these compounds.
The compounds of the present invention may be used to treat patients suffering from cancer or as intermediates for making compounds which can be used to treat cancer. In a preferred embodiment, the taxol analogues have improved in vivo activities for use as anti-cancer agents. In another preferred embodiment, the taxol analogues have improved water solubility as compared with taxol.
Compounds of the present invention include compounds having the general formula: ##STR4## wherein R 1 is an alkyl or substituted alkyl; R 5 is selected from the group consisting of H and C(O)R a ; R 2 is selected from the group consisting of H, OH, oxyprotecting groups (i.e. triethylsilyloxy), OR b , and OC(O)R b ; R 3 is selected from the group consisting of H, OH, and OC(O)R c , and wherein R a , R b , and R c are independently selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls; provided that R a is other than phenyl and 3-hydroxyphenyl; and R 4 is H or OH.
Alternate embodiments of the above-described compounds include compounds:
wherein R 2 is OH or an oxyprotecting group;
wherein R 5 is H or C(O)R a and R a is an alkyl or a substituted aryl;
wherein R 4 is OH and/or
wherein R 1 has the general formula: ##STR5## wherein Ar is an aryl; Z is selected from the group consisting of alkyls, alkenyls, alkynyls, alkoxys, and aryls; X is H or a protecting group, and Y is selected from the group consisting of H, protecting groups, alkyloyls, substituted alkyloyls, substituted aryloyls, and aryloyls.
Other preferred embodiments of the present invention include compounds having the formula: ##STR6## wherein R is selected from the group consisting of H and C(O)R a wherein R a is selected from the group consisting of alkyls, substituted alkyls, aryls, and substituted aryls; provided that R a is other than phenyl and 3-hydroxyphenyl.
Yet another preferred embodiment of the present invention includes compounds having the general formula: ##STR7## wherein Z is C(O)OC(CH 3 ) 3 ; R 1 is selected from the group consisting of H and C(O)OC(CH 3 ) 3 ; R 2 is selected from the group consisting of H and C(O)R a wherein R a is selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls (e.g. C 6 H 5 ), and substituted aryls; and R 3 is a protecting group (e.g. triethylsilyl, C(O)OC(CH 3 ) 3 ), or hydrogen.
Yet another preferred embodiment of the present invention comprises pharmaceutical compositions, which comprise an antineoplastically effective amount of at least one of the compounds described above.
The present invention also contemplates a method for treating cancer comprising the administration of an antineoplastically effective amount of at least one of the compounds described herein.
Another preferred embodiment of the present invention comprises a method of making a first compound having the general formula: ##STR8## wherein R 1 is an alkyl or substituted alkyl; R 2 is selected from the group consisting of H and C(O)R a ; R 3 is selected from the group consisting of H, protecting groups, R b , and C(O)R b ; R 4 is selected from the group consisting of H and C(O)R c , and wherein R a , R b , and R c are independently selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyle, arys, and substituted aryls; provided that R a is other than phenyl and 3-hydroxyphenyl; comprising the step of replacing a moiety situated at the C-2 position of a second compound wherein said second compound is selected from the group consisting of taxol and taxol analogues.
For example, the foregoing method may be employed wherein said second compound has the general formula: ##STR9## wherein R 5 is an alkyl or substituted alkyl; R 6 is selected from the group consisting of H and C(O)R d ; R 7 is selected from the group consisting of H, protecting groups, R b , and C(O)R e ; R 8 is selected from the group consisting of H and C(O)R c , and wherein R d , R e , and R c are independently selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls;
and further comprising a step wherein said second compound is reacted with lithium hydroxide;
and further comprising a reaction with an acylating agent, followed by the step of deprotection;
wherein the deprotection step comprises a reaction with formic acid; and
wherein said acylating agent comprises a reagent selected from the group consisting of acid halides, β-lactams, anhydrides, and carboxylic acids.
In another embodiment of the method described above said first compound has the formula: ##STR10## wherein R is selected from the group consisting of alkyl, substituted alkyl, aryl, and substituted aryl;
and wherein said second compound is taxol;
further comprising the step of reacting with di-t-buryl dicarbonate.
The second compound is thus converted into a compound having the formula: ##STR11## wherein R 3 is a protecting group and R is selected from the group consisting of alkyl, substituted alkyl, aryl, and substituted aryl.
The method further comprises the step of deprotection; said deprotection step occurring subsequent to the step of adding an acylating agent; and
wherein said deprotection step comprises the addition of formic acid.
The present invention also discloses a method for making a first compound having the formula: ##STR12## wherein R 3 is a protecting group and R is selected from the group consisting of alkyl, substituted alkyl, aryl, and substituted aryl.
The present invention also comprises analogues of taxol in which the benzoyl group has been replaced by an acyl, C(O)R a , wherein R a is selected from the group consisting alkyl, substituted alkyl, alkenyl, alkynyl, aryl, and substituted aryl;
provided that R a is not phenyl or 3-hydroxyphenyl.
Another preferred embodiment of the present invention includes a method for making taxol analogues having a hydroxy or acyloxy substituent, other than benzoyloxy and 3-hydroxybenzoyloxy, at the C-2 position of the B-ring of the taxane tetracyclic nucleus comprising the step of removing a benzoyl moiety from said C-2 position of a taxol congener having a benzoyloxy group at said C-2 position.
In a variation of the above-described method, said taxol analogues have the general formula: ##STR13## wherein R 1 is an alkyl or substituted alkyl; R 5 is selected from the group consisting of H and C(O)R a ; R 2 is selected from the group consisting of H, OH, oxyprotecting groups, OR b , and C(O)R b ; R 3 is selected from the group consisting of H, OH, and OC(O)R c , and wherein R a , R b , and R c are independently selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls; provided that R a is other than phenyl and 3-hydroxyphenyl; and R 4 is H or OH.
The subject matter of the present application includes taxol analogues comprising a substituted benzoyloxy substituent at the C-2 position. Non-limiting examples include meta-substituted benzoyls, meta- and para-substituted benzoyls, and ortho-substituted benzoyls. Analogues in which a heterocyclic moiety replaces the phenyl ring of the benzoyl moiety are also disclosed. Certain non-limiting examples of such compounds are shown in Table I, compounds 13a, 13c-13t, and 13y-13ee. Certain, non-limiting preparative methods are also described herein. The present invention also contemplates the use of these compounds in the treatment of cancer.
In a preferred embodiment of the present invention, it has been surprisingly discovered that, by acylating the C-2 hydroxyl of a taxol analogue with 3,5-fluorobenzoic acid, followed bydeprotection of the resulting compound, a compound having about 25,000 times taxol's antineoplastic activity as determined by a cell culture assay is formed. The compound prepared is shown below: ##STR14##
The compounds of treat patients ention may be used to treat patients suffering from cancer or as intermediates for making compounds which can be used to treat cancer. In a preferred embodiment, the taxol analogues have improved invivoactivities for use as anti-cancer agents. In another preferred embodiment, the taxol analogues have improved water solubility as compared with taxol.
In a preferred embodiment, compounds of the present invention are taxol or taxol congeners having a meta-substituted benzoyloxy group at the C-2 position of the B-ring of the tetracyclic nucleus. Preferred meta-substituents include, but are not limited to halogens (e.g., chlorine, bromine, fluorine, iodine), alkoxys (e.g., methoxy, ethoxy, etc.), diatomic species (e.g., CN, NC, etc.), linear triatomic species (e.g., N 3 , NCO, etc.), and azido containing moieties. The meta-substituted benzoyloxy group may additionally comprise a (non-hydrogen) para-substituent and/or ortho-substituents.
Another preferred embodiment of the present invention involves compounds having the general formula: ##STR15## wherein R 1 is an alkyl or a substituted alkyl, R 2 is selected from the group consisting of H, OH, alkyloxy, aryloxy, oxyprotecting groups (e.g. triethylsilyloxy) and OC(O)R a , R 3 is selected from the group consisting of H, OH, and OC(O)R b , wherein R a and R b can be the same or different and are selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls, wherein T, U, W, V, and X are any substituents, provided that T, U, W, V, and X are not all H and when T, U, W, and V are H, X is other than OH and when T, U, V, and X are H, W is other than OH; and R 4 is H or OH.
Other preferred embodiments of the present invention include the compound having the general formula described above wherein:
R 1 has the general formula: ##STR16## in which Ar is an aryl; Z is selected from the group consisting of alkyls, alkenyls, alkynyls, alkoxys, (e.g. OC(CH 3 ) 3 ) and aryls (e.g. C 6 H 5 ); and Y is selected from the group consisting of H, protecting groups, alkyloyls, and aryloyls; and
T, U, W, V, and X are independently selected from the group consisting of hydrogens, halogens, alkoxys, diatomics, and linear triatomics.
Alternatively, X may be selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls.
In many preferred embodiments, R 1 is the substituted alkyl appearing at the C-13 side-chain of taxol.
Particularly preferred compounds have the general formula: ##STR17## wherein T, U, V, W, and X are any substituents provided that T, U, V, W, and X are not all H and when T, U, V, and W are H, X is not OH, and when T, U, V, and X are H, W is not OH.
Alternative preferred embodiments of the present invention include the compounds having the general formula described above wherein X is selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, substituted alkyls, amides, amines, nitros, and carboxylates; or wherein T, U, V, W, and X are all fluorine.
The present invention contemplates methods of treating cancer comprising the administration of an antineoplastically effective amount of any of the taxol analogues described herein.
The present invention also provides a method for making a first compound having the formula: ##STR18## wherein R 1 is an alkyl or a substituted alkyl, R 2 is selected from the group consisting of H, OH, alkoxy, aryloxy, oxyprotecting groups and OC(O)R a , and R 3 is selected from the group consisting of H, OH, and OC(O)R b , wherein R a and R b can be the same or different and are selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls, and R 4 is H or OH; and T, U, V, W, and X are any substituents, provided that T, U, V, W, and X are not all H and when T, U, V, and W are H, X is not OH, and when T, U, V, and X are H, W is not OH;
comprising a step wherein the benzoyl moiety at the C-2 position of a second compound having the formula: ##STR19## wherein R 4 is H or OH, R 5 is an alkyl or a substituted alkyl, R 6 is selected from the group consisting of H, OH, alkyloxy, aryloxy, oxyprotecting groups (e.g. triethylsilyloxy) and OC(O)R a , and R 3 is selected from the group consisting of H, OH, and OC(O)R b , wherein R a and R b can be the same or different and are selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, and aryls;
is replaced by a substituted benzoyl moiety provided that if both ortho-substituents, the para-substituent, and one meta-substituent on said benzoyl moiety are H, the other meta-substituent is other than H or OH.
Alternative preferred embodiments of the method of making said first compound, described above, include:
wherein R 1 has the general formula: ##STR20## wherein Ar is an aryl; Z is selected from the group consisting of alkyls, alkenyls, alkynyls, alkoxys, (e.g. OC(CH 3 ) 3 ), and aryls (e.g. C 6 H 5 ); and Y is selected from the group consisting of H, protecting groups, alkyloyls, and aryloyls;
wherein T, U, V, and W are H and X is selected from the group consisting of halogens, diatomics and linear triatomics; and
wherein Y in said second compound is triethylsilyl and R 6 is triethylsilyloxy and further wherein said second compound is debenzoylated via reaction in a mixture comprising aqueous sodium hydroxide, a phase-transfer catalyst, and an organic solvent, to yield a compound having a hydroxyl at the C-2 position, wherein
said compound having a hydroxyl at the C-2 position is reacted in a subsequent step with meta-C 6 H 4 X--COOH.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the reaction of taxol with excess di-tert-butyl-dicarbonate in the presence of 4-dimethylaminopyridine (DMAP) to yield 2',7-di(t-butoxycarbonyloxy) taxol, 2',7,N-tri(t-butoxycarbonyloxy) taxol, and 1,2',7,N-tetra(t-butoxycarbonyloxy)taxol.
FIG. 2 illustrates the reaction of 2',7,N-tri(t-butoxycarbonyloxy) taxol with LiOH to yield 2',7,N-tri(t-butoxycarbonyloxy)-2-debenzoyl taxol; and prolonged reaction resulting in cleavage of the D-ring of the taxane skeleton.
FIG. 3 illustrates the reaction of 2',7,N-tri(t-butoxycarbonyloxy)-2-debenzoyl taxol with an acylating agent to yield 2',7N-tri(t-butoxycarbonyloxy)-2-debenzoyl-2-acyl taxol, followed by removal of the oxyprotecting groups with formic acid to yield 2-debenzoyl-2-acyl taxol.
FIG. 4 illustrates the reaction of taxol with one equivalent of di-tert-butyl dicarbonate in the presence of 4-dimethylaminopyridine to yield the 2'-t-butoxyycarbonyloxy derivative of taxol followed by reaction with triethylsilyl chloride to yield 2'-t-butoxycarbonyloxy-7-triethylsilyltaxol, and the subsequent reaction with an excess of di-t-butyl dicarbonate to yield 2',N-di-t-butoxycarbonyloxy-7-triethylsilyl taxol.
FIG. 5 illustrates the reaction of 2',N-t-butoxycarbonyloxy-7-(triethylsilyl)taxol with lithium hydroxide to yield 2',N-di-t-butoxycarbonyloxy-2-debenzoyl-7-(triethylsilyl)taxol followed by reaction with an acylating agent and subsequent deprotection with formic acid to yield 2-debenzoyl-2-acyl taxol.
FIG. 6 illustrates the reaction of taxol with triethylsilyl chloride in the presence of imidazole to yield 2',7-(triethylsilyl)taxol, followed by reaction with sodium hydroxide under phase-transfer conditions to yield 2-debenzoyl-2',7-(triethylsilyl)taxol followed by reaction with a carboxylic acid to yield 2-debenzoyl-2',7-triethylsilyl-2-acyl taxol.
DEFINITIONS
Unless clearly indicated by context or statement to the contrary, the terms used herein have the meanings as conventionally used in the chemical arts, and definitions incorporate those used in standard texts, such as but not limited to Grant & Hackh's Chemical Dictionary, 5th edition, McGraw-Hill, 1987; Streitwieser et al., Introduction to Organic Chemistry 2nd edition, Macmillan, 1981; and March, Advanced Organic Chemistry, 3rd Wiley, 1985.
The term alkyl refers to straight-chain or branched-chain hydrocarbons. In some preferable embodiments, alkyl refers to the lower alkyls containing from one to six carbon atoms in the principal chain and up to 10 carbon atoms; the lower alkyls may be straight or branched chain and by way of non-limiting example include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, and the like.
The term substituted alkyl refers to groups including, but not limited to, the alkyl groups discussed above which have as substituents halo (e.g., chloro, bromo), nitro, sulfate, sulfonyloxy, carboxy, carboxylate, phosphate (e.g., OP(O)(OH) 2 , OP(O)(OR)(OH)), carbo-lower-alkoxy (e.g., carbomethoxy, carboethoxy), amino, mono- and di-lower-alkylamino (e.g., methylamino, dimethylamino, carboxamide, sulfonamide, diethylamino, methylethylamino,) amide lower-alkoxy (e.g., methoxy, ethoxy), lower-alkanoyloxy (e.g., acetoxy), alkenyl, alkynyl, aryl, aryloxy, and combinations of these (e.g., alkylbenzenesulfonates).
The term aryl has the meaning known in the chemical arts, and aryl also refers to heterocyclic aryls. Substituted aryls have the same substituents discussed above for the substituted alkyls and also include, but are not limited to, aryls having lower alkyl substituents such as methyl, ethyl, butyl, etc.
The use of the term "any substituent" in the present application refers only to those substituents capable of bonding to the C-2 position of the taxane tetracyclic nucleus and which are not incompatible with the remainder of the taxol analogue structure (i.e. not so large as to preclude bonding to the C-2 position, or not so reactive as to lead to rapid decomposition of the structure of the taxol or taxol analogue). The term "analogues of taxol" refers to compounds comprising the taxane tetracyclic nucleus and an acetyl group at the C-4 position.
In the context of the present invention, protecting groups can be used to protect hydroxyls, or the NH group of an amide.
DETAILED DESCRIPTION OF THE INVENTION
The present invention pertains to the removal of the benzoyl group at the C-2 position of taxol and taxol analogues, thus resulting in a 2-debenzoyl taxol analogue. The 2-debenzoyl taxol analogues can be reacylated with acylating agents to produce 2-debenzoyl-2-acyl taxol analogues.
As illustrated in FIG. 1, treatment of taxol 1! with excess di-tert-butyl-dicarbonate (BOC 2 ) in the presence of 4-dimethylaminopyridine (DMAP) converts it over a period of five days to a mixture of 2',7-di(t-BOC)taxol 6!, 2',7,N-tri(t-BOC)taxol 7!, and 1,2',7,N-tetra(t-BOC)taxol 8! (t-BOC is tert butoxycarbonyl).
Compound 8 could be isolated after careful work-up that avoids acidic conditions, but it was most conveniently converted into the tri(t-BOC)taxol 7! by a mild acid treatment during work up. Using this procedure the tri(t-BOC)taxol 7! could be obtained in 41% yield and the di(t-BOC)taxol 6! in 32% yield, for a combined yield of 73%.
It has been surprisingly discovered that treatment of taxol analogues, in which the C-2' and C-7 positions have been protected with t-BOC groups with lithium hydroxide results in selective hydrolysis at the C-2 position. For example, with reference to FIG. 2, treatment of 2',7,N-tri(t-BOC)taxol with lithium hydroxide converted it into 2',7,N-tri(t-BOC)-2-debenzoyltaxol 9!. ##STR21## In this process the 2-benzoyl group is cleaved, but the t-BOC groups are not cleaved and neither are any of the other ester functions. If reaction with lithiumhydroxide is prolonged, conversion of 9 into the rearranged product 10 occurs, and it has not so far been possible to obtain 9 without some formation of 10.
Conversion of 2',7,N-tri-(t-BOC)-2-debenzoyltaxol 9! into 2-debenzoyltaxol was not possible with conventional t-BOC cleavage agents, because rearrangement occurs simultaneously with deprotection to yield the isotaxol 11. ##STR22##
FIG. 3 illustrates, by way of a non-limiting example, preparation of 2-debenzoyl-2-acyl taxols by reacylation of the debenzoyl derivative 9 with a desired acyl group to yield the protected derivative 12. Deprotection of 12 with 99% formic acid then yields the taxol analogue 13. ##STR23##
A second process for the preparation of 2-debenzoyl-2-acyl taxols involves the selective protection of the C-7 position with a protecting group such as a triethylsilyl. A preferred embodiment of a second process for the synthesis of C-2 analogues of taxol is illustrated in FIGS. 4 and 5. Taxol is first converted to its 2'-t-BOC derivative 14, and this is treated with triethylsilyl chloride to give the 2'-t-BOC, 7-triethylsilyl derivative 15. Finally 15 is treated again with di-t-butyl dicarbonate to give the N-t-BOC, 2'-t-BOC, 7-triethylsilyl derivative 16.
The taxol derivative 16 can be debenzoylated as described earlier to give the 2-debenzoyl analogue 17. Reacylation of 17 with a desired acyl group then yields the acyl derivative 18, where C(O)R is any desired acyl group. Deprotection of 18 with 99% formic acid then gives a 2-debenzoyl-2-acyltaxol derivative 13. One example of this chemistry is the conversion of 17 back to taxol by benzoylation to the benzoyl derivative 16 and deprotection to yield taxol. Reaction of 17 with 3-(3-(trifluoromethyl)-3H-diazirin-3-yl phenoxyacetic acid yields 2',N-di(t-BOC)-7-(triethylsilyl-2-debenzoyl-2(3-(3-trifluoromethyl,)-3H-diazirin-3-yl)phenoxyacetyltaxol, which can be subsequently deprotected to yield the compound shown below. ##STR24##
In a particularly advantageous process for the preparation of 2-debenzoyl-2-acyl taxol analogues, the substituent at the C-2 position is converted from an acyl to a hydroxy by base catalyzed hydrolysis under phase transfer conditions. An embodiment of this preferred process for the preparation of 2-debenzoyl-2-acyl taxol analogues is illustrated in FIG. 6. Conversion of taxol 1 to its 2',7-di(triethylsilyl) derivative 21 proceeds smoothly and in good yield on treatment of taxol with triethylsilyl chloride and imidazole in DMF. The key reaction is thus the hydrolysis of 21 under phase-transfer conditions with aqueous sodium hydroxide. This converts 21 to 2',7-di-(triethylsilyl)-2-debenzoyltaxol 22. Acylation of 22 with an appropriate benzoic, or substituted benzoic, or other carboxylic acid then gave the protected 2-debenzoyl-2-acyltaxol analogue 23, which could be deprotected readily to the 2-debenzoyl-2-acyltaxol 13.
Acylation of 22 with various aromatic carboxylic acids in the presence of dicyclohexylcarbodiimide and 4-pyrrolidinopyridine has led to the preparation of various 2-debenzoyl-2-acyl taxols 13. As shown in Table 1, the activities of several 2-debenzoyl-2-acyltaxols were determined in a cell culture assay using P-388 lymphocytic leukemia cells, and compared with that of taxol; compounds with an ED 50 /ED 50 (taxol) value of less than 1 are more active than taxol in this assay. For details of the cell culture assay, see Abbott, B. J., "Protocol 14 of Instruction 275," National Cancer Institute, National Institutes of Health, Jan. 24, 1978.
It was found that compounds lacking the benzoyl group, such as 13b!, were less active or about as active as taxol. Of particular significance compounds with an ortho-substituted benzoyl group, such as 13o, were found to have increased bioactivity as compared with taxol. Of particular significance is the discovery that compounds with a meta-substituted benzoyl group have much greater biological activity than taxol 13c, 13d, 13f!. For example, 2-debenzoyl-2-(m-azidobenzoyl)taxol 13f! shows activity against P-388 leukemia in vitro that is 500 times higher than that of taxol. The co-pending application also discloses that compounds with fluoro substituted benzoyls have especially high biological activity; for example 2-debenzoyl-2-(3,5-difluorobenzoyl)taxol 13t! shows activity against P-388 leukemia in vitro that is 25,000 times higher than that of taxol. The compounds disclosed in the co-pending U.S. application are thus highly promising candidates for use as anticancer drugs when administered in an antineoplastically effective amount to patients suffering from cancer.
Having shown the preparation of 2-debenzoyl taxols and 2-debenzoyl-2-(acyl) taxols, additional non-limiting preferred embodiments of this invention include congeners of 2-debenzoyl taxols and 2-debenzoyl-2-(acyl)taxols in which various modifications are made to the taxol structure, such as, but not limited to, varying substituents at the C-1 position, C-7 position, C-10 position and/or the C-13 side chain.
Particularly desired modifications include, but are not limited to, modifications which increase water solubility or stability of the 2-debenzoyl-2-(meta-substituted benzoyl) taxols and taxol congeners. Non-limiting examples of such water soluble derivatives can be produced by the methods disclosed in U.S. Pat. Nos. 5,059,699 and 4,942,184; the solubilizing groups described therein can likewise be attached to compounds of the present invention to increase their water solubility.
It is known that the C-7 hydroxyl group on taxol and Baccatin III can be readily epimerized, and that epimerization has little effect on bioactivity. See "The Chemistry of Taxol," Pharmac. Ther., 52, 1-34 (1991). It is therefore to be understood that this invention contemplates either or both C-7 enantiomers in the compounds of the present invention. Nonetheless, it is often preferred to prevent epimerization of the C-7 hydroxyl and in the Examples of the present invention epimerization is avoided by protecting the C-7 hydroxyl prior to exposing taxol or its analogues to conditions which catalyze epimerization.
In addition to the acylations and acyloxy to hydroxy conversions at the C-7 and C-10 positions, of which certain embodiments are exemplified in the literature; this invention also contemplates the removal of the oxy group(s) from the C-1, C-7, and/or C-10 positions. Certain, preferred embodiments of these removals are described below.
10-deacetoxytaxol can be prepared by treatment of 7-(triethylsilyl)-10-deacetylbaccatin III with carbon disulfide, methyl iodide, and sodium hydride to yield the 10-(methylxanthyl) derivative. Treatment of this with tributyltin hydride (TBTH) and azobisisobutyronitrile (AIBN) yields 7-(triethylsilyl)-10-deacetoxybaccatin III, which can be esterified with the taxol side-chain as previously disclosed. (Highly efficient, practical approach to natural taxol, J. Am. Chem. Soc., 1988, 110, 5917-5919). Treatment of this 10-deacetoxytaxol as described for taxol itself then converts it to the 10-deacetoxy-2-debenzoyl-2-acyl taxol analogues described.
7-deoxytaxol can be made by treatment of 2'-triethylsilyltaxol with sodium hydride, carbon disulfide, and methyl iodide to give the 7-(methylxanthyl) derivative, which is then deoxygenated with TBTH, and AIBN to yield 2'-(triethylsilyl)-7-desoxytaxol. This is then converted to its 2-debenzoyl-2-acyl derivative as previously described for taxol.
It is contemplated that 1-deoxytaxol can be made by treating 2',7-di(triethylsilyl)taxol with 2N NaOH in the presence of carbon disulfide, methyl iodide, benzene, and a phase-transfer catalyst, to give the 1-(methylxanthyl)-2-debenzoyl derivative. Acylation with a suitable substituted benzoic acid then yields the corresponding 2-aroyl derivative, which can be reduced to the 1-deoxy derivative with TBTH and AIBN. Deprotection of the 2'- and the 7-positions then gives a 1-desoxy-2-debenzoyl-2-aroyl taxol derivative.
In addition to the described alterations to the C-2 position, the C-2 position can also be converted to a methylene. For example, 1-benzoyl-2-deoxytaxol can be prepared by treating 2',7-di(triethylsilyl)taxol with sodium hydride, carbon disulfide, and methyl iodide, to yield 1-benzoyl-2-(methylxanthyl)2',7-di(triethylsilyl)taxol: the benzoyl group is transferred from the C-2 to the C-1 position during this reaction. Deoxygenation with AIBN and TBTH followed by removal of the 2',7-TES groups then yields 1-benzoyl-2-deoxytaxol.
METHODS AND MATERIALS
Specific reaction methods are described in more detail in the following non-limiting examples. Certain methods used herein are generally described in the "Journal of Organic Chemistry," 51, pp. 797-802 (1986). Low resolution mass spectrometry data were obtained on a VG 7070 E-HF mass spectrometer. All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.
EXAMPLES
Preparation of 2',7,N-tri(t-BOC)taxol (7)
Taxol (25 mg, 0.0293 mole) and acetonitrile (1.5 ml, freshly dried and distilled over calcium hydride) were added to a flame dried 25 ml round bottom flask, under argon atmosphere. To this solution was added 84.9 mg (0.389 mmole) of di-tert-butyl dicarbonate in 1.00 ml of dry acetonitrile under argon. After stirring for 5 min., DMAP (4.8 mg) was added. The reaction mixture, which became pale yellow to orange in color, was then stirred for five days; on the second and fourth days after initiating the reaction, 85 mg of di-tert-butyl dicarbonate in 0.5 ml of dry acetonitrile was added, followed by addition of 4.8 mg of DMAP. The reaction mixture was quenched by diluting it with ethyl acetate, followed by removal of the solvent on a rotary evaporator. The orange residue was then dissolved in ethyl acetate and washed with dilute HCl followed by a rapid wash with cold 0.05N NaHO 3 solution. The solution was washed with brine, dried with sodium sulfate, and the solvent was removed by use of a rotary evaporator. Purification by preparative thin layer chromatography (PTLC) (Analtech, 500 mm SiO 2 ) gave two major bands with R f 0.27 and 0.23. The band with R f 0.27 was scraped off and eluted with acetone to give the title compound on evaporation (11.1 mg, 33%) mp 188°-192° C. Elution of the band at R f 0.23 gave 2',7-di(BOC)taxol (10.1 mg, 33%). For 1 H-NMR, see Table 2; Mass Spectrometer, MS, gave m/z of 1053 (MH+).
Conversion of 2',7,N-tri-(t-BOC)-2-Debenzoyl taxol (9) to 2',7,N-tri-(t-BOC)taxol (7)
2',7,N-tri-(t-BOC)-2-debenzoyltaxol 9 (7 mg, 0.007 5 mmol), benzoic acid (24 mg, 0.198 mmol) and dicyclohexylcarbodiimide, DCC, (41 mg, 0.198 mmol) in 50 ml dry toluene were mixed under an argon atmosphere, and 4-pyrrolidinopyridine was added as a catalyst. The reaction mixture was stirred at room temperature (24° C.) overnight and then diluted with ethyl acetate. The residue was filtered and the filtrate was then purified by PTLC (Analtech 500 μm; hexane: ethyl acetate 1:1) to give 2',7,N-tri-(t-BOC)-taxol 7 (4.5 mg, 58%).
Preparation of 2',7,N-tri(t-BOC)-2-debensoyltaxol 9
To a stirred solution of 2',7,N-tri(t-BOC)taxol (34.5 mg, 0.034 mmole) in 2.5 ml of tetrahydrofuran (THF), 0.4 ml 0.1N lithium hydroxide solution at 0° C. was slowly added. After complete addition (about 5 minutes) the ice bath was removed and the reaction mixture was stirred for 1.5 hour at room temperature. TLC showed conversion of the starting material to two new products (R f 0.28 and 0.19 in hexane:ethyl acetate, 1:1), together with unreacted starting material. The reaction mixture was then diluted with 10 ml diethyl ether, washed with brine, and dried over sodium sulfate. The solvent was evaporated on a rotary evaporator to obtain crude product, which was purified by preparative TLC (Analtech, 500 μm, SiO 2 , hexane:ethyl acetate, 1:1) to yield 2',7,N-tri(t-BOC)-2-debenzoyl taxol (R f 0.19) (8.7 mg, 24.2%).
Conversion of 2',7,N-tri-(t-BOC)taxol 7 to Taxol
To a solution of 50% formic acid in dry methylene chloride (200 μl 99% formic acid +200 μl dry CH 2 Cl 2 ), 2',7,N-tri-(t-BOC)taxol (10 mg) was added and stirred for 5 hours at room temperature. The excess formic acid was removed by evaporation on a vacuum pump, and the reaction mixture was diluted with ethyl acetate, then washed with 5% NaHCO 3 , water and brine, dried, and evaporated. Purification of the crude material by PTLC (Analtech 500 mm; hexane:ethyl acetate 1:1) yielded taxol (3 mg, 38.5%), identical with an authentic sample.
Preparation of 2',7,N-tri(t-BOC)-2-debenzoyl isotaxol 10
If the preparation of compound 9 described above is allowed to proceed for a longer time, the spot with R f 0.28 becomes the major product. After a 3 hour reaction, 4.2 mg of this material could be isolated from 10.5 mg of starting material (56.7%). Characterization gave a melting point, Mp, of 158°-160° C.; for proton NMR data, see Table 2.
Preparation of 2-Debenzoylisotaxol 11.
A mixture of 2',7,N-tri-(t-BOC)-2-debenzoyl isotaxol 10 (14 mg, 0.0133 mmol), and 0.5 ml of 99% formic acid was stirred at room temperature in a 5 ml round bottom flask for 90 minutes under argon. The excess formic acid was removed under reduced pressure. The residue was diluted with ethyl acetate (10 ml), washed quickly with 0.05N aqueous NaHCO 3 and brine, dried with anhydrous sodium sulfate, and evaporated. The crude product was purified by PTLC (hexane:ethyl acetate, 1:1). The lower band of R f 0.1 was scraped and eluted several times with acetone. Removal of the solvent gave 2-debenzoyl isotaxol 11, 3.8 mg (34%). For 1 H-NMR data, see Table 2. MS gave m/z 772 (MNa+), 750 (MH+).
Preparation of 2,-(t-BOC)taxol 14.
Taxol (85.3 mg, 0.1 mmol) and acetonitrile (2 ml, freshly dried and distilled over calcium hydride) were added to a flame dried 25 ml round bottom flask under argon. To this solution at 0° C. was added 21.8 mg (0.1 mmol) of di-tert-butyldicarbonate in 2.00 ml of dry acetonitrile under argon. After stirring for 5 minutes, DMAP (5 mg) was added at 0° C. The reaction mixture was stirred for 2 hours at room temperature, and then worked up by diluting with ethyl acetate, followed by removing the solvent on a rotary evaporator. The pale yellow residue was then dissolved in ethyl acetate, and washed with dilute HCl, followed by a rapid wash with cold 0.05N NaHCO 3 . The organic solution was then washed with brine, dried over sodium sulfate, and evaporated to give 14 (95 mg, 99.6%), R f (hexane:ethyl acetate, 1:1) 0.36. For 1 H-NMR data, see Table 3.
Preparation of 2'-(t-BOC)-7-(triethylsilyl)taxol 15.
To a stirred solution of 2'-(t-BOC)taxol (95.3 mg, 0.1 mmol) in 2 ml dry DMF, imidazole (34 mg, 5 mmol) was slowly added, followed by addition of triethylsilyl chloride (83.9 ml, 0.5 mmol) at 0° C. under argon. The reaction mixture was stirred for 3 hours at room temperature, and then quenched by diluting with ethyl acetate and washing the organic layer several times with water and brine, followed by drying with sodium sulfate. The solvent was then evaporated to obtain the pure compound 15, (94.9 mg, 89%), R f (hexane:ethyl acetate, 1:1) 0.66. For 1 H-NMR, see Table 3.
Preparation of 2',N-di(t-BOC)-7-(triethylsilyl)taxol 16.
To a solution of 2'-(t-BOC)-7-(triethylsilyl)taxol (92.5 mg, 0.09 mmol) in 0.5 ml dry acetonitrile under argon atmosphere di-t-butyldicarbonate (377.6 mg, 20 mmol) in 0.5 ml of CH 3 CN was added. After stirring for 5 minutes at room temperature, DMAP (8 mg) was added. The reaction mixture was then stirred for 3 hours at room temperature, and then worked up by diluting with ethyl acetate, followed by removal of the solvent on a rotary evaporator. The residue was then diluted with ethyl acetate and washed with cold dilute HCl, cold 0.05N NaHCO 3 , water, and brine, and dried over sodium sulfate. The solvent was then evaporated to yield crude product, which was purified by passing through a small silica gel column to yield the pure compound 16 (89 mg, 88%). R f (hexane:ethyl acetate, 1:1) 0.55. For 1 H-NMR data, see Table 3.
Preparation of 2',N-di(t-BOC)-7-(triethylsilyl)-2-debenzoyl taxol 17.
To a stirred solution of 2',N-(di-t-BOC)-7-(triethylsilyl)taxol (45 mg, 0.038 mmol) in 4.5 ml of THF, 0.45 ml of 0.1N LiOH solution was added. The mixture was held at 0° C. with an ice bath during combination of the ingredients. After complete addition, the ice bath was removed and the solution was stirred for 2 hours at room temperature. TLC showed the presence of two new spots at lower R f along with starting material. The reaction was then worked up by diluting with ether and washing with brine. The brine layer was washed with fresh ether and the combined organic layer was dried over sodium sulfate and evaporated. The crude product was then purified on PTLC (Analtech, 500 μm, Hexane:EtOAc, 1:1). The slower moving band was scraped and extracted to give the debenzoyl product 17 (15.3 mg, 38%). The band corresponding to starting material was also recovered (23.3 mg). R f (hexane:ethyl acetate, 2:1) 0.21. For 1 H-NMR data, see Table 3. MS gave m/z 1064 (MH+, 100%).
Preparation of 2',N-di(t-BOC)-7-(triethylsilyl)taxol 16 From 2',N-di (t-BOC)-7-(triethylsilyl)-2-debensoyl taxol 17.
A sample of 2',N-di(t-BOC)-7-(triethylsilyl)-2-debenzoyl taxol (2 mg, 0.0018 mole) was treated with benzoic acid (4.59 mg, 0.0338 mole), DCC (7.75 mg, 0.038 mole), and a catalytic amount of 4-pyrrolidinopyridine in dry toluene (10 μL) under argon atmosphere. The mixture was stirred overnight at 50° C., and the solvent was then removed on a rotary evaporator. The crude reaction mixture was purified by PTLC (500 mM layer, EtOAc:hexane, 1:2) to yield 2',N-di(t-BOC)-7-(triethylsilyl)taxol 16 (1.5 mg, 68%), identical with material prepared directly from taxol.
Conversion of 2',N-di(t-BOO)-7-(triethylsilyl)taxol 16 to Taxol.
Compound 16 (9.5 mg) was treated with 99% formic acid (Fluka, 0.15 ml) with stirring for 30 minutes at room temperature. The formic acid was then removed by use of a vacuum pump, and the reaction mixture diluted with ethyl acetate, washed with 5% NaHCO 3 , water, and brine, dried and evaporated. Purification of the residue by PTLC (EtOAc:hexanes, 1:1) yielded taxol (2 mg, 28%), identical with an authentic sample.
Preparation of 2',N-di(t-BOC)-7-(triethylsilyl)-2-debensoyl-2(3-(3-(trifluoromethyl)-3H-diazirin-3-yl)phenoxyacetyltaxol,
2',N-di(t-BOC-7-triethylsilyl-2-debenzoyltaxol (17) (2.34 Mg, 0.002 mmol), 3-(3-(trifluoromethyl)-3H-diazirin-3-yl)phenoxyacetic acid (10.4 mg, 20 mmol) and DCC (8.25 mg, 20 mmol) in 50 μl of dry toluene were mixed at room temperature under argon and 4-pyrollidinopyridine was added as a catalyst. The reaction mixture was stirred at room temperature overnight and then diluted with ethyl acetate. The residue was filtered and the filtrate was purified by PTLC (Analtech, 500 μm:hexane:EtOAc, 1:1) to give 1.1 mg of the title compound (38.3%). 1 H-NMR, see Table 4.
Preparation of 2',7-Di(triethylsilyl)-2-debenzoyl taxol 22.
To a stirred solution of 2',7-di(triethylsilyl)taxol 21, (65.0 mg, 0.060 mmol) prepared according to the procedure described in "Modified Taxols. 5. Reaction of Taxol With Electrophilic Reagents and Preparation of a Rearranged Taxol Derivative with Tubulin Assembly Activity," J. Org. Chem., 56, 5114-5119 (1991). Benzene:methylene chloride (8 ml:1.2 ml) and tetrabutyl-ammonium hydrogen sulfate (500 mg) at room temperature 8 ml of aqueous 2N sodium hydroxide solution was added. The reaction mixture was stirred for 1.5-2 hours, and then diluted with 15 ml of benzene. The organic layer was separated, washed with water (3×10 ml), brine (10 ml), dried over MgSO 4 , and evaporated. The crude product was purified on PTLC (Analtech, 500 μm, hexane:EtOAc, 1:1). The slower moving band (R f =0.3) was extracted to give the 2',7-di (triethylsilyl)-2-debenzoyl taxol 2 (25.0 mg, 43%). For 1 H-NMR data, see Table 4. Two faster moving bands (R f 0.32 and 0.75) on extraction gave starting material 1 (25.0 mg) and 7-TES-baccatin-III (5.0 mg). Yield was 69% based on unrecovered starting material.
Acylation of 2',7-di(triethylsilyl)-2-debensoyl taxol With m-nitro-bensoic Acid
A mixture of 2',7-di(triethylsilyl)-2-debenzoyl taxol 22 (10.0 mg, 0.01 mmol), DCC (42.0 mg, 0.20 mmol), 4-pyrrolidinopyridine (catalytic quantity), p-nitrobenzoic acid (0.20 mmol), and toluene (0.1 mL) was stirred at room temperature for 12 hours and then diluted with (10 ml) of ethyl acetate, EtOAc. The organic layer was separated and washed with water (2×5 ml), brine (2×5 ml), dried over MgSO4 and evaporated. The crude product was purified on PTLC (Analtech, 500 μm, hexane:EtOAc, 1:1). The band (R f 0.72) was extracted to furnish 2-debenzoyl-2-(m-nitro benzoyl)-2',7-di(triethylsilyl)taxol 23c (yield 60 to 75%).
Deprotection of 2-debenzoyl-2-(m-nitrobenzoyl)-2',7-di(triethylsilyl) Taxol
A mixture of 2-debenzoyl-2-(m-nitrobenzoyl)-2',7-di(triethylsilyl)taxol 23c (10.0 mg) and (0.10 mL) of 5% HCl:MeOH was stirred at room temperature for 0.5 hours and then diluted with (10 mL) of EtOAc. The organic layer was separated and washed with water (2×5 mL), brine (5 mL), dried over MgSO 4 and evaporated. The crude product was purified on PTLC (Analtech, 500 μm, hexane:EtOAc, 1:1). The band (R f 0.2) was extracted to give 2-debenzoyl-2-(N-nitrobenzoyl)taxol derivative 13c (yield 80 to 90%). For 1 H-NMR, see Table 4.
Preparation of 2-(m-Azidobenzoyl)-2-debenzoyl-2',7-di(triethylsilyl) Taxol 23f.
To a solution of 2-debenzoyl-2',7'di(triethylsilyl)taxol 22, (21 mg, 0.002 mmol) in dry toluene (200 μl), 1,3-dicyclohexylcarbodiimide (88 mg, 0.043 mmol), m-azidobenzoic acid (70 mg, 0.043 mmol), and a catalytic amount of 4-pyrrolidinopyridine were added, and stirred at 50° C. for 3 hours. The crude reaction mixture was filtered through a short silica gel column using 20% ethyl acetate/80% hexane. The required product along with some inseparable impurities co-eluted, and hence the crude product (25 mg) was carried through the next reaction. For 1 H-NMR data, see Table 5.
Preparation of 2-(m-Azidobenzoyl)-2-debenzoyl Taxol 13f.
To crude 2-(m-azidobenzoyl)-2-debenzoyl-2',7-di(triethylsilyl)taxol (22.1 mg), 200 μl of freshly prepared 5% HCl in methanol was added. The reaction mixture was stirred at room temperature for 30 minutes, and then diluted with 20 ml of ethyl acetate. The organic layer was washed with water (10 ml×3) and brine and dried over sodium sulfate. The crude product was purified by PTLC (500 μM layer, hexane:ethyl acetate, 1:1) to yield 2-(m-azidobenzoyl)-2-debenzoyl taxol 13f (16 mg, 83%). For 1 H-NMR data, see Table 5.
In a preferred embodiment, compounds of the present invention having antineoplastic properties are administered in antineoplastic amounts to patients suffering from cancer. for example, 2-debenzoyl-2-meta-azido-benzoyl taxol can be administered in a pharmaceutically acceptable carrier in an antineoplastically effective amount to a patient suffering from cancer. Likewise, water soluble derivatives may be made of the antineoplastically effective compounds of the present invention and administered in an effective amount to cancer patients. Thus, the present invention discloses methods for selective deacylation and reacylation of the C-2 position on taxol and taxol analogues, as well as new antineoplastically effective compounds which result therefrom.
The compounds and methods of the present invention are not limited to the specific examples discussed in the section entitled Detailed Description of the Invention. The methods of the present invention are broadly applicable and can be used to prepare a large variety of taxol and baccatin III analogues in which the tetracyclic taxane nucleus is acylated at the C-2 position. A wide array of taxol and baccatin III analogues may be used as starting materials in the methods of the present invention. This invention further contemplates reactions, such as acylations, prior to and subsequent to acylation of the C-2 position which can produce a wide variety of compounds. Various synthetic steps such as protecting steps (for example at the C-2' and C-7 positions), and acylating and deacylating steps (for example at the C-10 and C-13 positions) may be those described herein or those otherwise known in the prior art. The products of the present invention may be prepared as either desired final products, or as intermediates in the synthesis of desired taxol analogues.
It is contemplated that substituents on the tetracyclic taxane nucleus be selected based upon the medicinal or synthetic characteristics that various substituents will impart to the taxol analogue. Workers of ordinary skill in the chemical and pharmaceutical arts will appreciate that the widely applicable methods of the present invention enable the strategic selection of substituents (from a very large number of possible substituents which could be placed on the tetracyclic taxane nucleus) at certain locations on the taxane tetracyclic nucleus.
Although preferred embodiments have been described herein, it is to be understood that the invention can be practiced otherwise than as specifically described.
TABLE I______________________________________CYTOTOXICITY OF SELECTED2-DEBENZOYL-2-ACYLTAXOLS AGAINST P-388 LEUKEMIA ##STR25##COMPOUND R ED.sub.50 /ED.sub.50 (taxol)______________________________________1 (Taxol) benzoyl 1.013a m-aminobenzoyl 150013b cinnamoyl 1013c m-nitrobenzoyl 0.313d m-chlorobenzoyl 0.113e m-dinitrobenzoyl 2.013f m-azidobenzoyl 0.00213g 3,4,5,- 0.5 trimethoxy benzoyl13h m-cyano 0.25 benzoyl13i m-trifluoro 15 methylbenzoyl13j m-fluorobenzoyl 0.3513k 2-thiophene- 10 carbonyl13l 3-thiophene- 4 carbonyl13m 3,4- 0.003 dichlorobenzoyl13n m-methylbenzoyl 0.0413o o-chlorobenzoyl 0.01113p m-methoxybenzoyl 0.000413q m-chlorobenzoyl 0.001413r m-phenoxybenzoyl 4.313s m-iodobenzoyl 0.02813t 3,5- 0.00004 difluorobenzoyl13u 2-naphthoyl 1013v 3-furoyl 1.413w acetyl 2813x phenoxyacetyl 0.713y p-fluorobenzoyl 0.513z p-(t-BOC)benzoyl 3013aa p-cyanobenzoyl 3013bb p-chlorobenzoyl 15013cc p-(methylthio) 12 benzoyl13dd p-nitrobenzoyl 8.313ee p-trifluoro 30 methylbenzoyl13ff p-acetylbenzoyl 30______________________________________
TABLE 2__________________________________________________________________________.sup.1 H-NMR Spectra of Compounds 6, 7, 10, 11 2',7,N- tri(t-BOC) 2',7,N-tri(t-BOC) 2',7,N- 2',7-di(t- 2-debenzoyl 2-debenzoyl tri(t-BOC) 2-Debenzoyl BOC) taxol isotaxol isotaxol taxol isotaxolprotons (6) (10) (10) (7) (11)__________________________________________________________________________C-2 5.75 d (7.0) 4.06 bd (6.5) 4.06 5.6 d (7.0) 4.17 bd brd (6.5) (3.2)C-3 3.95 brd (7.0) 3.36 bd (6.5) 3.36 3.9 d (7.0) 3.25 bd bd (6.5) (6.2)C-5 4.95 bd (10) 4.78 dd (9.0, 4.78 4.95 dd 3.78 2.0) dd (7.7, 2.0) m (9.0, 2.0)C-6 -- -- -- 2.65 m --C-7 5.35 m 4.33 m 4.33 5.35 dd 4.3 dd m (10.4, 3.5) (10.0, 4.0)C-10 6.52 s 6.59 s 6.59 s 6.47 s 6.20 sC-13 6.24 bt (8.5) 5.96 m 5.96 5.97 m 6.28 m dt (9.0, 2.0)C-16 Me 1.2 s 1.14 s 1.14 s 1.06 s 1.09 sC-17 Me 1.25 s 1.26 s 1.26 s 1.12 s 1.25 sC-18 Me 2.1 d (1.5) 1.86 (1.5) 1.86 1.86 d 1.76 (1.5) (1.5) bsC-19 Me 1.8 s 1.34 s 1.34 s 1.75 s 1.61 sC-20 4.2 d (8.5) 4.37 d (11.5) 4.37 d 4.38 d 4.38 d 4.35 d (8.5) 3.64 d (11.5) (11.5) (8.3) (11.5) 3.64 d 4.12 d 3.7 d (11.5) (8.3) (11.5)C-2' 5.4 d (3.0) 5.94 d (11.2) 5.94 d 5.94 d 4.67 (11.2) (11.2) dd (5.5, 2.0)C-3' 5.95 dd (9.0, 5.87 d (11.2) 5.87 d 5.87 d 5.7 d3' NH 6.96 d (9.0) -- -- -- 6.87 d (8.8)O Bz (o) 8.13 dd (8.5, -- -- 8.08 d -- 1.5) (7.1)O Bz (m + p) 7.76 dd (8.0, N-Bz 3'Ph = N-Bz 7.15-7.7 7.37-N-Bz 1.5) 7.33-7.63 (m) 3'Ph = (m) 7.543'-Ph (N-Bz), 7.35- 7.33- m 7.65 7.63 (m) O-Bz(m + p), (m) N-Bz (m + p), 3'Ph4-OAc 2.45 s 2.10 s 2.10 s 2.4 s 2.38 s10-OAc 2.15 s 2.3 s 2.3 s 2.18 s 2.23 sOCOC(CH.sub.3)3 1.45 bs 1.41 s 1.41 s 1.45 s 1.37 s 1.37 s 1.36 s 1.27 s2' OH -- -- -- -- 3.46 d (5.5)__________________________________________________________________________
TABLE 3______________________________________.sup.1 H-NMR Spectra of Compounds 14, 15, 16, 17 2',N-di(t- 2'- 2',N-di(t- BOC)-7-TES- 2'-(t-BOC) (t-BOC)-7- BOC)-7- 2-debenzoyl taxol TEStaxol TEStaxol taxolprotons (14) (15) (16) (17)______________________________________C-2 5.7 d (7.0) 5.7 d (7.0) 5.6 d (7.0) 3.86 bt (3.9)C-3 3.8 d (7.0) 3.84 d (7.0) 3.74 d (7.0) 3.37 d (6.8)C-5 4.97 d (7.5) 4.94 d 4.93 d (7.8) 4.95 d (8.39) (10.37)C-6 2.6 m 2.55 m 2.5 m 2.55 mC-7 4.45 dd ( ) 4.49 dd 4.46 dd 4.4 dd (6.58, 3.8) (6.64, 3.79) (6.4, 3.7)C-10 6.3 s 6.46 s 6.5 s 6.32 s13 6.28 t (5.9) 6.25 t (8.2) 5.97 m 6.0 m16 Me 1.13 s 1.18 s 1.18 s 1.18 sC-17 Me 1.21 s 1.22 s 1.2 s 1.25 sC-18 Me 1.9 s 2.04 s 2.18 s 2.15 sC-19 Me 1.68 s s 1.69 s 1.61 s 1.65 sC-20 4.32 d (8.4) 4.32 d (8.4) 4.27 d 4.58 bs 4.2 d (8.4) 4.18 d (8.4) (8.32) 4.06 d (8.32)C-2' 5.4 d (2.8) 5.4 d (2.8) 5.99 d 6.08 d (11.2) (10.9)C-3' 5.97 d (2.8) 5.99 d (2.8) 5.86 d 5.95 d 5.93 d (2.8) 5.95 d (2.8) (11.2) (10.9)3' NH 6.96 d 6.95 d -- -- (9.26) (9.25)O-Bz (O) 8.15 d (7.3) 8.14 d (7.3) -- --O-Bz 7.3-7.8 m 7.3-7.7 m 7.1-7.8 m 7.25-7.8 m(m + P)N-Bz3'-Ph4-OAc 2.5 s 2.45 s 2.38 s 2.3 s10-OAc 2.22 s 2.16 s 2.16 s 2.16 sOCOC(Me)3 1.45 s 1.47 s 1.48 s 1.48 s 1.4 s 1.3 sSiCH2CH3 0.59 q 0.59 q 0.59 q 0.92 t 0.92 t 0.92 tOther______________________________________ a Aromatic protons of diazirine ring b ArOCH.sub.2 COOR
TABLE 4______________________________________.sup.1 H-NMR Spectra of Compounds 22 and 13c 2',N-di(t-BOC)-7- triethylsilyl)-2- debenzoyl-2(3-(3- trifluoromethyl)- 2',7-DiTES-2- 2-Debenzoyl-2-m- 3H-diazirin-3- debenzoyltaxol NO.sub.2 -benzoyl-taxol yl)phenoxyacetyltprotons (22) (13c) axol______________________________________C-2 3.93 t (6.3) 5.66 d (7.2) 5.45 d (7.1)C-3 3.47 d (6.8) 3.86 d (7.2) 3.67 d (7.1)C-5 4.95 d (9.5) 4.98 d (8.1) 4.95 d (8.2)C-6 2.5 m 2.5 m 2.55 mC-7 4.41 dd 4.42 m 4.45 m (6.63, 10.52)C-10 6.36 s 6.29 s 6.4 sC-13 6.21 t (9.7) 6.20 t (8.7) 6.0 sC-16 Me 1.06 s 1.15 s 1.10 sC-17 Me 1.13 s 1.26 s 1.26 sC-18 Me 2.03 s 1.83 s 1.78 sC-19 Me 1.6 s 1.68 s 1.60 sC-20 4.6 m 4.7 dd (7.9, 4.4) 4.47 d (7.6) 4.2 d (7.6)C-2' 4.6 m 4.84 dd 6.03 d (10.9)C-3' 5.66 d (9.4) 5.75 dd 5.92 d (10.9) (1.5, 8.8)3'-NH 7.1 d (9.4) 6.85 d (8.8) --O-Bz(O) -- -- --O-Bz (m + p) 7.3-7.9 m 7.3-7.95 m 7.3-7.66 mN-Bz3'-Ph4-OAc 2.38 s 2.42 s 2.25 s10-OAc 2.13 s 2.25 s 2.12 sSiCH.sub.2 CH.sub.3 0.59 q 0.59 q 0.6 q 0.92 t 0.92 t 0.9 tOther 3.1.sup.d d (5.27) 8.44 m, 9.07 bbs 6.69 b s.sup.a, 6.90 dd.sup.a, 6.98 dd.sup.a 4.6 d.sup.b______________________________________ .sup.a 2'-hydroxy .sup.b 2"- and 4"-positions of the mnitrobenzoyl ring.
TABLE 5______________________________________.sup.1 H-NMR Spectra of Compounds 23f and 13f 2(m-azidobenzoyl-2- 2-(m-azidobenzoyl)-2- debenzoyl-2',7-di(triethysilyl debenzoyltaxolProtons taxol (23f) (13f)______________________________________C-2 5.67 d* 5.67 d (7.0)C-3 3.65 d (7.2) 3.81 d (7.0)C-5 4.95 d (9.1) 4.95 dd (7.7, 0.83)C-6 2.50 m 2.55 mC-7 4.48 m 4.41 mC-10 6.49 s 6.27 sC-13 6.21 bt* 6.21 bt (7.9)C-16 Me -- 1.14 sC-17 Me 1.24 sC-18 Me 1.80 sC-19 Me 1.68 sC-20 4.38 d (8.1) 4.33 d (7.79 4.20 d (8.1) 4.118 d (8.26)C-2' 4.70 s 4.77 bsC-3' 5.72 d* 5.75 dd (8.84, 2.21)3'-NH -- 6.95 d (8.87)O-Bz (O) --O-Bz (m + p) 7.10-7.55 m 7.20-7.55 mN-Bz3'-Ph4-OAc 2.55 s 2.36 s10-OAc 2.20 s 2.23 sSiCH.sub.2 CH.sub.3 0.50 t, 0.70 q 0.85 t, 1.00 qOther 7.70-7.95.sup.a 7.70-7.95.sup.a m______________________________________ *NMR signals are overlapped with impurity. .sup.a Aromatic protons of mazidobenzoyl group. | Compounds having the general formula: ##STR1## wherein R 1 is an alkyl or substituted alkyl; R 2 is selected from the group consisting of H and C(O)R a ; R 3 is selected from the group consisting of H, protecting groups, R b , and C(O)R b ; R 4 is selected from the group consisting of H and C(O)R c , and wherein R a , R b , and R c are independently selected from the group consisting of alkyls, substituted alkyls, alkenyls, alkynyls, aryls, and substituted aryls; provided that R a is other than phenyl and 3-hydroxyphenyl. | 2 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with Government support under Contract DE-AC0576RLO1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND
Redox flow batteries (RFB) have attracted considerable research interests primarily due to their ability to store large amounts of power and energy, up to multi-MW and multi-MWh, respectively. RFB systems are considered one of the most promising technologies to be utilized not only for renewable energy resources integration, but also to improve the efficiency of grid transmission and distribution. With the energy supplied from externally stored electrolytes, the dissociation of energy capacity and power capability offers unique design latitude for RFBs to be sized for a wide spectrum of power and energy storage applications. Other advantages of RFBs include high safety, quick response, long service life, deep discharge ability, etc.
Due to limits of the water electrolysis potential window and the solubility of the active materials in water, traditional aqueous RFBs are typically considered to be low energy density systems (<25 Wh/L in most true flow battery systems). While significant progress has been made to improve the energy density, aqueous RFB systems can still be severely hindered by the poor solubility and stability of the active materials in the solutions. In this regard, a non-aqueous energy storage system that utilizes at least some aspects of RFB systems is attractive because it offers the expansion of the operating potential window, which can have a direct impact on the system energy and power densities.
SUMMARY
This document describes energy storage systems having a separator separating first and second electrodes. The first electrode comprises a first current collector and a first volume containing a first active material. The second electrode comprises a second current collector and a second volume containing a second active material. The energy storage systems are characterized, during operation, by a first source operably connected to the first volume and configured to provide a flow of first active material, wherein the first active material comprises a redox active organic compound dissolved in a non-aqueous, liquid electrolyte and the second active material comprises a redox active metal.
The second active material can be a solid, a liquid, or a mixture of solid and non-aqueous liquid materials. In one embodiment, the second active material comprises lithium. An example of a mixture of solid and liquid materials includes, but is not limited to a flowable suspension. An example of a liquid includes, but is not limited to, a non-aqueous solution. In one embodiment, the second active material comprises redox active metal ions dissolved in a non-aqueous liquid. Preferably, the redox active metal ions comprise ions of transition metals. Particular examples can include, but are not limited to, titanium ions, zinc ions, chromium ions, manganese ions, iron ions, nickel ions, and copper ions. In some embodiments, wherein the second active material comprises liquid and is flowable, the energy storage systems can comprise a second source operably connected to the second volume and configured to provide a flow of second active material.
In one embodiment, the first active material has a concentration of redox active organic compound that is greater than, or equal to 0.1 M. In another embodiment, the concentration is greater than, or equal to, 0.2 M. A redox active organic compound, as used herein, can refer to a compound comprising at least a bond between a carbon and a hydrogen atom. Examples can include, but are not limited to, organic-soluble derivatives of anthraquinone (AQ) and 2,2,6,6-tetramethyl-1-piperidinyloxy (TEMPO). One instance of an organic-soluble derivative of AQ is 1,5-bis(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)anthracene-9,10-dione (15D3GAQ).
In one embodiment, the energy storage system is configured such that the first electrode functions as a cathode and the second cathode functions as an anode. The embodiments described herein are not limited to primary cells, but can encompass secondary (i.e., rechargeable) cells. In such cases, the mode of operation (i.e., charging or discharging) can determine the function of the electrodes. For example, the cathode might be considered to be the negative electrode and the anode might be considered the positive electrode during recharging. While discharging, the functions would be reversed.
Another embodiment described herein is an energy storage system having a separator separating a cathode and an anode. The cathode comprises a positive current collector and a cathode volume containing a cathode active material. The anode comprises a negative current collector and an anode volume containing an anode active material. The energy storage system is characterized during operation by a source operably connected to the cathode volume and configured to provide a flow of cathode active material, wherein the cathode active material comprises TEMPO or an organic-soluble derivative of AQ dissolved in a non-aqueous electrolyte and the anode active material comprises lithium metal. In a preferred embodiment, the concentration of the TEMPO or the organic-soluble derivative of AQ is greater than, or equal to, 0.2 M. In another embodiment, the anode active material is a solid. One instance of an organic-soluble derivative of AQ is 1,5-bis(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)anthracene-9,10-dione (15D3GAQ).
In yet another embodiment, the energy storage system is characterized during operation by a first source operably connected to the cathode volume and configured to provide a flow of cathode active material and by a second source operably connected to the anode volume and configured to provide a flow of anode active material, wherein the cathode active material comprises a redox active organic compound dissolved in a non-aqueous electrolyte at a concentration of at least 0.1 M, and the anode active material comprises a redox active metal. The anode active material can comprise a solid and flowable liquid materials. Preferably, the anode active material comprises redox active transition metal ions dissolved in a non-aqueous liquid.
The purpose of the foregoing abstract is to enable the United States Patent and Trademark Office and the public generally, 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.
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 various embodiments, including the preferred embodiments, have been shown and described. Included herein is a description 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 embodiments set forth hereafter are to be regarded as illustrative in nature, and not as restrictive.
DESCRIPTION OF DRAWINGS
Embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a schematic diagram depicting an energy storage system in which the second active material is a solid, according to embodiments of the present invention.
FIG. 2 is a schematic diagram depicting an energy storage system in which the second active material is flowable, according to embodiments of the present invention.
FIG. 3 a is an illustration depicting the redox mechanism of anthraquinone-based molecules.
FIG. 3 b is an illustration depicting the synthesis of one modified anthraquinone compound, 15D3GAQ.
FIG. 4 shows the CV curve of 15D3GAQ in 1.0 M LiPF 6 /PC electrolyte during the first cycle using Li foil as a counter electrode.
FIGS. 5 a and 5 b show, respectively, the charge/discharge profiles and the electrochemical cycling performance of an energy storage system based on the redox reaction between 15D3GAQ and Li/Li + in the 1M LiPF 6 /PC supporting electrolyte, according to embodiments of the present invention.
FIG. 6 is an illustration depicting the redox mechanism of a nitroxide radical compound.
FIGS. 7 a and 7 b show the electrochemical cycling performance of the energy storage system based on the redox reaction between TEMPO and Li/Li + in the 1M LiPF 6 in EC:DMC (1:1) according to embodiments of the present invention.
DETAILED DESCRIPTION
The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore the present description should be seen as illustrative and not limiting. While the invention is susceptible of various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
FIGS. 1-7 show a variety of embodiments of the present invention. Referring first to FIG. 1 , a schematic diagram depicts one embodiment in which the second active material 106 is a solid and comprises a redox active metal. The second active material is in electrical contact with a load 101 through a second current collector 104 . The second electrode is separated from the first electrode by a separator 103 . The first active material 110 comprises a redox active organic compound 109 dissolved in a non-aqueous electrolyte 108 . The first active material is in electrical contact with the load 101 through the first current collector 105 . The first active material can be flowed to the first volume from a source 107 in a batch or continuous manner. The first active material exits the first volume by pathway 102 . When operated as a rechargeable energy storage system, pathway 102 returns the electrolyte and first active material to an electrolyte reservoir (not shown) for recirculation to the first volume via 107 .
FIG. 2 is a diagram of an energy storage system in which both electrodes comprise flowable active materials. The first active material 214 comprises a redox active organic compound 212 dissolved in a non-aqueous electrolyte 209 . The second active material 211 comprises a redox active metal 213 that is either an ion dissolved in a non-aqueous liquid 210 or is a solid metal mixed with a non-aqueous liquid 210 in a flowable suspension. The first and second active materials can flow into the first and second volumes from separate sources 207 and 208 , respectively. The active materials flow out of the first and second volumes through pathways 202 and 203 , respectively. As described earlier, in some embodiments, a reservoir (not shown) can be arranged between 202 and 207 and between 203 and 208 . A separator 204 separates the first and second electrodes. As illustrated, the energy storage system can be connected to a load 201 through first and second current collectors 206 and 205 , respectively.
In one example, an energy storage system comprises a hybrid metal-organic redox flow battery based on a modified anthraquinone (AQ) molecule as the positive electrolyte and lithium metal as the negative electrode. As used herein, “hybrid” in the context of energy storage systems can encompass at least one of two different senses. In one sense, the energy storage system can be a hybrid RFB since one electrode comprises an active material that is fluid and can flow, while the other electrode comprises an active material that is a solid. In another sense, the energy storage system can be a hybrid RFB since the active materials are chemically very different—one a redox active organic compound and the other a redox active metal or dissolved metal ions. The redox active metal can be a solid or a solid portion in a mixture having flowable non-aqueous liquid materials.
In one example, an energy storage system comprises a hybrid metal-organic redox flow battery based on a modified anthraquinone (AQ) molecule as the positive electrolyte and lithium metal as the negative electrode. As used herein, “hybrid” in the context of energy storage systems can encompass at least one of two different senses. In one sense, the energy storage system can be a hybrid RFB since one electrode comprises an active material that is fluid and can flow, while the other electrode comprises an active material that is a solid. In another sense, the energy storage system can be a hybrid RFB since the active materials are chemically very different—one a redox active organic compound and the other a redox active metal or dissolved metal ions.
The redox mechanism of AQ involves a two-electron disproportionation in two stages during discharge processes: the formation of radical anions at the first stage followed by dianion formation in the second (see FIG. 3 a ). However, quinone-based compounds with short chain substituents typically have very low solubility (less than 0.05 M) in most electrolytes of relatively high polarity. Accordingly, embodiments of the present invention can utilize modified AQ cores that exhibit improved solubility as the energy bearing redox active agent.
One example of a modified AQ molecule is 1,5-bis(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)anthracene-9,10-dione (abbreviated as 15D3GAQ), shown in FIG. 3 b . The introduction of two triethylene glycol monomethyl ether groups into the AQ molecular structure has a large effect on the solubility, and the resulting molecule is soluble in most polar solvents and nonaqueous electrolytes. The compound was synthesized via nucleophilic aromatic substitution of 1,5-dichloroanthaquinone in the presence of triethylene glycol monomethyl ether as both reagent and solvent, and potassium hydroxide base to generate the nucleophile. The mixture was typically stirred at a temperature slightly below 100° C. for 3 h to ensure completion of the reaction. After purification the 15D3GAQ material was obtained as a pure yellow solid in a yield over 80%.
The nonaqueous electrolyte preparation and redox flow cell assembly were all completed inside a glove box filled with purified argon of moisture and oxygen content less than 1 ppm. The RFB electrolyte was prepared by dissolving 15D3GAQ with LiPF 6 in propylene carbonate (PC) at room temperature, with concentrations of 0.25 M 15D3GAQ and 1.0 M LiPF 6 . The available redox reactions and their reversibility and kinetics of 15D3GAQ were first investigated by cyclic voltammetry (CV) using a static cell. The cell was assembled with a graphite felt disk of 0.3 cm thick soaked in 0.2 mL of the above electrolyte as working electrode and a piece of lithium foil disk as counter electrode with a polypropylene (PP) separator in between. The whole assembly was subsequently sealed in the cell compartment. An electrochemical station was used to identify redox couples and electrochemical reversibility in the voltage range between 1.3 V and 3.5 V at a scan rate of 0.1 mVs −1 .
FIG. 4 shows the CV curve of 15D3GAQ in 1.0 M LiPF 6 /PC electrolyte during the first cycle, where the current density was normalized to the geometrical area of the working electrode. The CV spectrum of 15D3GAQ shows two well defined redox peaks. During the first cathodic scan, two sharp peaks at 2.27 V (pc 1 ) and 2.04 V (pc 2 ) correspond to the reductions of the first and second —C═O groups to the ═C—O − anions. The corresponding oxidative peaks are located at about 2.82 V (pa 1 ) and 2.50 V (pa 2 ). The peak separations for the two redox peaks are 0.55 V (pc 1 /pa 1 ) and 0.46 V (pa 2 /pc 2 ), respectively. Such a big difference between the redox peaks (˜0.5 V) indicates the large polarization of this material during charge and discharge processes. The electrochemical cycling performance of the 15D3GAQ static cell was evaluated using a constant-current method on a battery tester. The 15D3GAQ static cell was cycled in the voltage window between 1.8 V and 2.8 V at a constant current density of 1.0 mAcm −2 .
FIG. 5 a shows the charge/discharge profiles of the energy storage system based on the redox reaction between 15D3GAQ and Li/Li + in the 1M LiPF 6 /PC supporting electrolyte. Confirming the CV scan result, two voltage plateaus are clearly observed in a typical cell voltage profile during charge and discharge processes (see FIG. 5 a ). The voltage plateaus at ˜2.4 V during discharge and ˜2.45 V during charge correspond to the formation of radical anions, while the voltage plateaus at ˜2.15 V during discharge and ˜2.25 V during charge represent the dianion formation, as illustrated in FIG. 3 . The voltage profiles demonstrated by the 15D3GAQ static cell also exhibited two distinct voltage plateaus in the flow battery static cell tests.
FIG. 5 b shows the electrochemical cycling performance in terms of the energy efficiency and the discharge energy density of the hybrid metal organic RFB with 0.25 M 15D3GAQ in 1.0 M LiPF 6 /PC solution as the positive electrolyte (i.e., the positive cathode side) and lithium metal as negative electrode, in which an overall energy efficiency of ˜82% is achieved. The discharge energy density, representing the ultimate capability of the cell to deliver useful energy, is also plotted in FIG. 5 b . A specific volumetric energy density close to 25 WhL −1 is obtained, where the calculation was based on the positive electrolyte volume.
In another example, an energy storage system comprises a hybrid metal-organic redox flow battery based on a positive electrolyte containing 2,2,6,6-Tetramethyl-1-piperidinyloxy (TEMPO) free radical dissolved in a non-aqueous electrolyte solution of 1 mol/L LiPF 6 in EC:DMC (1:1). A lithium metal foil serves as the anode. As shown in FIG. 6 , the nitroxide radical possesses two redox couples, in which the TEMPO can be either oxidized to form the corresponding oxoammonium cation or reduced to form the aminoxy anion. Both redox reactions are reversible.
The nonaqueous electrolyte preparation and redox flow cell assembly were all completed inside a glove box filled with purified argon of moisture and oxygen content less than 1 ppm. The RFB electrolyte was prepared by dissolving TEMPO with LiPF 6 in EC:DMC (1:1) solvent at room temperature with concentrations of 0.5 M TEMPO and 1.0 M LiPF 6 .
The available redox reactions and their reversibility and kinetics of TEMPO were first investigated using a static cell. The cell was assembled with a graphite felt disk of 0.3 cm thick soaked with 0.2 mL of the above electrolyte as working electrode. A piece of lithium foil disk was used as a counter electrode. A polypropylene (PP) separator separated the two electrodes. The whole assembly was subsequently sealed into the cell compartment. The electrochemical cycling performance of the TEMPO static cell was evaluated using a constant-current method on a battery tester. The TEMPO static cell was cycled in the voltage window between 3.0 V and 4.0 V at a constant current density of 1.0 mAcm −2 .
FIG. 7 a shows the charge/discharge profiles of the energy storage system based on the redox reaction between TEMPO and Li/Li + in the 1M LiPF 6 in EC:DMC (1:1) supporting electrolyte. One voltage plateau was clearly observed in a typical cell voltage profile during charge and discharge processes. The voltage plateau at ˜3.5 V corresponds to the redox reactions of TEMPO free radical and oxoaminium cation as illustrated in FIG. 6 .
FIG. 7 b shows the electrochemical cycling performance in terms of the energy efficiency and the discharge energy density of the hybrid MORFB with 0.5 M TEMPO and 1.0 M LiPF 6 in EC:DMC (1:1) as the positive electrolyte solution and lithium metal as the negative electrode, in which an overall energy efficiency of close to 90% is achieved. A specific volumetric energy density close to ˜32 Wh/L is obtained, where the calculation was based on the positive electrolyte volume.
In yet another example, an energy storage system utilizes a second active material that is flowable. In particular, the second active material can comprise a mixture of solids and liquids, or it can comprise a liquid. One example of a mixture can include a powder comprising a redox active metal suspended in a liquid. Another example includes a powder with little or no liquid that can flow through the second volume under some motive force, such as can be provided by a pump or extruder.
A second active material that is a liquid can comprise a redox active metal ion in an electrolyte. The redox active metal ion can be a transition metal ion. In such an instance, the redox couple on one side of the separator involves a metal while the redox couple on the other side of the separator involves an organic compound. One example is to use the Cr 2+/3+ ions dissolved in non-aqueous solvent as the negative electrolyte (anolyte) and TEMPO dissolved in non-aqueous solvent as the positive electrolyte (catholyte) to form redox flow battery with operational voltage of approximately 2.3V.
While a number of embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims, therefore, are intended to cover all such changes and modifications as they fall within the true spirit and scope of the invention. | Redox flow batteries (RFB) have attracted considerable interest due to their ability to store large amounts of power and energy. Non-aqueous energy storage systems that utilize at least some aspects of RFB systems are attractive because they can offer an expansion of the operating potential window, which can improve on the system energy and power densities. One example of such systems has a separator separating first and second electrodes. The first electrode includes a first current collector and volume containing a first active material. The second electrode includes a second current collector and volume containing a second active material. During operation, the first source provides a flow of first active material to the first volume. The first active material includes a redox active organic compound dissolved in a non-aqueous, liquid electrolyte and the second active material includes a redox active metal. | 8 |
BACKGROUND OF THE INVENTION
The utilization of wave motion or other erratic motion as a power source has long been recognized and any number of suggestions have been put forward as to how the energy might but put to practical use. One of the earlier concepts along these lines is illustrated in the Hansen patent 1,799,848 where a wave motor is disclosed in the form of a floating barge with pistons connected between it and the bottom. The main difficulty in the operation of this type of device is the fact that wave motion is not uniform and it will not produce uniform pressure outputs with standard piston compressors. Therefore, it is advantageous to utilize a novel design of a compressor where in effect the head of the compressor may be varied in distance from the main pumping piston so that uniform output pressures can be achieved in spite of the fact that varying strokes may be encountered.
SUMMARY OF THE INVENTION
The instant invention relates to a variable stroke compressor which is preferably driven by a floating barge that is suitably anchored and which may be connected to the piston rod of the compressor by cables or other flexible means so as to exert an upward pull thereon. It consists basically of a casing with substantially closed upper and lower ends with inlet ports adjacent the lower end and an outlet port adjacent the upper end with a piston rod and piston received therein for reciprocal movement by having the piston rod coupled to the flexible means that is connected to the float. Slidably received about the piston rod within the casing is an upper piston with means attached thereto to control its rate of movement within the casing and both the upper and lower pistons themselves are provided with one-way check valves to allow flow in an upward direction.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view partly schematic showing a variable stroke compressor made in accordance with the invention coupled to a float;
FIG. 2 is an enlarged view in vertical section of the compressor made in accordance with the invention;
FIG. 3 is a view of a slightly modified form of variable stroke compressor embodying the concept of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, 10 generally designates a compressor made in accordance with the invention which is operatively connected to a wave powered driving apparatus designated 12. The compressor 10 is mounted on heavy anchor block 14 and, on this block 14, it should be understood that one or more compressors 10 may be mounted. The wave powered driving apparatus 12 can conveniently be a float that is anchored to the ocean floor by cables 16, 17 and which is coupled to the compressor by flexible cables generally indicated 18, such as, for instance, the piston rod of the compressor. The compressor 10, as will be seen referring to FIG. 2, comprises basically a casing 20 with an upper wall 22 and a lower wall 23 which close the compressor casing. The upper wall or end 22 is fitted with a guide bushing and packing 24 and through this extends a piston rod 26 which is connected to a lower piston 28. Also through the upper wall 22 is fitted an outlet conduit 29 and positioned in the entrance to the conduit is a check valve assembly, generally indicated at 30, which is suitable spring loaded to release on preset high pressure. The piston 28 is fitted with one or more low pressure check valves indicated at 32 and is provided with the usual packing as at 34. Through the lower end or bottom wall 23, there is provided an inlet port 36 which is fitted with a foot valve 38. In a preferred embodiment the anchor means 14 may be suitably provided with an open chamber generally designated 40 that will be connected to a source of air above the water.
The upper piston 42 is slidably received on the piston rod 26 with suitable sliding packing means as at 43 and with main casing packing means 44. Through the upper piston 42 a passage is provided at 45 and within this passage there is located a high pressure check valve 46. The wall of the upper piston is suitably cut out to provide a recess 48 and within this recess is located an arm 49 pivoted at 50, the arm carrying at its outer end a wheel 52 to which a ratchet 53 is attached with a suitable spring loaded detent 54. The arm is biased so that the wheel 52 is pressed against the inner wall of the casing 20 by means of a pull spring 55 and a release rod 56 slightly protrudes from the bottom wall of the upper piston.
Referring to FIG. 3 a slightly modified form if illustrated with identical parts except for the device retarding the downward movement of the upper piston. In lieu of the ratchet wheel, there is coupled to the upper piston 42' a descent control means for the upper piston designated 58. This is merely a hydraulic small piston 59 with an orifice means 60 to allow oil to flow from one side to the other of the piston 59 therewith within and serve in effect to retard the downward movement of the assemblage to a controlled rate. When the lower piston 28' engages the upper piston 42' a rod 61 actuates and opens a return valve diagrammed as 63 permitting rapid upward movement of both pistons.
OPERATION OF THE DEVICE
As has been generally described above, the float 12 is fastened to the piston rod 26 by cables 18 and with a wave rise, the piston rod 26 will be pulled upwardly pulling main piston 28 and upper piston 42 upwardly compressing any propellant or air that is trapped in the upper portion of the casing 20. If sufficient force is exerted, exhaust valve 30 will discharge through exhaust piping 29. During the upward movement of the lower piston 28 suction is created in the lower portion of the casing 20 opening foot valve 38 and permitting the lower portion of the compressor casing 20 to fill. Once tension is released on the pull cables 18, the weight of the main piston 28 will pull the same downward while the upper piston 42 will remain in its upward position with downward movement being exerted by a relatively higher pressure in the upper portion of casing 20. The friction means of the wheel 52 against the inner wall of the cylinder 20 or the means 58 retards and controls the descent. As the lower piston 28 descends, the check valve 32, which is a low pressure valve, will open and permit the propellant or air to pass through the main piston 28 and into the space now created between the upper piston and the lower piston. When the next wave comes along, the piston 28 will rise and the air or other propellant will be compressed between the upper piston 42 and the lower piston 28 until the same mean pressure is achieved between the upper part of the compressor and that between the two pistons at which time the valve 46 will open and the air or propellant will be driven into the upper part of the cylinder casing 20. This process will continue with the upper piston remaining substantially at a level that is dictated by the amount of stroke that is being imparted by the wave action so that the pressure developed by the device will be substantially constant although the stroke of the main piston may vary considerably.
It will be apparent that on occasion a large magnitude wave will raise the lower piston into contact with the upper piston. When this occurs, the release means consisting of either rod 56 or 61 will permit free travel of the upper piston with the lower piston without undue restraint, save for friction. | A variable stroke compressor is disclosed that includes a casing with an upper and lower piston, the lower piston being connected to a piston rod and the upper piston being slidably received for reciprocal movement on the piston rod. Means are provided on the upper piston to control its descent towards the lower piston. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to netting platforms useful for supporting in spread condition garments of knitted or crocheted material, such as sweaters, to be air-dried after washing.
2. Prior Art
The Sublette U.S. Pat. No. 2,521,100, issued Sept. 5, 1950, discloses a garment drier composed of two frame sections having supported thereon sheets of reticulated fabric material such as window screening fabric having relatively large openings between which garments of the knitted or crocheted type, such as sweaters, can be retained while being dried. The patent does not appear to state how the fabric material sheets are supported on the frames. The frames can be hung vertically by a hook projecting from a frame edge.
The Weiss et al. U.S. Pat. No. 3,358,388, issued Dec. 19, 1967, discloses a drying and storing frame for knit goods carrying a foraminous backing membrane in the form of nylon netting of 16 strands per inch covering a porous sheet or blanket formed of polyurethane foam which in turn is covered by a cover membrane of 26 strands per inch. After the garment has been placed on the netting back membrane, it is covered with the foam sheet or blanket instead of both sides of the garment being freely exposed to air. A hook is provided by which the frame and garment can be hung.
The Perkins U.S. Pat. No. 1,049,596, issued Jan. 7, 1913, shows a bedclothes airing device including a frame of wire bent into a rectangular form which carries a wire screen of comparatively large mesh. The individual wires of the screen are secured to the frame members 7, presumably by welding.
The McCarthy U.S. Pat. No. 2,084,854, issued June 22, 1937, discloses a clothes drier having side and end members joined to form a rectangle with a screen or other reticulated material stretched between them. The screen is secured to the side members by screws which pull together marginal members at opposite sides of the screen to clamp the screen margin between such marginal members. The screen may be supported in elevated position by crossed legs. The upper end of one of such legs can be detached from the screen so that the crossed legs can be retracted into parallel positions alongside the screen.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a netting platform on which knitted garments can be laid for drying and which can be supported conveniently in a horizontal position raised above any surface beneath the platform so that air can circulate freely above and below the garment to dry it effectively.
Another object is to provide a frame and netting that can be integrated readily to maintain the netting taut.
A further object is to provide means for supporting the netting platform conveniently in a variety of ways depending on the particular accommodations available for supporting the platform.
The foregoing objects can be accomplished by stretching large mesh or coarse twine netting by a marginal frame of rectangular shape and providing suction cups on the corner of the frame for supporting the frame directly, folding legs as an alternative means for supporting the frame and a suspension sling or bridle having leg loops that can be caught around the suction cups for attaching the sling to the frame and detaching it from the frame quickly and easily.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an edge elevation of the netting platform of the present invention showing legs in full lines in retracted condition and illustrating the extended condition of the legs in broken lines.
FIG. 2 is a top plan of the netting platform with parts broken away.
FIG. 3 is a top perspective of the netting platform shown in suspended condition.
FIG. 4 is a top perspective of the netting platform shown in position spanning a bathtub.
DETAILED DESCRIPTION
The frame of the platform is preferably of rectangular shape as shown in FIG. 2 and is constructed of four elbows 1 connecting the adjacent ends of straight end marginal members 2 and straight side marginal members 3. Such elbows and marginal members can all be made of round tubing of nonmetallic plastic material so as to be of light weight and rustproof while having adequate strength.
Legs that can be used to support the platform are composed of tees 4 mounted on the side marginal frame members 3 by such side members passing snugly through the through bore of the tees. The lateral bores of the tees are fitted to the ends of tubular legs 5 that can be of any length. Usually such legs will be of a length greater than one-half the length of the end marginal members 2. The tees 4 will be mounted on the opposite side members 3 adjacent to the corner elbows 1, but the tees carried by the opposite side members will be offset so that when the legs are swung into retracted positions generally coplanar with the frame 2, as shown in FIG. 2 and in solid lines in FIG. 1, the opposite legs of each pair will lie alongside each other.
The legs carried by the opposite frame side members 3 can be swung from their parallel coplanar positions shown in FIG. 2 and in solid lines in FIG. 1, in which they are also generally coplanar with the frame, into the depending positions shown in broken lines in FIG. 2 for supporting the frame in elevated position. Boots or tips 6 may be provided on the swinging ends of the legs to close the ends of the tubular legs and protect a surface engaged by the legs from being marred by the tube ends.
The through bores of the mounting tees 4 provide sufficient purchase on the side marginal members 3 so as to minimize tilting of the legs in the planes of the side members when the legs are in their extended depending positions.
As shown in FIGS. 2, 3 and 4, the coarse twine netting panel 7 is of large mesh so that, as shown in these figures, the width of the apertures between the strands of the netting is greater than the width of the frame end marginal members 2 and the frame side marginal members 3. The coarse netting may, for example, have a mesh of approximately one-half strand per inch, so that the widths of the net apertures are as great as two inches. Such greater width of the mesh apertures enables the side and end frame members to be braided through the marginal coarse of the netting apertures by being threaded through such marginal apertures of the netting.
The lengths of the frame end marginal members 2 and of the frame side marginal members 3 should be selected with relation to the size of the netting panel desired, so that when the frame members have been braided through the netting marginal apertures and are spread apart sufficiently so that their adjacent ends can be inserted into the joining elbows 1 forming the corners of the frame, the netting will be stretched taut within the frame so as to support garments on it without appreciable sagging. The netting twine or cord is preferably made of material which does not absorb water readily, but which is strong, such as of nylon.
It may not always be convenient to support the platform by the legs 5, in which event the legs can be retracted into the positions shown in FIG. 2 and in solid lines in FIG. 1, generally coplanar with each other and with the frame. Additional supporting means which can be used alternatively to the legs include suction cups 8 mounted on the bottom of each elbow 1. By making the frame side marginal members 3 of a length to span the width of a bathtub, the platform can be supported with its opposite end marginal members 2 in registration with the opposite sides, respectively, of the bathtub while the suction cups 8 carried by side portions of the corners of the frame and projecting laterally beyond the frame, as shown in FIG. 1, can engage and grip the bathtub rim for supporting the platform stably slightly elevated from the bathtub rim, as shown in FIG. 4. Any dripping which may pass from a garment on the platform through the netting will then be caught in the bathtub.
Particularly for outdoor drying, it may be desirable to suspend the knitting platform, such as from a clothesline. For this purpose a suspension sling or bridle is shown in FIG. 3, composed of a suspension fitting in the form of ring 9 that may be placed over a hook and four leg cords 10 of equal length diverging downward from the ring 9 to the four corners respectively of the platform frame. As shown in FIG. 3, the downwardly extending legs of the sling are in the form of loops, the lower ends of which straddle the elbows 1 and are caught behind the suction cups 8 to anchor such loops to the platform corners. Each sling leg loop can be spread easily to span an elbow and pass over the suction cup beneath it so as to be caught behind the suction cup. The loop can be detached from the corner of the platform as readily simply by spreading it again, pulling it out from behind the suction cup and slipping it over the suction cup to release it from the platform corner. | A clothes-drying platform composed of coarse nylon netting stretched taut between frame members knitted through the marginal courses of the netting can be supported alternatively by swingable retractable legs, by suction cups on the corners of the platform and by a suspension sling including loop legs attachable to the platform corners by being caught behind the suction cups. | 3 |
This is a continuation of copending application Ser. No. PCT/AT 98/00151, filed Jun. 17, 1998.
BACKGROUND OF THE INVENTION
The present invention relates to a method of producing lyocell-type cellulose fibers by processing a spinnable solution of cellulose in an aqueous tertiary amine oxide according to the dry/wet-spinning process.
In the past few years, a number of processes have been described as alternatives to the viscose process, processes in which cellulose is dissolved in an organic solvent, a combination of an organic solvent and an inorganic salt or in aqueous salt solutions, without the formation of a derivative. Cellulose fibers produced from such solutions were given the generic name of lyocell by BISFA (The International Bureau for the Standardisation of man-made Fibers). The term “lyocell” as defined by BISFA means a cellulose fiber obtained from an organic solvent by a spinning process. The term “organic solvent” as defined by BISFA means a mixture of an organic chemical and water.
Yet, to date, only a single method for the production of a lyocell type cellulose fiber has found acceptance to the extent of actual industrial realization, namely the amine oxide process. The preferred solvent used with this method is N-methylmorpholine-N-oxide (NMMO). For the purposes of the present specification, the abbreviation “NMMO” is substituted for the term “tertiary amine oxides”, wherein the term NMMO additionally denotes N-methylmorpholine-N-oxide, which latter is preferably used today.
Tertiary amine oxides have been known to be alternative solvents for cellulose for a long time. From U.S. Pat. No. 2,179,181 it is f.i. known that tertiary amine oxides have the ability to dissolve high-grade chemical pulp without derivatization and that from such solutions cellulose molded bodies, such as fibers, can be obtained by precipitation. U.S. Pat. Nos. 3,447,939, 3,447,956 and 3,508,941 describe further methods of preparing cellulose solutions, with cyclic amine oxides being used as the preferred solvents. In all of these methods, cellulose is physically dissolved at elevated temperatures.
In the applicant's EP-A-0 356 419, a method is set forth which is preferably performed in a thin-film treatment apparatus in which a suspension of the shredded pulp in an aqueous tertiary amine oxide is spread in the form of a thin layer and transported over a heating surface, wherein the surface of that thin layer is exposed to a vacuum. As the suspension is transported over the heating surface, water is evaporated and the cellulose can be dissolved, a spinnable cellulose solution being hence discharged from the Filmtruder.
A method of spinning cellulose solutions is known fi. from U.S. Pat. No. 4,246,221. According to this method, the spinning solution is extruded into filaments through a spinnerette, which filaments are passed across an air gap into a precipitation bath in which the cellulose is precipitated. In the air gap, the filaments are stretched, thus enabling favorable physical properties, such as improved strength, to be imparted to the fiber. By precipitating the cellulose in the precipitation bath these favorable physical properties are fixed, and thus no further stretching will be required. This process is generally known as the dry/wet-spinning process.
In accordance with U.S. Pat. No. 4,144,080, the freshly spun filaments can be cooled with air in the air gap. Further, it is suggested to wet the surface of the filaments with a precipitating agent so as to reduce the danger of adhesion between the filaments. Yet, a disadvantage of such wetting is that the cellulose on the filament surface is precipitated, which renders it more difficult to adjust the properties of the fibers by stretching.
EP-A-0 648 808 describes a method of forming a cellulose solution, the cellulose ingredients of the solution comprising a first component made up of a cellulose having an average degree of polymerization (DP) of 500 to 2000 and a second component made up of a cellulose having a DP of less than 90% of the DP of the first component in the range from 350 to 900. The weight ratio of the first to the second component should be 95:5 to 50:50.
Applicant's WO 93/19230 improves the dry/wet-spinning process and enhances its productivity. This is effected by a particular blowing technique using an inert cooling gas, wherein the cooling is provided immediately below the spinnerette. In this way it is possible to markedly reduce the adhesiveness of the freshly extruded filaments and thus spin a denser filament curtain, i.e. to use a spinnerette having a high hole density, namely up to 1.4 holes/mm 2 , whereby the productivity of the dry/wet-spinning process can of course be considerably enhanced. Air having a temperature between −6° C. and +24° C. is used for cooling the freshly extruded filaments.
Applicant's WO 95/02082 likewise describes a dry/wet-spinning process. With this process there is used a cooling air having a temperature between 10° C. and 60° C. The humidity of the supplied cooling air is between 20 g H 2 O and 40 g H 2 O per kilogram.
WO 95/01470 and WO 95/04173 by the applicant describe spinning methods employing a spinnerette having a hole density of 1.59 holes/mm 2 and a spinnerette having a total of 15048 holes, respectively. In each case, the cooling air has a temperature of 21° C.
WO 94/28218 quite generally suggests using spinnerets having 500 to 100,000 holes. The temperature of the cooling air is between 0° C. and 50° C. The person skilled in the art can gather from that document that the moisture lies between 5.5 g H 2 O and 7.5 g H 2 O per kilogram air. Hence this creates a relatively dry climate in the air gap.
WO 96/17118 also deals with the climate that prevails in the air gap, stating that the climate ought to be as dry as possible, namely 0.1 g H 2 O to 7 g H 2 O per kilogram air, at a relative humidity of less than 85%. The temperature proposed for the cooling air is 6° C. to 40° C. The person skilled in the art hence gathers from this literature that the climate during spinning is to be kept as dry as possible.
This can also be gathered from WO 96/18760, which suggests a temperature within the air gap of between 10° C. and 37° C. and a relative humidity of 8.2% to 19.3%, which results in 1 g H 2 O to 7.5 g H 2 O per kilogram air.
Applicant's WO 96/20300 i.a describes the use of a spinnerette having 28392 spinning holes. The air within the air gap has a temperature of 12° C. and a humidity of 5 g H 2 O per kilogram air. Hence, the tendency of keeping the climate within the air gap rather dry and cool, particularly when using a die with a substantially increased number of spinning holes, i.e. when spinning a relatively dense filament curtain, can be gathered from this literature, too.
WO 96/21758 is likewise concerned with the climate to be adjusted in the air gap, suggesting a two-step blowing technique using different cooling airs, and using a less humid and cooler air for blowing in the upper region of the air gap.
One drawback of using low-humidity air is that such air can only be conditioned at a certain expense. Considerable technical means are necessary in order to provide major quantities of low-humidity cooling air for the amine oxide process.
Also, it has been found that the cooling air becomes increasingly warmer and more and more humid as it passes through the filament curtain, since the freshly extruded fibers emerging from the spinnerette exhibit a temperature of more than 100° C. and a water content of about 10% and give off heat and moisture to the cooling air. The applicant has in fact found out that with very dense filament curtains such increasing uptake of water can lead to the situation that the necessary climate can only by adjusted through technically complex blowing devices and that without such devices the filament density cannot be further increased.
SUMMARY OF THE INVENTION
The invention therefore has as its object to obviate these disadvantages and provide a method of producing lyocell-type cellulose fibers by processing a spinnable solution of cellulose in an aqueous tertiary amine oxide according to the dry/wet-spinning process, allowing a dense filament curtain to be spun without the need for the blowing air to be dry. In spite of these conditions, the method is to be performed realizing a good spinnability, wherein spinnability is deemed the better, the smaller the minimum titer that can be achieved (see below).
In a method of the kind initially defined this is achieved in that a solution having a content of between 0.05% by mass and 0.70% by mass, in particular between 0.10 and 0.55% by mass, and preferably between 0.15 and 0.45% by mass, based on the mass of the solution, of cellulose and/or another polymer with a molecular weight of at least 5×10 5 (=500,000) is used for spinning.
The molecular weight is determined according to the chromatographic method described hereinbelow. For the purposes of the present specification, cellulose molecules or other polymer molecules that in accordance with the below-described chromatographic method produce signals corresponding to a molecular weight of at least 5×10 5 are referred to as long-chain molecules.
The invention is based on the recognition that the presence of long-chain cellulose molecules and/or other polymers in the spinning solution in the concentration range indicated improves the spinning behavior in such a way as to allow using a blowing air that need not be dry. Hence, even when blowing against very dense filament curtains a good spinnability is ensured even in those areas of the filament curtain that are located further outwards if viewed in the direction of blowing and that therefore can be reached only by “spent”, i.e. considerably warmed and humid, blowing air.
It is essential for the invention that the indicated content of long-chain cellulose molecules be present in the spinning solution immediately before spinning. Since, as is generally known, the cellulose chains in a spinning solution are gradually degraded, one must try to already provide so large a portion of long-chain molecules when preparing the spinning solution that the degradation of the cellulose from the time of producing the spinning solution up to the time of actual spinning will not be so large that the minimum concentration according to the invention, i.e. 0.05% by mass, is fallen short of. It has been found that when using humid blowing air or at a humid climate within the air gap, the spinnability will markedly deteriorate if the content of long-chain molecules in the dope is below 0.05% by mass.
On the other hand, spinnability also deteriorates considerably if the concentration of long-chain molecules is above 0.70% by mass. This is true for spinning with both humid and dry blowing air.
With the method of the invention there are preferably used pulp mixtures that exhibit the indicated content of long-chain molecules in the spinning solution.
In this respect it can also be surprisingly shown that by spinning of a dope which contains such a pulp mixture, fibers with a lower tendency to fibrillation result. This effect even increases if air with a higher humidity is employed in the air gap.
N-methyl-morpholine-N-oxide has proved the most efficient tertiary amine oxide.
The invention further relates to the use of a spinnable solution of cellulose in an aqueous tertiary amine oxide, which solution has a content of between 0.05 and 0.70% by mass, particularly between 0.10 and 0.55% by mass, and preferably between 0.15 and 0.45% by mass, based on the mass of the solution, of cellulose with a molecular weight of at least 5×10 5 , for producing cellulose fibers having a titer of maximally 1 dtex. Such lyocell fibers are novel.
The invention also relates to a lyocell-type cellulose fiber that is characterized in that it can be obtained by the process of the invention.
The invention also relates to a lyocell-type cellulose fiber that is characterized in that it exhibits a titer of maximally 1 dtex.
A preferred embodiment of the fiber of the invention has a content of between 0.25 and 7.0% by mass, particularly between 1.0 and 3.0% by mass, based on the mass of the cellulose fiber, of cellulose with a molecular weight of at least 5×10 5 .
Another preferred embodiment of the fiber of the invention is the staple fiber.
The invention further relates to a method of producing cellulose fibers of the lyocell type by processing a spinnable solution of cellulose in an aqueous tertiary amine oxide by the dry/wet-spinning process, which method is characterized in that
(1) a solution having a content of between 0.05 and 0.70% by mass, particularly between 0.10 and 0.55% by mass, and preferably between 0.15 and 0.45% by mass, based on the mass of the solution, of cellulose with a molecular weight of at least 5×10 5 is used for spinning and
(2) a spinnerette having more than 10,000 spinning holes is employed for spinning, which holes are arranged in such a manner that neighboring spinning holes are spaced maximally 3 mm apart and that the linear density of the spinning holes it at least 20.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 d are graphs of the molecular weight profile for Viscokraft LV pulp, Alistaple LD 9.2 Pulp, mixture of Viscokraft LV and Alistaple LD 9.2 pulp, and pulp precipitated from dope made from such mixture, respectively;
FIG. 2 is a graph of minimum titer (dtex) versus concentration of cellulose molecules having a molecular weight at least 500,000 in a cellulose solution; and
FIG. 3 is a perspective view of a rectangular spinning die.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term “linear density” is a critical value defined by the applicant and indicates the number of fibers per millimeter of filament curtain that are flown through by the blowing air. The linear density can be calculated by dividing the total number of spinning holes of the die by the so-called area of incidence (in mm 2 ) and multiplying it by the length (in mm 2 ) of the air gap. The “area of incidence” is the area located at right angles to the spinning bath surface, which area is formed by the air gap (in mm) and by the row of filaments reached first by the blowing gas and the matching “row of holes” of the spinnerette and the line (total length in mm) formed thereby. For better clarity, reference is made to the appended FIG. 3 .
FIG. 3 diagrammatically illustrates a rectangular die 1 having spinning holes 2 from which the filaments 3 are extruded. The length of the air gap is denoted “l”. After passing the air gap, the filaments 3 enter the precipitation bath (not illustrated). In FIG. 3, the filaments have been illustrated only in the air gap.
The area of incidence is the mathematical product of the length “ 1 ” of the air gap and the width “b” of the first row of filaments. The linear density is therefore given by the following mathematical relation: linear density = spinning holes of the die area of incidence mm 2 × air gap ( mm )
In the following, the invention will be described in greater detail.
1. General method for determining the molecular-weight profile of pulps
The molecular-weight profile of a pulp can be obtained through gel permeation chromatography (GPC), wherein the “differential weight fraction” in [%] is plotted as the ordinate against the molecular weight [g/mol; logarithmic plotting] in a diagram. There, the value “differential weight fraction” describes the percentage frequency of the mol mass fraction.
For examination by means of GPC, the pulp is dissolved in dimethyl acetamide/LiCl and is chromatographed. Detection is carried out by measuring the index of refraction and by so-called “MALLS” (=Multi Angle Laser Light Scattering) measurement (HPLC pump: by Kontron; sample collector: HP 1050, by Hewlett Packard; eluant: 9 g LiCl/L DMAC; RI detector: type F511, by ERC; laser wavelength: 488 nm; increment dn/dc: 1.36 ml/g; evaluation software; Astra 3d, Version 4.2, by Wyatt; column equipment: 4 columns, 300 mm×7.5 mm, packing material: PL Gel 20μ- Mixed - A, by Polymer-Laboratories; sample concentration: 1 g/l eluant; injection volume: 40 μl, flow rate: 1 ml/min.
The measuring apparatus is calibrated by measures well-known to those skilled in the art.
Signal evaluation is carried out according to Zimm, wherein Zimm's formula has to be adjusted in the evaluation software, if necessary.
1.1. Molecular-weight profile of pulps
FIG. 1 a provides an exemplary illustration of the molecular-weight profile for the Viscokraft LV pulp (manufactured by: International Paper). The diagram of FIG. 1 a shows that this pulp for a great part is made up of molecules with a molecular weight of about 100,000 and that this pulp contains practically no portions (about 0.2%) with a molecular weight in excess of 500,000. A 15% cellulose solution solely of this pulp (for preparation, see below) in an aqueous amine oxide (=dope) thus does not correspond to the one used in accordance with the invention.
In comparison thereto, FIG. 1 b shows the molecular-weight profile of the Alistaple LD 9.2 pulp (manufactured by: Western Pulp). With this pulp, a maximum of the frequency of mol mass is at roughly 200,000, and the diagram also shows that this particular pulp has a high percentage (about 25%) of molecules with a molecular weight greater than 500,000. A dope which exclusively contains this type of pulp in the amount of 15% by mass has roughly 4% (based on the mass of the solution; not allowing for degradation during the preparation of the solution) cellulose molecules with a molecular weight greater than 500,000 and thus does not correspond to the dope utilized in accordance with the invention either.
FIG. 1 c shows the molecular-weight profile of a pulp mixture of 70% Viscokraft LV and 30% Alistaple LD 9.2. With this pulp mixture, the maximum is at about 100,000, and the diagram also shows that this pulp mixture comprises a portion of some 7% of molecules having a molecular weight in excess of 500,000.
A dope containing 15% of such a mixture—if not allowing for the degradation of the molecules during preparation of the solution—would contain roughly 1% (based on the mass of the solution) of cellulose molecules having a molecular weight in excess of 500,000. Yet, as already mentioned, the cellulose molecules are subject to degradation while dissolving in the aqueous amine oxide, whereby the content of long-chain molecules decreases, and a dope prepared from said mixture has a significantly lower portion of these long-chain molecules. This is shown by FIG. 1 d, which depicts the molecular-weight profile, drawn up by means of GPC, of the pulp precipitated from the dope immediately before spinning. This dope is the solution of cellulose immediately before spinning, has only 0.4% by mass long-chain molecules left, and hence is a cellulose solution as utilized according to the invention.
A pulp of the type Solucell 400 (manufactured by the firm of Bacell SA, Brazil) likewise exhibits a molecular-weight distribution suitable for the production of a cellulose solution that is in accordance with the invention.
2. Preparation of the dope (spinnable solution of cellulose in an aqueous tertiary amine oxide)
The shredded pulp or a mixture of shredded pulps is suspended in aqueous 50% NMMO, placed in a kneading machine (type: IKA-Laborkneter HKD-T; manufactured by: IKA-Labortechnik) and left to impregnate for an hour. Subsequently, water is evaporated by heating the kneading machine using a heating medium kept at a temperature of 130° C. and by lowering the pressure, until the pulp has completely gone into solution.
3. Spinning of the solution and determination of the maximum drawing rate or the minimum titer (spinnability)
As the spinning apparatus, there is employed a melt-flow index apparatus commonly used in plastics processing, by the firm of Davenport. This appliance consists of a heatable, temperature-controlled steel cylinder into which the dope is poured. By means of a piston which is loaded with a weight the dope is extruded through the spinnerette arranged on the lower face of the steel cylinder, which spinnerette is provided with a hole 100 μm in diameter.
For the assays, the dope (cellulose content: 15%) that has been placed in the spinning apparatus is extruded through the spinning hole and passed across an air gap having a length of 3 cm into an aqueous precipitation bath, deflected, drawn off over a godet provided following the precipitation bath and thus is stretched. The output of dope through the nozzle is 0.030 g/min. The extrusion temperature is 80° C. to 120° C.
The minimum spinnable titer is used to simulate the spinning behavior. To that end, the maximum drawing rate (m/min) is determined in that the drawing rate is increased until the filament breaks. This velocity is written down and used in calculating the titer by the formula set forth below. The higher this value, the better the spinning behavior or the spinnability.
The titer given at the maximum drawing rate is calculated by the following general formula: titer ( dtex ) = 1.21 × K × A × 100 G × L
where K is the concentration of cellulose in % by mass, A is the output of dope in g/minute, G is the drawing rate in m/minute, and L is the number of spinning holes of the spinnerette. In the following examples, the concentration of cellulose is 15%, A=0.030 g/minute, and L= 1 .
4. Blowing in the air gap Blowing against the filaments in the air gap was effected over their entire length and at right angles to them. The humidity of the air was adjusted by means of a thermostatting device.
5. Spinning behavior of cellulose solutions
5.1. Cellulose solutions having too low a portion (<0.05% by mass) of long-chain molecules
In accordance with the working method set forth above, a dope was prepared using the Viscokraft LV pulp (manufactured by: International Paper Corp.) whose molecular-weight profile is depicted in FIG. 1 a and said dope was spun at different humidities in the air gap and in doing so the maximum drawing rate and the minimum spinnable titer were determined. The results are presented in Table 1.
In Table 1, “temp.” means the temperature of the dope in °C., “humidity” means the humidity of the air in the air gap in g water/kg air, and “max. draw. rate” means the maximum drawing rate in m/minute. The titer was calculated by the above formula, and its unit is dtex.
TABLE 1
Pulp Viscokraft LV
temp.
humidity
max. draw. rate
titer
″
115
0
176
0.31
″
115
20
99
0.55
″
115
48
63
0.86
″
120
0
170
0.32
″
120
22
83
0.66
″
120
47
52
1.05
The results presented in Table 1 show that as the humidity in the air gap increases, the maximum drawing rate and the minimum titer decrease and increase, respectively. This means that he spinnability of a solution of this pulp, which is practically devoid of long-chain portions, deteriorates as the humidity in the air gap increases.
5.2 Cellulose solutions having too high a portion (>0.70% by mass) of long-chain molecules
In accordance with the working method set forth above, a dope was prepared using the Alistaple LD 9.2 pulp (manufactured by: Western Pulp) whose molecular-weight profile is depicted in FIG. 1 b, and said dope was spun at different humidities in the air gap and, in the process, the maximum drawing rate and the minimum spinnable titer were determined. A reversed result was obtained: Spinnability was slightly better at higher humidities within the air gap than at lower humidities. However, the spinnability of such dopes is in sum markedly poorer, as is obvious from the minimum titer, since the content of high-molecular components is too high already.
5.3 Spinning behavior of cellulose solutions with different portions of long-chain molecules
In accordance with the working method set forth above, a dope containing 15% by mass of a mixture of 30% Alistaple LD 9.2 and 70% Viscokraft LV was produced. Immediately before spinning, the pulp mixture exhibited a molecular-weight distribution as shown in FIG. 1 d. The dope was spun at a temperature of 120° C. at different humidities in the air gap. The result of these assays is given in Table 2 below:
TABLE 2
Pulp mixture
(Alistaple/Viscokraft)
humidity
max. draw. rate
titer
30/70
30
116
0.47
30/70
50
118
0.46
30/70
70
127
0.43
It can be clearly seen in the Table that, unlike with a dope having 15% Viscokraft pulp, there is no deterioration of the minimum achievable titer as the humidity prevailing in the air gap increases, but that even a slight improvement can be achieved. Yet, compared with a dope having 15% Alistaple pulp, markedly lower titers can be achieved. It can further be seen that the spinnability of this dope of the invention is relatively independent of the climate prevailing in the air gap.
In numerous spinning trials, for which these or similar pulp mixtures were employed and during which spinning dopes with a composition according to the invention were obtained, the applicant observed that the fibrillation tendency of fibers so prepared was lower compared with the fibrillation tendency of fibers which are not prepared according to the invention. In this respect, during the spinning of dopes which are in accordance with the invention, the fibrillation tendency of the fibers so prepared further decreases with a higher humidity in the air gap.
FIG. 2 shows the spinning behavior of cellulose solutions with varying portions of long-chain molecules, the minimum titer (dtex) being plotted as the ordinate and, as the abscissa, the concentration of those cellulose molecules of the respective cellulose solution that have a molecular weight of at least 500,000. The concentrations were determined immediately before spinning.
The portion of long-chain molecules was adjusted by admixing appropriate amounts of Alistaple LD 9.2 to Viscokraft LV. The concentration of cellulose in the solution was 15% by mass in all cases.
For each solution of cellulose, the spinning behavior was determined both at a humidity in the air gap of 30 g H 2 O (curve “a”) and at 0 g H 2 O (dry) (straight line “b”).
From FIG. 2 it can be seen that:
there is a connection between the spinnability and the concentration of long-chain molecules;
if dry air prevails in the air gap (straight line “b”), spinnability will improve in an approximately linear manner as the concentration of long-chain molecules decreases;
if humid air prevails in the air gap (curve “a”), spinnability initially will become better and better as the concentration of long-chain molecules decreases, but from a concentration of about 0.25% by mass downwards will deteriorate again, with the deterioration being particularly pronounced from 0.05% by mass downwards.
In FIG. 2, the range of the invention (0.05 to 0.70% by mass) is marked in the drawing. In that range, the minimum titer only varies within the range between about 0.4 dtex and 0.75 dtex, namely irrespective of the humidity within the air gap. This means that within that range the spinnability is practically independent of the moisture in the air gap and that dopes with long-chain molecules in the concentration range indicated in the invention can be spun into dense filament curtains in which the air humidity has practically no negative effect on spinnability, thus eliminating the need for expensive climatization and conditioning of the blowing air.
Through extensive experimentation, applicant has discovered that in this manner filament curtains of high linear density, namely a linear density of at least 20, which are blown against with normal air, can be spun.
6. Fibrillation properties of fibers made from dopes according resp. not according to the invention
According to the method described in para. 2 ., cellulose dopes with a total cellulose concentration of 15 weight percent were prepared.
As the cellulosic material, the following pulps and pulp mixtures were employed:
1) Viscokraft LV (100%)
2) Viscokraft LV (85%), Alistaple LD 9.2 (15%)
The cellulose dope containing 100% Viscokraft LV as the cellulosic material did immediately before spinning not correspond to a dope utilized in accordance with the invention.
The cellulose dope containing 85% Viscokraft LV and 15% Alistaple LD 9.2 as the cellulosic material did immediately before spinning correspond to a dope utilized in accordance with the invention.
From these cellulose dopes, fibers were prepared according to the method described in para. 3 . In the separate trials, air with different humidities was employed for the blowing against the filaments in the air gap (cf. 4.), whilst all other parameters remained constant. From the fibers so prepared, the fibrillation tendency was measured according to the following test method:
The abrasion of the fibers among each other during the washing process respectively during finishing processes in the wet condition was simulated by the following test: 8 fibers with a length of 20 mm were introduced to a 20 ml sample bottle with 4 ml of water and shaken over a nine hour period in a laboratory mechanical shaker of the type RO-10 from the company of Gerhardt, Bonn (FRG), at level 12. Following this, the fibrillation behavior of the fibers was evaluated under the microscope by counting the number of fibrils for each 0.276 mm of fiber length.
RESULTS:
The fibrillation property determined according to the above test method is listed in the following table:
humidity of
blowing air
Pulp employed
titer (dtex)
(g H 2 O/kg air)
number of fibrils
100% Viscokraft LV
1.7
10
>50
15% Alistaple LD 9.2
1.7
10
24
85% Viscokraft LV
15% Alistaple LD 9.2
1.7
20
12
85% Viscokraft LV
From the table it can be easily seen that the tendency to fibrillation of fibers made from cellulose dopes with a composition according to the invention is lower compared with fibers made from cellulose dopes with a composition which is not in accordance with the invention. Furthermore, it can be seen from the table that the tendency to fibrillation of fibers made from cellulose dopes with a composition according to the invention even further decreases if air with a higher humidity is employed for the blowing against the filaments. | The invention relates to a method of producing lyocell-type cellulose fibers by processing a spinnable solution of cellulose in an aqueous tertiary amine oxide according to the dry/wet-spinning process, which method is characterized in that a solution having a content of between 0.05% and 0.70% by mass, based on the mass of the solution, of cellulose with a molecular weight of at least 5×10 5 is used for spinning. The method of the invention allows the use of a spinnerette having more than 10,000 spinning holes for the spinning operation, which holes are arranged in such a manner that neighboring spinning holes are spaced maximally 3 mm apart and that the linear density of the spinning holes it at least 20. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to apparatus for modifying the properties of a flow field and to a method of selecting an apparatus to achieve a desired flow field. Embodiments of the invention can be used to control the mixing of fluids, heat transfer within and between fluids, acoustic noise, oscillations in fluids, microchip cooling, structural vibrations and chemical reactions. One particular application to which embodiments of the invention are particularly well suited is airbrakes on airborne vehicles.
BACKGROUND OF THE INVENTION
[0002] The capability to predict and control flow field characteristics has been the subject of scientific research for a significant period of time. However, as has been realised in the course of many and diverse research projects, flow field behaviour is extremely complex and thus difficult to control by means of artefacts placed within a flow field.
[0003] In the period between 1963 and 1966, Corrsin and co-workers spearheaded a research effort directed towards controlling the turbulence within a conduit by means of a grid comprising a two-dimensional uniform mesh disposed symmetrically within the conduit (as comprehensively described in S. Corrsin, Handbook de Physik (1963) 8:254). This research effort showed that low Reynolds number, essentially isotropic and homogeneous turbulence flow, can be generated downstream of the grid. In the period since 1966, various different shaped grids have been tested, but for each of these grids, the cross section of individual grid elements has been identical to that of other elements in the grid.
[0004] The feature that is common to the measurement data obtained for any of these known two-dimensional grids is that the turbulence levels, that is to say the fluctuations in velocity over time downstream of the grid, has been limited to extremely low levels. Thus the range of control that is achievable with, and applicability of, such grids to applications such as mixing and noise control, is extremely limited.
[0005] It is an objective of the present invention to increase the range within which flow field parameters can be controlled.
SUMMARY OF THE INVENTION
[0006] In accordance with a first aspect of the present invention, there is provided fluid flow modification apparatus for creating turbulence in a fluid when said fluid is moving relative to the fluid flow modification apparatus, the apparatus comprising:
[0007] a plurality of turbulence-creating elements, each turbulence-creating element having a first surface portion against which the fluid can flow and a second surface portion along which the fluid can flow, each surface portion having a surface area association therewith; and
[0008] a support for holding the turbulence-creating elements in the fluid so as to allow movement of the fluid relative to the turbulence-creating elements,
[0009] wherein said turbulence-creating elements include at least two different types of element, including a first type of element and a second type of element, and
[0010] wherein the first type of element has a first surface area and the second type of element has a second surface area, different to said first surface area, said first and second surface areas having a relationship selected to control the turbulence-creating characteristics of said fluid flow modification apparatus.
[0011] As described above, in embodiments of the invention, the surface area of the first element differs from that of the second element. The turbulence-creating elements can be defined such that the first surface portion of the first type of element has a first width and the first surface portion of the second type of element has a second width, so that the variation in surface area can be achieved by setting the second width to be different to the first width. Alternatively and/or additionally the turbulence-creating elements can be defined such that the first surface portion of the first type of element has a first length and the first surface portion of the second type of element has a second length so that the variation in surface area can be achieved by setting the second length to be different to the first length.
[0012] As will be expected from the foregoing, since the first surface portion is a surface against which the fluid flows, the first surface portion effectively presents an obstruction to the oncoming fluid, causing the fluid to pass around the turbulence-creating elements. The second surface portion, however, is a surface along which the fluid flows, and therefore presents resistance to the oncoming flow (in the form of friction) as it passes around the elements, leading to development of a shear layer along the second surface portion. The characteristics of the shear layer that is created thereby are dependent on the width of the second surface portion, and since the properties of the shear layer have a significant bearing on the flow field downstream of the fluid flow modification apparatus, the turbulence created by the fluid flow modification apparatus can further be controlled by varying the width of the second surface portion between respective types of elements.
[0013] Embodiments of fluid modification apparatus are referred to herein as grids and because the grids are composed of elements having different surface areas, the levels of turbulence that can be generated downstream of a given grid are greater than is achievable using the classical grids of Corrsin described above. By varying the surface area of the second type of elements, either in absolute terms or compared with that of the first type of elements, the levels of turbulence can be modified.
[0014] Preferably the turbulence-creating elements are arranged such that at least one of said first type of element is attached to at least one of said second type of element. The turbulence-creating elements can be generally elongate and of generally uniform thickness along their length, and can be arranged in a generally planar configuration.
[0015] Preferably the turbulence-creating elements are arranged in a multi-scale configuration. By multi-scale is meant that the thickness and/or length and/or depth of turbulence-creating elements of the first type of turbulence-creating element differs from that (or those) of the second type of turbulence-creating element. This relationship can most conveniently be quantified in terms of a ratio between the types of turbulence-creating elements: in one arrangement the turbulence-creating elements can be arranged in a fractal configuration comprising two or more fractal levels, such that the ratio of thickness and/or length and/or depth of turbulence-creating elements is constant between the fractal levels; in an alternative arrangement the turbulence-creating elements can be arranged in a multi-fractal configuration comprising two or more multi-fractal levels, such that the ratio of thickness and/or length and/or depth of turbulence-creating elements varies between respective multi-fractal levels.
[0016] In the case of a fractal configuration, the ratio of thickness and/or length and/or depth between turbulence-creating elements at different fractal levels can be within the ranges of 1.1 and 3; 1.2 and 2.7; or 1.3 and 2.6. The ratio can be chosen to be 1.35, 1.71, 2.05, 2.35 or 2.58, but any suitable values falling within the afore-mentioned ranges could be selected.
[0017] Conveniently the grids can be described as comprising a plurality of sets of said turbulence-creating elements: in a first arrangement a first said set comprises one of said first type of turbulence-creating elements and a second set comprises a plurality of said second type of turbulence-creating elements. In another arrangement the grid comprises three or more sets of turbulence-creating elements, the structures of at least one of the sets comprising turbulence-creating elements of a surface area different to the surface area associated with another of the sets of structures.
[0018] In a particularly preferred configuration, the turbulence-creating elements are arranged in structures, each said structure including a plurality of elongate members. The structures can include a structure having two elongate members, in which one said elongate member is attached to the other said elongate member part way along respective lengths of respective elongate members so as to form a cross-shaped structure. Alternatively the structures can include a structure having three elongate members, in which a first said elongate member has two ends and is attached to a second elongate member and to a third elongate member at respective ends of the first elongate member so as to attach to the second elongate member and the third elongate member part way along their respective lengths. An I-shaped structure is an example of one such structure. As a further alternative the structures can include a structure having a plurality of elongate members such that each member is in an end-to-end relationship with another elongate member so as to form a polygon (comprising three or more members); a particularly preferred example of this type comprises four elongate members so that the structure is square-shaped.
[0019] The elongate members can be integrally formed with other elongate members of a given structure, or the structures can comprise an attachment point for providing separable interconnection between respective elongate members of the structure. In the latter case the structures might be interconnected so as to form a grid that comprises a plurality of planes. In one arrangement the grids are arranged such that elongate members of the first structure engage with elongate members of at least one second structure; in the case where the structures are fabricated from a planar sheet such engagement between elongate members is inherent in the grid design.
[0020] According to a further aspect of the present invention there is provided a fractal fluid flow modification structure comprising:
[0021] a plurality of turbulence-creating elements; and
[0022] a support for holding the turbulence-creating elements in the fluid so as to allow movement of the fluid relative to the turbulence-creating elements,
[0023] wherein said turbulence-creating elements include at least two different types of element, including a first type of element and a second type of element, and
[0024] wherein the turbulence-creating elements are arranged in a fractal structure, the first type of element being arranged at a first level in said fractal structure and the second type of element being arranged at a second level in said fractal structure.
[0025] In one arrangement each turbulence-creating element comprises two ends, and an end of one turbulence-creating element is joined to an end of another turbulence-creating element such that the turbulence-creating elements are joined in an end-to-end configuration so as to form a given fractal structure. An example of such a fractal structure is a polygon fractal structure, and a particularly preferred polygon fractal structure is a square fractal structure.
[0026] In another arrangement each fractal structure comprises two turbulence-creating elements, one said turbulence-creating element being attached to the other said turbulence-creating element part way along respective lengths of respective turbulence-creating elements. An example of such a fractal structure is a cross-grid fractal structure.
[0027] In yet another arrangement each fractal structure comprises three turbulence-creating elements: in this arrangement a first said turbulence-creating element has two ends and is attached to a second turbulence-creating element and to a third turbulence-creating element at respective ends of the first turbulence-creating element so as to attach both to the second turbulence-creating element and to the third turbulence-creating element part way along their respective lengths. An example of such a fractal structure is an I-shaped fractal structure, and this structure is preferably embodied as a planar fractal structure.
[0028] In arrangements according to this aspect of the invention the turbulence-creating elements can be of uniform or different thickness between fractal levels, and/or of uniform or different depth between fractal levels.
[0029] According to a yet further aspect of the present invention there is provided a fractal fluid flow modification structure comprising:
[0030] a plurality of turbulence-creating elements; and
[0031] a support for holding the turbulence-creating elements in the fluid so as to allow movement of the fluid relative to the turbulence-creating elements,
[0032] wherein said turbulence-creating elements are arranged in an end to end configuration, and
[0033] wherein the turbulence-creating elements are arranged in a fractal structure, the fractal structure having at least two levels.
[0034] In arrangements according to this aspect of the invention the turbulence-creating elements can be of uniform or different thickness between fractal levels, and/or of uniform or different depth between fractal levels.
[0035] According to a yet further aspect of the invention there is provided a computer-implemented method of determining one or more properties related to turbulence in a fluid when said fluid is moving relative to a fluid flow modification apparatus, the fluid flow modification apparatus comprising:
[0036] a plurality of turbulence-creating elements, each turbulence-creating element having a first surface portion against which the fluid can flow and a second surface portion along which the fluid can flow, each surface portion having a surface area association therewith; and
[0037] a support for holding the turbulence-creating elements in the fluid so as to allow movement of the fluid relative to the turbulence-creating elements,
[0038] wherein said turbulence-creating elements include at least two different types of element, including a first type of element and a second type of element, and
[0039] wherein the first type of element has a first surface area and the second type of element has a second surface area, different to said first surface area, said first and second surface areas having a relationship selected to control the turbulence-creating characteristics of said fluid flow modification apparatus,
[0040] said method comprising:
[0041] i) determining said one or more properties for a first set of data relating to said first and second surface areas, wherein said first and second surface areas are related by a first relationship in said first set of data; and
[0042] ii) determining said one or more properties for a second set of data relating to said first and second surface areas, wherein said first and second surface areas are related by a second relationship, different to said first relationship, in said second set of data.
[0043] The method can most conveniently be used when the relationship is a ratio that is varied between said first and second sets of data so as to generate different values for the turbulence properties. Alternatively or additionally the first and second sets of data can include data indicative of an amount of blockage presented by the plurality of turbulence-creating elements to the fluid, and the method includes varying the amount of blockage between said first and second sets of data.
[0044] The method can be applied to determine turbulence intensity in a direction substantially perpendicular to the direction of said relative movement of the fluid and/or turbulence intensity in a direction substantially parallel to the direction of said relative movement of the fluid. To this end the method includes performing a calculation which takes into account said relationship whereby to determine said one or more properties of the fluid. This calculation can proceed according to various expressions, the actual form of which is selected in dependence on the form of the grid. For example, for grids comprising cross-shaped structures, the method includes performing a calculation according to the formula (u′/U) 2 =t r 2 C ΔP f 1 (x/M eff ) so as to determine said one or more properties of the fluid. For grids comprising I-shaped structures, however, the method includes performing a calculation according to the formula (u′/U) 2 =t r C ΔP (T/L max ) 2 f 2 (x/M eff ).
[0045] The computer-implemented method is conveniently performed by a computer, or a suite of computers, adapted to process a set of instructions according to the method and the method can be stored as a computer program, or a suite of computer programs, that holds such a set of instructions.
[0046] Embodiments of the invention can conveniently be applied in a variety of situations involving relative movement between an object and fluid, such as landing of aircraft; in such an application a grid according to the invention is used as an air break and attached to an aircraft wing, the wing comprising: a wing element having a leading edge and a trailing edge; at least one slat comprising a plurality of turbulence-creating elements, wherein the slat acts cooperatively with the wing element to control the speed of the aircraft, wherein said turbulence-creating elements are arranged in a generally planar configuration, and wherein the turbulence-creating elements are arranged in a fractal structure, the fractal structure having at least two levels.
[0047] Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 a is a schematic diagram of a conduit in which fluid modification apparatus according to an embodiment of the invention can operate;
[0049] FIG. 1 b is a schematic diagram showing side and end view of a wind tunnel section arranged to accommodate fluid modification apparatus according to embodiments of the invention;
[0050] FIGS. 2 a and 2 b are schematic diagrams showing fluid modification apparatus according to a first embodiment of the invention;
[0051] FIG. 2 c is a perspective diagram showing a three dimensional view of a section of the fluid modification apparatus shown in FIGS. 2 a and 2 b;
[0052] FIGS. 3 a - 3 e are schematic diagrams showing different arrangements of the fluid modification apparatus according to the first embodiment shown in FIG. 2 b;
[0053] FIG. 4 is a schematic diagram showing normalised pressure drop across grids according to the invention;
[0054] FIGS. 5 a and 5 b are schematic diagrams showing fluid modification apparatus according to a second embodiment of the invention;
[0055] FIGS. 6 a - 6 j are schematic diagrams showing different arrangements of the fluid modification apparatus according to the second embodiment shown in FIG. 5 b;
[0056] FIGS. 7 a , 7 b and 7 c are schematic diagrams showing fluid modification apparatus according to a third embodiment of the invention;
[0057] FIGS. 8 a - 8 g are schematic diagrams showing different arrangements of the fluid modification apparatus according to the third embodiment shown in FIG. 7 c;
[0058] FIG. 9 shows a graphical representation of measurement data taken in the axial direction along a centre line of the conduit shown in FIG. 1 b for fluid modification apparatus according to various of the first embodiments shown in FIGS. 3 a - 3 e;
[0059] FIG. 10 shows a graphical representation of measurement data taken in the axial direction along a centre line of the conduit shown in FIG. 1 b for fluid modification apparatus according to various of the second embodiments shown in FIGS. 6 a - 6 e;
[0060] FIG. 11 shows a graphical representation of measurement data taken in the axial direction along a centre line of the conduit shown in FIG. 1 b for fluid modification apparatus according to various of the third embodiments shown in FIGS. 8 a - 8 g;
[0061] FIG. 12 is a schematic flow diagram showing steps involved in a grid selection routine according to an embodiment of the invention;
[0062] FIG. 13 is a schematic flow diagram showing steps involved in a grid selection routine according to another embodiment of the invention;
[0063] FIG. 14 is a schematic diagram showing use of a grid as an airbrake; and
[0064] FIG. 15 is a schematic diagram showing an arrangement comprising a plurality of the airbrakes shown in FIG. 14 affixed to a portion of a wing.
[0065] In the figures, the same reference numerals are used to refer to the same parts and process steps; in relation to any given part, different embodiments thereof are assigned the same reference number as utilised in other embodiments, incremented by 100.
DETAILED DESCRIPTION OF THE INVENTION
[0066] As described above, embodiments of the invention are concerned with controlling the properties of a flow field, the flow field being generated by relative movement between fluid and a body. In a first arrangement this relative movement is generated by fluid F flowing through a conduit such as conduit 101 , shown part-open in FIG. 1 a . The conduit 101 can be any channel suitable for carrying fluid, of rectangular, circular or other suitable cross-section, and capable of accommodating fluid modification apparatus 100 therein.
[0067] In one arrangement the conduit 101 comprises a wind tunnel, which, as known in the art, typically comprises a contraction section 101 a for directing the fluid into a test section 101 b , within which fluid modification apparatus 100 is situated, and an exit section 101 c , which acts to diffuse the fluid as it exits the conduit. The wind tunnel facilitates measurement of the effects of the fluid modification apparatus 100 on the flow field. The test section 101 b of the wind tunnel comprises a rectangular cross section, of width T and height H, and the fluid modification apparatus 100 extends across the full cross section of the test section 101 b.
[0068] Turning now to FIGS. 2 a and 2 b , a first embodiment of the fluid modification apparatus 100 , hereinafter referred to as a grid, will be described. The grid 100 comprises a plurality of grid elements that are arranged symmetrically with respect to the axis of the test section 101 b ; the grid elements are selected so as to generate turbulence within fluid flow therethrough and in this embodiment the grid elements are embodied as generally elongate members, substantially uniform along their length, and arranged so as to form a cross-like structure 102 a shown in FIG. 2 a.
[0069] In this particular example the grid 100 comprises three structures: the first structure 102 a is composed of elongate members S 1 b 1 and S 1 b 2 ; the second structure 102 b is composed of elongate members S 2 b 1 and S 2 b 4 ; and the third structure 102 c is composed of elongate members S 2 b 2 and S 2 b 3 . For each respective structure the elongate members are interconnected via an attachment point, indicated in FIG. 2 a for the first structure 102 a by reference S 1 A 1 . The attachment point is either embodied as an attachment means that enables respective elongate members to separably attach to one another, or is an integral part of the respective elongate members, and configured such that any given structure is part of one planar sheet. It will be noted that the individual members of a given structure abut those of another structure: the grid 100 is configured such that these abutting members engage with one another so as to prevent relative movement between individual structures while the fluid flows therethrough; when the grid 100 is embodied as an integral planar sheet, prevention of lateral movement is an inherent feature of the grid design.
[0070] Whilst not shown in FIG. 2 b , the grid 100 also includes a support for engaging the grid 100 with a positioning mechanism within the wind tunnel 101 b , the support being configured so as to enable relative movement between the grid 100 and fluid.
[0071] As can be seen from FIG. 2 b , and according to a first grid definition (hereinafter referred to as the non-symmetrical definition) the elongate members S 1 b 1 and S 1 b 2 of the first structure 102 a have a thickness different to that of the members of the second and third structures 102 b , 102 c , and the thickness of these second and third structures 102 b , 102 c is identical. Accordingly, in this example the grid comprises two sets S 1 , S 2 of structures, and respective sets differ from one another by virtue of the thickness of the members of the structures.
[0072] In the example shown in FIG. 2 b , the first set S 1 comprises one cross structure 102 a and the second set S 2 comprises two structures 102 b , 102 c ; alternative arrangements can include three, or more, sets of structures, and the actual number of sets, numbers of structures within a set, and the thickness of individual members of the respective structures, serve to define the nature and degree of blockage presented by the grid 100 to the incoming fluid F. These features can be defined by means of the following grid parameters: Number of sets of structures, N; blockage ratio, σ (i.e. the amount of the cross-sectional area of the conduit 101 is blocked by the grid); ratio of the thickness between the thickest and thinnest members in the grid, t r ; and the effective mesh size,
[0000]
M
eff
(
=
4
T
2
(
1
-
σ
)
1
/
2
P
,
[0000] where P is roughly twice the sum of all of the lengths of members making up the grid 100 ). It is to be noted that according to the foregoing definition of the grid 100 , the elongate members structures S 2 b 1 and S 2 b 4 ; S 2 b 2 and S 2 b 3 making up structures 102 b , 102 c respectively of the second set S 2 each form a non-symmetrical cross structure (non-symmetrical in so far as the attachment point is not located half-way along the lengths of respective elongate members).
[0073] According to an alternative definition of the grid 100 (hereinafter referred to as the symmetrical definition), a structure is considered to be a member of a successive set if it is symmetrically disposed around a structure of the previous set; in accordance with this definition the second set S 2 of grid 100 could alternatively be viewed as comprising four symmetrical cross structures, each of the four being disposed in a quadrant of the structure 102 a of the first set S 1 . According to this symmetrical definition, the elements of the grid 100 are arranged in a fractal configuration, since the grid can be subdivided into parts, each of which is a smaller copy of the whole grid.
[0074] Turning now to FIG. 2 c , which shows a perspective view of the cross structure 102 a shown in FIG. 2 a , it can be seen that fluid F flows against a first surface portion 201 and along, or past, a second surface portion 203 of the grid 100 . Thus the first surface portion 201 presents an obstruction to the incoming flow F, while the second surface portion 203 lies parallel to, and is responsible for, the shear layer that builds up along the second surface portion 203 of each structure. In the arrangement shown in FIG. 2 c , individual elongate members are shown as having a rectangular cross-section, but it will be appreciated that they can alternatively have a circular cross-section, in which the case the surface portions 201 , 203 , would comprise curved surface portions.
[0075] In the foregoing description of the first embodiment of the invention, the turbulence generated downstream of the grid 100 is controlled by means of thickness variation between sets S 1 , S 2 of structures, which in terms of FIG. 2 c amounts to variation in width 207 of the first surface portion 201 ; however, the turbulence could alternatively be modified by varying the length 205 between sets S 1 , S 2 of structures, or indeed by modifying the width 209 of the second surface portion 203 . It can be expected that selection of a given geometric parameter—for the purposes of modification—will be dependent on the intended use of the grid, since turbulence distribution, homogeneity and magnitude differs with configuration of respective turbulence-creating elements. It should be noted that for clarity purposes the second and third embodiments discussed below are described in the context of the effects of modification of the width (“thickness”) of the first surface portion 201 between sets S 1 , S 2 of structures; however, it should be appreciated that, as for the cross-grids and discussed with reference to FIG. 2 c , the length 205 or depth 209 of structures of these embodiments could additionally or alternatively be varied.
[0076] FIGS. 3 a - 3 d show various different grid configurations for which there are three sets of structures and for which the grid is situated within a tunnel having width, T, of 0.46 m: in a first configuration ( FIG. 3 a ), σ is 40%, t r is 3.3; and M eff =114 mm; in a second configuration ( FIG. 3 b ), σ is 17%, t r is 5.0; and M eff =57 mm; in a third configuration ( FIG. 3 c ), σ is 21%, t r is 2.8; and M eff =57 mm; and in a fourth configuration ( FIG. 3 d ), σ is 29%, t r is 2.0; and M eff =57 mm.
[0077] According to the non-symmetrical definition of a given structure adopted in FIG. 2 b , in the configurations of FIGS. 3 a - 3 c , the first set S 1 comprises one structure and the second set S 2 comprises two structures, whereas in the fourth configuration ( FIG. 3 d ) the second set S 2 comprises six structures. In relation to the third set, S 3 , the first configuration ( FIG. 3 a ) comprises four structures, the second and third configurations ( FIGS. 3 b , 3 c ) comprise twelve structures and the fourth configuration ( FIG. 3 d ) comprises six structures. In each of these four grid configurations ( FIG. 3 a - FIG. 3 d ) the relationship between thicknesses of structures of respective sets can be quantified as a ratio, which in the case of a fractal grid, is constant between respective sets of structures; if t 1 denotes the thickness of structures in the first set S 1 , t 2 denotes the thickness of structures in the second set S 2 , and t 3 denotes the thickness of structures in the third set S 3 , and assuming grid to be a fractal grid (meaning that the ratio is constant between the three sets S 1 , S 2 , S 3 ) then
[0000]
t
1
t
2
=
t
2
t
3
=
R
t
.
[0000] As defined above, the ratio between the thickest and the thinnest elongate members is given by
[0000]
t
r
:
t
1
t
3
=
t
r
,
[0000] so that
[0000]
t
2
=
t
1
t
r
and
t
3
=
t
2
t
r
.
[0000] Alternatively the ratio R t could vary between sets of structures, leading to what is herein referred to as a multi-fractal grid.
[0078] FIG. 3 e shows a particularly preferred arrangement in which the number of sets is four: again, according to the non-symmetrical definition of the grid 100 , the first set S 1 comprises one structure, the second set S 2 comprises two structures, the third set S 3 comprises four structures and the fourth set S 4 comprises eight structures.
[0079] Turning now to FIGS. 5 a and 5 b , a second embodiment of the grid 200 will now be described; in this embodiment the grid elements comprise a plurality of structures 202 , each in the form of the I structure 202 a shown in FIG. 5 a ; in the example shown in FIG. 5 b there are five such structures: the first structure 202 a is composed of elongate members S 1 b 1 , S 1 b 2 , S 1 b 3 ; the second structure 202 b is composed of elongate members S 2 b 1 , S 2 b 2 , S 2 b 3 ; the third structure 202 c is composed of elongate members S 2 b 4 , S 2 b 5 , S 2 b 6 ; the fourth structure 202 d is composed of elongate members S 2 b 7 , S 2 b 8 , S 2 b 9 ; and the fifth structure 202 e is composed of elongate members S 2 b 10 , S 2 b 11 , S 2 b 12 . For each respective structure the elongate members are interconnected via an attachment point, indicated in FIG. 5 a for the first structure 202 a by references S 1 A 1 and S 1 A 2 . As for the first embodiment, the attachment points are either embodied as an attachment means that enables respective elongate members to separably attach to one another, or as an integral part of the respective elongate members, such that any given structure is part of one planar sheet.
[0080] It will be noted that the ends of individual members of the first structure 202 a abut members of the other four structures: the grid 200 is configured such that individual structures engage with one another at the abutment points so as to prevent relative movement while the fluid flows therethrough (in the case where the grid 200 is manufactured from a planar sheet, suppression of relative movement between sets of structures is inherent).
[0081] The number of structures making up a given set is constrained by a symmetry condition, which specifies that, with the exception of structures in the last set, each unconnected end of an elongate member in a given set is required to abut a structure in the next set. Accordingly, grid elements according to this second embodiment are arranged in a fractal configuration, since the grid 200 comprises a geometric pattern that is repeated at various scales and can be subdivided into parts, each of which is a smaller copy of the grid as a whole.
[0082] As can be seen from FIG. 5 b , the elongate members S 1 b 1 , S 1 b 2 , S 1 b 3 of the first structure 202 a have a thickness different to that of the members of the second-fifth structures 202 b . . . 202 e , and the thickness of these second-fifth structures 202 b . . . 202 e is identical. Accordingly, for an example in which the grid 200 comprises two sets S 1 , S 2 of structures, respective sets differ from one another by virtue of the thickness of the members of the structures.
[0083] Whilst the examples shown in FIG. 5 b comprise two sets of structures, S 1 , S 2 , the grid 200 can comprise any number of sets of structures within the constraints of the overall grid configuration, namely that none of the elongate members should cross over another elongate member. This constraint gives rise to a set of geometrical constraints for the ratio between thicknesses of members of respective structures (R t , as described above), and the ratio between lengths of members of respective structures, R L , which, for fractal grids, is constant between sets of structures and for multi-fractal grids can vary between sets of structures (in the case of fractal grids
[0000]
L
1
L
2
=
L
2
L
3
=
R
L
[0000] where L 1 denotes the length of structures in the first set S 1 , L 2 denotes the length of structures in the second set S 2 , and L 3 denotes the length of structures in the third set S 3 ). For example, in the case of a fractal grid, one such set specifies R L ≦0.6 and R t ≦1.
[0084] The parameter R L is related to a further grid parameter, namely the fractal dimension D f of a given grid:
[0000]
D
f
≈
log
B
log
(
1
/
R
L
)
,
[0000] where B is the multiplier between the number of structures in successive sets of structures (when a grid is defined according to the symmetrical definition such that a structure is considered to be a member of a successive set if it is symmetrically disposed around structure of the previous set), and as can be seen from FIG. 5 b , B=4.
[0085] FIGS. 6 a - 6 e show various different grid configurations for which there are four sets of structures and for which the grid is situated within a tunnel having a width, T, of 0.46 m: in each configuration the blockage ratio, σ is 25% and the fractal dimension of the grids, D f , is 2.0. In the first configuration ( FIG. 6 a ) t r is 2.5 and M eff =36.9 mm; in a second configuration ( FIG. 6 b ), t r is 5.0 and M eff =36.4 mm; in a third configuration ( FIG. 6 c ), t r is 8.5 and M eff =35.9 mm; in a fourth configuration ( FIG. 6 d ), t r is 13.0 and M eff =35.7 mm; and in a fifth configuration ( FIG. 6 e ), t r is 17.0 and M eff =35.5 mm. In each configuration shown in FIGS. 6 a - 6 e , the first set S 1 comprises one structure, the second set S 2 comprises two four structures, the third set S 3 comprises sixteen structures and the fourth set S 4 comprises sixty-four structures; it will thus be appreciated that according to the symmetrical definition, the number of structures n i associated with a given set S i , n i =4 (i-1) .
[0086] Further grid configurations according to the second embodiment are shown in FIGS. 6 f - 6 j : FIG. 6 f shows a grid 200 having five sets of structures, and FIGS. 6 g - 6 j shows grids having six sets of structures and fractal dimensions D f of 1.98, 1.87, 1.79 and 1.68 respectively; these latter Figures clearly show the effect of fractal dimension D f on blockage distribution across the grid 200 . It will be appreciated from the foregoing that a grid can comprise various numbers of structures and indeed sets of structures, and should not be limited to the 2, 3, 4, 5 or 6 sets of structures illustrated in the accompanying figures.
[0087] Turning now to FIGS. 7 a , 7 b and 7 c , a third embodiment of the grid 300 will be described; in this embodiment the grid elements comprise a plurality of structures 302 , each in the form of a polygon. In the examples shown in FIGS. 7 a - 7 c the polygon is embodied as a square, but it could alternatively be triangular, rectangular, hexagonal or any other structure comprising members joined in an end-to-end configuration; in the case of the grid elements comprising square structures, and for the example shown in FIG. 7 a there are five such structures: the first structure 302 a is composed of elongate members S 1 b 1 , S 1 b 2 , S 1 b 3 , S 1 b 4 ; the second structure 302 b is composed of elongate members S 2 b 1 , S 2 b 2 , S 2 b 3 , S 2 b 4 ; the third structure 302 c is composed of elongate members S 2 b 5 , S 2 b 6 , S 2 b 7 , S 2 b 8 ; the fourth structure 302 d is composed of elongate members S 2 b 9 , S 2 b 10 , S z b 11 , S 2 b 12 ; and the fifth structure 302 e is composed of elongate members S 2 b 13 , S 2 b 14 , S 2 b 15 , S 2 b 16 . For each respective structure the elongate members are interconnected via an attachment point, indicated in FIGS. 7 a and 7 b for the first structure 302 a by references S 1 A 1 , S 1 A 2 , S 1 A 3 and S 1 A 4 . As for the first and second embodiments, the attachment points are either embodied as an attachment means that enables respective elongate members to separably attach to one another, or is an integral part of the respective elongate members, such that the grid 300 is manufactured from one planar sheet.
[0088] In a first arrangement of this third embodiment, shown in FIG. 7 a , the elongate members of a given structure have the same thickness as that of members of any other structure, since a grid structure comprising grid elements, or elongate members, joined in an end-to-end configuration is itself novel. In an alternative arrangement, and as can be seen from FIG. 7 c , the elongate members of the first structure 302 a can have a thickness different to that of the members of the second-fifth structures 302 b . . . 302 e , and the thickness of these second-fifth structures 302 b . . . 302 e is identical. From a review of FIGS. 7 a and 7 c it will be noted that in either arrangement, each of the structures 302 b - 302 e of the second set S 2 abut two of the elongate members of the structure 302 a of the first set S 1 (for example, members S 2 b 3 and S 2 b 4 of structure 302 b abut elongate members S 1 b 2 and S 1 b 2 respectively of the first structure 302 a ). As a result each elongate member of a structure in a given set has two crossing points and the grid 300 is configured such that these crossing points are arranged so as to prevent relative movement between structures while the fluid flows therethrough (in the case where the grid 300 is manufactured from a planar sheet, suppression of relative movement between sets of structures is inherent).
[0089] As for the first and second embodiments, grid elements according to the third embodiment are arranged in a fractal configuration, since the grid comprises a geometric pattern that is repeated at various scales and can be subdivided into parts, each of which is a smaller copy of the grid as a whole.
[0090] FIGS. 8 a - 8 e show various different grid configurations for which there are four sets of structures and for which the grid is situated within a tunnel having a width, T, of 0.46 m: in each configuration the blockage ratio, σ is 25% and the fractal dimension of the grids, D f , is 2.0. In the first configuration ( FIG. 8 a ) t r is 2.5 and M eff =26.6 mm; in a second configuration ( FIG. 8 b ), t r is 5.0 and M eff =26.5 mm; in a third configuration ( FIG. 8 c ), t r is 8.5 and M eff =26.4 mm; in a fourth configuration ( FIG. 8 d ), t r is 13.0 and M eff =26.3 mm; and in a fifth configuration ( FIG. 8 e ), t r is 17.0 and M eff =26.2 mm. It is to be noted that, as for the example of two sets shown in FIG. 7 c , each elongate member in a given set has two crossing points where the member abuts members of structures within the next set (for all sets for which there is a next set).
[0091] In each configuration shown in FIGS. 8 a - 8 e , and according to the symmetrical grid definition, the first set S 1 comprises one structure, the second set S 2 comprises four structures, the third set S 3 comprises sixteen structures and the fourth set S 4 comprises sixty-four structures; it will thus be appreciated that for this embodiment, the number of structures n i associated with a given set S i , n i =4 (i-1) . In the case of a grid comprising triangular structures, the number of structures associated with a given set S i , n i =3 (i-1) ; thus for a grid comprising a closed p-sided structure, the number of structures n i associated with a given set S i , n i =p (i-1) . The total number of structures in a grid having q sets can then be derived from the following expression:
[0000]
Total
no
.
structures
=
∑
i
=
1
i
=
q
p
i
-
1
[0092] Further grid configurations are shown in FIGS. 8 f and 8 g : FIG. 8 f shows a grid 300 having five sets of structures, D f of 2.0 and t r of 17.0 and 28.0 respectively; these latter Figures clearly show the effect of fractal dimension thickness ratio, t r , on blockage distribution across the grid 300 .
[0093] Turning back to FIG. 4 , it can be seen that for a given blockage ratio, σ, the normalised static pressure drop,
[0000]
C
Δ
P
(
where
C
Δ
P
≡
2
Δ
P
ρ
U
∞
2
)
[0000] achievable across the grid, is significantly greater when using grids according to the invention than is achievable using known grids (which, as described in the introductory section, comprise a plurality of structures of a uniform size). Furthermore, and particularly surprisingly, the inventors have identified that for a given blockage ratio the pressure drop C ΔP is independent of how the blockage is distributed: in other words, the pressure drop C ΔP appears to be insensitive to different arrangements of sets of structures having the same blockage ratio.
[0094] In the course of designing these new and inventive grids, many measurements have been performed in order to characterise the flow field downstream thereof. One such set of measurements involves the turbulence field with axial distance away from the grid (i.e. with increasing values of x). In the course of reviewing the flow field data the inventors identified that for each of the embodiments, the flow field downstream of any grid according to that embodiment could be normalised by certain grid parameters, such that, as a fraction of the mean velocity, the turbulence decay is the same irrespective of grid configuration. This effect is shown in FIG. 9 for the case of grids according to the first embodiment, in respect of which the flow field can be normalised by the effective mesh size M eff and the thickness ratio t r ; importantly it is to be noted that the flow fields associated with grids according to the prior art (for which the thickness of the elongate members is uniform across the entire grid) can also be normalised by the effective mesh size M eff and the thickness ratio t r (these grids are identified by the label “classic”). FIG. 10 shows normalised turbulence decay for grids according to the second embodiment, and FIG. 11 shows the logarithmic normalised turbulence decay for grids according to the third embodiment.
[0095] The inventors then realised that these relationships can be used to design a grid configuration selection tool in order to generate a desired turbulence field (u′/U)—in other words, provided the grid can be described by physical parameters thickness ratio, blockage ratio and mesh perimeter (t r , σ and P (by virtue of the definition of the effective mesh size,
[0000]
M
eff
,
=
4
T
2
(
1
-
σ
)
1
/
2
P
)
)
,
[0000] the turbulence field downstream of the grid can be predicted.
[0096] For grids according to the first embodiment of the invention the expression that governs this grid selection is as follows:
[0000] ( u′/U ) 2 =t r 2 C ΔP f 1 ( x/M eff ) (1)
[0000] where f 1 (x/M eff ) is derivable from the empirical data shown in FIG. 9 . It is to be noted that axial distance from the grid 100 is metered by units of M eff rather than absolute distance, x. As stated above, for any given blockage ratio, σ, the pressure drop C ΔP has been found to be substantially constant; accordingly, given C ΔP and M eff the turbulence intensity u′/U and indeed axial decay of turbulence intensity can be controlled by varying the thickness ratio, t r .
[0097] Turning again to FIG. 10 , for the case of grids according to the second embodiment, the expression that governs grid selection is as follows:
[0000] ( u′/U ) 2 =t r C ΔP ( T/L max ) 2 f 2 ( x/M eff ) (2)
[0000] where L max is the length of the elongate member S 1 b 1 of the structure in the first set S 1 and f 2 (x/M eff ) is derivable from the empirical data shown in FIG. 10 . Again, axial distance from the grid 200 is metered by units of M eff rather than absolute distance, x and the thickness ratio, t r , is a significant parameter in the control of the magnitude, and axial decay, of turbulence.
[0098] In relation to the grids according to the third embodiment, the inventors identified the following relationship as unifying the turbulence decay downstream of the grids:
[0000] u′ 2 =u′ 2 peak exp[−( x−x peak )/ l turb ] (3)
[0000] where x peak is the absolute axial distance downstream of the grid 300 at which the turbulence field is a maximum and l turb is the distance for which the turbulence persists downstream of the grid 300 . Referring to FIG. 11 , an interesting unifying feature of the grids emerges when the logarithmic of this expression is taken:
[0000]
ln
(
U
u
′
)
2
=
ln
(
U
u
peak
′
)
2
+
[
x
-
x
peak
l
turb
]
,
[0000] from which it can be seen that the various flow field profiles 1101 , 1103 , 1105 , 1107 , 1109 converge onto linear portion 1111 , which corresponds to the latter part of this expression, namely
[0000]
x
-
x
peak
l
turb
.
[0000] The point at which the profiles converge onto linear portion 1111 corresponds to the point downstream at which the turbulence field is at a maximum: x peak . The value of this parameter is dependent on the thickness ratio t r and it can be seen that the higher the thickness ratio t r , the further upstream (i.e. closer to the grid 300 ) the profile converges onto linear portion 1111 . The parameter x peak is defined by various grid parameters, namely
[0000]
x
peak
=
75
t
m
i
n
T
L
m
i
n
[0000] where t min and L min are the thickness and length respectively of the smallest structures in the grid 300 , while the distance downstream for which the turbulence persists is governed by l turb , where
[0000]
l
turb
=
0.1
λ
0
U
λ
0
v
,
[0000] ν being the kinematic viscosity of the fluid F.
[0099] FIGS. 9 , 10 and 11 are concerned with turbulence decay and identifying those grid parameters that have a controlling influence thereon. However, another important flow field characteristic is that of homogeneity, which defines the variation in turbulence intensity in the three axial dimensions x, y, z. It has been identified that homogeneity increases with fractal grid dimension, D f , so that for example in the case of grids 200 according to the second embodiment, the grid shown in FIG. 6 j , having the lowest value of D f , generates the least homogeneous turbulence field, while the grid shown in FIG. 6 g , having the highest value of D f , generates the most homogeneous turbulence field. It is to be noted that the effect of grid arrangement on homogeneity is completely decoupled from its effect on turbulence decay, as can be seen from FIG. 10 .
[0100] The following description, together with FIGS. 12 and 13 , describe how expressions (1)-(3) can be used in a grid selection routine. Starting with expression (1), and referring to FIG. 12 , grid selection for the first embodiment starts by specifying the mean velocity U des and desired pressure drop C ΔP, des (step S 12 . 1 ); from the empirical data relating pressure drop C ΔP to blockage ratio, σ, a corresponding blockage ratio is identified at step S 12 . 3 . Having established the blockage ratio, σ, a first effective grid size, M eff is selected, by setting a value for the perimeter P of the grid (step S 12 . 5 ); next a first predefined value of the thickness ratio t r is selected (step S 12 . 7 ), and these values are inserted into expression (1) for a predefined range of values for x, in order to establish the turbulence velocity values as a function of M eff /x (step S 12 . 9 ). Once the range of turbulence velocity values has been established, the routine returns to step S 12 . 7 for a second predefined value of the thickness ratio t r , and step S 12 . 9 is repeated for this second value. This is repeated for all of the predefined values of thickness ratio t r , whereupon the routine returns to step S 12 . 5 for different values of grid perimeter P, and indeed the routine can return to step S 12 . 1 and the entire process be repeated for a different pressure drop and thus blockage ratio.
[0101] The routine for grids according to the second embodiment is essentially the same as the routine shown in FIG. 12 , but step S 12 . 9 involves invoking expression (2); in addition, and in view of the fact that expression (2) includes parameter L max , an additional iteration can be invoked outside of step S 12 . 1 , involving varying of L max .
[0102] The output of these routines will be a sequence of values of the turbulence intensity, u′, for grid parameter values set at instances of steps S 12 . 1 , S 12 . 5 and S 12 . 7 , and a particular grid can be selected from a comparison between the predicted turbulence decay field and a desired turbulence decay field. Such a tool is particularly useful for applications such as mixing of fluids (whether it be mixing of different fluids or mixing streams of the same fluids, the streams having different temperatures), where the mixing rate is highly correlated with turbulence intensity.
[0103] Turning now to the selection routine for grids according to the third embodiment, as will be appreciated from the foregoing, the flow downstream of all of these grids 300 converge onto
[0000]
x
-
x
peak
l
turb
;
[0000] the routine shown in FIG. 13 can be used to determine the point at which the turbulence field is a maximum (x peak ), in other words the axial distance at which the measurement data converge onto linear portion 1111 , and the associated turbulence intensity can be derived from where this value of x peak intersects the linear portion 1111 .
[0104] It will be appreciated that expressions (1) and (2) can be rearranged so as to express the thickness ratio, t r , as a function of the other parameters in the expression. When suitably rearranged, the expressions can then be used to identify a thickness ratio as a function of these other parameters such that the amount of turbulence intensity would be specified instead of being the subject of the calculations. As a result, and in order to identify the thickness ratio corresponding to specified sets of turbulence intensities, a slightly modified grid selection algorithm to those shown in FIGS. 12 and 13 would be used.
[0105] The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. For example, individual structures could be configured as Koch curve structures and, if the cross section of the conduit 101 were circular instead of rectangular, the grids could be configured so as to have a circular, rather than rectangular, profile.
[0106] In relation to the first aspect of the invention, it is assumed that for a grid comprising two or more sets of structures, the surface area (width, length or depth) of elongate members of each respective set of structures is different; it should be appreciated that for grids comprising three or more sets of structures, the surface area of the structures in the third set can be the same as the surface area of one of the other sets. Similarly, for increasing numbers of sets, and provided the minimum condition of two sets having different thicknesses is satisfied, the thickness of a given set of structures can be replicated in respect of different set(s) of structures.
[0107] Whilst in the foregoing embodiments any given grid comprises structures of the same shape, a grid could alternatively comprise a plurality of structures, each of a different shape; for example, the first set S 1 could comprise a cross-shaped structure, the second set S 2 could comprise I-shaped structures, the third set S 3 could comprise polygon-shaped structures etc. In addition or as a further alternative, the orientation of structures could vary between sets: for example the polygon-shaped structures could, in some sets, be rotated by an angular extent relative to a previous set.
[0108] In the arrangements described above, and as exemplified in the appended Figures, any given grid comprises a symmetrical arrangement of fractal structures. However, a grid could alternatively comprise a non-symmetrical distribution of fractal and/or multi-fractal structures, which is to say that the distribution of fractal/multi-fractal structures within the grid can vary in a non-uniform manner.
[0109] As described above, and referring back to FIG. 2 c , fluid F flows against a first surface portion 201 and along, or past, a second surface portion 203 of the grid 100 ; the turbulence can be modified by varying the width 209 of the second surface portion 203 , essentially introducing flow control via a third dimension. It has been noted by the inventors that varying this third dimension precipitates the decay of the turbulence field downstream of the grid 100 , thereby providing a further means of tuning mixing efficiencies and vibration control.
[0110] It has been noted that the turbulence control can be realised in a particularly economic and efficient manner with grids according to embodiments of the invention: in particular, grids according to embodiments of the invention enable realisation of a given mixing and/or reaction rate using less energy than is required with known configurations. In particular, embodiments of the invention provide an improved mechanism for mixing in so-called micro channels in which there is otherwise no turbulence. Embodiments of the invention provide a means of introducing flow irregularities over a broad range of small-scales down to the micron scale, thereby artificially introducing turbulence and forcing mixing within the channel. In one arrangement the channel dimension and corresponding overall fractal grid size is of the order 1 cm, but channel dimensions of between 2.5 cm and 10 microns (and corresponding grid sizes) fall within the definition of micro channels, and are thus possible applications for embodiments of the invention. Similarly, fractal grids of the micron-scale can be used for microchip cooling technology as an aid to improving heat transfer from the chips (the use of micron chip sizes presents overheating problems).
[0111] In view of the fact that fluid modification apparatus according to embodiments of the invention have a significant effect on flow field parameters such as pressure drop and turbulence intensity, embodiments of the invention can be used in applications such as air braking (e.g. for aeroplanes); aerodynamic control of fluid flow around motor vehicles and motorbikes; control of wind characteristics in sailing applications; among many others: in such applications it will be appreciated that the relative movement is induced by physical movement of the grid relative to the surrounding fluid, in which case the support structure would be affixed, e.g. to the wing of the aeroplane. Alternatively relative movement could be provided by movement on the part of both the grid and the fluid. In addition, fluid modification apparatus according to embodiments of the invention could be used to control of mixing of reacting fluids in vessels and combustion chambers.
[0112] Experimental data taken during landing of an aircraft indicate that, compared with the amount of noise associated with conventional (solid) wing slats and flaps, a reduced amount of noise is generated during landing of an aircraft when the landing slats include fractal airbreaks. FIG. 14 shows an airbrake comprising a grid 100 according to an embodiment of the invention, the airbrake being hingedly connected to an aircraft wing 1400 between the leading edge 1401 and the trailing edge 1403 thereof. The fixing arrangement for connecting the fractal airbrake 100 to the wing 1400 preferably includes a lowering and raising mechanism, the operation of which can be dependent on airspeed and controlled by an actuation system (such a configuration being employed in conventional leading edge wing slats mechanisms). One example arrangement is illustrated in FIG. 15 , which shows a plurality of slats having been deployed, each slat comprising fractal airbrakes 100 . As a general design principle, the type of fractal grid and its adaptation can be determined as functions of a number of various fractal, aerodynamic and structural parameters. Indeed, whilst the example shown in FIG. 15 shows a similar geometrical configuration between respective fractal airbrakes, each or some of the individual fractal airbreaks could alternatively have different configurations, either in terms of structures making up a given airbreak and/or fractal dimension D f and/or thickness ratio t r .
[0113] Furthermore the fluid modification apparatus can be used to reduce structural vibrations that would otherwise be induced by aerodynamic loading.
[0114] Other applications of embodiments of the invention include heat transfer and/or flow oscillations, specifically as a means to control acoustic noise and/or heat transfer to walls of a channel (since embodiments of the invention improve the mixing within the channel, and thereby flatten the heat transfer profile across a given channel cross section).
[0115] Whilst the measurement data show that the fluid modification apparatus affects the flow field so as to modify the turbulence intensity therein, the fluid modification apparatus can also be used to modify chemical structures within the fluid, for example, if the elongate members were coated with a catalyst material or a material that reacts with the incoming fluid.
[0116] It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. | Embodiments of the invention relate to apparatus for modifying the properties of a flow field and to a method of selecting an apparatus to achieve a desired flow field. The invention finds particular application in the control of the mixing of fluids, heat transfer within and between fluids, acoustic noise, oscillations in fluids, microchip cooling, structural vibrations and chemical reactions. Embodiments of the invention comprise a fractal fluid flow modification structure comprising: a plurality of turbulence-creating elements; and a support for holding the turbulence-creating elements in the fluid so as to allow movement of the fluid relative to the turbulence-creating elements, wherein said turbulence-creating elements include at least two different types of element, including a first type of element and a second type of element, and wherein the turbulence-creating elements are arranged in a fractal structure, the first type of element being arranged at a first level in said fractal structure and the second type of element being arranged at a second level in said fractal structure. Since the fluid flow modification structure comprises a plurality of levels of fractal structures, the surface area of the first type of element differs from that of the second type of element: varying the respective surface areas between fractal levels provides a convenient mechanism for controlling turbulence levels in the fluid. | 1 |
BACKGROUND OF INVENTION
[0001] Many discharge-based extreme ultraviolet (EUV) sources require the launching of high currents (10 kA or more) off electrode surfaces [for example, U.S. Pat. No. 5,504,795 “Plasma X-Ray Source”, McGeoch (1996); U.S. Pat. No. 6,541,786 “Plasma Pinch High Energy with Debris Collector”, Partlo et al., (2003)]. A principal and long-standing problem associated with this activity is a degree of electrode heating and erosion that limits the peak current, pulse duration and pulsed operating life of such devices. The default mode at very high current is “super-emission” of electrons from an extremely hot surface created by ion bombardment but this condition is still accompanied by evaporation of electrode material. In a previous US patent filing [U.S. application Ser. No. 12/854,375 “Z-Pinch Plasma Generator and Plasma Target”, McGeoch (2010)] there has been disclosed a magnetically-assisted cathode with two advantages over conventional cathodes. Firstly, azimuthal drift of electrons in the crossed electric field of the plasma-electrode sheath and the applied magnetic field spreads the current very uniformly, thereby eliminating surface hot spots. Secondly, the spiralling path of surface secondary electrons produces more efficient ionization by maintaining the electron energy close to the energy of the maximum ionization cross section, so ion impacts on the surface that produce secondaries are less energetic, and hence there is reduced sputtering and surface heating. In the applicant's laboratory, cathodes based on this principle have produced >8 kA current pulses of 2 μsec duration for more than 100 million pulses with negligible surface erosion, in a Z-Pinch plasma-generating device running on a mixture of helium and lithium.
[0002] The magnetically-assisted cathode has been operated in a concave cathode configuration for Z-pinch generation [U.S. application Ser. No. 12/854,375 “Z-Pinch Plasma Generator and Plasma Target”, McGeoch (2010)]. While this approach confers the above advantages of uniformity and more efficient electron amplification, it does not provide magnetic shielding of the electrode from the converging hot plasma. Also, the concave approach does not provide focusing of the compressed gas in any more than two dimensions, i.e. a cylindrical plasma shell is compressed without length change onto the axis of the device, so the line density of the pinch is limited. However, when extreme ultraviolet light (EUV) generation from lithium vapor is attempted, a high line density is needed in the pinch, and it is difficult to arrange this via two-dimensional compression alone, because of a limited available lithium vapor pressure.
SUMMARY OF INVENTION
[0003] The present invention introduces three-dimensional compression of a working gas, which may be lithium vapor, via the use of convex, tapered magnetically-assisted electrodes. An initial cylindrical plasma shell is defined by the intersection of the magnetic field lines with a circular aperture perpendicular to the common axis of the electrodes and the field. The electrodes are arranged with convex surfaces opposed, so that when the plasma shell is compressed by the pinch effect of a high current, the interior magnetic field is compressed onto their surface, and the working gas is impelled toward the central inter-electrode gap. There is thus a three-dimensional gas compression and many times greater pinch density than from two-dimensional compression.
[0004] The first function of the applied magnetic field (the magnetic assist) is to spread the initiation plasma azimuthally via ExB drift. The azimuthal symmetry is essential to the final formation of a hot plasma precisely on the device axis. Because the plasma responds to the applied voltage pulse via increased surface ionization, there is a skin depth limitation to the radial extent of dense plasma. A cylindrical shell of plasma therefore forms, guided by the applied magnetic field, and defined at its outer surface by the size of the circular aperture. The ends of the cylinder are located where the applied magnetic field intersects the electrodes.
[0005] The next function of the field is to protect the electrodes from plasma heat. When a short high current pulse is passed down the plasma shell between the electrodes, the shell begins to move inward and to compress the interior magnetic field, which can not enter the electrodes on the timescale of the current pulse. The field is sandwiched between the incoming plasma shell and the electrodes, so that it forms a high field insulating layer, preventing plasma heat from reaching the electrodes. For this to be the case, the diffusion time of the plasma shell across the applied magnetic field has to be much longer than the compression time.
[0006] The inward moving plasma shell squeezes the working gas from each end toward the center, so that a beneficially high density is achieved when the shell approaches the center from all directions. As the shell converges on the axis of the device, compressional heating and ionization of the working gas occurs. The high current that is flowing by that time becomes a major source of Ohmic heating, contributing the energy that is converted through ionic excitation into EUV radiation. The current path remains on the outside surface of the magnetic layer that protects the electrodes, and does not concentrate at the electrode tips, thereby avoiding excessive local heating and sputter erosion. The much higher temperature and density near the axis provide locally a rate of magnetic field diffusion sufficient to allow the high current to penetrate as far as the axis.
[0007] In accordance with embodiments of the invention, a pulsed generator of a pinch plasma is provided. The pulsed generator comprises two opposed coaxially aligned electrodes with convex profiles; a steady magnetic field applied parallel to the common axis of the electrodes; a limiter disc located between the electrodes with a hole centered on the axis, and a fill of low pressure gas, wherein: a pulsed voltage between the electrodes drives a current initially in a cylindrical sheet of diameter defined by the said hole, the current sheet being collapsed by the plasma pinch effect onto the convex surfaces of the electrodes, compressing the static magnetic field into a protective sheath over each surface, and forming a dense, high temperature plasma pinch on the axis between the electrodes.
BRIEF DESCRIPTION OF DRAWINGS
[0008] For better understanding of the present invention, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:
[0009] FIG. 1A is a cross-sectional view of a plasma generation configuration with cylindrical symmetry, in accordance with an embodiment of the invention;
[0010] FIG. 1B is a cross-sectional view showing the converging plasma shell within the configuration of FIG. 1A ;
[0011] FIG. 2A is a cross-sectional view of the plasma initiation in one embodiment of the invention;
[0012] FIG. 2B is a cross sectional view of the electrode configuration of FIG. 2A , along the axis thereof;
[0013] FIG. 3 is a cross-sectional view of a plasma generation configuration incorporating lithium enclosures within its electrodes and a plurality of limiter discs;
[0014] FIG. 4 is a cross-sectional view of a plasma generation configuration with an initiation pre-pulse generator;
[0015] FIG. 5 is a cross-sectional view of an EUV source system that incorporates an embodiment of the plasma generation configuration; and
[0016] FIG. 6 is a cross-sectional view of an asymmetric plasma generation configuration, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0017] The operation of a first embodiment of the invention is described with reference to
[0018] FIGS. 1A and 1B , which show two stages of plasma evolution in an electrode configuration with cylindrical symmetry about axis of rotation 15 . Electrodes 10 , 20 have rotational symmetry about axis 15 and are opposed, with convex surfaces facing each other. A disc 30 with a central circular hole is positioned mid-way between electrodes 10 , 20 with its center on the symmetry axis 15 . A pulsed voltage and current generator 50 is connected via conductors 40 across electrodes 10 , 20 . Generator 50 , in a preferred embodiment of the invention, supplies pulses of alternating polarity to the electrodes. A steady applied magnetic field B is present, with field lines 60 parallel to the axis of symmetry 15 . A working gas 70 fills the inter-electrode space. This gas may be chosen for its spectral line emissions to match the wavelength required for an application. For example, lithium vapor is chosen for the generation of 13.5 nm light useful in the patterning of semiconductors, the radiating species being the doubly-ionized Li 2+ state.
[0019] In a preferred embodiment of the invention, the voltage and current pulses are applied at a sufficiently high frequency for there to be residual ionization in gas 70 at the time of the succeeding pulse. In the case of lithium vapor this frequency would have to exceed approximately 1 kHz. Rapid application of the voltage pulse initiates ionization in a cylindrical plasma shell 75 , defined by the inner diameter of annular disc 30 , and the steady applied magnetic field lines 60 that run perpendicular to the disc. The thickness of the shell is related to the plasma skin depth at the frequency components within the applied voltage pulse. The plasma shell is initiated with excellent azimuthal uniformity owing to the azimuthal drift of surface-produced secondary electrons, described below with reference to FIGS. 2A and 2B . As the applied current pulse ramps up, plasma shell 75 is accelerated inward by the self-magnetic field of this current interacting with the electrons carrying the current—the so-called pinch effect.
[0020] In FIG. 1B a later location 85 of the plasma shell is shown. In this snapshot the ends of the shell nearest the electrodes have compressed the interior magnetic field lines into a thin layer 65 over the electrode surfaces, and the field amplitude in this layer increases toward the electrode tips. The field can not enter the electrodes by more than the electrode skin depth, which is rather small for the MHz frequency components of interest. The working gas that had formerly been around the outer parts of the electrode has been squeezed by the converging plasma shell and propelled toward the center of the device. In the last stage of compression, a dense gas cylinder 90 has formed between the electrode tips, and because of inertial energy delivered at stagnation on axis, the gas has been heated to high temperature, possibly through several stages of ionization. The continued input of heat via dissipation of the applied current (Ohmic heating) supplies energy for the emission of short wavelength radiation. The applied current is launched at the outer ends of the electrodes and guided by the surface contours, without contact, by virtue of magnetic insulation to converge at the highest density position within cylinder 90 and deposit heat.
[0021] FIGS. 2A and 2B illustrate the development of an azimuthally uniform plasma shell. In FIG. 2A an initial low density plasma shell 75 has developed in response to the application of voltage from generator 50 . Where shell 75 meets electrodes 10 , 20 there is a plasma sheath 95 across which there is a voltage drop, and an electric field oriented perpendicular to the electrode surface. Secondary electrons leaving the surface execute a crossed-field, or ExB drift, as shown in FIG. 2B . The azimuthal motion of these electrons ensures good azimuthal symmetry, both in location and density, of plasma shell 75 prior to its inward motion under the plasma pinch effect, described above with reference to FIGS. 1A and 1B . This high degree of symmetry ensures an accurate final location for dense plasma 90 .
[0022] In a second embodiment of the invention, illustrated in FIG. 3 , there is provision for the use of a working gas such as lithium, for which a useful density may be obtained via evaporation from a heated reservoir of liquid metal. In this case, electrodes 10 , 20 have internal reservoirs 110 that contain an amount of the liquid metal 120 . Aperture holes 130 located on the axis of symmetry 15 communicate the metal vapor into the operating gas volume 70 . Lithium (or the metal in question) is evaporated either by spare heat from the electrodes or by installed heaters 140 within the electrodes, or by a combination of these. It is contained by a wide angle heat pipe [U.S. Pat. No. 7,479,646 “Extreme Ultraviolet Source with Wide Angle Vapor Containment and Reflux”, McGeoch (2009)] of which the conical condensation and return surface structures 30 , 35 are shown. Three such structures, each with two surfaces having rotational symmetry around axis 15 , are shown in FIG. 3 , but there may be a plurality of such structures. The electrode outer surfaces 150 are also part of the heat pipe. In the case of lithium gas, a helium buffer gas 160 is present in the outer parts of the heat pipe, to contain lithium as described in [U.S. Pat. No. 7,479,646 McGeoch (2009)]. In steady operation, heat from the electrical discharge driven by pulser 50 , augmented if necessary by heaters 140 , maintains a temperature in the electrode reservoirs 110 appropriate for the metal vapor density desired in the discharge region 70 . Additionally, the temperature of the inner boundary of heat pipe structures 30 , 35 is raised in steady operation via the delivery of exhaust plasma heat or via other heater means, to a similar temperature to reservoirs 110 , facilitating the re-evaporation of metal that has flowed inward after condensing on structures 30 , 35 . All surfaces in contact with metal vapor are therefore at similar temperature, ensuring that there is not a net migration of metal onto any one cool spot in the device. Having established the desired operating density of metal vapor, the operation of the plasma generation configuration proceeds as described above with reference to FIGS. 1A and 1B , in which the numbering coincides with FIG. 3 .
[0023] In a further embodiment of the invention, illustrated in FIG. 4 , there is an ignition voltage pulse V 1 supplied by generator 55 to limiter disc 30 in the period prior to the main high voltage pulse V that is supplied by generator 50 . In the plasma generator, the electrodes 10 , 20 are typically connected to each other through low impedance pulse generator 50 , so that a voltage V 1 applied between one of the electrodes 10 , 20 and the limiter disc 30 is typically also experienced between the other electrode and disc 30 . Ignition generator 55 is typically a higher impedance generator than 50 , so it does not deliver a significant current or contribute a significant pinch effect prior to the main current pulse delivered from generator 50 . However, it serves to create a base ionization from which an ionization avalanche may occur to create plasma shell 75 upon application of the main pulse.
[0024] The plasma generation configuration of the present invention may be incorporated into an EUV source system, one embodiment of which is illustrated in FIG. 5 . In that Figure an embodiment of the plasma generation configuration is located within vacuum chamber 400 , which may have rotational symmetry about axis 15 . The required static magnetic field 60 (labelled B) is provided by Helmholtz coils 300 , which may be located outside of chamber 400 . Mirror 190 , which may be of ellipsoidal section, re-focuses EUV light rays 180 from dense plasma region 90 toward position 200 , where the radiation may be used. Barrier 500 is substantially transparent to the EUV light but presents a barrier to the movement of the working gas, or the helium buffer gas, in the case of a metal vapor contained in a wide angle heat pipe. This allows isolation of the point of use 200 located in region 420 from the from the working gas or buffer gas located in region 410 . Barrier 500 may consist of narrow passages parallel to the reflected rays, presenting a high impedance to the flow of gas, but transmitting most of the EUV light. Alternately, or in conjunction with the first, barrier 500 may comprise a thin membrane that transmits most of the EUV light, mounted on a support mesh. This type of membrane is well known in the literature and has been further developed for use with EUV light by Shroff et al. [Proc SPIE 6151 paper 615104 (2006)]. Laser beam 600 can be focused onto dense plasma 90 in order to enhance EUV generation in a small interaction region, thereby increasing the brightness of the EUV source in a Laser Heated Discharge Plasma (LHDP) source [US Patent Publication No. US 2009/0212241, “Laser Heated Discharge Plasma EUV Source”, McGeoch (2009)]. Laser beam 600 enters chamber 400 through a lens or a window (not shown in FIG. 5 ) and passes through a hole in the collection mirror 190 to reach the center of the device. Other arrangements of the same components are possible, including ones in which the symmetry axes of the chamber or the ellipsoidal mirror are not parallel to symmetry axis 15 of the plasma generation configuration. The foregoing is only one example of many different systems that may incorporate as a sub-component the present invention as defined in the claims attached hereto, and is not to be construed as limiting the scope of the present invention.
[0025] A further embodiment of the invention is illustrated in FIG. 6 . This embodiment shows an asymmetrical electrode pair 10 , 20 , both convex in accordance with the invention, but each electrode having a different convex outer profile, and only one electrode ( 20 ) having a central hole 130 with access to a liquid metal reservoir 110 . This embodiment has three limiter discs 30 , 35 , 35 that constitute a wide-angle heat pipe for capture and recirculation of metal vapor. Operation is as described with reference to FIG. 3 . All possible asymmetrical configurations are implied in the scope of the invention.
[0026] At least one embodiment of the invention has been brought to practice in the laboratory of the applicant. In one such embodiment, the diameter of the hole in the limiter disc was 25 mm, and the length of the starting plasma cylinder was 30 mm. A steady magnetic field of 0.04 T was applied parallel to the axis of the generator, and symmetrical electrodes with a 3 mm diameter central hole were employed, giving access to chambers containing lithium. In operation a helium pressure of 2.5 torr was used to contain lithium in the wide angle heat pipe. Four limiter discs were used and a pre-ignition pulse was applied to the central two of these. A pulse of duration 2 μsec and peak current 10 kA was applied in order to compress the plasma shell. The generator was pulsed at up to 2 kHz and produced several hundred watts of 13.5 nm extreme ultraviolet radiation. This is only one example out of many possible embodiments that differ widely in physical scale, and require different peak currents, pulse durations or applied magnetic field, depending upon the working gas and wavelength requirements.
[0027] Further realizations of this invention will be apparent to those skilled in the art. Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. | A magnetically shielded, efficient plasma generation configuration for a pulsed discharge extreme ultraviolet (EUV) light source comprises two opposed convex electrodes mounted with axes parallel to a static magnetic field. A limiter aperture disposed between the electrodes, in conjunction with the field lines, defines a hollow plasma cylinder connecting the electrodes. A high pulsed voltage and current compresses the plasma cylinder and its interior magnetic field onto the electrode surfaces to create a magnetic insulating layer at the same time as propelling the working gas from each side toward the space between the electrode tips. The plasma then collapses radially in a three-dimensional compression to form a dense plasma on the axis of the device with radiation of extreme ultraviolet light. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent Application having Ser. No. 61/884,071 filed on Sep. 29, 2013. The entirety of the provisional patent application is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Embodiments of the invention relate to video recording. More specifically, embodiments of the invention relate to a video recording device positioner based on relative head rotation.
[0004] 2. Description of the Related Art
[0005] As known in the video recording industry, there are many forms of devices for the recording of motion video, such as video cameras, smart phones, and tablet computers. However, these devices require the user to hold or manually position the camera to capture the desired area of interest. In some recording situations, the user may have the device pointed in a first direction while the user is visually viewing the desired area of interest in a second direction. Therefore, there is a need for a device positioner that is capable of movement based on relative head rotation of the user.
BRIEF SUMMARY OF THE PRESENT INVENTION
[0006] In one aspect, a recording device positioner is provided. The recording device includes a base having a connection portion that is configured to receive a recording device. The recording device positioner further includes a positioning sensor configured to sense the movement of a user. Additionally, the recording device positioner includes a motor attached to the base, the motor being configured to rotate the recording device relative to the base based upon signals sent by the positioning sensor.
[0007] In another aspect, a method of recording a desired area of interest using a recording device positioner is provided. The recording device positioner has a position sensor and a base configured to receive a recording device. The method includes the step of attaching the positioning sensor to a body portion of a user. The method also includes the step of inputting a zero reference direction of the recording device positioner. Additionally, the method includes the step of rotating the recording device relative to the based upon signals sent by the positioning sensor.
[0008] In a further aspect, a device positioner for moving a video recording device based on movements of a user is provided. The device positioner includes a base. The device positioner further includes a positioning sensor configured to be attached to a body portion of the user and sense the movement of the user. The device positioner also includes a rotation member disposed in the base, the rotation member being configured to rotate the video recording device relative to the base. Additionally, the rotation member includes a microcontroller configured to receive signals from the positioning sensor and to send control signals to the rotation member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
[0010] FIG. 1 shows a perspective view of a video recording positioner according to one embodiment.
[0011] FIG. 2 illustrates ranges of rotation of a base in the video recording positioner.
[0012] FIG. 3 illustrates the operational flow logic of the video recording positioner.
[0013] FIG. 4 is a schematic of the basic operational principles of the video recording positioner.
[0014] FIG. 5 is a flow chart illustrating the procedure routine of the video recording positioner.
DETAILED DESCRIPTION
[0015] Generally, filming of video has traditionally required the viewer to position a video recording device manually to capture the area of interest. This invention provides a motorized video recording device positioning system which utilizes the relative rotation of the viewers head position to rotate the field of view of the video recording device.
[0016] The use of gyroscopes, accelerometers, tilt sensors, and compass devices have been used in radio controlled and unmanned vehicles to determine directional heading. These sensors are used together to provide a compass heading direction which does not vary based on the tilt of the sensor in the pitch and yaw directions. The present invention seeks to utilize the sophisticated directional heading and movement sensors to position a video camera corresponding to the relative rotation of the user's head about the spine axis. To better understand the aspects of the invention, the invention will be described in relation to the following figures.
[0017] FIG. 1 shows a perspective view of a video recording positioner 60 according to one embodiment. The positioner includes a base 16 having a rotating platform 28 which allows movement about a fixed axis. A camera may be attached to the rotating platform 28 . In one embodiment, the rotating platform 28 may include the camera. In another embodiment, a connection portion may be provided on the rotating platform 28 to support a camera, mobile device, smart phone, tablet computer, or other recording device. In another embodiment, the device may be utilized with a still photography camera. Connection of the devices to the rotating platform 28 may include a connection member such as screws, a cradle, or fasteners similar to Velcro.
[0018] The rotating platform 28 may be connected to the base 16 by a rotation member such as motor 22 . The motor 22 may be a servo motor similar to a Hitec HS-55. The motor 22 may also be a stepper motor or a magnetic movement device. A power supply 24 may provide the power needed for the video recording positioner 60 . The power supply 24 may be a DC battery. A power switch 26 may control the on/off state of the video recording positioner 50 .
[0019] The base 16 may be provided with a connection point to allow mounting to a traditional camera tripod. The base 15 may also be handheld, connected to a handle, connected to a body attachment device, or to a specialized bracket. When filming an event, it may be necessary to restrict the limits of rotation of the rotating platform 28 to limit the rotation of the camera. A range of travel setting 20 is used to reduce the rotational range of the rotating platform 28 . The range of travel setting 20 may be a potentiometer.
[0020] FIG. 4 is a schematic of the basic operational principles of the video recording positioner 60 . A zero reference direction 30 is first established by the user from which a position sensor 14 measures the rotation of the user's head about the spine axis and thereby moves the rotating platform 28 . The position sensor 14 may be a Devantech CMPS10. The position sensor 14 may include an accelerometer, tilt sensor, or magnetometer. The positioning of the rotating platform 28 is based on the relative movement of the user's head. To determine the center and starting reference point, the user depresses the zero reference button 12 to establish the zero reference direction 30 . The position sensor 14 may be attached to a bracket which allows the user to wear the sensor on the ear. In another embodiment, the position sensor 14 may be attached to an article of clothing worn by the user, such as a shirt, a hat, visor, or glasses. In other embodiment, the position sensor 13 may connect to the user's body to detect relative rotational change and may include such parts as the user's shoulder, arm, or chest. The position sensor 14 may connect to the base 16 utilizing flexible wiring 18 . In another embodiment, wireless communication may also be used and may include radio frequency signals, infrared, or Bluetooth signals that would allow the user to be physically separated from the base 16 , thereby allowing the base to be located at an optimal recording location which may differ from the user's location.
[0021] Referring back to FIG. 1 , the video recording positioner 60 may also include a microcontroller 10 . The microcontroller 10 can be chosen from any number of commercially available products which include a central processing unit, random access memory (RAM), and input/output (I/O) ports similar to a Parallax Propeller. The microcontroller 10 may be separate as shown in FIG. 1 or in another embodiment may be incorporated to be included within the packaging of the positioning base 16 , for example located embedded in the base below the rotating platform 28 . In another embodiment the microcontroller 10 may be incorporated within the packaging of the position sensor 14 , for example contained within the ear piece worn by the user. An alternate improvement may include the use of a smartphone, laptop, or mobile computing device in lieu of the microcontroller 10 to perform the operational flow logic identified in FIGS. 3 and 5 . In another embodiment, a smartphone or similar device application may provide a user interface to the video recording positioner 60 which may include allowing the user to input and change the range of travel setting 20 and establish the zero reference button 12 input to the system.
[0022] FIG. 2 is a top view of the base 16 indicating the ranges of rotation. The zero reference direction is indicated in FIG. 2 as reference number 30 . This zero reference direction 30 is established when the user presses the zero reference button 12 (see FIG. 1 ). The full range of travel of movement for the rotating platform 28 is identified as reference number 34 . This is the full rotational range of the rotating platform 28 . The range of movement can be limited by the user by adjusting the range of travel setting 20 . The range of travel can be limited to a range less than the full range, as shown by reference number 36 .
[0023] FIG. 3 depicts the operational flow logic of the video recording positioner 60 . With the power supply 24 providing power to the system through the on/off switch 26 the microcontroller 10 waits for the depression of the zero reference button 12 to establish the zero reference direction 30 . The position sensor 14 measures the head rotational movement of the user and provides this information to the microcontroller 10 to determine the change of rotation of the user's head from the zero reference direction 30 . The range of travel setting 20 provides an input to the microcontroller 10 to limit the range of rotation of the rotating platform 28 . As the position sensor 14 input changes from the zero reference heading 30 the microcontroller 10 outputs a position movement to the motor 22 proportional to the change in heading. The microcontroller 10 monitors the range of travel setting 20 to establish the limits of rotation of the motor 22 . The microcontroller 10 limits the output to the motor 22 in order not to exceed the calculated limits of rotation of the motor 22 .
[0024] When the power switch 26 is enabled to allow power to the video recording positioner 60 , the microcontroller 10 starts the routine in FIG. 5 , and advances to decision block 40 to determine if the zero reference button 12 has been pressed and if it has not it loops back as shown. If it is determined that the zero reference button 12 has been pressed, the routine proceeds to block 42 wherein it establishes the zero reference direction 30 as the current positional output from the position sensor 14 , outputs a signal to motor 22 directing it to move the rotational platform 28 to the center position, stores the positional output in the memory of the microprocessor 10 as the last positional reading, and then proceeds to decision block 44 . At decision block 44 , the microprocessor 10 determines whether the current positional output from the position sensor 14 is different from the last stored positional reading. If a difference is identified, the microcontroller 10 calculates the output signal for the motor 22 , stores the positional output in the memory of the microprocessor 10 as the last positional reading, and proceeds to decision block 48 . At decision block 48 it is determined whether the calculated output signal for the motor exceeds the range of travel limit 36 and proceeds to block 50 if it is affirmative. If it is not, then the routine proceeds to block 52 and outputs the signal to the motor 22 to move the rotational platform 28 . At block 50 , the microcontroller 10 limits the output to the motor 22 to the range of travel limit 36 and proceeds to block 52 where this limited signal is outputted to motor 22 . The routine operates in a continual loop, returning to decision block 44 .
[0025] The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. | In one aspect, a recording device positioner is provided. The recording device includes a base having a connection portion that is configured to receive a recording device. The recording device positioner further includes a positioning sensor configured to sense the movement of a user. Additionally, the recording device positioner includes a motor attached to the base, the motor being configured to rotate the recording device relative to the base based upon signals sent by the positioning sensor. In another aspect, a method of recording a desired area of interest using a recording device positioner is provided. In a further aspect, a device positioner for moving a video recording device based on movements of a user is provided. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a polymer powder based on polyamide or on copolyamides, preferably nylon-12, which comprises phosphonate-containing flame retardant, to a process for producing this powder, and also to moldings produced by a layer-by-layer process which selectively melts regions or selectively binds them to one another, from this powder.
2. Discussion of the Background
Very recently, a requirement has arisen for the rapid production of prototypes. Selective laser sintering is a process particularly well suited to rapid prototyping. In this process, polymer powders in a chamber are selectively irradiated briefly with a laser beam, resulting in melting of the particles of powder on which the laser beam falls. The molten particles fuse and solidify again to give a solid mass. Three-dimensional bodies, including those of complex shape, can be produced simply and rapidly by this process, by repeatedly applying fresh layers and irradiating these.
The process of laser sintering (rapid prototyping) to realize moldings made from pulverulent polymers is described in detail in patent specifications U.S. Pat. No. 6,136,948 and WO 96/06881 (both DTM Corporation). A wide variety of polymers and copolymers is claimed for this application, e.g. polyacetate, polypropylene, polyethylene, ionomers, and polyamide.
Nylon-12 powder (PA 12) has proven particularly successful in industry for laser sintering to produce moldings, in particular to produce engineering components. The parts manufactured from PA 12 powder meet the high requirements demanded with regard to mechanical loading, thus having properties particularly close to those of the mass-production parts subsequently produced by extrusion or injection molding.
A PA 12 powder with good suitability here has a median particle size (d 50 ) of from 50 to 150 μm, and is obtained as in DE 19708946 or as in DE 4421454, for example. It is preferable here to use a nylon-12 powder whose melting point is from 185 to 189° C., whose enthalpy of fusion is 112 J/g, and whose freezing point is from 138 to 143° C., as described in EP 0911142.
Other processes with good suitability are the SIB process, as described in WO 01/38061, or a process as described in EP 1015214. The two processes operate using infrared heating over an area to melt the powder, and selectivity is achieved in the first process by applying an inhibitor, and in the second process by way of a mask. Another process which has found wide acceptance in the market is 3D printing, as in EP 0431924, where the moldings are produced by curing of a binder applied selectively to the powder layer. Another process is described in DE 10311438, in which the energy required for melting is introduced by way of a microwave generator, and selectivity is achieved by applying a susceptor.
For these processes, use may be made of pulverulent substrates, in particular polymers or copolymers, preferably selected from polyester, polyvinyl chloride, polyacetal, polypropylene, polyethylene, polystyrene, polycarbonate, poly(N-methylmethacrylimide) (PMMI), polymethyl methacrylate (PMMA), ionomer, polyamide, copolyester, copolyamides, terpolymers, acrylonitrile-butadiene-styrene copolymers (ABS), or a mixture of these.
Although the known polymer powders intrinsically have good properties, moldings produced using these powders still have some disadvantages. A particular disadvantage with the polymer powders currently used is their high flammability and combustibility. This currently inhibits the use of processes described above in short runs in aircraft construction, for example.
SUMMARY OF THE INVENTION
It was therefore an object of the present invention to provide a polymer powder which can be used in one of the processes described above to produce parts of lower flammability. In particular, the intention here is to achieve the Underwriters Laboratories (UL®) V-0 classification; wherein a V-0 classification means that burning stops within 10 seconds on a vertical specimen, and no drips are allowed; a V-1 classification means that burning stops within 30 seconds on a vertical specimen, and no drips allowed; and a V-2 classification means that burning stops within 30 seconds on a vertical specimen, and drips of flaming particles are allowed.
Surprisingly, it has now been found that addition of phosphonate-containing flame retardants to polymers can produce polymer powders which can be used in layer-by-layer processes in which regions are melted or selectively bound, to produce moldings which achieve markedly better UL® classification than moldings composed of conventional polymer powders. For example, this method can achieve UL® V-0 classification. It is particularly advantageous if the mechanical properties of the components are simultaneously retained.
DETAILED DESCRIPTION OF THE INVENTION
The present invention therefore provides a polymer powder for processing in a layer-by-layer process in which regions are selectively melted or bound to one another, wherein the powder comprises at least one polymer and at least one phosphonate-containing flame retardant.
The present invention also provides a process for producing polymer powder of the invention, which comprises mixing at least one polymer powder in the presence of a solvent in which the phosphonate-containing flame retardant has at least low solubility, and then removing the dispersion medium/solvent. The melting points of the flame retardants used must, of course, be above room temperature.
The present invention also provides moldings produced by a layer-by-layer process in which regions are selectively melted or selectively bound to one another, wherein the moldings comprise phosphonate-containing flame retardant and at least one polymer.
The polymer powder of the invention has the advantage that it can be used in a layer-by-layer process in which regions are selectively melted or selectively bound to one another to produce moldings which have low flammability and combustibility. Moldings which achieve UL® V-0 classification are therefore obtainable. Addition of flame retardant mostly impairs the mechanical properties of the moldings. Nevertheless, the moldings of the invention retain good tensile strain at break and an only slightly reduced modulus of elasticity, when compared with moldings composed of material to which no flame retardant has been added. This opens up application sectors which were inaccessible hitherto for reasons of poor combustibility classification.
The polymer powder of the invention is described below, as is a process for its production, but there is no intention that the invention be restricted thereto.
A feature of the polymer powder of the invention for processing in a layer-by-layer process in which regions are selectively melted or selectively bound to one another is that the powder comprises at least one polymer or copolymer and at least one phosphonate-containing flame retardant.
A polyamide preferably present in the polymer powder of the invention is a polyamide which has at least 8 carbon atoms per carbonamide group. The polymer powder of the invention preferably comprises at least one polyamide which contains 10 or more carbon atoms per carbonamide group. The polymer powder particularly preferably comprises at least one polyamide selected from nylon-6,12 (PA 612), nylon-11 (PA 11), and nylon-12 (PA 12).
The polymer powder of the invention preferably comprises polyamide with a median particle size of from 10 to 250 μm, preferably from 45 to 100 μm, and particularly preferably from 50 to 80 μm.
A polymer powder particularly suitable for laser sintering is a nylon-12 powder whose melting point is from 185 to 189° C., preferably from 186 to 188° C., whose enthalpy of fusion is 112±17 J/g, preferably from 100 to 125 J/g, and whose freezing point is from 133 to 148° C., preferably from 139 to 143° C. The process for the production of the polyamide powder on which the polymer powders of the invention are based is well-known, and in the case of PA 12 may be found by way of example in the publications DE 2906647, DE 3510687, DE 3510691, and DE 4421454, which are incorporated by way of reference in the disclosure content of the present invention. The polyamide pellets required may be purchased from various producers, and by way of example nylon-12 pellets are supplied as VESTAMID® by Degussa AG.
For the processes which do not use a laser, a copolymer powder has particularly good suitability, in particular a copolyamide powder.
The polymer powder of the invention preferably comprises, based on the entirety of the components present in the powder, from 1 to 30% by weight of at least one phosphonate-containing flame retardant, preferably from 5 to 20% by weight of a phosphonate-containing flame retardant, particularly preferably from 8 to 15% by weight of a phosphonate-containing flame retardant, and very particularly preferably from 10 to 12% by weight of a phosphonate-containing flame retardant.
If the content of the phosphonate-containing flame retardant is below 1% by weight based on the entirety of the components present in the powder, there is a marked reduction in the desired effect of low flammability and low combustibility. If the content of the phosphonate-containing flame retardant is above 30% by weight, based on the entirety of the components present in the powder, the mechanical properties of the moldings produced from these powders become markedly poorer, the modulus of elasticity for example.
The phosphonate-containing flame retardant present in the polymer powder of the invention is preferably Antiblaze 1045, which is commercially available and can be purchased from Rhodia.
For applying the powders to the layer to be processed it is advantageous if the phosphonate-containing flame retardant encapsulates the polymer grains, this being achievable by wet-mixing of polymer dispersions in a solvent in which the phosphonate-containing flame retardant has at least low solubility, because the resultant treated particles have particularly good distribution of the flame retardant. However, it is also possible to use powders with phosphonate-based flame retardant incorporated by compounding in bulk, with subsequent use of low-temperature milling to give powder. Suitable flow aids, such as fumed aluminum oxide, fumed silicon dioxide, or fumed titanium dioxide, may be added to the resultant powder.
Polymer powder of the invention may therefore comprise these, or else other, auxiliaries, and/or filler. By way of example, these auxiliaries may be the abovementioned flow aids, e.g. fumed silicon dioxide or else precipitated silicas. By way of example, fumed silicon dioxide is supplied with the product name Aerosil® with various specifications by Degussa AG. Polymer powder of the invention preferably comprises less than 3% by weight, with preference from 0.001 to 2% by weight, and very particularly preferably from 0.05 to 1% by weight, of these auxiliaries, based on the entirety of the polyamides present. By way of example, the fillers may be glass particles, metal particles, or ceramic particles, e.g. solid or hollow glass beads, steel shot, granulated metal, or else color pigments, e.g. transition metal oxides.
The median grain size of the filler particles here are preferably smaller than or approximately equal to that of the particles of the polyamides. The median grain size d 50 of the fillers should preferably not exceed the median grain size d 50 of the polyamides by more than 20%, with preference 15%, and with very particular preference 5%. A particular limitation on the particle size results from the permissible overall height or, respectively, layer thickness in the layer-by-layer apparatus.
Polymer powder of the invention preferably comprises less than 75% by weight, with preference from 0.001 to 70% by weight, particularly preferably from 0.05 to 50% by weight, and very particularly preferably from 0.1 to 25% by weight, of these fillers, based on the entirety of the components present.
If the stated maximum limits for auxiliaries and/or fillers are exceeded, depending on the filler or auxiliary used, there can be marked impairment of mechanical properties of moldings produced from these polymer powders.
The polymer powders of the invention can be produced simply, preferably by the process of the invention for producing polymer powder of the invention, by mixing at least one polyamide with at least one phosphonate-containing flame retardant, preferably by incorporation through wet-mixing. By way of example, a polymer powder obtained by reprecipitation or by milling may be dissolved or suspended in an organic solvent and mixed with the phosphonate-containing flame retardant, or else the polymer powder may be mixed in bulk with phosphonate-containing flame retardant. In the case of operation in a solvent, the phosphonate-containing flame retardant is preferably present in solution, or at least to some extent in solution, in a solvent when mixed with a solvent which comprises the polymer, whereupon either this solvent may comprise the dissolved polymer and the polymer powder is obtained by precipitation of the polymers from the flame-retardant-containing solvent, or the solvent may comprise the suspended pulverulent polymer and the polymer powder is obtained by removing the solvent.
In the simplest embodiment of the process of the invention, a very wide variety of known methods may be used to achieve a fine-particle mixture. For example, the mixing method may be wet-mixing in low-speed assemblies—e.g. paddle driers or circulating screw mixers (known as Nautamixers)—or by dispersion of the phosphonate-containing flame retardant and of the polymer powder in an organic solvent, followed by distillative removal of the solvent. In this procedure it is advantageous if the organic solvent dissolves the phosphonate-containing flame retardant, at least at low concentration, because the flame retardant can encapsulate the polyamide grains during the drying process. Examples of solvent suitable for this variant are lower alcohols having from 1-3 carbon atoms, and ethanol may preferably be used as solvent.
In one of these first variants of the process of the invention, the polyamide powder may be a polyamide powder intrinsically suitable as a laser sintering powder, phosphonate-containing flame retardant simply being admixed thereto. For this, it is advantageous for at least the flame retardant to be at least to some extent dissolved or heated, in order to reduce viscosity. In another embodiment, the polyamide grains may also be in suspended form.
In another variant of the process, the phosphonate-containing flame retardant is mixed with a, preferably molten, polyamide through incorporation by compounding, and the resultant flame-retardant-containing polyamide is processed by (low-temperature) grinding or reprecipitation to give laser sintering powder. The compounding process usually gives pellets which are then processed to give polymer powder. This conversion process may take place via milling or reprecipitation, for example. The process variant in which the flame retardant is incorporated by compounding has the advantage, when compared with the pure mixing process, of achieving more homogenous distribution of the phosphonate-containing flame retardant in the polymer powder.
In this instance, a suitable flow aid will be added to the precipitated or low-temperature-ground powder to improve flow behavior, examples being fumed aluminum oxide, fumed silicon dioxide, or fumed titanium dioxide.
In another preferred process variant, the phosphonate-containing flame retardant is admixed with an ethanolic solution of the polymer before the process of precipitation of the polymer has been completed. By way of example, DE 3510687 and DE 2906647 describe this precipitation process. This process may be used by way of example to precipitate nylon-12 from an ethanolic solution via controlled cooling, following a suitable temperature profile. Reference is made to DE 3510687 or DE 2906647 for a detailed description of the precipitation process.
The person skilled in the art may use this process variant in a modified form for a broad range of polymers, polymer and solvent being selected here in such a way that the polymer dissolves in the solvent at an elevated temperature, and that the polymer precipitates from the solvent at a lower temperature and/or on removal of the solvent. The corresponding laser sintering polymer powders of the invention are obtained by adding phosphonate-containing flame retardant to this solution, and then drying.
The phosphonate-containing flame retardant used may preferably comprise a phosphonate containing cyclic ester structures, e.g. Antiblaze 1045®, this being a commercially available product which can be purchased from Rhodia.
To improve processibility, or for further modification of the polymer powder, this may receive additions of inorganic color pigments, e.g. transition metal oxides, stabilizers, e.g. phenols, in particular sterically hindered phenols, flow aids, e.g. fumed silicas, or else filler particles. The amount of these substances added to the polymer powder, based on the total weight of components in the polymer powder, is preferably such as to comply with the concentrations stated for fillers and/or auxiliaries for the polymer powder of the invention.
The present invention also provides processes for producing moldings by selective laser sintering, by using polymer powders of the invention, which comprise polymers and phosphonate-containing flame retardants. The present invention in particular provides a process for producing moldings by a layer-by-layer process which selectively melts or selectively binds parts of a phosphonate-containing precipitation powder based on a nylon-12 whose melting point is from 185 to 189° C., whose enthalpy of fusion is 112±17 J/g, and whose freezing point is from 136 to 145° C., the use of which is described in U.S. Pat. No. 6,245,281.
These processes are well-known, and are based on the selective sintering of polymer particles, layers of polymer particles being briefly exposed to laser light with resultant binding between the polymer particles exposed to the laser light. Three-dimensional objects are produced by successive sintering of layers of polymer particles. By way of example, details of the selective laser sintering process are found in the publications U.S. Pat. No. 6,136,948 and WO 96/06881.
The moldings of the invention, produced by selective laser sintering, comprise a phosphonate-containing flame retardant and polymer. The moldings of the invention preferably comprise at least one polyamide which contains at least 8 carbon atoms per carbonamide group. Moldings of the invention very particularly preferably comprise at least one nylon-6,12, nylon-11, and/or one nylon-12, and at least one phosphonate-containing flame retardant.
Other processes with good suitability are the SIB process, as described in WO 01/38061, or a process as described in EP 1015214. The two processes operate using infrared heating over an area to melt the powder, and selectivity is achieved in the first process by applying an inhibitor, and in the second process by way of a mask. Another process which has found wide acceptance in the market is 3D printing, as in EP 0431924, where the moldings are produced by curing of a binder applied selectively to the powder layer. Another process is described in DE 10311438, in which the energy required for melting is introduced by way of a microwave generator, and selectivity is achieved by applying a susceptor.
For these processes, use may be made of pulverulent substrates, in particular polymers or copolymers, preferably selected from polyester, polyvinyl chloride, polyacetal, polypropylene, polyethylene, polystyrene, polycarbonate, poly(N-methylmethacrylimide) (PMMI), polymethyl methacrylate (PMMA), ionomer, polyamide, copolyester, copolyamides, terpolymers, acrylonitrile-butadiene-styrene copolymers (ABS), or a mixture of these.
The flame retardant present in the molding of the invention is preferably a cyclic organic phosphonate containing ester structures. It contains from 10 to 25% of phosphorus, particularly preferably from 18 to 22%. An example of a flame retardant of this type is Antiblaze 1045 from Rhodia.
The molding of the invention preferably comprises, based on the entirety of the components present in the molding, from 1 to 50% by weight of phosphonate-based flame retardants, preferably from 5 to 30% by weight, particularly preferably from 8 to 20% by weight, and very particularly preferably from 10 to 12% by weight.
The moldings may also comprise fillers and/or auxiliaries, e.g. heat stabilizers and/or antioxidants, e.g. sterically hindered phenol derivatives. Examples of fillers are glass particles, ceramic particles, and also metal particles, e.g. iron shot, or corresponding hollow beads. The moldings of the invention preferably comprise glass particles, very particularly preferably glass beads. Moldings of the invention preferably comprise less than 3% by weight, with preference from 0.001 to 2% by weight, and very particularly preferably from 0.05 to 1% by weight, of these auxiliaries, based on the entirety of the components present. Moldings of the invention also preferably comprise less than 75% by weight, with preference from 0.001 to 70% by weight, particularly preferably from 0.05 to 50% by weight, and very particularly preferably from 0.5 to 25% by weight, of these fillers, based on the entirety of the components present.
The examples below are intended to describe the polymer powder of the invention and its use, without restricting the invention to the examples.
The BET surface area determination carried out in the examples below complied with DIN 66131. Bulk density was determined using an apparatus to DIN 53466. A Malvern Mastersizer S, version 2.18, was used to obtain the laser scattering values.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only, and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
Incorporation of Antiblaze™ 1045 by Reprecipitation.
40 kg of unregulated PA 12 prepared by hydrolytic polymerization (the preparation of this type of polyamide being described by way of example in DE 2152194, DE 2545267, or DE 3510690) with a relative solution viscosity η rel. of 1.61 (in acidified m-cresol) and with an end group content of 72 mmol/kg COOH and 68 mmol/kg NH2 are heated to 145° C. with 0.3 kg of IRGANOX® 1098 and 4.44 kg of Antiblaze™ 1045, and also 350 L of ethanol, denatured with 2-butanone and 1% water content, within 5 hours in a 0.8 m 3 stirred tank (diameter=90 cm, height=170 cm), and held for 1 hour at this temperature, with stirring (blade stirrer, diameter=42 cm, rotation rate=91 rpm). The jacket temperature was then reduced to 120° C., and the internal temperature was brought to 120° C. at a cooling rate of 45 K/h, at the same stirrer rotation rate. From this juncture onward, with the same cooling rate, the jacket temperature was maintained below the internal temperature by from 2 K to 3 K. Using the same cooling rate, the internal temperature was decreased to 117° C., and was then held constant for 60 minutes. The internal temperature was then brought to 111° C., using a cooling rate of 40 K/h. At this temperature, the precipitation began and was detectable through evolution of heat. After 25 minutes, the internal temperature decreased, indicating the end of the precipitation. The suspension is cooled to 75° C. and then transferred to a paddle drier. The ethanol is removed therefrom by distillation at 70° C. and 400 mbar with the stirrer system running, and the residue was then further dried at 20 mbar and 85° C. for 3 hours. A sieve analysis was carried out on the resultant product and gave the following result.
TABLE 1
Sieve analysis of product
produced in Example 1
Particle Size, μm
% by wt.
<32 μm:
8%
<40 μm:
17%
<50 μm:
46%
<63 μm:
85%
<80 μm:
95%
<100 μm:
100%
BET: 6.8 m 2 /g
Bulk density: 430 g/L
Laser diffraction: d(10%): 44 μm, d(50%): 69 μm, d(90%): 97 μm.
Example 2
Incorporation of Antiblaze™ 1045 by Compounding and Reprecipitation
40 kg of regulated PA 12 (L1600) prepared by hydrolytic polymerization, with a relative solution viscosity η rel. of 1.61 (in acidified m-cresol) and with an end group content of 106 mmol/kg of COOH and 8 mmol/kg of NH 2 are extruded at 225° C. in a twin-screw compounder (Bersttorf ZE 25) with 0.3 kg of IRGANOX® 245 and 4.44 kg of Antiblaze® 1045, and strand-pelletized. This compounded material was then heated with 350 L of ethanol, denatured with 2-butanone and 1% water content, within 5 hours in a 0.8 m 3 stirred tank (diameter=90 cm, height=170 cm), and held for 1 hour at this temperature, with stirring (blade stirrer, diameter=42 cm, rotation rate=91 rpm). The jacket temperature was then reduced to 120° C., and the internal temperature was brought to 120° C. at a cooling rate of 45 K/h, at the same stirrer rotation rate. From this juncture onward, with the same cooling rate, the jacket temperature was maintained below the internal temperature by from 2 K to 3 K. Using the same cooling rate, the internal temperature was decreased to 117° C., and then held constant for 60 minutes. The internal temperature was then decreased to 111° C., using a cooling rate of 40 K/h. At this temperature, the precipitation began and was detectable through evolution of heat. After 25 minutes, the internal temperature decreased, indicating the end of the precipitation. The suspension was cooled to 75° C. and then transferred to a paddle drier. The ethanol was removed therefrom by distillation at 70° C. and 400 mbar with the stirrer system running, and the residue was then further dried at 20 mbar and 85° C. for 3 hours. A sieve analysis was carried out on the resultant product and gave the following result:
BET: 7.3 m 2 /g Bulk density: 418 g/L Laser diffraction: d(10%): 36 μm, d(50%): 59 μm, d(90%): 78 μm.
Example 3
Incorporation of Antiblaze™ 1045 in Ethanolic Suspension
The procedure is as described in Example 1, but the flame retardant was not added initially, but 4.44 kg of Antiblaze™ 1045 were added at 75° C. only after the precipitation of the freshly precipitated suspension in the paddle drier. Drying and further work-up takes place as described in Example 1.
BET: 5.3 m 2 /g Bulk density: 433 g/L Laser diffraction: d(10%): 40 μm, d(50%): 61 μm, d(90%): 79 μm.
Example 4
Incorporation of Antiblaze™ 1045 in Ethanolic Suspension
The procedure is as described in Example 3, but 4.7 kg of Antiblaze™ 1045 were added at 75° C. to the freshly precipitated suspension in the paddle drier, and drying was completed as described in Example 1.
BET: 5.1 m 2 /g Bulk density: 422 g/L Laser diffraction: d(10%): 45 μm, d(50%): 65 μm, d(90%): 84 μm.
Example 5
Incorporation of Antiblaze™ 1045 in Ethanolic Suspension
The procedure is as described in Example 3, but 4.21 kg of Antiblaze™ 1045 were added at 75° C. to the freshly precipitated suspension in the paddle drier, and drying was completed as described in Example 1.
BET: 5.6 m 2 /g Bulk density: 437 g/L Laser diffraction: d(10%): 42 μm, d(50%): 55 μm, d(90%): 81 μm.
Example 6
Incorporation of Antiblaze™ 1045 within a Dry Blend
4444 g of (10% by weight) of Antiblaze™ 1045 were mixed in a dry-blend process utilizing a Schugi Flexomix mixer at 3000 rpm with 40 kg of nylon-12 powder produced as in DE 2906647 with a median grain diameter d 50 of 53 μm (laser diffraction) and with a bulk density to DIN 53466 of 443 g/L. This is a vertical tube of diameter 100 mm in which there is a moving rotor with spray nozzles. For this process, it is preferable to heat the flame-retardant additive in order to reduce the viscosity.
Example 7
Incorporation of Antiblaze™ 1045 within a Dry Blend
4444 g of (10% by weight) of Antiblaze™ 1045 were mixed in a dry-blend process utilizing a Schugi Flexomix mixer at 3000 rpm with 40 kg of copolyamide powder (Vestamelt 470) prepared as in DE 2906647 with a median grain diameter d 50 of 78 μm (laser diffraction) and with a bulk density to DIN 53466 of 423 g/L. This is a vertical tube of diameter 100 mm in which there is a moving rotor with spray nozzles. For this process, it is preferable to heat the flame-retardant additive in order to reduce the viscosity.
BET: 2.2 m 2 /g Bulk density: 423 g/L Laser diffraction: d(10%): 38 μm, d(50%): 78 μm, d(90%): 122 μm.
Comparative Example 1
40 kg of unregulated PA 12 prepared by hydrolytic polymerization, with a relative solution viscosity η rel. of 1.61 (in acidified m-cresol) and with an end group content of 72 mmol/kg of COOH and 68 mmol/kg of NH 2 were brought to 145° C. with 0.3 kg of IRGANOX® 1098 in 350 ml of ethanol, denatured with 2-butanone and 1% water content, within a period of 5 hours in a 0.8 m 3 stirred tank (diameter=90 cm, height=170 cm), and held for 1 hour at this temperature, with stirring (blade stirrer, diameter=42 cm, rotation rate=91 rpm). The jacket temperature was then reduced to 120° C., and the internal temperature was brought to 120° C. at a cooling rate of 45 K/h, at the same stirrer rotation rate. From this juncture onward, with the same cooling rate, the jacket temperature was maintained below the internal temperature by from 2 K to 3 K. Using the same cooling rate, the internal temperature was decreased to 117° C., and then held constant for 60 minutes. The internal temperature was then decreased to 111° C., using a cooling rate of 40 K/h. At this temperature, the precipitation began and was detectable through evolution of heat. After 25 minutes, the internal temperature fell, indicating the end of the precipitation. The suspension was cooled to 75° C. and then transferred to a paddle drier. The ethanol was removed therefrom by distillation at 70° C. and 400 mbar with the stirrer system running, and the residue was then further dried at 20 mbar and 85° C. for 3 hours.
BET: 6.9 m 2 /g Bulk density: 429 g/L Laser diffraction: d(10%): 42 μm, d(50%): 69 μm, d(90%): 91 μm.
Further Processing
All of the specimens from Examples 1 to 7 were treated for 1 minute with 0.1% by weight of Aerosil 200 in a CM50 D Mixaco mixer, at 150 rpm. These powders were then used on an EOSINT P360 laser sintering system to construct dumbbell specimens to ISO 3167, and also fire-protection test specimens of 80×3.2×10 mm (length×width×height). A tensile test to EN ISO 527 was used to determine (Table 2) mechanical values on the components. Density was determined by a simplified internal method. For this, the tensiles produced to ISO 3167 (multipurpose test specimen) were measured, and from these measurements the volume was calculated, the weight of the tensile specimens was determined and density was calculated from volume and weight.
TABLE 2
UL ® Classification of the Specimens from Examples 1-7
Parts composed from
powders produced as
described in
UL
Modulus of
Thickness,
Example No.
Classification
elasticity, N/mm 2
mm
Example 1 a
V-0
1588
3.9
Example 2 b
V-0
1711
4.0
Example 3 c
V-0
1501
4.0
Example 4 d
V-0
1454
4.1
Example 5 e
V-2
1673
3.7
Example 6 f
V-0
1632
3.9
Example 7 g
V-0
1207
3.8
Comparative Example 1
Unclassified
1601
3.6
a Reprecipitation.
b Compounding and reprecipitation or milling.
c Suspension 10%.
d Suspension 15%.
e Suspension 5%.
f Dry Blend, Copolyamide.
As can be seen in Table 2, the incorporation of phosphonate-containing flame retardant by mixing achieves the improvement described in the following. Starting at a concentration of 10% of the phosphonate-containing flame retardant, a UL® V-0 classification is achieved. The components become only slightly thicker, but this can be corrected by reducing the amount of energy introduced by the laser.
The priority document of the present application, DE Application 10334497.7, filed Jul. 29, 2003, is incorporated herein by reference.
Obviously, numerous modifications and variations on the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | The present invention relates to a polymer powder composed of polyamide or of copolyamides, which also comprises flame retardant, in particular phosphonates, to a layer-by-layer process which selectively melts regions or selectively binds them, and also to moldings produced from this polymer powder. Compared with conventional products, the moldings constructed using the powder of the invention exhibit marked advantages in flammability and combustibility and drop behavior, particularly with respect to UL® (Underwriters Laboratories) classification. Furthermore, moldings produced from polymer powder of the invention have adequately good mechanical properties when compared with moldings based on polymer powders without flame retardant, in particular in terms of modulus of elasticity and tensile strain at break. In addition, these moldings also have a density close to that of injection moldings. | 1 |
[0001] This invention relates to improvements in biodegradable polymeric products particularly injection mouldable starch based polymers.
BACKGROUND OF THE INVENTION
[0002] There is an increasing demand for many plastic products to be biodegradable. One product that has been the subject of attention is the tampon applicator which conveniently should be water flushable water dispersible and biodegradable. Difficulties have been encountered in producing starch based polymers particularly for injection moulding. The molecular structure of the starch is adversely affected by the shear stresses and temperature conditions needed to plasticise the starch and pass it through the extrusion die. For most products foaming has to be avoided and this generally requires attention because of the water content of the starch. Foaming has been avoided by degassing the melt prior to exiting the die as suggested in U.S. Pat. Nos. 5,314,754 and 5,316,578. The latter patent also avoids adding water to the starch. As explained in U.S. Pat. No. 5,56,9692 by not drying starch and avoiding the addition of water the starch can be processed at temperatures between 120° C. and 170° C. because the water bound to the starch does not generate a vapour pressure such as to require high pressures.
[0003] Another approach to improving the melt processability of starch is to provide an additive as in U.S. Pat. No. 5,362,777 which reduces the melting point of the starch. The additive is selected from dimethyl sulfoxide, a selection of polyols and amino or amide compounds.
[0004] U.S. Pat. No. 5,043,196 discloses a high amylose starch for injection moulding.
[0005] U.S. Pat. No. 5,162,392 to an injection moldable corn starch and LDPE biodegradable polymer.
[0006] In order to produce starch polymers for particular applications they have been blended with a range of other polymers. Biodegradable blown films are disclosed in U.S. Pat. Nos. 5,322,866 which blends raw starch, polyvinyl alcohol and talc with glycerol and water. U.S. Pat. No. 5,449,708 discloses compositions of starch ethylene acrylic acid and a salt of stearic acid plus a glycerol based lubricant. Flexible and clear transparent sheets are disclosed in U.S. Pat. No. 5,374,304. These are composed of a high amylose starch and a glycerol plasticizer. The use of starch in conjunction with high amylose or modified starches has also been proposed. U.S. Pat. Nos. 5,314,754, and 5,316,578 both suggest the use of modified starches including hydroxypropyl substituted starches. Hydroxypropylation reportedly increases elongation at break and burst strength and improved resilience in the polymers.
[0007] Patent WO00/36006 discloses biodegradable water soluble formulations using a major amount of modified starch and a minor amount of a water soluble poly vinyl alcohol. These formulations are thermo formable but there are no examples of injection mouldable compositions.
[0008] Biodegradable tampon applicators are the subject of a number of patents.
[0009] U.S. Pat. No. 5,759,569 discloses trans polyisoprene as biodegradable polymer for diaper top sheets and tampon applicators.
[0010] Patent applications 2003/0036721 and 2003/0040695 relate to flushable tampon applicators comprised of polyethylene oxides and other components.
[0011] U.S. Pat. No. 5,002,526 discloses a polyvinyl alcohol tampon applicator.
[0012] U.S. Pat. No. 5,350,354 discloses a tampon applicator composed of starch or modified starch, at least 5% of a plasticizer such as glycerol and water.
[0013] U.S. Pat. No. 5,804,653 to a moldable polyvinyl alcohol composition for tampon applicators.
[0014] It is an object of this invention to provide an injection mouldable biodegradable polymer which can be processed have acceptable properties for intended uses such as tampon applicators.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The present invention provides a biodegradable injection mouldable polymer having the composition on a dry weight basis of
a) from 50 to 85% by weight of a starch and/or a modified high amylose starch b) from 4 to 13% by weight of a water soluble polymer selected from polyvinyl alcohol, polyvinyl acetate and copolymers of ethylene and vinyl alcohol which have a melting point compatible with the molten state of the starch components c) from 10 to 35% by weight of a polyol plasticizer d) from 0.5% to 10% of a polyethylene oxide or polyethylene glycol e) from 0 to 1.5% by weight of a C 12-22 fatty acid or salt and f) from 0.25% to 3% of a food grade emulsifier
[0022] The compositions defined are suitable for forming injection moulded products including medical devices such as urine sample collectors and tampon applicators.
[0023] The upper limit to the content of the modified starch is determined by its cost. This component contributes structural benefits to the resulting material including good cohesive and elongational properties, good optical properties, and resistance to retrogradation. The term retrogradation has been applied to describe the return to crystallinity by the starch components during storage after the heating and cooling operations. This process is what is generically referred to as staling and explains the hardening (or stiffening) of starch-based foods during extended storage.
[0024] Hydroxypropylation helps to inhibit crystallinity. Typical modified starches include those having an hydroxyalkyl C 2-6 group or starch modified by reaction with an anhydride of a dicarboxylic acid. A preferred component is hydroxypropylated amylose. Other substituents can be hydroxyethyl or hydroxybutyl to form hydroxyether substitutions, or anhydrides such as maleic phthalic or octenyl succinic anhydride can be used to produce ester derivatives. The degree of substitution (the average number of hydroxyl groups in a unit that are substituted) is preferably 0.05 to 2. The preferred starch is a high amylose maize starch. A preferred component is a hydroxypropylated high amylose starch A939 marketed by Penford Australia. The minimum level of hydroxypropylation used is 6.0%. Typical values are 6.1 to 6.9%.
[0025] For cost savings and for property optimisation reasons one may substitute part of this starch with:
[0026] 1) Higher or lower levels of hydroxypropylation
[0027] 2) A higher level of unmodified starch. This may be possible in particular if the level of hydroxypropylation of the modified starch is increased;
[0028] 3) A starch modified with octenyl succinic anhydride (OSA), which has a higher degree of hydrophobicity. The addition of this modified starch increases water resistance with increasing degree of substitution. The acetyl linkages in the OSA starch ensure that the material retains biodegradability upon access to water and a biologically active environment.
[0029] 4) A starch co-polymer, preferably consisting of a styrene butadiene grafted with starch. This material improves impact resistance of the product.
[0030] The other starch component is any commercially available starch. This may be derived from wheat, maize, potato, rice, oat, arrowroot, and pea sources. Generally the moisture content (wet basis) is about 5 to 15%. Unmodified starch is a cheap biodegradable raw material from renewable resources that contributes to the barrier properties of the final product, therefore highly attractive for this application. However, its use is limited by the occurrence of retrogradation (crystallisation resulting in brittleness), limited optical clarity of the resulting formed products, limited film-forming properties and limited elasticity for stretching. High-amylose starch is less sensitive to retrogradation (because it is found to be predominantly associated with the crystallization of Amylopectin within the cooked starch). A preferred concentration range for unmodified starch as a fraction of the total amount of starch is 0 to 50%.
[0031] The polymer component b) of the composition is preferably compatible with starch, water soluble, biodegradable and has a low melting point compatible with the processing temperatures for starch. Polyvinyl alcohol is the preferred polymer but polymers of ethylene-vinyl alcohol, ethylene vinyl acetate or blends with polyvinyl alcohol may be used. Water solubility of the selected polymer should preferably not occur at room temperature conditions. PVOH offers a combination of excellent film forming and binder characteristics, good elasticity and aids processing of starch-based formulations. PVA (Polyvinyl Alcohol) is produced by the hydrolysis of polyvinylacetate which is made by the polymerization of vinyl acetate monomer.
[0032] The fully hydrolyzed grades contain few, if any, residual acetate groups; while partially hydrolyzed grades retain some of the residual acetate groups. Fully hydrolyzed grades dissolve in hot (200° F.) water, and remain in solution when cooled to room temperature. Preferred grades of PVOH include DuPont Elvanol 71-30 and Elvanol 70-62. Their properties are listed in Table 1.
TABLE 1 Properties of PVOH grades used in this invention Grade 71-30 70-62 Weight Average MWt 93,700 107,000-112,000 Intrinsic viscosity (mPa · s) 27-33 58.0-68.0 Hydrolysis (%) 99.0-99.8 99.4-99.8
[0033] The higher molecular weight grade appears to reduce brittleness and potentially also water sensitivity. The maximum level is mainly determined by costs. Increasing the level of PVOH significantly decreases Young's modulus. Film forming may be difficult below 6%. A preferred concentration range for injection moulding material is 6 to 13%.
[0034] The preferred plasticiser is a mixture of polyols, in particular sorbitol, and one or more other polyols particularly maltitol, glycerol, mannitol and xylitol, although erythritol, ethylene glycol and diethylene glycol are also suitable. The plasticizer plays a triple role: it provides suitable rheology for the extrusion compounding process and for the injection moulding process whilst also positively affecting the mechanical properties of the product. Cost, food-contact or skin/mucosal membrane contact are important issues in choosing the appropriate plasticizer.
[0035] Processing performance, mechanical properties and shelf life of the end product depend on the exact composition of the polyol mixture. At zero or very low water content, the plasticizer content is preferably 10% to 35%, more preferably 20%. Dependent on the type of plasticizer(s) used, the equilibrium moisture content of the injection moulded product, as measured by standard moisture balance method, is around 2-5%.
[0036] Sorbitol, Maltitol and Glycerol blends are particularly suitable for modifying the mechanical properties of the formulation, as is Xylitol and blends of Xylitol with Sorbitol and Glycerol. Sorbitol and Xylitol are particularly good humectants. However, when using Glycerol in particular below a certain threshold, an anti-plasticisation may occur, where due to the temporary increased mobility of the polymer chains due to the presence of the plasticiser, crystallisation or at least a high degree of ordering may occur causing an increased stiffness and brittleness of these formulations compared to the un-plasticised starch formulation.
[0037] Furthermore crystallisation is observed when Sorbitol is used on its own. Some polyols (Sorbitol and Glycerol in particular) may exhibit migration to the surface, where either an opaque crystalline film may form in the case of Sorbitol, or an oily film in the case of Glycerol. Blending various polyols inhibits this effect to varying degrees. Stabilisation may be enhanced with the addition of glycerol monostearate and sodium stearoyl lactylate as emulsifiers. Furthermore, synergistic effects with salt result in stronger effects on mechanical properties.
[0038] An alternative plasticiser is epoxidised linseed oil at 5% to 10%. This plasticiser, preferably stablilised with an emulsifying system aids processing but does not result in a significant further reduction in Young's modulus.
[0039] Water is present during the compounding process to ensure appropriate starch gelatinization. Excess water may be removed during compounding by means of venting or on/off line pellet drying, and may be further regulated to desired levels prior to injection moulding by means of e.g. hopper drying. The humectant properties of the selected blend of polyols will dictate the suitable and stable moisture content of the product. Depending on the polyol blend utilized, the plasticizer content is preferably 10 to 35% and the water content is 10 to 0%. For highly flexible injection moulding components the plasticizer content is preferably higher than for rigid injection moulding or sheet products.
[0040] The polyethylene oxide and polyethylene glycol alternately or together ensure that the composition is biocompatible and can be used in medical devices that have contact with mucosal tissues, including urine sample collectors and tampon applicators. The preferred polyethylene oxide is one having a molecular weight above 20,000. For medical applications the formulations must pass Cytoxicity (ISO 10993-5), Sensitisation (ISO 10993-10) and Irritation (ISO 10993.10) tests. A preferred additive is Polyethylene oxide (PEG-5000 with a Mw of 210,000) added at 0.57% or 2% instead of stearic acid results in zero lysis in the cytoxicity test and when added at 5% in addition to stearic acid at 0.57% it also results in zero lysis. Polyethylene oxide and polyethylene glycol alternately or together furthermore provide an increased water resistance to the formulation, to prevent excessive swelling which may result in delamination in particular in multi-layer structures (MLS).
[0041] The fatty acid or fatty acid salt component is preferably present in concentrations of 0.5 to 1.5%. Stearic acid is the preferred component. Sodium and potassium salts of stearic acid can also be used. Again cost can be a factor in the choice of this component but lauric, myristic, palmitic, linoleic and behenic acids are all suitable. Stearic acid is preferred as a lubricating agent because it has shown better compatibility with starches. As well as stearic acid, the salts such as calcium stearate may be used. The stearic acid appears to migrate to the surface of starch-based polymers.
[0042] It is thought that starch may form complexes with fatty acids. The starch glucopyraniside (glucose) is a six-membered ring in the “chair” configuration. The perimeter of the ring is hydrophilic, while the faces are hydrophobic. The starch chain forms a helix, with about six residues per turn. The result is a hollow cylinder with a hydrophilic outer surface and a hydrophobic inner surface. The inner space is about 4.5 Å in diameter and straight chain alkyl molecules like stearic acid can fit into it. In the same manner, the fatty acid part of emulsifiers such as GMS can form a complex with gelatinized starch, retarding starch crystallization, thereby slowing the process of staling. The amount of monoglyceride that complexes with amylose (the linear component in starch) and with amylopectin (the branched component in starch), is dependent upon the degree of saturation of the fatty acid portion of the emulsifier. Unsaturated fatty acids have a bend produced by the double bond in the fatty acid chain that limits their ability to form a complex.
[0043] Stearic acid is particularly useful as a processing aid, however in the presence of PEO or PEG it may not be necessary. The choice of appropriate processing aid is largely limited by the required resistance to delamination in MLS.
[0044] The emulsifier is preferably a food grade emulsifier and assists in maintaining the lipid and hydrophilic components homogenously dispersed in the composition. Typically the selection is dependent on the HLB (hydrophilic lipophilic balance) value. The preferred emulsifiers are selected from food grade emulsifiers with HLB numbers between 2 and 10 and include Propylene glycol monostearate, Glycerol Monoleate, Glycerol monostearate, Acetylated monoglycerides (stearate), Sorbitan monooleate, Propylene glycol monolaurate, Sorbitan monostearate, Calcium stearoxyl-2-lactylate, Glycerol monolaurate, Sorbitan monopalmitate, Soy lecithin, Diacetylated tartaric acid esters of monoglycerides, Sodium Stearoyl lactylate, Sorbitan monolaurate. Sodium Stearoyl Lactylate and Glycerol Monostearate are commonly used in starch systems.
TABLE 2 Hydrophobic/Hydrophilic Balance (HLB) Values for some Emulsifiers Emulsifier HLB Value Sodium Stearoyl Lactylate (SSL) 21.0 Polysorbate 80 (Sorbitan Monooleate) 15.4 Polysorbate 60 (Sorbitan Monostearate) 14.4 Sucrose Monostearate 12.0 Polysorbate 65 (Sorbitan Tristearate) 10.5 Diacetyl Tartaric Ester of Monoglyceride (DATEM) 9.2 Sucrose Distearate 8.9 Triglycerol Monostearate 7.2 Sorbitan Monostearate 5.9 Succinylated Monoglyceride (SMG) 5.3 Glycerol Monostearate (GMS) 3.7 Propylene Glycol Monoester (PGME) 1.8
[0045] Glycerol monostearate added at levels ranging from 1-1.5% acts as an emulsifier to stabilise mechanical properties and increase homogeneity of the blend. Sodium Stearoyl Lactylate at 0.25% to 1.5% added to a plasticiser system further stabilizes mechanical properties and increases homogeneity of the blend. Stearoyl Lactlylate (as the sodium or calcium salt) is also commonly used as a dough strengthener and may hence act as an anti-retrogradation agent. Combinations of glycerol monostearate and sodium stearoyl lactylate result in faster stabilisation of properties. The HLB value follows the additive rule and is of order 4 to 10 for a suitable mixture of SSL and GMS.
[0046] Water is added for the purpose of “gelatinising” (also called destructurising or melting) the starch into a polymeric gel structure. Water also may act like a plasticiser in the end-product in that it softens the material or reduces the modulus. The moisture contents of the material may vary at water activities or relative humidities (RH) below 30% or superior to 75%. In many applications, the local RH to which the material is exposed may reach values of up to 90%. For stable mechanical, lamination properties and for ease of processing at all temperatures, non-volatile plasticisers are preferred. Therefore some or all of the water may be dried off during or after the compounding stage and/or in the feeding stage of the subsequent injection moulding or film forming. This may be achieved with venting the extruder barrel, and/or on-line drying of the pellets. Extrusion processing of unplasticised formulations is possible with water concentrations as low as 10% and formulations with Polyol plasticisers may be dried to 0% free water before injection moulding. The preferred moisture content is the equilibrium moisture content of the formulation at the in-use RH range of the end product as determined by moisture sorption experiments. This depends on the specific composition of the formulation but is in the range of 3-12%.
[0047] For a tampon applicator a more preferred formula on a dry weight basis is
[0048] a) from 50 to 70% by weight of starch, of which 50-100% is modified
[0049] b) from 5 to 13% by weight of a water soluble polymer selected from polyvinylacetate, polyvinyl alcohol and copolymers of ethylene and vinylalcohol which have a melting point compatible with the molten state of the starch components
[0050] c) from 15 to 35% by weight of a polyol plasticizer
[0051] d) from 0.5 to 5% of a polyethylene oxide of molecular weight above 20,000
[0052] e) from 0 to 1% by weight of a C 12-22 fatty acid or salt and
[0053] f) from 0.25% to 1.5% of a food grade emulsifier
[0054] The moisture content of the tampon applicator is about 2 to 4%.
DETAILED DESCRIPTION OF THE INVENTION
[0055] In the drawings:
[0056] FIG. 1 illustrates mechanical properties as a function of the type of plasticiser;
[0057] FIG. 2 illustrates mechanical properties as a function of the amount of plasticiser;
[0058] FIG. 3 illustrates the Young's modulus as a function of amount of PVOH;
[0059] FIG. 4 illustrates the Elongation at break as a function of amount of PVOH;
[0060] FIG. 5 illustrates the equilibrium moisture content of injection moulded tensile bars as a function of granulate moisture content.
[0061] A preferred formulation will be described with reference to a preferred application of the formulation to products such as tampon applicators which need to be injection moulded in large quantities and be inexpensive, disposable by means of the waste water system (e.g. flushing), suitable for food contact or medical devices and biodegradable. Formulations meeting all these criteria are not currently available in the market.
[0062] Tampon applicators are usually made by injection moulding low density polyethylene (LDPE) in a multi cavity tool typically with more than 100 cavities.
[0063] Tampon applicators are usually a two part product comprising a barrel with an optional rounded tip consisting of flexible wings that open up when the tampon is pushed forward and an inner plunger which are assembled with the tampon and packed in flow wrap. The typical desirable mechanical properties for the polymer to be used in a tampon applicator are Young's modulus less than 400 MPa, elongation at break greater than 30% and tensile stress at break greater than 10 MPa. The applicator should not show instantaneous tackiness on contact with water and should be resistant to mould growth.
[0064] A preferred tampon applicator contains 55 to 65% of hydroxypropylated high amylose starch; 11 to 13% polyvinyl alcohol; 18 to 21% of a polyol mixture containing sorbitol, and at least two of maltitol, glycerol and xylitol; 1.5 to 2.5% of polyethylene oxide with a molecular weight in the range of 100,000 to 400,000; 0.5 to 1.5% of glycerol monostearate and sodium stearoyl lactylate; 0.7 to 0.9% of stearic acid.
[0065] Based on cost and performance considerations a suitable formulation for a tampon applicator is (on dry and wet basis):
TABLE 3 Hydroxy propylated Polyol Sodium high-amylose plasticizer Glycerol Stearic stearoyl Moisture starch mixture PVOH PEO monostearate Acid lactilate Content 63.5% 19.8% 12.7% 1.98% 0.99% 0.79% 0.25% Dry basis 62.8% 19.6% 12.6% 1.96% 0.98% 0.78% 0.25% 3% Injection moulding product 58.36% 18.2% 11.7% 1.82% 0.91% 0.73% 0.23% 10% max granulate moisture content
[0066] In this formulation the polyol composition is preferably [Sorbitol]>2[Maltitol]≧[Glycerol]. Dependent on the composition of plasticizer(s) used, the equilibrium moisture content of the injection moulded product, as measured by standard moisture balance method, is of order 2-5%, see FIG. 5 . This equilibrium is reached within 24 h, or even instantly after processing, as long as the granule moisture content is below 10%. This formulation has a Young's modulus of 165 MPa, a stress at break of 13.7 MPa, and an elongation at break of 112%.
[0067] The applicators are biodegradable and have strength and flexibility properties comparable to the non biodegradable materials currently used. The costs of production are also comparable.
[0068] The material is manufactured by means of extrusion compounding, using co- or counter-rotating twin screw or selected design single screw extruders. The preferable process is twin screw co-rotating compounding, with an extrusion pressure of at least 20 Bar and with a screw speed of at least 100 RPM. Water may be added to the process (by means of liquid injection together with the plasticisers) dependent on the level and nature of other plasticisers. Removal of water may be carried out by means of convective drying for the extrudate strands, a centrifuge and a fluidised bed for granulate, or barrel venting or both. Granulate may be obtained by means of underwater pelletising, die face cutting or strand cooling and cutting.
[0069] A suitable process involves compounding and injection moulding in tandem, where the extrudate is accumulated in a shooting pot and injected into the mould. Here the injection moulder inlet moisture content is optimised for best processing conditions and minimal shrinkage.
[0070] If required, further drying of the injection moulded parts may occur in a drying tunnel, drum, or fluidised bed.
[0071] The material may be injection moulded using conventional screw driven or injection driven processes with hot or cold runner systems. The viscosity of the formulation given above is comparable or lower than that of LDPE at shear rates typical for the injection moulding process. This means that pressures for multi-cavity processing will be comparable to the conventional process. For single-cavity injection moulding conditions for selected formulations of this invention, injection pressures are of order 50-500 Bar, barrel temperatures 90-180° C., nozzle temperature 80-120° C., mould temperature 25-90° C. The other key aspect affecting injection moulding efficiency is cycle time which is dominated by the time taken for the part to become sufficiently solidified after moulding. The low processing temperature for the formulations of this invention, and the absence of an actual molten state, results in short solidification time, hence short cycle time comparable to polyethylene. This makes the formulation suitable for high volume injection moulding operations.
CONTROL EXAMPLE
[0072] To illustrate how the formulations of this invention achieve properties specific for the application of this invention, the listed Examples are compared to a Control example which is a biodegradable starch-PVOH based material suitable for thermoforming applications, described in patent specification WO00/36006.
EXAMPLE 1
[0073] A formulation was developed which contained the same grades and relative proportions of starch, PVOH and stearic acid as the “Control” formulation but 23% plasticizer (on dry basis). The plasticizer system consist of a mixture of glycerol, maltitol and sorbitol in the ratios 3.3:1.5:1. In addition this formulation contains 1% of a polyethylene oxide for biocompatibility and 1.7% glycerol monostearate as emulsifier. It meets all the mechanical property requirements for the tampon applicator, as illustrated in Table 5.
EXAMPLE 2
[0074] The second formulation is identical to Example 1 with the exception of the composition of the plasticizer, which consists of glycerol, maltitol and sorbitol in ratios 4.3:1:3.5. This significantly higher sorbitol level results in a higher Young's modulus as illustrated in Table 4.
EXAMPLE 3
[0075] The Control formulation is not suitable for tampon applicators, because it fails the Cytotoxicity test required to ensure biocompatibility to the level required of a medical device class IIA. In this Example, stearic acid which is instrumental in the cytotoxicity was removed and PEO added at a level of 0.6%.
EXAMPLE 4
[0076] Also developed to verify the determining factors in cytotoxicity, this Example has a 5.5% level of PEO, whilst maintaining the same level of stearic acid as the Control formulation.
EXAMPLE 5
[0077] For comparative purposes with the Control, Example 3 and Example 4 this formulation contains no stearic acid, and a 2% level of PEO. The biocompatibility of these formulations is discussed later and tabulated in table 8. Furthermore this formulation is comparable to Example 2, except for a higher level of PVOH. The ratio PVOH to (dry) starch is 0.20 compared to a ratio of 0.11 for Example 2. This results in a significant reduction in Young's modulus, and a significant increase in elongation at break, as illustrated in FIG. 3 and FIG. 4 respectively and in Table 4.
EXAMPLE 6
[0078] This formulation is plasticized to 21% with the Glycerol, Maltitol, Sorbitol, mixture of Example 1. It contains an emulsifier system of 1% GMS and 0.28% SSL, and 0.5% PEO. It meets all the mechanical property requirements for the tampon applicator, as illustrated in Table 5.
EXAMPLE 7
[0079] This formulation is comparable to Example 1, except for a higher level of PVOH. The ratio PVOH to (dry) starch is 0.23 compared to a ratio of 0.11 for Example 1. This results in a significant reduction in Youngs modulus, and a significant increase in elongation at break, as illustrated in FIG. 3 and FIG. 4 respectively and in Table 4.
EXAMPLE 8
[0080] This formula is plasticised to 32% with the polyol mixture of Example 1. The higher level of plasticization significantly reduces the Young's modulus, the is tensile strength, and increases elongation at break dramatically. The properties are stabilized with a GMS/SSL mixture at 1% and 0.25% respectively, and cytotoxicity is overcome by 1% PEO.
EXAMPLE 9
[0081] The following three examples were developed to quantify the dependence of mechanical properties on the level of plasticizer used, illustrated in FIG. 2 and Table 4. The plasticizer polyol mixture is that of Example 1. This formula contains 14% plasticiser. The GMS/SSL emulsifier is incorporated at a 0.3%/0.1% level, PVOH at the same ratio as the Control example and no PEO is added.
EXAMPLE 10
[0082] This formula has the same PVOH/Starch ratio, and the same type and level of emulsifier, and the same type of plasticizer as Example 9, but with a plasticizer level of 23% instead of 14%. At the equilibrium 4% moisture content, the resulting tensile test bars meet all the mechanical property requirements for the tampon applicator, as illustrated in Table 5.
EXAMPLE 11
[0083] This formula has the same PVOH/Starch ratio, and the same type and level of emulsifier, and the same type of plasticizer as Example 9, but with a plasticizer level of 32%. This formulation is also comparable to Example 8, except for a lower level of PVOH. The ratio PVOH to (dry) starch is 0.11:1 compared to a ratio of 0.18 for Example 8. This results in a significant reduction in Young's modulus, and a significant increase in elongation at break, as illustrated in FIG. 3 and FIG. 4 respectively, and in Table 4.
EXAMPLE 12
[0084] The following four examples were developed to quantify the dependence of mechanical properties on the type of polyol plasticizer used, illustrated in FIG. 1 and table 4. The GMS/SSL emulsifier is incorporated at a 1%/0.25% level. The PVOH to starch ratio is 0.21, and no PEO is added. Each of the four formulas contains 35% plasticizer (on dry basis). The plasticizer polyol mixture in this formuation consists of a Glycerol, Maltitol, Sorbitol mixture with ratios 4:2:1. As discussed later and tabulated in table 6, these formulations show a different humectant behaviour, which is believed to be instrumental in the mechanical properties and their stability.
EXAMPLE 13
[0085] To compare polyol plasticizers this material contains 35% Sorbitol. Sorbitol is the strongest humectant of the three compared plasticizer systems, resulting in the lowest moisture loss measurement at 130° C. as shown in Table 6. The humectant behaviour as well as the higher melting temperature of Sorbitol results in the highest Young's modulus, as illustrated in FIG. 1 . It meets all the mechanical property requirements for the tampon applicator, as illustrated in Table 5. However, pure sorbitol exhibits a bloom effect, causing an opaque white crystalline layer on the injection moulded object surface, which may be eliminated by mixing sorbitol with minor amounts of maltitol and glycerol as in the preferred formulation of this invention.
EXAMPLE 14
[0086] To compare polyol plasticizers this material contains 35% Xylitol.
EXAMPLE 15
[0087] To compare polyol plasticizers this material contains 35% Glycerol.
[0088] Advantageous properties of this formulation that make it particularly suitable for ISO standard 10993 class 2A medical devices such as tampon applicators are:
[0089] 1. Low Youngs Modulus (<400 MPa)
[0090] The stiffness of the material may be manipulated with the level and composition of polyol plasticiser and may range from 1145 MPa for unplasticised formulations, to 10 MPa for the examples with the highest levels of plasticiser. This makes these grades suitable for a wide range of injection moulding applications.
[0091] As shown in Table 4, using a range of plasticiser systems, the Youngs modulus (of compression moulded dogbones) has been reduced significantly from the base case formulation, which only contains water as plasticizer (Test method ASTM638).
TABLE 4 Mechanical properties of plasticised formulations Young's Tensile Elongation PVOH/ Emulsifier Plasticiser system PEO Modulus strength at break starch (% wt on dry basis) (MPa) (MPa) (%) Example ratio GMS SSL Glycerol Maltitol Sorbitol Other mean (stdev) control 0.12 1145 (143) 24.8 (4.5) 29.2 (5.1) 1 0.11 1.7% 13% 6% 4% 1% 375 (12) 9.6 (0.3) 36 (10.7) 2 0.11 1.7% 11% 2.6% 9% 1% 449 (13) 10.5 (0.5) 30.1 (8.5) 5 0.20 1.1% 11% 2.6% 9% 2% 230 (16) 6.9 (0.1) 117 (7.3) 6 0.12 1.1% 0.28% 12% 5% 3.5% 0.5% 111 (6.2) 11.1 (0.8) 186 (24) 7 0.23 1.1% 13% 6% 4% 2% 53.6 (6.5) 8.8 (0.5) 284 (38) 8 0.18 0.9% 0.23% 19% 8% 6% 1% 10.6 (1.2) 4.5 (0.1) 389 (29) 9 0.11 0.3% 0.1% 8% 3.5% 2% 418 (2.3) 18.4 (0.6) 101.5 (5.1) 10 0.10 0.3% 0.1% 13% 6% 4% 103 (11) 8.1 (0.4) 105 (5.4) 11 0.11 0.3% 0.1% 18% 8% 5% 42.9 (7.6) 5.4 (0.2) 127 (7.6) 12 0.21 1.0% 0.25% 20% 10% 5% 19.3 (1.5) 6.4 (0.3) 254 (34) 13 0.21 1.0% 0.25% 35% 74.5 (5.9) 11.8 (0.2) 291 (22) 14 0.21 1.0% 0.25% Xylitol 35% 49.4 (5.5) 8.3 (0.3) 336 (20)
[0092] 2. Strain at Break (>30% )
[0093] The exensional behaviour of the material may be manipulated with the level of plasticiser and may range from 30% minimum, for unplasticised formulations, to 390% for the examples with the highest levels of plasticizer and PVOH. This makes these grades suitable for a wide range of injection moulding applications.
[0094] 3. Tensile Strength (>10 MPa)
[0095] The tensile strength of the material may be manipulated with the level of plasticiser and may range from 4.5 MPa for highly plasticised formulations to 25 MPa for the examples with low levels or zero plasticizer. Hence, grades may be prepared suitable for a wide range of injection moulding applications.
[0096] Table 5 summarises the formulations that meet all the mechanical property requirements simultaneously. Here the listed moisture contents is measured using a Perkin lemer HB43 moisture balance at 130° C. after conditioning the specimens for 40 h as per ASTM638.
TABLE 5 Formulas that meet mechanical requirements for tampon applicator Young's Tensile Elongation MC Modulus (MPa) strength (MPa) at break (%) Example (%) 1 mean (stdev) mean (stdev) mean (stdev) Example 1 3.0% 375 (12) 9.6 (0.3) 36 (10.7) Example 6 2.5% 111 (6.2) 11.1 (0.8) 186 (24) Preferred 3.3% 165 (31) 13.7 (2.6) 112 (9.5) formula Example 10 1.8% 84.9 (11) 10.2 (0.4) 232 (27) Example 13 1.4% 74.5 (5.9) 11.8 (0.2) 291 (22)
[0097] An issue with starch-based polymers has been in the past that mechanical properties alter over time, as a result of moisture loss and/or crystallisation effects. Many of the compositions developed here show sustainable, non-hardening, mechanical properties. The time required for reaching equilibrium properties depends on the drying stages in the process as well as the plasticizer and emulsifier system used, and its humectant properties. Table 6 illustrates the superior humectant properties of the plasticizer system used in Example 13 (Sorbitol) and Example 14 (Xylitol) compared to Example 12 (mixture of glycerol>maltitol>sorbitol) and Example 15 (Glycerol). The table shows the measured moisture contents by means of a halogen moisture balance at 130° C., compared to the actual water content in the compounded formulas, which were not dried for the purpose of this test.
TABLE 6 Moisture loss at 130° C. of undried granulates with different humectant composition Moisture content Measured Plasticiser in compounded moisture Example at 35% formula (%) loss (%) Example 12 Glycerol/Maltitol/ 17.58% 16.55% Sorbitol Example 13 Sorbitol 18.82% 5.53% Example 14 Xylitol 20.13% 7.83% Example 15 Glycerol 18.76% 16.72%
[0098] A combination of barrel venting and granulate drying is recommended to reach equilibrium moisture content in the injection moulded part on-line. Formulations made without granulate drying/venting show a significant hardening within the first 100 h. Any subsequent hardening would then be due to crystallisation and/or antiplasticisation effects. Formulations with the preferred polyol composition processed at the appropriate moisture contents do not show aging of mechanical properties, as shown in Table 7. Any observed changes do not follow repeatable trends across the Examples, and are most likely due to the small sample size and the experimental scale of the part manufacture.
TABLE 7 Mechanical property stability as function of storage conditions Example 9 Example 10 Example 11 Temperature 23° C. 37° C. 23° C. 37° C. Time lapse 2 months 3 weeks 2 months 3 weeks Change in 2.80 0.17 1.01 −0.49 Tensile Strength (MPa) Tensile 18% 2% 14% −13% Strength (% change) Change in 2.53 −4.12 −13.0 11.4 Elongation at Break (%) Elongation 3% −3% −11% 10% at Break (% change)
[0099] 4. Shrinkage Comparable to Conventional LDPE
[0100] Shrinkage of injection moulded tensile test bars was observed. Many formulations showed comparable or lower shrinkage than for LDPE, even before any process optimisation. Others showed higher shrinkage and would require further optimization, but shrinkage behaviour was found controllable for all grades.
Example Shrinkage (machine direction) Example 6 6.6% ± 1.3% (N = 11) Example 12 4.5% ± 0.5% (N = 40) Example 14 2.9% ± 0.4% (N = 9) Example 13 2.6% ± 0.2% (N = 10)
[0101] 5. Biodegradable
[0102] The compositions of this invention are biodegradable and compostable according to international standards, in particular EN13432:2000 for commercial composting facilities and waste water management systems. Biodegradation tests were carried out according to EN13432 requirements, in particular ISO 14855 in compost and ISO 14851 or ISO 14852 in aqueous medium. EN13432-specified disintegration tests demonstrated the required levels of disintegration in simulated conditions for commercial composting.
[0103] 6. Flushable
[0104] The compositions of this invention disintegrate substantially in simulated conditions for waste water treatment and may therefore be considered flushable. Two example materials (control formula as a 1 mm thick sheet and formula Example 5 as a 1 mm thick injection moulded part) were tested for flushability in comparison to toilet paper.
[0105] For flushability testing, a modified version of standard method CEN TC 249 WI 249510 (“Plastics—Evaluation of disposability in waste water treatment plants—Test scheme for final acceptance and specifications”) was used. Modifications to the method were: a) Sample drying was eliminated because complete drying of natural materials may change the microstructure and hence moisture sorption behaviour of the material; b) Different vessel and agitation conditions were used to better mimic the turbulent conditions experienced by flushed materials; c) The residue collected on the sieve was washed with excess water to better replicate the screening procedures at waste treatment plants. A ‘flushability factor’ was defined as the fraction of material that passes a 10 mm mesh sieve after 16 hours agitation in water.
[0106] It was found that both the Control and the formula of Example 5 achieved a flushability factor of 1.0, indicating that these materials may be considered flushable.
[0107] 7. Biocompatible
[0108] Biocompatibility testing was conducted as required for medical devices of Class 2A according to ISO standard 10993 “Biological evaluation of medical devices”. This class represents devices suitable for contact with mucosal membranes with single or multiple use or contact likely to be up to 24 h. Devices of this type must pass the following tests:
[0109] Cytotoxicity (ISO 10993-5)
[0110] With the use of cell culture techniques, these tests determine the lysis of cells (cell death), the inhibition of cell growth, and other effects on cells caused by medical devices, materials and/or their extracts. There are two methods that may be used to determine Cytotoxicity. One is the ISO Elution method, the other an Agar Overlay method. The former is a more sensitive test and was used for the evaluation of this invention.
[0111] Sensitisation (ISO 10993-10)
[0112] These tests estimate, using an appropriate model, the potential of medical devices, materials and/or their extracts for contact sensitization. These tests are appropriate because exposure or contact to even minute amounts of potential leachables can result in allergic or sensitization reactions. Sensitization tests are described in ISO 10993-10.
[0113] The formulations of this invention comply with this test.
[0114] Irritation (ISO 10993-10)
[0115] These tests estimate the irritation potential of medical devices, materials and/or their extracts, using appropriate sites for implant tissue such as skin, eye and mucosal membrane in a suitable model. Irritation tests are described in ISO 10993-10.
[0116] Biodegradable starch-PVOH material (Control) is not biocompatible, in that it fails the cytotoxicity test, likely due to the effect of stearic acid which acts as a surfactant on the exposed cells. In order to ensure biocompatibility of the formulations of this invention, polyethylene oxide (or polyethylene glycol) was added at various levels and is shown to be effective both in the presence and absence of stearic acid. Table 8 summarises the formulation Examples that were submitted to biocompatibility testing.
TABLE 8 Biocompatibility test results Stearic UPS acid (% wt PEO (% wt Cytotox- Irri- Systemic Example dry basis) dry basis) icity tation toxicity Control 0.6% 0% fail pass pass Example 3 0% 0.6% pass Not carried out Example 4 0.6% 5.5% pass Example 5 0% 2.1% pass
[0117] The Cytotoxicity test was passed by the formulation Example 3, Example 4 and Example 5 of this invention (ISO Elution method IX Minimal Essential Media Extract (MEM) which is conducted at 37° C.). Furthermore, the Irritation test, and a USP systemic toxicity test in mouse, which was suggested to us as a screening test for the Sensitisation test, was passed by the control formulation of this invention, which does not include additives intended to increase biocompatibility, therefore it was not deemed necessary to test the biocompatibilised Example 3, Example 4 and Example 5.
[0118] 8. Low Cost.
[0119] The current formulations are significantly lower in cost than any biodegradable materials that meet some of the key criteria for this application, and not inhibitively more expensive to current non biodegradable or non-flushable tampon applicators (at most a factor 2-3 compared to current LDPE prices). This kind of formulation does not experience the level of price fluctuation that oil-derived polymers do.
[0120] The combination of low Young's modulus, high elongation at break, suitable tensile strength, biocompatibility, biodegradability, flushability and injection mouldability make these formulations ideally suitable for pharmaceutical and hygiene devices such as tampon applicators.
[0121] The performance and appearance of tampon applicators are acceptable and as good as conventional non-biodegradable applicators. Whilst not qualified at this stage, the material has a softer, more natural, feel than many conventional polymers. The significant advantage of the applicators made from the composition of this invention is that disposal is much simpler, more convenient and hygienic.
[0122] From the above description and examples it can be seen that the present invention provides a biodegradable starch polymer that is comparable in price and performance characteristics to conventional non-biodegradable injection moldable polymers. Consequently tampon applicators can be just as presentable and attractive with the added benefit of being environmentally friendly.
[0123] Those skilled in the art will realize that although the present invention has been illustrated in relation to tampon applicators the injection moulding compositions of this invention can also be used for other applications by tailoring the specific composition content to the desired properties of the product. The composition may be used to mould other medical or food associated products, including cotton buds, urine collection aids, cutlery, scoops and spatulas where flushability and biodegradability are desirable. These properties also make the composition useful in products which currently represent a litter or waste management problem including toilet roll cores, toilet brush heads, clips and ties used in packaging, aesophagus clips used in meat processing, temporary sewer plugs in buildings, inert ammunition simulators, mosquito repellant buckets. | A biodegradable injection mouldable polymer having the composition a) from 50 to 85% by weight of a starch and or a modified high amylose starch b) from 4 to 13% by weight of a water soluble polymer selected from polyvinylacetate, polyvinyl alcohol and copolymers of ethylene and vinylalcohol which have a melting point compatible with the molten state of the starch components c) from 10 to 35% by weight of a polyol plasticizer d) from 0.5 to 10% of a polyethylene oxide or polyethylene glycol e) from 0 to 1.5% by weight of a C 12-22 fatty acid or salt and f) from 0.25% to 3% of a food grade emulsifier. The polymers are suitable for biodegradable, flushable tampon applicators and other medical or industrial products where flushability and bio degradability are desirable | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an internal combustion engine provided with an auxiliary combustion chamber having no intake valve and designed to effect scavenging with a stream of sucked gas.
2. Description of the Prior Art
Various methods have been proposed to eliminate toxic substances contained in the exhaust gases from internal combustion engines. One of those methods consists of burning a lean fuel-air mixture. This is a very effective method, taking advantage of the fact that burning a fuel-air mixture with a large proportion of air reduces toxic substances, especially NOx, in the exhaust gases.
Usually, lean fuel-air mixtures are not readily ignited and slowly propagate the flame, which decreases the thermal efficiency of the cycle and gives rise to the problem of after-burning. This phenomenon occurs when the caloric force of an ignition source, which sets fire to the lean fuel-air mixture, is weak. Accordingly, this problem can be solved by increasing the ignition caloric force. To realize this solution, it was proposed to provide an auxiliary combustion chamber in addition to a main combustion chamber so that a lean fuel-air mixture in the latter chamber will be ignited by the flame from the former chamber. In a typical example of this type, a relatively rich fuel-air mixture is supplied to the auxiliary combustion chamber through an intake valve fitted thereto. This relatively rich fuel-air mixture in the auxiliary combustion chamber is ignited and burnt by an ignition spark plug. The flame thus produced flows into the main combustion chamber to burn a lean fuel-air mixture therein. This method is very effective because ignition in the auxiliary combustion chamber can be readily accomplished. However, the structure of the auxiliary combustion chamber became complex, because of the necessity of providing the intake valve therefor.
There is another method that provides an auxiliary combustion chamber having no intake valve adjacent to the main combustion chamber. According to this method, a lean fuel-air mixture in the main combustion chamber is forced into the aforesaid auxiliary combustion chamber on the compression stroke and ignited by the ignition spark plug. The flame produced is sent into the main combustion chamber to burn the lean fuel-air mixture therein. This method has a shortcoming that the exhaust gases resulting from the combustion on the preceding stroke remain in the auxiliary combustion chamber, which makes it difficult to ignite the mixture on the next stroke.
To do away with this shortcoming, the inventors have previously proposed an internal combustion engine that comprises a main and auxiliary combustion chamber communicated by a plurality of passages, wherein part of the passages is directed toward a stream of sucked air in order to scavenge the auxiliary combustion chamber.
SUMMARY OF THE INVENTION
An object of this invention is to insure the scavenging of the auxiliary combustion chamber of the internal combustion engine of the above-described type by the use of the stream of sucked gas and to increase the durability of the auxiliary combustion chamber.
Another object of this invention is to provide an internal combustion engine with an auxiliary combustion chamber having no intake valve that is easy to construct by increasing the degree of freedom with which the ignition spark plug can be fitted.
The feature of this invention lies in the fact that, in an internal combustion engine that comprises a main combustion chamber, an auxiliary combustion chamber having no intake valve and positioned near the intake port in the main combustion chamber and provided with an ignition spark plug on its inside, and a plurality of passages intercommunicating the main and auxiliary combustion chambers, the passages comprise a first passage means, which comprises at least one passage, opening toward a stream of sucked gas deflected by the disc portion of an intake valve in the main combustion chamber, with the direction of flow therein intersecting at an acute angle with the interior wall of the auxiliary combustion chamber lying symmetrical with respect to the central axis thereof, and a second passage means, comprising at least one passage, opening asymmetrically to said first passage with respect to the central axis of the auxiliary combustion chamber, and the stream of sucked gas introduced through the first passage means is turned successively by the inside walls on the opposite side, at the top, and on the first passage means side of the auxiliary combustion chamber and then expelled through the second passage means flowing like the loop scavenged gas in a two-stroke cycle engine.
This invention with the above-described construction permits efficient scavenging of the auxiliary combustion chamber, increases the ease with which the fuel-air mixture is ignited, and also increases the proportion of air in the mixture. Furthermore this invention simplifies the structure of the auxiliary combustion chamber and improves its durability.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will now be described in detail, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic cross-sectional view of a conventional internal combustion engine, in which an auxiliary combustion chamber having no intake valve is scavenged with a stream of sucked gas;
FIG. 2 is a schematic cross-sectional view of an internal combustion engine according to this invention which has an auxiliary combustion chamber without an intake valve;
FIG. 3 is a front view of an auxiliary combustion chamber element separated from the cylinder;
FIG. 4 is a cross-sectional view taken along the line A--A of FIG. 3;
FIG. 5 is a front view showing an auxiliary combustion chamber element in another embodiment of this invention; and
FIG. 6 is a cross-sectional view taken along the line B--B of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, the scavenging of an auxiliary combustion chamber having no intake valve in an internal combustion engine of the known type will be described first.
Through an intake passage 5 and an intake valve 6, a lean fuel-air mixture is drawn into a main combustion chamber 4 that consists of a clearance space defined by a piston 2 fitted in a cylinder 1 and a cylinder head 3. Near an intake port 7 in the cylinder head 3 is fitted an auxiliary combustion chamber element 8 to form an auxiliary combustion chamber 9. An electrode 11 of an ignition spark plug 10 is within the auxiliary combustion chamber 9, and the auxiliary combustion chamber element 8 is formed with two passages 12 and 13 communicating the auxiliary and main combustion chambers 9 and 4. Of these two passages, the passage 12 opens toward the intake port 7 side of the auxiliary combustion chamber element 8, while the other passage 13 opens on the opposite side. Inside the auxiliary combustion chamber element 8 is provided a diaphragm 14 which approximately bisects the auxiliary combustion chamber 9. A rich fuel-air mixture supply pipe 15 is fitted inside the intake passage 5, so that one end thereof opens against that edge of the disc portion 16 of the intake valve 6 which is closer to the auxiliary combustion chamber element 8. When the intake valve 6 closes, the one end of the pipe 15 is closed by the disc portion 16 (as illustrated by a dot-dash line).
A description of the operation of the scavenging of the above-described auxiliary combustion chamber having no intake valve in the internal combustion engine of the known type will now be given.
As the internal combustion engine enters the induction stroke, the piston 2 fitted in the cylinder 1 moves downward to open the intake valve 6 and thereby draws a lean fuel-air mixture from the intake passage 5. This stream of sucked gas flows into the main combustion chamber 4 as shown by the arrow. Part of the stream P, however, is deflected by the disc portion 16 of the intake valve 6 and is drawn into the auxiliary combustion chamber 9 through the passage 12 formed in the auxiliary combustion chamber element 8. This stream P flows along the diaphragm 14 in the auxiliary combustion chamber 9 and into the main combustion chamber 4 through the other passage 13. By means of the stream of sucked gas P, the auxiliary combustion chamber 9 can be scavenged perfectly free of residual combustion gas produced on the preceding stroke. This removes the residual exhaust gas from the region at and adjacent to the electrode 11 of the ignition spark plug 10 to thereby improve its igniting function. In addition the rich fuel-air mixture from the supply pipe 15 mixes with the stream of sucked air P only. This decreases the proportion of air in the stream P and thus makes it easier to ignite in the auxiliary combustion chamber 9. On the other hand, the proportion of air in the lean fuel-air mixture drawn through the intake passage 5 can be increased, which, in turn, decreases such toxic substances in the exhaust gases as HC, CO and NOx.
With all the above-described advantages, the conventional combustion engine having the auxiliary combustion chamber without an intake valve has the following shortcomings. The auxiliary combustion chamber 9 is not thoroughly scavenged because the stream of sucked air P, turning several times in the auxiliary combustion chamber 9, suffers from a great pressure loss. If the cross-sectional areas of the passages 12 and 13 are increased to improve the efficiency of scavenging, the lean fuel-air mixture in the main combustion chamber 4 would be burnt, which in turn would decrease the flame ejected through the passages 12 and 13. Further, the diaphragm 14 is disposed in that area of the auxiliary combustion chamber 9 where the temperature becomes highest. Therefore, the diaphragm 14, molded in one piece with the auxiliary combustion chamber element 8, must be made of some highly heat-resistant, costly material. In addition, the presence of the diaphragm 14 limits the position of not only the ignition spark plug 10, but also its electrode 11, inserted in the auxiliary combustion chamber 9. This decreases the degree of freedom of construction of the engine. Also, the diaphragm 14, being superheated, causes advanced ignition in the auxiliary combustion chamber 9.
This invention improves the above-described shortcomings of the conventional internal combustion engine having the auxiliary combustion chamber without an intake valve. Embodiments of this invention will now be described with reference to FIGS. 2, 3, 4, 5 and 6.
The engine shown in FIG. 2 is similar to that shown in FIG. 1 except for the structure of the auxiliary combustion element 8. In order to simplify the description, similar parts are denoted by similar reference numerals and their detailed description is omitted.
In FIGS. 2 through 4, an auxiliary combustion chamber element 17 of this invention has a first passage 18 opening toward a stream of sucked air (shown as Q) deflected by the disc portion 16 of the intake valve 6 and second passages 19 and 20, preferably two in number, opening approximately symmetrical to the first passage 18 with respect to the central axis O of the auxiliary combustion chamber 9. The passage 18 and each of the passages 19, 20, are however disposed asymmetrically with respect to the central axis O (see FIG. 4). The passage 18 and the passages 19 and 20 are not limited in number. However, their cross-sectional areas are limited in order to make the flame of the combustion gas in the auxiliary combustion chamber 9 suitable for the combustion of a lean fuel-air mixture in the main combustion chamber 4. The auxiliary combustion chamber element 17 according to this invention does not include the diaphragm 14 formed in the conventional auxiliary combustion chamber element 8 and therefore does not present any obstacle or obstruction against the flow in the auxiliary combustion chamber 9. Also, the auxiliary combustion chamber 9 has a cylindrical shape. The passage 18 is provided at such an angle relative to the central axis O as described hereunder. The stream of sucked air Q flowing through the passage 18 intersects at an acute angle θ (FIG. 4) with the internal wall 21 of the auxiliary combustion chamber lying symmetrical to the first passage 18 with respect to the central axis O of the auxiliary combustion chamber. Also, the passage 18 must be long enough to make the stream of sucked air Q to flow in a desired direction, preferably of a length equal to 1/2 or more of its inside diameter. In this embodiment, to obtain the necessary length, the passage 18 is provided in a thicker portion 22 formed on the auxiliary combustion chamber element 17. Further, in order to raise the scavenging efficiency in the auxiliary combustion chamber 9, an opening 23 of the passage 18 in the auxiliary combustion chamber is positioned near the central axis O of the auxiliary combustion chamber, and openings 24 and 25 of the passages 19 and 20, respectively, are positioned symmetrical with respect to the longitudinal, central plane X--X along the stream Q flowing through the passage 18, with the opening 23 therebetween (see FIG. 3). The stream of sucked air Q, drawn in through the passage 18, turns inside the auxiliary combustion chamber 9, impinging successively on that side of the auxiliary combustion chamber element 17 where the passages 19 and 20 open, the top of the auxiliary combustion chamber 9, and that side of the auxiliary combustion chamber element 17 where the passage 18 opens. The stream thus deflected flows out through the passages 19 and 20, travelling along a flow path similar to a curve that is followed in effecting the loop scavenging of the two-stroke cycle engine (as illustrated by Q in FIG. 2). The passages 19 and 20 also form such an angle relative to the central axis O to discharge the deflected stream Q smoothly.
The operation of this embodiment as described above will now be described.
As the internal combustion engine enters the induction stroke, the piston 2 fitted in the cylinder 1 descends to open the intake valve 6 and thereby draws in a lean fuel-air mixture from the intake passage 5. This stream of sucked gas flows into the main combustion chamber 4 as illustrated by the arrow. Part of this sucked stream Q is deflected by the disc portion 16 of the intake valve 6 and is drawn into the auxiliary combustion chamber 9 through the passage 18 formed in the auxiliary combustion chamber element 17. This stream Q thus introduced makes a turn in the form of a loop and goes out through the passages 19 and 20. In this construction also, the rich fuel-air mixture from its supply pipe 15 mixes with said sucked stream Q only and thereby decreases the proportion of air in the auxiliary combustion chamber 9, which makes the mixture easier to ignite therein. Furthermore, this construction permits increasing the proportion of air in the lean fuel-air mixture drawn through the intake passage 5.
In the above-described embodiment, the auxiliary combustion chamber 9 is provided by fitting the auxiliary combustion chamber element 17 in the cylinder head 3. The auxiliary combustion chamber 9, however, may be integrally formed in the cylinder head 3. Also, the rich fuel-air mixture supply pipe 15 does not need to be provided in the intake passage 5. Instead, a lean fuel-air mixture may be drawn into the auxiliary combustion chamber 9 having no intake valve in order to accomplish its scavenging.
Another embodiment of the invention is shown in FIGS. 5 and 6. In this embodiment, an auxiliary combustion chamber 26, elliptical in longitudinal cross-section and circular in transverse cross-section, is provided with two ignition spark plugs 27 and 28 on its inside. The spark plug 27 is disposed at a position most remote from the passages 18, 19 and 20, whereas the spark plug 28 is provided in an internal wall 29 approximately at the center of the ellipse. According to this embodiment, the stream of sucked air Q flows smoothly, following a loop path, along the elliptical internal wall 29 of the auxiliary combustion chamber, thus improving the scavenging efficiency greatly. Also, the provision of the two ignition spark plugs makes it easier to ignite the mixture.
This invention, which is constructed and functions as described above, has several advantages which are given below. Because the stream of sucked gas drawn into the auxiliary combustion chamber makes a looping turn before being discharged therefrom, the stream flows in one direction, resulting in less pressure loss. As a consequence, the combustion gas of the preceding stroke remaining in the region at and adjacent to the electrode of the ignition spark plug can be effectively scavenged which improves the ignitability in the auxiliary combustion chamber and thereby increases the operating efficiency and reliability of internal combustion engines using lean fuel-air mixtures. The absence of unessential structure (such as the diaphragm in the known example described previously) in the auxiliary combustion chamber eliminates the possibility of overheating which thereby improves the durability of the auxiliary combustion chamber and prevents the occurrence of advanced ignition due to its partial overheating. This absence of unessential structure also increases the degree of freedom of construction with regard to the installation of the ignition spark plug or plugs. More specifically, the position of the electrode of the ignition spark plug or plugs may be selected with more relative freedom. The position of the electrodes exerts a great influence on ignitability. Therefore, it is an important advantage in constructing an engine that the position of the electrodes may be selected more freely. | An internal combustion engine having a main combustion chamber associated with intake and exhaust valves and an auxiliary combustion chamber having no intake valve. The auxiliary combustion chamber is positioned adjacent the intake port and has an electrode of a spark plug or plugs positioned therewithin. A plurality of passages fluidly communicate the main and auxiliary combustion chambers. One passage opens toward the intake valve and at least one other passage opens asymmetrically relative to the first passage about the central axis of the auxiliary combustion chamber. The auxiliary combustion chamber is free of any internal fluid flow obstructions. A stream of sucked gas introduced into the auxiliary combustion chamber through the one passage is turned by the interior walls of the auxiliary combustion chamber to flow in a path in the form of a loop and is then expelled through the other passage. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This invention claims priority pursuant to 35 U.S.C. § 119 of U.S. provisional patent application Ser. No. 60/632,564, filed on Dec. 1, 2004. This provisional application is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates generally to a system, apparatus, and method of conducting measurements of a borehole penetrating a geological formation. More particularly, the system, apparatus and/or method relates to conducting measurements of the borehole, such as borehole caliper profile and preferably while drilling.
[0003] The collection of data on downhole conditions and movement of the drilling assembly during the drilling operation is referred to as measurement-while-drilling (“MWD”) techniques. Similar techniques focusing more on the measurement of formation parameters than on movement of the drilling assembly are referred to as logging-while-drilling (“LWD”) techniques. The terms “MWD” and “LWD” are often used interchangeably, and the use of either term in the present disclosure should be understood to include the collection of formation and borehole information, as well as of data on movement of the drilling assembly. The present invention is particularly suited for use with both MWD and LWD techniques.
[0004] Measurements of the subject borehole are important in the measurement of the parameters of the formation being penetrated and in the drilling of the borehole itself. Specifically, measurements of borehole shape and size are useful in a number of logging or measurement applications. For example, it is known to measure the diameter, also known as the caliper, of a borehole to correct formation measurements that are sensitive to size or standoff.
[0005] The prior art provides wellbore caliper devices for making these borehole measurements. These devices include the wireline tools described in U.S. Pat. Nos. 3,183,600, 4,251,921, 5,565,624, and 6,560,889. For example, the '921 patent describes a wireline tool having a tool body equipped with caliper arms that can be extended outward to contact the wall of the borehole. The wireline tool employs potentiometers that are responsive to extension of the caliper arms, thereby allowing for measurement of the arms' extension. Each of the above patent publications is hereby incorporated by reference for all purposes and made a part of the present disclosure.
[0006] Indirect techniques of determining borehole diameters have also been employed. For example, acoustic devices are employed to transmit ultrasonic pressure waves toward the borehole wall, and to measure the time lag and attenuation of the wave reflected from the borehole, thereby measuring the distance between the drilling tool and the borehole wall. For more detailed description of such prior art, references may be made to U.S. Pat. Nos. 5,397,893, 5,469,736, and 5,886,303.
[0007] The prior art further includes devices that obtain indirect caliper measurements from formation evaluation (“FE”) measurements. The response of sensors is modeled with the standoff as one of the variables in the model response (along with the formation property of primary interest). This is typically done to correct the FE measurement for the effect of sensor standoff. The standoff measurement is therefore obtained indirectly and as a byproduct of the processing of the response data. Examples of such devices are discussed in U.S. Pat. Nos. 6,384,605, 6,285,026, and 6,552,334.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention, a method is provided for conducting measurements of a borehole while drilling the borehole in a geological formation. The method includes the step of providing a rotatable drilling assembly having thereon, at a forward end, a drill bit and a borehole measurement tool connected rearward of the drill bit. The measurement tool includes at least one caliper arm extendible outward from the measurement tool. The method involves drilling the borehole by operating the rotatable drilling assembly. While drilling, the wall of the borehole is contacted with at least one extendable caliper arm of the borehole measurement tool and the extension of the caliper arm contacting the borehole wall is measured, thereby determining a distance between the measurement tool and the borehole wall. The method repeats the contacting and measuring steps at multiple positions of the drilling assembly during drilling. Preferably, the drilling step includes maintaining contact between the caliper arms and the borehole wall during rotation of the drilling assembly.
[0009] Preferably, the contacting and measuring steps are performed at a plurality of angular positions of the drilling assembly, and the method further involves determining the angular orientation of the drilling assembly relative to the borehole for each measurement of the extension of the caliper arm (e.g., using a pair of magnetometers). Most preferably, the lateral position of the measurement tool in the borehole is also detected for each measurement of the extension of the caliper arm. For example, the detecting step may include measuring the lateral accelerations of the drilling assembly (e.g., using a pair of accelerometers) during drilling and deriving, from the measurements of lateral acceleration, the lateral positions of the borehole measurement tool.
[0010] In another aspect of the invention, a borehole measurement apparatus is provided in a rotatable drilling assembly for drilling a borehole penetrating a geological formation. The borehole measurement apparatus includes a support body integrated with the drilling assembly and rotatably movable therewith. The apparatus also includes at least one caliper arm (in some applications, two or more arms), that is mounted to the support body and extendable therefrom to contact the borehole wall during drilling. Furthermore, a sensor is provided and positioned proximate the caliper arm and is operable to detect the distance between the extended arm and the support body. The caliper arm preferably includes a driving element positioned to urge the caliper arm radially outward from said body. The driving element may include a spring positioned to urge the caliper arm radially outward to contact the borehole wall. Alternatively, the driving element may include a hydraulic actuator positioned to urge the caliper arm radially outward to contact the borehole wall.
[0011] Preferably, the apparatus includes a sensing device operatively associated with the body to detect the angular orientation of the support body relative to the borehole wall and a sensing device operatively associated with the support body to detect the lateral position of the support body (i.e., the measurement apparatus) relative to the borehole. In one embodiment, the sensing device includes a pair of accelerometers positioned in generally perpendicular relation on a plane generally perpendicular to the longitudinal axis of the drilling assembly. The accelerometers are positioned to detect the lateral accelerations of the support body (from which the lateral positions of the drilling assembly may be derived). In another embodiment, a pair of magnetometers is positioned to detect the orientation of the support body with respect to the earth's magnetic field. The pair of magnetometers is positioned in generally perpendicular relation on a plane that is generally perpendicular to the longitudinal axis of the support body.
[0012] In yet another aspect of the present invention, a steerable rotary drilling assembly is provided for drilling a borehole penetrating a geological formation. The drilling assembly includes a drill bit positioned on a forward end to rotatably engage the formation, and a bias unit positioned rearward of the drill bit. The bias unit is connected with the drill bit for controlling the direction of drilling of the drill bit. The bias unit further includes an elongated tool body, a plurality of movable pads affixed to the tool body and which are extendable radially outward of the tool body to maintain contact with the borehole wall during rotation of the drilling assembly, and a sensor positioned to detect the relative position of the arm during extension.
[0013] Other aspects and advantages of the invention will be apparent from the following Description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a simplified, diagrammatic section of a rotary drilling installation including a drilling assembly, according to the present invention;
[0015] FIG. 2 is an elevation view of a drilling assembly of the kind with which the present invention may be applied and in accordance with the present invention;
[0016] FIG. 3 is a simplified cross-sectional view of the drilling assembly in FIG. 2 , according to the present invention;
[0017] FIG. 4 is a simplified, cross-sectional view of an alternative borehole measuring apparatus, according to the invention; and
[0018] FIG. 5 is a simplified perspective of a section of the borehole measuring apparatus, according to the present invention.
DETAILED DESCRIPTION
[0019] FIGS. 1-5 illustrate a rotary drilling installation and/or components thereof, embodying various aspects of the invention. For purposes of the description and clarity thereof, not all features of actual implementation are described. It will be appreciated, however, that although the development of any such actual implementation might be complex and time consuming, it would nevertheless be a routine undertaking for those of ordinary skill in the relevant mechanical, geophysical, or other relevant art, upon reading the present disclosure and/or viewing the accompanying drawings.
[0020] FIG. 1 illustrates, in simplified form, a typical rotary drilling installation 100 suitable for incorporating and implementing the inventive system, apparatus, and/or method. The installation includes a drill string 102 having connected thereto, at a leading end, a drilling assembly 112 including a rotary drill bit 104 . The drill string 102 is rotatably driven from a surface platform 106 , by means generally known in the art, to penetrate an adjacent geological formation 108 . The leading drilling assembly 112 which includes the drill bit 104 , may be referred to as a bottom hole assembly (“BHA”) 112 . As the drill string 102 and the BHA 112 turn, the drill bit 104 engages and cuts the earthen formation. The bottom hole assembly 112 also includes a modulated bias unit 114 connected rearward of the drill bit 104 . As is known in the art, the bottom hole assembly 112 also includes a control unit 118 , which controls operation of the bias unit 114 (see e.g., U.S. Pat. Nos. 5,685,379 and 5,520,255). The bias unit 114 may be controlled to apply a lateral bias to the drill bit 104 in a desired direction, thereby steering the drill bit 104 and controlling the direction of drilling. The bottom hole assembly 112 further includes communications systems (e.g., telemetry equipment) for transmitting measurements and other data to the surface.
[0021] As used herein and in respect to the relative positions of the components of the bottom hole assembly 112 , the directional term “forward” shall refer to the direction or location closer to the leading end of the drilling assembly 112 where the drill bit 104 is positioned. The relative term “rearward” shall be associated with the direction away from the leading or forward end.
[0022] Now referring to FIG. 2 , a lower portion of the modulated bias unit 114 consists of an elongate support or tool body 200 . The body 200 is provided, at an upper end, with a threaded pin 202 for connecting to a drill collar incorporating the control unit 118 (which is, in turn, connected to the forward or lower end of the drill string 102 ). A lower end 204 of the body 200 is formed with a socket to receive a threaded pin with the drill bit 104 . The drilling assembly 112 of FIGS. 1 and 2 is of a rotary, steerable type operable to directionally drill a borehole 110 .
[0023] Typical rotary drilling installations, drilling assemblies, and/or bias units are further described in U.S. Pat. Nos. 5,520,255 and 5,685,379. These patent documents provide additional background that will facilitate the understanding of the present invention and the improvements provided by the invention. In one aspect of the invention, the system and apparatus, as further described below, are particularly suited for modification of the rotary steerable system described in these patents. Accordingly, these patent documents are hereby incorporated by reference and made a part of the present disclosure.
[0024] The modular bias unit 114 is equipped around its periphery and toward the lower or leading end 204 , with three equally spaced hinge pads or articulated caliper arms 208 . The arms 208 are extendible outward by operation of a hydraulic actuator, spring device, or the like. A more detailed description of a typical hydraulic actuated hinge pad is provided in U.S. Pat. No. 5,520,255. Further reference should also be made to U.S. Pat. Nos. 3,092,188 and 4,416,339. These two patents provide detailed description of hinge pad devices, which are suitable for incorporation with the inventive system and apparatus and thus, provide specific background helpful in the understanding of the present invention. Accordingly, these patent documents are also hereby incorporated by reference and made a part of the present disclosure.
[0025] The cross-section of FIG. 3 illustrates, in simplified form, the modular bias unit 114 modified to also function as a borehole measurement tool 300 according to the invention. The modular bias unit 114 is shown operating inside borehole 110 and rotating in the clockwise direction ZZ. During drilling of borehole 110 , the tool 300 contacts a circumferential wall 110 a of the borehole 110 .
[0026] For purposes of the present description, the terms “borehole measurement” and/or “conducting measurements of a borehole” or “in a borehole” refers to physical measurements of certain dimensions of the borehole. Such measurements include borehole caliper measurements and borehole shape and profile determinations.
[0027] In a preferred embodiment, the borehole measurement tool 300 employs the hinged pads as caliper arms 208 for measuring the distance between the tool 300 and the borehole wall 110 a at different angular and axial positions along the borehole wall 110 a . The measurement tool 300 may have a plurality of caliper arms 208 positioned about the outer periphery of the tool body 200 . The tool 300 of FIG. 3 employs two caliper arms 208 . Each caliper arm 208 has a partly-cylindrical curved outer surface 208 c and is pivotally supported on a support frame 214 . The support frame 214 defines a cavity in which electrical and mechanical components operably associated with the arm 208 may be disposed, including a proximity sensor or probe 220 and a thrust pad or piston 218 . Each arm 208 is hinged near a leading edge 208 a and about a hinge pin 210 supported in the frame 214 . The arm 208 is therefore, pivotally movable in the direction of rotation ZZ. The caliper arm 208 further includes a trailing edge 208 b that is pivotally extendible to make contact with the borehole wall 110 a.
[0028] The hinge pins 210 are oriented in parallel relation to a central longitudinal axis XX of the body 200 . Preferably, the caliper arm 208 is movable by a linear actuator in the form of a linear spring-driven push rod 218 . A linear spring 212 is incorporated into the push rod 218 and is positioned and preloaded to engage the caliper arm 208 proximate trailing edge 208 b and urge the arm 208 radially outward against borehole wall 110 a . The spring 212 is preloaded against a stationary body 230 , which is secured into the body 200 .
[0029] In an alternative embodiment, the spring 212 is activated by pressure within the tool 300 (i.e., when there is flow through the tool body 200 ). In this way, the springs 212 are designed to be in bias engagement with the arms 208 only when pumping flow is directed through the body 200 . In the absence of flow, the arms 208 are retracted. In other embodiments, torsional springs acting about the hinge 210 axes or leaf springs acting between the tool body and the caliper arms are used.
[0030] As illustrated in FIG. 3 , the circumference of the borehole wall 110 a may be far from being circular (round) and the central axis XX of the body 200 may deviate from the center of the borehole 110 . The spring bias maintains the trailing edge 208 b of the caliper arm 208 in contact with the circumference of the borehole wall 110 , throughout rotation of the drill string. When the caliper arm 208 encounters borehole circumferential variations while extended, the impact exerted by the borehole wall 110 a pushes the trailing edge 208 b (and the rest of the arm 208 ) to rotate back to a closed or retracted position. In this way, the caliper arm 208 tracks the borehole wall 110 a , or more particularly, the diameter variations of the borehole wall 110 a . The spring force is chosen to provide no more force than is necessary to ensure that the caliper arm 208 tracks the borehole wall 110 a . This minimizes the effect of the caliper arm 208 on the dynamics of the drilling assembly 112 .
[0031] In an alternative embodiment, wherein the inventive borehole measurement tool is incorporated with a modulated bias unit such as that described in U.S. Pat. Nos. 5,520,255 and 5,685,379, the caliper arms 208 are hydraulically operated hinge pads that, in conjunction with a control unit, also serves to steer the drill bit and thus, the drilling assembly. The unit employs a movable thrust member (e.g., a piston) and a hydraulic system for actuating the thrust member. In further embodiments, the caliper arms may be operated by a motor and coupling combination, springs, and the like.
[0032] Referring now to the simplified schematic of FIG. 5 , the caliper arms 208 are preferably affixed to the side of the body 200 at equally spaced intervals. The caliper arms 208 are positioned outwardly of the normal surface of the body 200 and are rotatable about axes that are in parallel relation with the central axis XX. As shown in FIG. 5 , the caliper arms 208 are preferably provided in a stabilizer blade or pad form with a curved outer surface.
[0033] More preferably, the unit 114 also employs kick pads 502 installed on either side (forward and rearward) of the caliper arms 208 to protect the caliper arms 208 . The kick pads 502 are preferably solid metal deflectors that are very rugged and inexpensive to replace. The kick pads may also be formed or otherwise provided integrally with the body 200 and equipped with a wear-resistant coating (that may be re-applied as necessary). The kick pads 502 function to deflect axial impact from the caliper arms 208 . Such impact may be encountered as the drilling assembly 112 treads inwardly or downwardly in the borehole 110 . Preferably, the caliper arms 208 are slightly recessed below the working surface (or radial position) of the pads 502 when fully retracted and are able to extend outwardly to contact the borehole wall 110 a even when the borehole 110 is enlarged beyond its normal size. This ensures that the caliper arms 208 maintain contact with the borehole wall 110 a , while being protected from impact and abrasion on the body 200 when the tool body 200 makes forceful contact with the borehole wall 110 a . By using blades or pads that are approximates the size of the borehole, the range of motion required of the arms 208 is minimized and the motion of the tool body 200 is restricted within the borehole 110 .
[0034] In preferred embodiments, depicted particularly in FIG. 3 , the measurement tool 300 employs a proximity probe 220 to monitor and/or measure the extension of the caliper arm 208 during travel of the tool body 200 . As shown in FIG. 3 , the proximity probe 220 may be installed adjacent the face of the tool body 200 in support frame 214 and directed toward the underside of the caliper arm 208 . The proximity probe 220 is calibrated, as is known in the art, to sense the complete range of motion of 208 , thereby obtaining the linear distance or movement of the caliper arm 208 from its rest position.
[0035] FIG. 4 illustrates, in a simplified cross-section, an alternative embodiment of the present invention, wherein like reference numerals are used to refer to like elements. In particular, a measurement tool 300 is shown operating in the same borehole 110 and rotating in the clockwise direction ZZ. The tool 400 in this variation employs three spaced apart caliper arms 208 disposed about the periphery of the tool 300 . In FIG. 4 , the borehole 110 shown has a irregular circumferential profile. Accordingly, caliper arms 208 are extended radially outward at varying extent, so as to maintain urging contact with the borehole wall 110 a.
[0036] Sensor selection, installation, and operation suitable for the present invention may be accomplished in several ways. In alternative embodiments, a linear transducer is linked to each of the caliper arms. In another embodiment, an angular transducer (e.g., a resolver or optical encoder) is placed inside the tool body and driven by the caliper arm hinge. In another embodiment, a sensor that provides a capacitance that is dependent on angle is used to measure the caliper arm 208 angles. In yet another embodiment, a linear transducer is embedded in the tool body, sealed by a bellows or pistons, and driven by a cam profile on the hinge pad or arm. In yet another embodiment, linear capacitance sensors are located between the arms and the meeting surfaces of the protective pads. In yet another embodiment, an electromagnetic signal is transmitted from an antenna embedded in a pad or blade and received by a second antenna embedded in the adjacent caliper arm (or vice-versa). A measurement of the absolute phase shift in the signal is used to determine the distance between the antennae, and therefore determine the caliper arm extension. For further understanding, reference may be made to U.S. Pat. No. 4,300,098 (herein incorporated by reference and made a part of the present disclosure).
[0037] It should be noted that each of the above methods of measuring or monitoring the position of the tool body or the caliper arm employs means that is known to one skilled in the relevant mechanical, instrumentation or geological art. Incorporation of these means into the modular bias unit or equivalent drilling tool will be apparent to one skilled in this art, upon reading and/or viewing the present disclosure.
[0038] In one method according to the invention for measuring the circumference of the borehole, the position of the tool body is assumed to be constant during rotation. As long as the bottom hole assembly is well stabilized, such an assumption is reasonably valid and the resulting measurements can be used to make a fairly accurate measurement of the borehole shape. In this method, the caliper measurements are used with simultaneous measurements of the angular orientation of the tool body. In cases where the bottom hole assembly is poorly stabilized, and is moving laterally within the borehole, it is preferred that multi-caliper arm designs are employed. Measurements from these multi-arm tools improve the quality of the measurement. In one embodiment, two diametrically opposed caliper arms are employed to directly caliper the borehole, while the bottom hole assembly rotates. This allows detection of borehole ovalization, although distortions in the derived borehole shape may still occur when the bottom hole assembly is not centralized. Accordingly, three or more arms may be employed as necessary to obtain more accurate and stable characterization of the borehole profile.
[0039] In some cases, even more accurate borehole measurements are obtained by employing a means for tracking movement of the tool body in the borehole, particularly lateral movement and deviation of the center axis XX from the center axis of the borehole. Such means is readily available and generally known to one skilled in the relevant art. In one embodiment, lateral movement (and thus the lateral position at any given time and/or borehole axial position) of the tool body 200 is tracked using a pair of accelerometers mounted generally perpendicularly to each other in a plane of the body 200 generally perpendicular to the longitudinal axis XX. The accelerometers provide measurements of the transverse or lateral acceleration of the tool body 200 . These measurements are then numerically double integrated (to obtain, first, the velocity and second, the position) to calculate the change in the position of the tool body 200 . These calculations are performed continuously throughout drilling, thereby tracking the position of the tool 300 at all times.
[0040] In addition, the angular orientation of the tool body 200 may be determined for each caliper arm extension measurements. The measurement tool 300 preferably employs a pair of magnetometers mounted in the same way (as the accelerometers) to measure the orientation of the tool body 200 with respect to the earth's magnetic field. More specifically, a pair of magnetometers are mounted generally perpendicular to one another and on a plane of the tool body that is generally perpendicular to the longitudinal axis XX. The rotation of the tool body 200 is tracked in this way.
[0041] In one embodiment, as illustrated in the cut-away section of FIG. 2 , a rod-like chassis 250 is situated near an upper portion of the bias unit 114 . The chassis 250 is preferably positioned coaxial with the central, longitudinal axis XX, and is provided with slots or cavities, in which sensors may be mounted. In this embodiment, a pair of accelerometers 260 and a pair of magnetometers 270 are mounted in suitable fashion in slots of the chassis 250 . As described above, the accelerometers 260 and magnetometers 270 are employed to determine the lateral position and angular orientation of the measurement tool 300 (for corresponding caliper arm extension movements).
[0042] When the measurements of the tool body motion (lateral position) and angular orientation are combined with measurements of the caliper arm extensions, the location of the contact point of the borehole wall may be determined in respect to an initial reference frame. Thus, as the device rotates, it traces the true shape of the borehole at that particular axial position. The shape data is preferably recorded at regular intervals and stored in tool memory, for retrieval at the surface. The quantity of stored data may be reduced by comparison to previous sets of stored shaped data and only storing the new set of data when significant deviation is detected. In the alternative, data representing only the change in shape relative to the previous measurements may be stored. Such techniques are commonly used in digital image and video compression. As a further example, borehole shape data may be communicated to the surface in compressed form by way of a telemetry system incorporated into an MWD tool that is connected to the borehole measurement tool.
[0043] While the methods, system, and apparatus of the present invention have been described as specific embodiments, it will be apparent to those skilled in the relevant mechanical, instrumentation and/or geophysical art that variations may be applied to the structures and the sequence of steps of the methods described herein without departing from the concept and scope of the invention. For example and as explained above, various aspects of the invention may be applicable to a drilling device other than the modulated bias unit or drilling assembly described herein, such as an in-line stabilizer. All such similar variations apparent to those skilled in the art are deemed to be within this concept and scope of the invention as defined by the appended claims. | A method is provided for conducting measurements of a borehole while drilling the borehole in a geological formation. First, a rotatable drilling assembly is provided that has, at a forward end, a drill bit and a borehole measurement tool connected rearward of the drill bit. The measurement tool includes at least one caliper arm extendible outward from the measurement tool. The method involves drilling the borehole by operating the rotatable drilling assembly. While drilling, the wall of the borehole is contacted with at least one extendable caliper arm of the borehole measurement tool and the extension of the caliper arm contacting the borehole wall is measured, thereby determining a distance between the measurement tool and the borehole wall. During rotation of the drilling assembly, contact is maintained between the caliper arm and the borehole wall and the measuring step is repeated at multiple positions of the drilling assembly. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a pneumatic tire. The present invention specifically relates to a pneumatic tire capable of suppressing stone trapping.
[0003] 2. Description of the Related Art
[0004] Stones are sometimes trapped within grooves that are formed on the tread area of pneumatic tires of vehicles. When the stones are trapped within the grooves, so-called “stone drilling” may occur. The stone drilling is a phenomenon that stones penetrate the bottoms of the grooves due to rolling of the pneumatic tire to cause damage to the tread area. To take care of this issue, some of the conventional pneumatic tires have protrusions in the grooves to minimize stone trapping in the grooves. Due to the provision of the protrusions, even if stones enter the grooves, the stones are ejected to the outside of the grooves by the elastic force of the protrusion.
[0005] When manufacturing pneumatic tires having protrusions in the grooves, however, the protrusions become obstacle to flow of rubber for forming the tread area inward in the tire radial direction of the protrusion. This may increase the pressure of the rubber located inward of the protrusion in the tire radial direction, and associated with this, a breaker ply located inward of the protrusion in the tire radial direction can get deformed into a wavy shape. If the breaker ply is deformed in this manner, abnormal wear may occur to the pneumatic tire due to the deformation in the breaker ply when a vehicle to which the pneumatic tires are fit travels.
[0006] Some of the conventional pneumatic tires have a configuration that makes it possible to suppress the deformation of the breaker ply when the protrusions are provided in the grooves. For example, in Japanese Patent Application Laid-Open No. S61-291203, a plurality of protrusions are provided in grooves that extend in a zigzag shape in the tire circumferential direction, and connection members for connecting the protrusions to the sidewalls of the grooves are provided in locations where the adjacent protrusions in the tire circumferential direction are provided alternately in the tire width direction. In such a structure, the rubber located inward of the protrusion in the tire radial direction can escape in the direction of a land during manufacture of the pneumatic tire. It is, therefore, possible to prevent the pressure of the rubber located inward thereof in the tire radial direction from becoming too high. Consequently, it is possible to suppress the deformation of the breaker ply located inward of the protrusion in the tire radial direction and to reduce the abnormal wear.
[0007] The protrusion provided in the groove ejects the stone entering the groove to the outside of the groove by the elastic force of the protrusion, and prevents the stone trapped within the groove from reaching the breaker ply by the volume of the protrusion. Therefore, the protrusion needs to have a predetermined height and a predetermined volume to fulfill these functions. Greater effect of suppressing stone trapping can be obtained if the height is larger or if the volume is larger. However, if the protrusion is too large, then the rubber does not satisfactorily flow into a mold for forming the protrusion, and it is difficult to discharge the air present between the mold and the rubber during manufacture of the pneumatic tire. As a result, the pneumatic tire is manufactured without obtaining a targeted shape of the protrusion, which causes failure in manufacture, i.e., occurrence of “bare” (depressed area).
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to at least partially solve the problems in the conventional technology.
[0009] According to an aspect of the present invention, a pneumatic tire having a tread area, the tread area being divided into a plurality of lands by virtue of a plurality of grooves, includes a plurality of protrusions on a bottom of each of the grooves, a height of the protrusion from the bottom of the groove in a profile of the protrusion in a circumference direction of the pneumatic tire being variable, the protrusion including at least one peak portion that protrudes away from a center of the pneumatic tire; and a connection member between the protrusion and an adjacent one of the lands, the connection member having a first end toward the land and a second end toward the peak portion, a height of the first end from the bottom of the groove being larger than that of the second end.
[0010] The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a diagram of a tread area of a pneumatic tire according to an embodiment of the present invention;
[0012] FIG. 2 is a detailed diagram of the portion A of FIG. 1 ;
[0013] FIG. 3 is a cross-section taken along the line B-B of FIG. 2 ;
[0014] FIG. 4 is a cross-section taken along the line C-C of FIG. 3 ;
[0015] FIG. 5 is a perspective view of a protrusion and a connection member;
[0016] FIG. 6 is a cross-section of the pneumatic tire for explaining a state in which a stone is trapped within a groove of the pneumatic tire;
[0017] FIG. 7 is a cross-section of the pneumatic tire for explaining how the stone shown in FIG. 6 moves;
[0018] FIG. 8 is a schematic of a mold and a tread rubber for explaining a state before the tread area is subjected to vulcanization molding;
[0019] FIG. 9 is a schematic of the mold and the tread rubber for explaining the state in which the tread area is being subjected to the vulcanization molding;
[0020] FIG. 10 is a schematic of the mold and the tread rubber for explaining the state in which the tread area is being subjected to the vulcanization molding and which is subsequent to the state shown in FIG. 9 ;
[0021] FIG. 11 is a detailed cross-section of a pneumatic tire according to another embodiment of the present invention; and
[0022] FIG. 12 is a cross-section taken along the line D-D of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Exemplary embodiments of the present invention are explained in detail below with reference to the accompanying drawings. It is to be noted that the present invention is not limited by the embodiments. Constituent elements explained in the following embodiments include those easily replaceable therewith by persons skilled in the art, or those substantially equivalent thereto. Types of pneumatic tires include a block type tread, a ribbed tread, and a ribbed-lug tread. In the following embodiments, the pneumatic tire having the block type tread will be explained as an example of the pneumatic tire.
[0024] In the embodiments, a tire width direction means a direction parallel to a rotating axis of the pneumatic tire, an inward in the tire width direction means a direction toward an equatorial plane in the tire width direction, and an outward in the tire width direction means a direction opposite to the direction toward the equatorial plane in the tire width direction. Moreover, a tire radial direction means a direction orthogonal to the rotating axis, and a tire circumferential direction indicates a direction of the tire rotating around the rotating axis.
[0025] FIG. 1 is a schematic of a tread area 10 of a pneumatic tire 1 according to an embodiment of the present invention. The tread area 10 , which is made of an elastic rubber material, is formed on an outermost side in the tire radial direction. A surface of the tread area 10 , namely, a portion of the pneumatic tire 1 contacting a surface of the road when a vehicle (not shown) on the pneumatic tires 1 runs, is formed as a tread surface 11 . A plurality of grooves 20 including those formed in predetermined directions is formed in the tread area 10 . The grooves 20 include a plurality of longitudinal grooves 21 formed in the tire circumferential direction and a plurality of lateral grooves 22 formed in the tire width direction. The tread area 10 is divided by the longitudinal grooves 21 and the lateral grooves 22 into a plurality of blocks 15 , which blocks are to serve as lands. Protrusions 30 are arranged at intervals in the grooves 20 for both the longitudinal grooves 21 and the lateral grooves 22 , respectively.
[0026] The longitudinal groove 21 and the lateral groove 22 are not necessarily formed accurately in the tire circumferential direction or the tire width direction. It suffices that each longitudinal groove 21 is formed substantially in the tire circumferential direction. Namely, the longitudinal groove 21 can be formed aslant with respect to the tire width direction, formed to be curved, or formed into a zigzag shape. It suffices that each lateral groove 22 is formed substantially in the tire width direction. Namely, the lateral groove 22 can be formed aslant with respect to the tire circumferential direction, formed to be curved, or formed into a zigzag shape.
[0027] FIG. 2 is a detailed diagram of the portion A of FIG. 1 . FIG. 3 is a cross section taken along the line B-B of FIG. 2 . FIG. 4 is a cross section taken along the line C-C of FIG. 3 . FIG. 5 is a perspective view of the protrusion 30 and a connection member 40 . The protrusion 30 made of the same rubber material as that of the tread area 10 is formed apart from the blocks 15 or from groove walls 23 of the grooves 20 . The protrusion 30 is formed to protrude outward in the tire radial direction from a groove bottom 24 of the groove 20 . The protrusion 30 is also formed so that its height is smaller than that of the block 15 , namely, smaller than a distance from the groove bottom 24 to the tread surface 11 .
[0028] The height of the protrusion 30 thus formed, from the groove bottom 24 , is changed. In other words, the protrusion 30 includes a convex portion 31 and a slope 35 . The convex portion 31 protrudes outward in the tire radial direction. The slope 35 is formed such that its height from the groove bottom 24 is getting smaller as it is farther from the convex portion 31 . The convex portion 31 has a top 32 that is the highest from the groove bottom 24 and parallel to the groove bottom 24 . The slope 35 is provided on each side of the convex portion 31 in the direction in which the groove 20 is formed. The convex portion 31 and the slopes 35 of the protrusion 30 are respectively formed to be generally rectangle when the protrusion 30 is viewed in the depth direction of the groove 20 .
[0029] The connection member 40 is formed between the protrusion 30 thus shaped and the block 15 . The connection member 40 is connected to both the convex portion 31 of the protrusion 30 and the block 15 . A connection end of the connection member 40 , which end is connected to the convex portion 31 is a convex-side end 41 , and a connection end of the connection member 40 , which end is connected to the block 15 is a block-side end 42 or a land-side end. The convex-side end 41 is connected to a block 15 -side surface of the convex portion 31 , and the block-side end 42 is connected to a protrusion 30 -side surface of the block 15 or to a portion of the groove wall 23 opposing the convex portion 31 . The block-side end 42 is formed so that its height from the groove bottom 24 is larger than that of the convex portion 31 from the groove bottom 24 .
[0030] More specifically, an outward surface 43 of the connection member 40 , which surface is located outward in the tire radial direction, is inclined with respect to the groove bottom 24 . The outward surface 43 is inclined in the direction in which it is farther from the groove bottom 24 as it directs from the convex-side end 41 toward the block-side end 42 . Alternatively, the outward surface 43 is inclined to be gradually located outward in the tire radial direction. In other words, the connection member 40 is formed so that its height from the groove bottom 24 is getting larger from the convex-side end 41 toward the block-side end 42 . Therefore, the relation between the convex portion 31 and the connection member 40 is represented by h 2 <h 1 , where h 1 is the height of the convex portion 31 from the groove bottom 24 and h 2 is the height of the connection member 40 from the groove bottom 24 . Namely, the height of any part of the connection member 40 from the groove bottom 24 is always larger than that of the convex portion 31 from the groove bottom 24 .
[0031] An inclination angle θ of the outward surface 43 with respect to the groove bottom 24 , i.e. an inclination angle θ with respect to the groove bottom 24 from the convex-side connection end 41 over the block-side end 42 is preferably in a range from 3 degrees to 45 degrees. Furthermore, a width of the connection member 40 in the direction in which the groove 20 is formed is preferably almost the same as that of the convex portion 31 in the same direction or as that of the top 32 in the same direction. Moreover, the connection member 40 is preferably formed to satisfy the relation represented by 0.05h 1 ≦W≦1.0h 1 , where h 1 is the height of the convex portion 31 from the groove bottom 24 and W is the width of the connection member 40 in the direction in which the groove 20 is formed.
[0032] FIG. 6 is a cross-section of the pneumatic tire 1 for explaining a state in which a stone 50 is trapped within the groove. FIG. 7 is cross-section of the pneumatic tire for explaining how the stone 50 shown in FIG. 6 moves. When the vehicle with the pneumatic tires 1 runs, the pneumatic tire 1 rotates while a lower part of the tread surface 11 is in contact with the road surface (not shown). At this time, the stone 50 is often present on the road surface. If the groove 20 passes through the road surface on which the stone 50 is present, the stone 50 often enters the groove 20 and is trapped within the groove 20 . If the stone 50 is trapped within the groove 20 , then the stone 50 contacts with the road surface through rotation of the pneumatic tire 1 , and is forced inward in the tire radial direction. The stone 50 forced inward in the tire radial direction contacts with the groove bottom 24 or the protrusions 30 .
[0033] When the vehicle is running, the pneumatic tire 1 rotates even in this state. Therefore, the stone 50 that is pushed out of the groove 20 due to its size which is greater than the depth of the groove 20 , that is, the stone 50 protruding from the tread surface 11 outward in the tire radial direction contacts with the road surface when the stone 50 is present on the road surface side by rotation of the pneumatic tire 1 . At this time, frictional force acts between the stone 50 in contact with the road surface and the road surface. Furthermore, because of the rotation of the pneumatic tire 1 , a force for moving the stone 50 in the opposite direction to the rotation direction of the pneumatic tire 1 in the groove 20 in the direction in which the groove 20 is formed acts on the stone 50 .
[0034] The protrusions 30 are provided at intervals in the groove 20 , and each of the protrusions 30 includes the slopes 35 . Each of the slopes 35 is formed so that its height from the groove bottom 24 is getting smaller as it is farther from the convex portion 31 . In other words, the slope 35 is formed so that its height from the groove bottom 24 is getting larger from a location apart from the convex portion 31 toward the convex portion 31 .
[0035] The protrusion 30 is made of the same rubber material as that of the tread area 10 is formed. Therefore, the protrusion 30 has an elastic force. Because of the elastic force of the protrusion 30 , if the stone 50 is to touch the protrusion 30 , the stone 50 is affected by the force that moves the stone 50 from the state in which it is trapped within the groove 20 .
[0036] When the pneumatic tire 1 rotates, the force for moving the stone 50 in the direction opposite to the rotation direction also acts on the stone 50 trapped within the groove 20 . The stone 50 , therefore, moves in the direction in which the groove 20 is formed. If the stone 50 touches the slope 35 of the protrusion 30 , the stone 50 moves along the slope 35 . Furthermore, if the moving direction of the stone 50 along the slope 35 is a moving direction from a position apart from the convex portion 31 toward the convex portion 31 , the stone 50 moves toward the top 32 of the convex portion 31 along the slope 35 . The moving direction of the stone 50 along the slope 35 is often a moving direction from a position near the convex portion 31 toward a position apart from the convex portion 31 . In the latter case, similarly to the former case, the stone 50 further moves to touch the slope 35 of the adjacent protrusion 30 because a plurality of protrusions 30 are formed at intervals in the groove 20 . The stone 50 thereby moves toward the top 32 of the convex portion 31 when moving along the slope 35 .
[0037] In either case, the stone 50 moving in the groove 20 moves in the direction in which the groove 20 is formed, and also moves outward in the tire radial direction. When the stone 50 reaches the position of the top 32 , a large part of the stone 50 is exposed from the groove 20 and a part thereof trapped within the groove 20 decreases. As a result, the stone 50 is ejected to the outside of the groove 20 . Consequently, penetration of the stone 50 into the tread area 10 such as the groove bottom 24 can be suppressed. That is, the occurrence of stone drilling can be minimized.
[0038] The movement of the stone 50 trapped within the groove 20 in the direction in which the groove 20 is formed according to the rotation of the pneumatic tire 1 occurs mainly when the stone 50 is trapped within the longitudinal groove 21 . However, if the lateral groove 22 is formed aslant or if the vehicle with the pneumatic tire 1 is in the cornering mode, i.e., taking a turn at a corner of the road, the stone 50 trapped within the lateral groove 22 sometimes moves in the direction in which the lateral groove 22 is formed due to the rotation of the pneumatic tire 1 . Therefore, whether the groove 20 trapping the stone 50 is the longitudinal groove 21 or the lateral groove 22 , the stone 50 moves in the direction in which the groove 20 is formed, and the protrusion 30 causes the stone 50 to move outward in the tire radial direction and to be ejected to the outside of the groove 20 . Consequently, penetration of the stone 50 into the tread area 10 such as the groove bottom 24 can be suppressed, and the occurrence of stone drilling can be minimized.
[0039] FIG. 8 is a schematic of a mold 60 and a tread rubber 70 for explaining a state before the tread area 10 is subjected to vulcanization molding. Part of manufacturing processes for the pneumatic tire 1 is explained below. If the tread area 10 is to be molded during manufacture of the pneumatic tire 1 , the mold 60 is used for vulcanizing the tread area 10 . The mold 60 is formed into such a shape that convex and concave portions of the tread surface 11 are reversed. More specifically, the mold 60 includes a block-part mold 61 and a groove-part mold 62 . The block-part mold 61 is of the concavely shape, which is reverse to the shape of the block 15 formed on the tread surface 11 . The groove-part mold 62 is of the convex shape, which is reverse to the shape of the groove, 20 formed in the tread area 10 . The groove-part mold 62 includes a protrusion-part mold 63 and a connection-member-part mold 64 which are of the concave shapes, which are reverse to the protrusion 30 and the connection member 40 formed convexly in the groove 20 , respectively.
[0040] The connection-member-part mold 64 is located between the protrusion-part mold 63 and the block-part mold 61 and connected to both the protrusion-part mold 63 and the block-part mold 61 . This is similar to the connection member 40 of the pneumatic tire 1 which is connected to both the protrusion 30 and the block 15 . A vent hole 65 is formed in the block-part mold 61 to communicate the block-part mold 61 with the outside of the mold 60 .
[0041] When the pneumatic tire 1 is to be vulcanized using the mold 60 thus formed, the mold 60 is situated in the outward of the tread rubber 70 in the tire radial direction. The tread rubber 70 is rubber that corresponds to the tread area 10 , and that is part of a green tire which is the pneumatic tire 1 before the vulcanization molding. At this time, the mold 60 is directed so that the block-part mold 61 , the groove-part mold 62 , the protrusion-part mold 63 , and the connection-member-part mold 64 oppose the tread rubber 70 .
[0042] FIG. 9 is a schematic of the mold 60 and the tread rubber 70 for explaining the state in which the tread area 10 is being subjected to the vulcanization molding. When the pneumatic tire 1 is to be vulcanized, pressure is applied to the green tire from the inward to the outward in the tire radial direction. As a result, the tread rubber 70 contacts with the mold 60 . The pressure is further applied to the green tire outward in the tire radial direction. The tread rubber 70 is thereby deformed to fit the shape of the mold 60 of the part opposing the tread rubber 70 . In other words, the tread rubber 70 located in the block-part mold 61 flows into the concave block-part mold 61 . Likewise, the tread rubber 70 flows into the concave protrusion-part mold 63 and the concave connection-member-part mold 64 . Conversely, the tread rubber 70 contacts with the convex groove-part mold 62 in the early stage of the vulcanization molding.
[0043] In this manner, the tread rubber 70 is pressurized against the mold 60 from the inward to the outward in the tire radial direction during the vulcanization molding. However, because the tread rubber 70 contacts with the mold 60 from its part located inward of the mold 60 in the tire radial direction, the air present between the mold 60 and the tread rubber 70 flows from the inward to the outward in the tire radial direction. For example, the tread rubber 70 flows into the protrusion-part mold 63 from the inward to the outward in the tire radial direction. The air in the protrusion-part mold 63 flows to the outward in the tire radial direction. Furthermore, the convex portion 31 is formed on the protrusion 3 and is a portion of the protrusion 30 , which portion protrudes outward in the tire radial direction. The air flowing in the tire radial direction during the vulcanization molding, therefore, flows to a portion of the protrusion-part mold 63 where the convex portion 31 is molded.
[0044] The connection-member-part mold 64 is connected to the protrusion-part mold 63 . The connection-member-part mold 64 is formed outward in the tire radial direction relative to the protrusion-part mold 63 , and connected to both the protrusion-part mold 63 and the block-part mold 61 . This is similar to the connection member 40 formed so that its height from the groove bottom 24 is larger than that of the convex portion 31 . Therefore, the tread rubber 70 flows into the protrusion-part mold 63 . The air in the protrusion-part mold 63 flowing outward in the tire radial direction thereby flows in the direction of the block-part mold 61 through the connection-member-part mold 64 .
[0045] More specifically, the connection member 40 is formed so that its height from the groove bottom 24 is getting larger from the convex-side end 41 toward the block-side end 42 . The connection-member-part mold 64 is, therefore, formed to correspond to the connection member 40 . Namely, the connection-member-part mold 64 is formed to gradually extend outward of the protrusion-part mold 63 in the tire radial direction from the protrusion-part mold 63 to the block-part mold 61 . Therefore, the air flowing between the protrusion-part mold 63 mold 64 and the tread rubber 70 easily flows from the position corresponding to the convex-side end 41 toward the position corresponding to the block-side end 42 . The air can thereby flow more surely from the 18 . direction of the protrusion-part mold 63 to the direction of the block-part mold 61 .
[0046] The air in the block-part mold 61 flows outward in the tire radial direction by the flow of the tread rubber 70 into the block-part mold 61 . Because the vent hole 65 is provided in the block-part mold 61 , the air in the block-part mold 61 flowing outward in the tire radial direction flows into the vent hole 65 , and is discharged from the vent hole 65 to the outside of the mold 60 . With this discharge, the air in the protrusion-part mold 63 flowing in the direction of the block-part mold 61 through the connection-member-part mold 64 is also discharged to the outside of the mold 60 through the vent hole 65 .
[0047] FIG. 10 is a schematic of the mold 60 and the tread rubber 70 for explaining the state in which the tread area 10 is being subjected to the vulcanization molding and which is subsequent to the state shown in FIG. 9 . The tread rubber 70 is pressed outward in the tire radial direction during the vulcanization molding of the pneumatic tire 1 as shown in FIG. 9 . The air in the protrusion-part mold 63 thereby flows in the direction of the block-part mold 61 through the connection-member-part mold 64 , while the tread rubber 70 contacts with the mold 60 from its inward part in the tire radial direction.
[0048] Therefore, during the vulcanization molding of the pneumatic tire 1 , the tread rubber 70 in the protrusion-part mold 63 contacts with the mold 60 more early than the tread rubber 70 in the connection-member-part mold 64 . Consequently, almost all of the air present between the protrusion-part mold 63 of the mold 60 and the tread rubber 70 flows in the direction of the block-part mold 61 through the connection-member-part mold 64 . Therefore, when the tread rubber 70 located in the protrusion-part mold 63 contacts with the protrusion-part mold 63 while the tread rubber 70 is continuously pressed, no air is left between the protrusion-part mold 63 and the tread rubber 70 . In addition, almost all the tread rubber 70 located in and opposing the protrusion-part mold 63 directly contacts with the protrusion-part mold 63 .
[0049] The tread rubber 70 located in the connection-member-part mold 64 contacts with the connection-member-part mold 64 after almost all the tread rubber 70 located in and opposing the protrusion-part mold 63 contacts with the protrusion-part mold 63 . At this time, almost all the air between the connection-member-part mold 64 and the tread rubber 70 flows in the direction of the block-part mold 61 because the connection-member-part mold 64 is connected to the block-part mold 61 . Therefore, when the tread rubber 70 in the connection-member-part mold 64 contacts with the connection-member-part mold 64 , no air is left between the connection-member-part mold 64 and the tread rubber 70 . In addition, almost all the tread rubber 70 located in and opposing the connection-member-part mold 64 directly contacts with the connection-member-part mold 64 .
[0050] Because the vent hole 65 is formed in the block-part mold 61 , the air present between the block-part mold 61 and the tread rubber 70 is discharged to the outside of the mold 60 through the vent hole 65 . By continuously pressing the tread rubber 70 , therefore, the air present between the block-part mold 61 and the tread rubber 70 is discharged to the outside of the mold 60 . Accordingly, when the tread rubber 70 in the block-part mold 61 contacts the block-part mold 61 , no air is left between the block-part mold 61 and the tread rubber 70 and almost all the tread rubber 70 located in and opposing the block-part mold 61 directly contacts with the block-part mold 61 .
[0051] In this manner, the pneumatic tire 1 includes the protrusion 30 provided in each of the grooves 20 of the tread area 10 and formed so that its height from the groove bottom 24 is changed. The convex portion 31 of the protrusion 30 and the block 15 are connected to each other by the connection member 40 . The connection member 40 is formed so that its height from the groove bottom 24 in the block-side end 42 is larger than that in the convex-side end 41 . During manufacture of the pneumatic tire 1 , the mold 60 for molding the tread area 10 is disposed outward of the tread rubber 70 in the tire radial direction, and the pressure is applied to the tread rubber 70 from inward to outward of the tread rubber 70 in the tire radial direction, thereby vulcanization-molding the tread area 10 . During the vulcanization molding, the air present between the tread rubber 70 and the mold 60 flows into the portion located further outward in the tire radial direction. Accordingly, the air present between the tread rubber 70 and the protrusion-part mold 63 flows into the portion of the protrusion-part mold 63 , which portion corresponds to the convex portion 31 of the protrusion 30 . Furthermore, the height of the connection member 40 from the groove bottom 24 is larger than that of the convex portion 31 . Therefore, the air present between the tread rubber 70 and the mold 60 flows from the protrusion-part mold 63 for molding the convex portion 31 to the connection-member-part mold 64 . Moreover, because of the connection of the connection-member-part mold 64 to the block-part mold 61 , the air between the connection-member-part mold 64 and the tread rubber 70 flows from the connection-member-part mold 64 to the block-part mold 61 . Furthermore, the vent hole 65 is formed in the block-part mold 61 .
[0052] With these features, during the vulcanization molding, the air between the protrusion-part mold 63 and the tread rubber 70 moves in the direction of the block-part mold 61 through the connection-member-part mold 64 , and is discharged from the vent hole 65 to the outside of the mold 60 . Therefore, the tread rubber 70 easily flows into the protrusion-part mold 63 . Consequently, even if the height of the protrusion 30 is made larger or the volume thereof is increased to ensure the capability of preventing the stone 50 from being trapped within the groove 20 when the stone 50 enters the groove 20 , that is, to ensure anti-stone-trapping capability, the tread rubber 70 can more reliably flow into the mold 60 for forming the protrusion 30 during manufacture of the pneumatic tire 1 . Therefore, it is possible to reduce failure in manufacture or so-called “occurrence of bare”, and to more surly obtain the targeted shape of the protrusion 30 . Consequently, the occurrence of bare can be reduced while the anti-stone-trapping capability is ensured.
[0053] The height of the connection member 40 from the groove bottom 24 becomes gradually larger from the convex-side end 41 toward the block-side end 42 . Therefore, when the pneumatic tire 1 is manufactured, the air between the protrusion-part mold 63 of the mold 60 and the tread rubber 70 and flowing from the protrusion-part mold 63 to the block-part mold 61 through the connection-member-part mold 64 more easily flows in the direction of the portion corresponding to the block-side end 42 which is the portion located outward in the tire radial direction. With this feature, the tread rubber 70 can more reliably flow into the protrusion-part mold 63 , which makes it possible to more surely obtain the targeted shape of the protrusion 30 . Consequently, the occurrence of bare can be more reliably reduced.
[0054] When the connection member 40 is formed so that its inclination angle θ with respect to the groove bottom 24 from the convex-side end 41 over the block-side end 42 is in the range from 3 degrees to 45 degrees, the occurrence of bare can be reduced while the anti-stone-trapping capability is more reliably ensured. More specifically, the inclination angle θ with respect to the groove bottom 24 from the convex-side end 41 over the block-side end 42 is set to 3 degrees or more, and it is thereby possible to prevent a difference in the tire radial direction between the convex portion 31 and the block-side end 42 from becoming too small. Therefore, because the block-part mold 61 side of the connection-member-part mold 64 is formed more surely outward in the tire radial direction than the protrusion-part mold 63 side thereof, the air flowing from between the protrusion-part mold 63 of the mold 60 and the tread rubber 70 to the direction of the block-part mold 61 through the connection-member-part mold 64 can more reliably flow in this direction during the vulcanization molding. With this feature, the tread rubber 70 can more surely flow into the protrusion-part mold 63 , thus more reliably obtaining the targeted shape of the protrusion 30 .
[0055] The inclination angle θ with respect to the groove bottom 24 from the convex-side end 41 over the block-side end 42 is set to 45 degrees or less. It is thereby possible to prevent the rigidity of the connection member 40 from becoming too high, and associated with this, the rigidity of the protrusion 30 connected to the connection member 40 can be prevented from being too high. With this feature, the protrusion 30 is formed to be elastic, and this allows the ejection action on the stone 50 by the elastic force of the protrusion 30 to be ensured, and the anti-stone-trapping capability can thereby be ensured. Therefore, by forming the connection member 40 so that its inclination angle θ with respect to the groove bottom 24 is in the range from 3 degrees to 45 degrees, the targeted shape of the protrusion 30 can be more surely obtained, and the stone 50 , which has entered the groove 20 , can be more reliably ejected. Consequently, the occurrence of bare can be reduced while the anti-stone-trapping capability is more surely ensured.
[0056] When the connection member 40 is formed so that the relation between the height h 1 of the convex portion 31 and the width W of the connection member 40 is in the range of 0.05h 1 ≦W≦1.0h 1 , the occurrence of bare can be reduced while the anti-stone-trapping capability is more reliably ensured. More specifically, by setting the width W of the connection member 40 to be 0.05 times or more of the height h 1 of the convex portion 31 , the width of the connection member 40 can be increased to a predetermined width or more, and associated with this, the width of the connection-member-part mold 64 can be made to a predetermined width or more. This allows the air to easily flow between the connection-member-part mold 64 and the tread rubber 70 during the vulcanization molding. The air can, therefore, easily flow from the protrusion-part mold 63 to the block-part mold 61 during the vulcanization molding, and hence, the tread rubber 70 can easily flow into the protrusion-part mold 63 . It is thereby possible to more surely obtain the targeted shape of the protrusion 30 .
[0057] By setting the width W of the connection member 40 to be 1.0 time or less of the height h 1 of the convex portion 31 , the rigidity of the connection member 40 can be prevented from becoming too high, and associated with this, the rigidity of the protrusion 30 connected with the connection member 40 can be prevented from becoming too high. By so setting, the protrusion 30 can be formed to be elastic, and hence, the ejection action on the stone 50 by the elastic force of the protrusion 30 can be ensured, and the anti-stone-trapping capability can thereby be ensured. Therefore, by forming the connection member 40 so that the relation between the height h 1 of the convex portion 31 and the width W of the connection member 40 is in the range of 0.05h 1 ≦W≦1.0h 1 , the targeted shape of the protrusion 30 can surely be obtained, and the stone 50 , which has entered the groove 20 , can thereby be more reliably ejected therefrom. Consequently, the occurrence of bare can be reduced while the anti-stone-trapping capability is more surely ensured.
[0058] FIG. 11 is a detailed cross-section of a pneumatic tire according to another embodiment of the present invention. FIG. 12 is a cross-section taken along the line D-D of FIG. 11 . In the preceding embodiment, one convex portion 31 is formed in one protrusion 30 , but a plurality of convex portions 31 can be formed in one protrusion 30 . For example, as shown in FIG. 11 and FIG. 12 , in the protrusion 30 , concavity and convexity may be repeated in the tire radial direction and a plurality of convex portions 31 which are convex outward in the tire radial direction are obtained. In this case, a plurality of connection members 40 may be formed so as to connect a plurality of the convex portions 31 to blocks 15 , respectively. The convex portions 31 are formed on the protrusion 30 , which allows improvement of the anti-stone-trapping capability. In addition, by connecting the connection members 40 to the convex portions 31 , the targeted shape can be more surely obtained even if the convex portions 31 are formed in the protrusion 30 . Consequently, the occurrence of bare can be reduced while the anti-stone-trapping capability is more reliably ensured.
[0059] Although only one connection member 40 is connected to one convex portion 31 , a plurality of connection members 40 can be connected to one convex portion 31 . For example, the connection member 40 is provided from one convex portion 31 toward both of opposite groove walls 23 , and the connection members 40 can be connected to the respective groove walls 23 , i.e. the respective blocks 15 . In other words, the two blocks 15 , which include the opposite groove walls 23 , and the convex portion 31 of the protrusion 30 , which is located between these blocks 15 , can be connected to each other by the two connection members 40 . With this structure, when the vulcanization molding is carried out, the air in the protrusion-part mold 63 is allowed to flow in the directions of two block-part molds 61 through two connection-member-part molds 64 . Therefore, the tread rubber 70 can more surely flow into the protrusion-part mold 63 . Consequently, the occurrence of bare can be more reliably reduced.
[0060] Although the height of the connection member 40 is getting larger from the convex-side end 41 toward the block-side end 42 , the height of the connection member 40 from the groove bottom 24 can be changed step by step. Even if the height of the connection member 40 does not gradually change, the air between the protrusion-part mold 63 of the mold 60 and the tread rubber 70 can flow from the connection member 40 to the block-part mold 61 if the height of the connection member 40 from the groove bottom 24 is larger than that of the convex portion 31 from the groove bottom 24 . This allows the tread rubber 70 to more surely flow into the protrusion-part mold 63 . Consequently, the occurrence of bare can be more surely reduced.
[0061] Even if the height of the connection member 40 is not gradually changed, the connection member 40 is preferably formed so that its inclination angle θ with respect to the groove bottom 24 from the convex-side end 41 over the block-side end 42 is in the range from 3 degrees to 45 degrees. More specifically, even if the height of the connection member 40 is not gradually changed, the connection member 40 is preferably formed so that its inclination angle θ with respect to the groove bottom 24 is in the range from 3 degrees to 45 degrees, the inclination angle being from a portion of the convex-side end 41 located in its outside end in the tire radial direction to a portion of the block-side end 42 located in its outside end in the tire radial direction. By forming the connection member 40 so that the relation between the convex-side end 41 and the block-side end 42 falls within the range, the occurrence of bare can be reduced while the anti-stone-trapping capability is more reliably ensured.
[0062] The width of the connection member 40 in the direction in which the groove 20 is formed is almost equivalent to the width of the convex portion 31 of the protrusion 30 in the same direction as above. However, the width of the connection member 40 can be set different from the width of the convex portion 31 . Widths of the connection member 40 and the convex portion 31 can be either equal to or different from each other. If both of them are connected to each other, the air can flow from the protrusion-part mold 63 of the mold 60 to the connection-member-part mold 64 during the vulcanization molding. In addition, the tread rubber 70 can more reliably flow into the protrusion-part mold 63 . Consequently, the occurrence of bare can be more surely reduced.
[0063] As one example of the pneumatic tire 1 , the pneumatic tire 1 including the block type tread has been explained above. However, the pneumatic tire 1 to which the present invention is applied can be the pneumatic tire 1 including any one of the ribbed tread, the ribbed-lug tread, and the like other than the block type tread. Even if the pneumatic tire 1 is other than the pneumatic tire 1 including the block type tread, it suffices that the connection member 40 is formed such that its height from the groove bottom 24 is larger than the height of the convex portion 31 of the protrusion 30 from the groove bottom 24 . In addition, it suffices to form such a connection member 40 in the groove 20 , in which it is connected to both the convex portion 31 and the land, similarly to the pneumatic tire 1 including the block type tread. In this manner, if the pneumatic tire 1 is the one that the protrusion 30 and the connection member 40 made in the above manner can be formed in the groove 20 , a desired pattern can be used for the pattern shape of the tread. Even if the pneumatic tire 1 has any pattern shape, the occurrence of bare can be reduced while the anti-stone-trapping capability is ensured by forming the protrusion 30 and the connection member 40 in the groove 20 in the above manner.
[0064] Performance evaluation tests conducted on the conventional pneumatic tire and the pneumatic tire. 1 according to the embodiments of the present invention are explained below. The performance evaluation test was conducted on two items, i.e., anti-bare capability and the anti-stone-trapping capability.
[0065] The performance evaluation test was conducted using the pneumatic tire 1 of 11R22.5 size. Each test item was evaluated as follows. The anti-bare capability was evaluated by vulcanization-molding 20 pieces of pneumatic tires 1 and by determining how many pieces out of the 20 pneumatic tires 1 bare occurred to. It is assumed that if bare occurred to fewer pneumatic tires 1 , then the pneumatic tires 1 are determined more excellent in the anti-bare capability. It is also assumed that if bare occurred to two pieces or less out of the 20 pieces of the pneumatic tires 1 , then the pneumatic tires 1 are determined effective in the anti-bare capability.
[0066] The anti-stone-trapping capability was evaluated by attaching each of the pneumatic tires 1 to be tested assembled with a rim to a vehicle, performing a test run of the vehicle on a fixed course, and determining how many stones were trapped within the grooves 20 after the test run. The number of stones were evaluated using an index in which the number of stones in comparative example 1 explained later was set to 100. It is assumed that a higher index indicates more excellence in the anti-stone-trapping capability. It is also assumed that the anti-stone-trapping capability is ensured if the index is up to 95.
[0067] The pneumatic tires 1 to be tested include those according to seven examples (hereinafter, “examples 1 to 7”) of the present invention, and those according to two comparative examples (hereinafter, “comparative examples 1 and 2”). These pneumatic tires 1 were tested in the above method. Each of the pneumatic tires 1 according to the examples 1 to 7 and the comparative examples 1 and 2 includes zigzag-shaped longitudinal grooves 21 . In addition, a plurality of protrusions 30 are formed in each longitudinal groove 21 . Each of the protrusion 30 has a height from the groove bottom 24 of four millimeters, a width in the groove width direction of 2.5 millimeters, and a length in the direction, in which the longitudinal groove 21 is formed, of 40 millimeters.
[0068] Among the pneumatic tires 1 including the protrusions 30 thus formed and to be tested, the pneumatic tire 1 according to the comparative example 1 includes no connection member 40 . The pneumatic tire 1 according to comparative example 2 includes the connection member 40 . However, the relation between the height h 1 of the convex portion 31 from the groove bottom 24 and the height h 2 of the connection member 40 from the groove bottom 24 is h 2 =h 1 . The inclination angle of the outward surface 43 of the connection member 40 with respect to the groove bottom 24 is zero degree. In addition, the ratio (W/h 1 ) of the width W of the connection member 40 to the height h 1 of the convex portion 31 is 0.15.
[0069] On the other hand, according to the examples 1 to 7, the relation between the height h 1 of the convex portion 31 from the groove bottom 24 and the height h 2 of the connection member 40 from the groove bottom 24 is h 2 <h 1 . Furthermore, in the example 1, the inclination angle of the outward surface 43 of the connection member 40 with respect to the groove bottom 24 is two degrees, and the ratio (W/h 1 ) of the width W of the connection member 40 to the height h 1 of the convex portion 31 is 0.5. Likewise, in the example 2, the inclination angle is four degrees and the ratio (W/h 1 ) is 0.5. In the example 3, the inclination angle is four degrees and the ratio (W/h 1 ) is 0.05. In the example 4, the inclination angle is 15 degrees and the ratio (W/h 1 ) is 0.5. In the invention 5 , the inclination angle is 40 degrees and the ratio (W/h 1 ) is 0.5. In the example 6, the inclination angle is 50 degrees and the ratio (W/h 1 ) is 0.2. In the example 7, the inclination angle is 4 degrees and the ratio (W/h 1 ) is 1.0.
[0070] The evaluation tests were conducted on the pneumatic tires 1 according to the comparative example 1 and the comparative example 2 and according to the examples 1 to 7 using the method. Test results are shown in Table 1 to Table 2. Table 1 depicts the results of the evaluation tests conducted on the pneumatic tires 1 according to the comparative example 1 and the comparative example 2 and the pneumatic tires 1 according to the examples 1 to 3. Table 2 depicts the results of the evaluation tests conducted on the pneumatic tires 1 according to the examples 4 to 7.
TABLE 1 Com- Com- parative parative Example 1 Example 2 Example 1 Example 2 Example 3 Connection Not h2 = h1 h2 > h1 h2 > h1 h2 > h1 Member provided Inclination — 0 2 4 4 angle (°) Width of — 0.15 0.5 0.5 0.05 Connection Member (W/h1) Number of 18 9 2 0 1 occurrences of bare (/20 pieces) Anti-stone- 100 100 100 100 100 trapping capability
[0071]
TABLE 2
Example 4
Example 5
Example 6
Example 7
Connection Member
h2 > h1
h2 > h1
h2 > h1
h2 > h1
Inclination angle (°)
15
40
50
4
Width of
0.5
0.5
0.2
1.0
Connection Member
(W/h1)
Number of
0
0
0
0
occurrences of bare
(/20 pieces)
Anti-stone-trapping
100
100
97
96
capability
[0072] As clear from the test results shown in Tables 1 and 2, if the connection member 40 is not formed, the air between the tread rubber 70 and the protrusion-part mold 63 in the mold 60 could not be easily discharged during the vulcanization molding, and the tread rubber 70 does not easily flow into the protrusion-part mold 63 . Due to this, bare easily occurs (see comparative example 1). If the connection member 40 is formed but the height h 2 of the connection member 40 from the groove bottom 24 is equal to the height h 1 of the convex portion 31 of the protrusion 30 , the air between the tread rubber 70 and the protrusion-part mold 63 in the mold 60 does not easily flow in the direction of the connection-member-part mold 64 during the vulcanization molding of the pneumatic tire 1 . Easiness of flow of the tread rubber 70 into the protrusion-part mold 63 is not, therefore, much improved. As a result, it is difficult to reduce the occurrence of bare (see comparative example 2).
[0073] On the other hand, according to the examples 1 to 7, the connection member 40 is formed so that the relation between the height h 2 of the connection member 40 from the groove bottom 24 and the height h 1 of the convex portion 31 of the protrusion 30 is h 2 <h 1 . The connection member 40 is connected to the protrusion 30 . Therefore, the air between the tread rubber 70 and the protrusion-part mold 63 in the mold 60 can easily flow in the direction of the connection-member-part mold 64 during the vulcanization molding of the pneumatic tire 1 . Easiness of flow of the tread rubber 70 into the protrusion-part mold 63 can be thereby improved, thus allowing reduction in the occurrence of bare. Because of the reduction in the occurrence of bare, the targeted shape of the protrusion 30 can be obtained. It is, therefore, possible to ensure the anti-stone-trapping capability by providing the protrusions 30 in the groove 20 .
[0074] According to one aspect of the present invention, the occurrence of bare can be reduced while ensuring the anti-stone-trapping capability.
[0075] Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth. | A pneumatic tire includes a plurality of protrusions on a bottom of each of the grooves. The height of the protrusion is variable in a profile of the protrusion in a circumference direction of the pneumatic. The protrusion has at least one peak portion that protrudes away from a center of the pneumatic tire. The pneumatic tire further includes a connection member between the protrusion and an adjacent one of the lands, the connection member having a first end toward the land and a second end toward the peak portion, a height of the first end from the bottom of the groove being larger than that of the second end. | 8 |
FIELD OF THE INVENTION
The invention relates to a method for surface treatment of aluminiferous metal-containing structures with acidic conversion treatment baths. The method is particularly useful for treating the surfaces of car bodies, household electrical appliances, and the like, with phosphate conversion coating baths, chromate treatment baths, and they like. Particularly, the present invention relates to a method for reproducibly controlling the chemical activity of fluorine in conversion treatment baths.
BACKGROUND OF THE INVENTION
The addition of fluorine to acidic conversion treatment baths for treating aluminiferous metal-containing structures is well known. One example of this methodology is taught in Japanese Patent Application Sho 63-157879 (157,879/1988).
RELATED ART
The fluoride ion concentration in an aqueous solution is generally measured directly using a fluorine ion meter. Japanese Patent Application Sho 63-17879 discloses a measurement method that relates to phosphate conversion treatment solutions. In the disclosed method, the fluoride ion concentration in a sample is measured after calibration of the fluorine ion electrode with fluorine reference solutions of known fluorine ion concentration. Using the fluoride ion concentration calculated based on the results of this measurement the phosphate conversion treatment is operated by adjusting the bath components to maintain the fluoride ion concentration within a specified range.
A chromate conversion treatment wherein the fluoride ion concentration is maintained within a prescribed range is disclosed in Japanese Patent Application Hei 3-48271 (48,271/1991) .
Although not intended for controlling the activity of conversion treatment baths, a method is disclosed in Z. Anal. Chem. 245 67 (1969) for the measurement of fluorine concentration through a potentiometric titration which uses a fluorine ion electrode as indicator electrode, and an aluminum nitrate solution, lanthanum nitrate solution, or the like as titrant. The method measures the total fluorine content in aqueous solutions, and requires that the sample be pre-treated by adjustment of the pH to a range of 4 to 7.
Several problems are associated with direct concentration measurement of the fluoride ion concentration in acidic conversion treatment baths using a fluorine ion meter. The fluorine ion electrode ultimately degrades with time during the measurement process, which necessitates frequent calibration with, reference solutions. Moreover, due to a progressive deterioration of the fluorine ion electrode, the current state of the art of measurement of fluoride ion concentration in acidic aqueous solutions requires frequent performance of complex operations such as washing the electrode, electrode calibration and the like.
However, even when the fluoride ion concentration is accurately measured and maintained the conversion film thickness and the coating add-on per unit area is subject to substantial variations when conversion treatment is operated continuously while holding the fluoride ion concentration as well as other managed parameters (e.g., pH, total acidity) at their respectively prescribed values. Since the film weight is an indication of the conversion treatment performance, in conversion treatments such as zinc phosphate conversion treatment, the film weight value can be taken as an index of the conversion treatment performance. When conversion treatment is implemented based on the fluoride ion measurement instability is observed not only in the corrosion resistance and paint adherence of the treated substrate, but also in the corrosion resistance and adherence of the paint film.
Methods based on potentiometric titration as disclosed in Z Anal. Chem. 245 67 (1969), offer the advantages of no troublesome fluorine ion electrode calibration and low measurement error due to electrode deterioration. However, due to the preliminary adjustment of the sample pH to the range of 4 to 7, the fluoride ion concentration measured by this method is the total fluorine concentration, and the concentration of fluorine effectively available for participation in conversion treatment cannot be measured. Since the total fluorine concentration is not necessarily a parameter that controls the conversion characteristics of acidic conversion treatment processes, the method is unsuitable as a means for controlling acidic conversion treatment processes and therefore suffers from the same problems the method of Japanese Applicant Sho 63-157,879.
BRIEF DESCRIPTION OF THE INVENTION
Extensive research was conducted in order to solve the problems in the prior art method. Methods were examined for measuring the concentration of fluorine effectively available for participation in the conversion process (component in acidic conversion treatment baths that contributes to the conversion process). It was confirmed that the fluorine concentration that effectively contributes to the conversion reactions can be rapidly and reproducibly measured while at the same time countering deterioration of the fluorine ion electrode. According to the invention, the fluorine concentration which contributes to the activity of an acidic conversion treatment bath having a pH below about 4 is directly potentiometrically titrated, without pH adjustment, using a fluorine ion electrode as indicator electrode and using as titrant an aqueous solution containing aluminum ion, lanthanum ion, yttrium ion, zirconium ion, gallium ion, cerium ion, or beryllium ion. The effective fluorine concentration (EFC) is determined from the quantity of titrant addition up to the inflection point on the potential curve of the fluorine ion electrode. The problems associated with the prior art are solved by operating conversion treatment processes based on this measurement method.
The EFC value afforded by the measurement method of the present invention has a better correlation with the conversion process in acidic conversion treatment baths than the fluoride ion concentration values measured heretofore (detection of the total fluorine concentration or free fluoride ion concentration).
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a graph of the relationship between the EFC (points) and the Film Weight.
FIG. 2 is a graph of the relationship between the Total Fluorine concentration and the Film Weight.
FIG. 3 is a graph of the relationship between the Fluoride Ion concentration and the Film Weight.
DETAILED DESCRIPTION OF THE INVENTION
The present invention was developed based in the discovery that with respect to a process for acidic conversion treatment of alumininferous metal, the process can be improved by monitoring the EFC in a fluorine-containing, acidic conversion treatment bath having pH <4 by potentiometrically titrating samples of the bath, without prior pH adjustment, using a fluorine ion electrode as indicator electrode and using as titrant an aqueous solution containing at least one of aluminum ion, lanthanum ion, yttrium ion, zirconium ion, gallium ion, cerium ion, or beryllium ion and measuring the quantity of titrant addition up to the inflection point on the potential curve for the fluorine ion electrode and adding a fluorine-containing chemical to the bath when the EFC falls below a specified range.
The conversion treatment bath used in the practice of the invention can be a phosphate conversion treatment bath or chromate treatment bath. The method is effective for all bath compositions which contain fluoride known to be useful for conversion treatment of aluminum and aluminum alloys. The bath compositions are not particularly restricted. Operative conversion treatment baths are, for example, the phosphate conversion treatment bath disclosed in Japanese Patent Publication Hei 3-38343 (38,343/1991) by the present applicant and the chromate treatment bath disclosed in Japanese Patent Publication Sho 63-66906 (66,906/1988) by the present applicant.
According to the present invention, the particular conversion treatment is operated while maintaining the EFC value determined by the measurement method described hereinafter (points of effective fluorine concentration EFC value) within a predetermined range. The EFC value is preliminarily determined as a function of the type of conversion treatment, bath composition, metal being treated, temperature and .other parameters known to those skilled in the art. When the EFC value (points) exceeds the upper limit of the predetermined range, metal etching by fluoride becomes excessive and the resulting conversion film is heavier than required. When the EFC value (points) falls below the lower limit of the predetermined range, etching of the metal by the fluoride is inadequate and an adequate conversion coating is not formed. A characteristic feature of the present invention is the maintenance of the EFC value in a desired range in the conversion treatment bath, by the addition of a fluorine-containing composition such as, for example, fluoroboric acid, fluoroborate, hydrofluoric acid, sodium fluoride, sodium fluorosilicate and fluorosilicic acid.
In addition, the parameters ordinarily measured and controlled during conversion treatment processes such as the pH, total acidity, redox potential, and the like, must still be measured, and controlled at the same time as the EFC value is measured and controlled. Methods for measuring the parameters of a conversion treatment bath are known, and, for example, are described in Japanese Patent Publication Number Hei 3-59989 (59,989/1991).
The method for measuring the EFC value (points of effective fluorine concentration) is as follows:
1. A known quantity (A, mL) of the acidic conversion treatment bath is taken as the sample.
2. Optionally, the sample can be diluted.
The sample (a known quantity of acidic conversion treatment bath) may be optionally diluted with a liquid that does not form compounds with fluorine, such as pure water, ethanol and the like.
3. A fluoride ion electrode is brought into contact with the sample of the treatment bath. The fluoride ion electrode useful in the practice of the invention must show a variation in emf as a function of the fluoride ion concentration in the treatment bath. (Since the method of the invention does not require measurement of the total fluoride ion concentration, calibration of the fluorine ion electrode with a fluoride ion reference solution is not required.)
4. The sample of the acidic conversion treatment bath is then titrated using as titrant an aqueous solution that contains aluminum ion, lanthanum ion, yttrium ion, zirconium ion, gallium ion, cerium ion, or beryllium ion (B, mol/L).
5. The relationship between the quantity of titrant and the electromotive force (emf) of the fluorine ion electrode is plotted as a titration curve, and the quantity of titrant up to the inflection point on the titration curve is determined (C, mL). The titration curve denotes a graphical plot on the two coordinate axes of the electromotive force (E,mV) of the fluoride ion electrode and the quantity of titrant addition (V,mL). The inflection point on the titration curve is the point at which the value of dE/dV (differential value for the electromotive force) determined from the graph passes through a relative maximum. The values of A and B in this measurement procedure are not specifically restricted, although of course they will have optimal ranges.
6. Using the values of A, B, and C, the EFC value (points) is calculated using Equation 1.
Equation 1
Points of Effective
Fluorine Concentration (EFC) =400×B×C/A
As an example, when 20 mL is used for A (sample size) and 0.05 mol/L is used for B, the value of C (mL) is then equivalent to the EFC value (points of effective fluorine concentration).
The water-soluble metal salts used as the titrant comprise, for example, the nitrates, sulfates, chlorides, or other water soluble salts of the specified metals. The concentration of the water-soluble salt may be adjusted as necessary as a function of the sample size and fluorine concentration in the sample, but is preferably approximately 0.01 to 0.1 mol/L in the case of acidic conversion treatment baths such as zinc phosphate conversion treatment baths, chromate treatment baths, and the like. At below 0.01 mol/L, the potential of the fluoride ion electrode undergoes only a slow variation with respect to the amount of titrant added. Conversely, at values above 0.1 mol/L, the electrode potential varies so sharply that it becomes difficult to determine the inflection point in the titration curve. The treatment bath sample is optimally approximately 10 to 100 mL in order to be convenient for automatic titration.
The fluorine component in acidic conversion treatment baths makes a major contribution to the etching of the metal workpiece being treated. In the particular case of aluminum and aluminum-containing metal workpieces, the fluorine component has a substantial effect on the conversion treatment process. However, the conversion activity is not determined simply by the total fluorine concentration in the treatment bath, but depends on the bath's EFC value, i.e., on the concentration of fluorine that is active with respect to the metal workpiece being treated. In addition, measurement must be carried out without altering the pH of the treatment bath because the EFC value changes with pH.
Although it is a general practice to directly measure the fluoride ion concentration in aqueous solutions using a fluoride ion electrode, fluoride ion meter, and calibration with fluoride reference solutions, in this particular procedure the electromotive force of the fluoride ion electrode declines over the course of long-term application. The electrode cannot tolerate long-term service and a deteriorated electrode does not yield accurate measurement values.
The present invention measures the EFC value at the treatment bath pH by using a sample of the treatment bath itself as the sample solution. Moreover, the present invention employs measurement by a titration technique in order to counter electrode deterioration.
In the measurement method according to the present invention, a fluoride ion electrode is first brought into contact with a sample of the treatment bath. An aqueous solution that contains a known concentration of aluminum ion, lanthanum ion, yttrium ion, zirconium ion, gallium ion, cerium ion, or beryllium ion is then dripped into the sample of treatment bath. Each of these metal salts forms a complex with the fluoride ion in the treatment bath, and the fluoride ion concentration in the treatment bath therefore declines in proportion to the amount of metal ion in the titrant.
Accordingly, in the case of the fluoride ion electrode used as indicator electrode in the present invention, the fluoride ion concentration is not directly calculated from the electrode's electromotive force; rather, the fluoride ion concentration in the sample being titrated, which declines during the course of titration, is measured by examining only the change in electrode emf and determining therefrom an inflection point, which is used to determine the end point of a titration as described above. This serves to avoid the problems associated with the decline in electrode emf that is caused by electrode deterioration, during long-term service.
The use of the inflection point in the titration curve, as the titration end point, makes it possible to determine the titration end point by a simple procedure and to determine the EFC value (points) which closely correlates with the conversion performance of an acidic conversion treatment bath.
Stable conversion treatment performance can be provided by managing the bath components so as to maintain the EFC value (points) by the aforementioned method within a prescribed range. Generally the EFC is maintained in the range from about 0.70 to about 7.5 (pt.), preferably in the range of about 0.9 to about 6.5, and most preferably in the range from about 1.1 to about 4.4.
Several specific examples of embodiments of the method of the invention are provided to further illustrate the method of the invention.
First, the EFC value (Points of Effective Fluorine Concentration), the fluoride ion concentration, and the total fluorine concentration were determined by the measurement methods described below, on 4 zinc phosphate conversion treatment baths (PB-L3020 from Nihon Parkerizing Company, Limited) that were differentiated by their different fluorine containing component.
Table 1 reports the fluorine component systems in the zinc phosphate conversion treatment baths. Table 2 reports the measurement results for the fluorine concentrations of the treatment baths (immediately after the beginning of measurement and at 100 measurements at the rate of one measurement a day) and the measurement results for the film weight on an aluminum alloy plate (JIS-5052) treated at the time the EFC value measurement was made.
TABLE 1______________________________________ Treatment Bath A B C D______________________________________Total Fluorine 1000 250 2000 600Concentration (ppm)Additive System For The Fluoro- Hydro- Fluoro- Hydro-Fluorine Component silicic fluoric silicic fluoric Acid Acid Acid Acid______________________________________
Method For Measuring The EFC value (points)
1) 20 mL of acidic conversion treatment bath was taken as sample.
2) The sample was diluted with deionized water to 50 mL.
3) A fluoride ion electrode (model 7200-0.65W from DKK) was inserted in the sample.
4) Titration was carried out using 0.05 mol/L aqueous aluminum nitrate.
5) The relationship between the quantity of titrant and fluoride ion electrode emf was plotted as a titration curve, and the quantity of titrant (mL) up to the inflection point on the titration curve was taken as the EFC value (points of effective fluorine concentration).
Method for measuring the fluoride ion concentration
1) 100 ppm and 1,000 ppm fluoride ion reference solutions were prepared by the addition of sodium fluoride to 1.0 mol/L aqueous sodium nitrate, and the pH of the solution was adjusted to 5 using nitric acid or sodium hydroxide.
2) A fluoride ion electrode (model 7200-0.65W from DKK) was calibrated with the fluoride ion reference solutions.
3) The calibrated fluoride ion electrode was inserted directly into the acidic conversion treatment bath and the fluoride ion concentration was measured from the electrode emf.
Only step 3) was executed for the second and subsequent measurements
Method For Measuring The Total Fluorine Concentration
1) 20 mL of acidic conversion treatment bath was taken as a sample.
2) The sample was adjusted to pH 5 with aqueous sodium hydroxide and brought to 50 mL with deionized water.
3) A fluoride ion electrode (model 7200-0.65W from DKK) was inserted in the sample.
4) Titration was carried out using 0.05 mol/L aqueous aluminum nitrate.
5) The quantity of titrant for complete consumption of the fluorine component was determined from the potentiometric titration curve for the fluoride ion electrode. The total fluorine concentration was calculated using a consumption of 3 mol fluorine per 1 mol aluminum.
The data from the determinations are shown in Table 2.
TABLE 2______________________________________ Treatment Bath A B C D______________________________________First DayEFC value (pt) 1.1 1.9 2.9 4.4Fluoride Ion Concen- 72 111 154 273tration (ppm)Total Fluorine Concen- 788 196 1876 491tration (ppm)Film Weight (g/m.sup.2) 0.5 1.1 1.8 2.5100th DayEFC value (pt) 1.1 1.8 2.7 4.5Fluoride Ion Concen- 115 174 246 406tration (ppm)Total Fluorine Concen- 790 199 1885 494tration (ppm)Film Weight (g/m.sup.2) 0.6 1.1 1.6 2.5______________________________________
The data in Table 2 illustrates that the film weight provided on the aluminum alloy plate, varied as a function of the fluorine component in the zinc phosphate conversion treatment bath (acidic conversion treatment bath).
Although the film weight varied little between the 1st and 100th day, the Fluoride Ion Concentration underwent large increases. The Total Fluorine Concentration remained steady over the period for a particular bath composition. However, the Total Fluorine Concentration relationship to the coating weight is dependent on the source of fluorine. The Total Fluorine Concentration cannot be used to predict the activity of a conversion treating bath unless the source of fluorine remains constant during the life of the bath. As can be seen from a comparison of Treatment Baths A and C where the initial fluorine source was fluorosilcic acid, with Treatment Bath B and D where the initial fluorine source was hydrofluoric acid, the Total Fluorine Concentration bears no relation to the activity of the Conversion Treatment baths over the various initial sources of fluorine.
In contrast to the Fluoride Ion Concentration and total Fluorine Concentration, the EFC value measured according to the present invention, provides a measurement which closely correlates with the conversion activity of the treatment bath independently of the source of fluorine. The method of the invention is a general method and is useful for monitoring the conversion treating activity of any of the conversion treating baths, the activity of which relies on the presence of an active form of fluorine. The method of the invention measures the effective fluorine species in the bath and therefore closely correlates with the conversion activity of the bath. The close correlation can be readily seen from the graph of FIG. 1.
The data confirms that conversion treatment processes based on Fluoride Ion Concentration or Total Fluorine Concentration cannot provide a stable conversion treatment performance. In contrast, the film weight and the EFC value measurement underwent very similar variations.
In order to clarify these trends, the relationships between the film weights and values measured by the methods of Example 1 are plotted in FIGS. 1, 2, and 3, respectively. In the graphs in FIGS. 1, 2 and 3, X designates the measurement values immediately after the start of measurement and Y designates the measurement values at the 100th day.
Based on these plots, the EFC value (points) exhibits a correlation coefficient with the film weight of >0.99 for both X and Y. Not only does this parameter exhibit a good correlation, but it also exhibits good reproducitility since the X and Y plots are very similar. In contrast, measurement of the, Total Fluorine Concentration, while exhibiting reproducibility, has a correlation coefficient <0.20 for both X and Y, which indicates a poor correlation with film weight. Finally, measurement of the Fluoride Ion concentration has a correlation coefficient of ≧0.95 for both X and Y; however, this method suffers from problems with measurement reproductibility since the Fluoride Ion Concentration values of the X and Y plots are widely separated.
Example 2
Based on the results from the preliminary tests, a zinc phosphate conversion treatment, as outlined below, was run on aluminum sheet (70×150×6 -8 mm). The bath was managed so as to yield film weights of 0.5 to 1.5 g/m 2 by using a range of 1.9 to 2.5 for the EFC valued (points). The conversion treatment was carried out as follows:
______________________________________(1) Degreasing of aluminum sheet Fine Cleaner L4460 (strong alkaline degreaser from Nihon Parkerizing Company, Limited) 43° C., 120 seconds, spray(2) Water Rinse (tapwater) room temperature, 30 seconds, spray(3) Surface Conditioning Prepalene-ZN (titanium colloid surface conditioner from Nihon Parkerizing Company, Limited) room temperature, 20 seconds, spray(4) Zinc phosphate conversion treatment 43° C., 120 seconds, immersion bath compositionZn: 0.8-1.2 g/LNi: 0.5-1.0 g/LMn: 0.8-0.8 g/LPO.sub.4 : 12-20 g/LNO.sub.3 : 0.5-8.0 g/L The EFC value (points) was measured every 10 treatments, and 0.1 g/L HF was added when the EFC value fell below the lower limit.(5) Water rinse (tapwater) room temperature, 20 seconds, spray(6) Rinse with de-ionized water (de-ionized water with conductivity = 0.2 micromhos/cm) room temperature, 20 seconds, spray(7) Drain and Dry 110° C., 180 seconds______________________________________
This method gave a film weight within the forementioned range over the course of the conversion treatment of 100 sheets at the rate of 1 aluminum sheet per treatment.
As discussed hereinbefore, the conversion treatment method according to the present invention is a superior method for the accurate, highly reproducible measurement of the fluorine concentration that effectively participates in the conversion reactions in acidic conversion treatment baths (effective fluorine concentration). | The invention is a method for the accurate control of the conversion film thickness produced on aluminiferous metal materials by fluorine-containing acidic conversion treatment baths; and a simple method for determining the EFC value (Effective Fluorine Concentration). The EFC value is determined by potentiometric titration of a fluorine-containing acidic conversion treatment bath having pH<4 without prior pH adjustment using a fluorine ion electrode as indicator electrode. The titrant is an aqueous solution containing the Al ion, La ion, Y ion, Zr ion, Ga ion, Ce ion, or Be ion, an inflection point in the potential curve is used as an indication of the activity of the conversion treatment bath. | 2 |
FIELD OF THE INVENTION
The invention is directed to an assembly of a label and a substrate, and to a method for making it, wherein the label assembly has an oversheet attached peripherally to the substrate so as to define a zone between the oversheet and the substrate. The oversheet can capture an inserted item such as a folded product information sheet, which is intended to be extracted by a consumer who tears away a portion of the oversheet. The oversheet preferably is substantially clear and is attached at perforated edge strips to the substrate. The assembly is useful for providing product information to consumers, for example as an attachment to a product, package, promotional handout, ad in a publication, etc.
BACKGROUND OF THE INVENTION
Insert-receiving label assemblies can be useful in a number of situations in which a supplemental item needs to be carried on a substrate. The substrate might be a product or product container. The substrate could also be a sheet such as a printed promotional brochure or mailing. The insert might be a small product sample, a supplemental publication or instructional sheet, etc.
Supplemental publications or instructional sheets are particularly useful for distribution with or in connection with regulated products such as medicines, pesticides, potentially poisonous or dangerous substances and the like. These products may have extensive associated warnings, contraindications, instructions for use, instructions for amelioration of accidents, and the like. Even with relatively small print, the printed area that is needed for copies of the instructions, warnings and the like, might take more space than the entire surface area of the product packaging or the product promotional material involved. It is undesirable to obscure a product brochure or a product package wholly with cautionary information or this type.
For these and similar products, a folded up printed item advantageously is packaged and distributed together with the products and/or is affixed as some sort of addendum to promotional pieces. In the case of promotional pieces (e.g., mailings, magazine pages, handouts), the promotional piece may typically be a brightly printed glossy advertisement with pictures and logos. The informational material may typically be a black-and-white printed portion with small font size, either placed in an inner part of the advertisement (e.g., at the end) or contained in one or more separate sheets that are included. One technique is adhesively to attach envelope-like packages to the promotional pieces, the packages containing the warning sheet as a folded insert. The user tears open the envelope to obtain access to the insert.
Apart from inserts in envelopes affixed to printed promotional sheets and mailings, a similar supplemental item can be affixed to products or their packages, such as consumer products. Inserts are apt for product packages for the same reasons as above, namely to provide printed information that cannot advantageously be printed on the product or the container for the product.
Pharmaceutical products that are sold over the counter generally have some associated warnings and often are sold as vials or other containers packaged in boxes together with patient information inserts in the form of folded paper printed sheets. Frequently, such an information sheet or brochure is discarded with the box when the container is removed from the box. As a result, if a need for detailed information arises later, the printed sheets are no longer available.
Several ways are known to attach a detailed information sheet or leaflet as described, to a product container. The attachment could be more or less permanent, depending on expectations for how it will be used. Once the information sheet or leaflet is detached, and assuming there is no outer container or box, it is likely that the information sheet will be permanently separated from the product and lost.
Some similar problems are confronted with respect to product information sheets that are used with advertising brochures. Such brochures are used as handouts, mailings and the like. They are advantageously composed and printed in bright and attractive colors. They are advantageously associated with detailed information sheets or leaflets in small print, containing warnings that are perhaps necessary but that detract from the appearance of the brochure. U.S. Pat. No. 6,270,121 discloses a brochure with a removably attached product information patch for containing such an information sheet or leaflet. The product information patch consists of a base label that has adhesive applied over its surface facing the brochure, whereby the base label is permanently affixed to the brochure. A small-print folded product information sheet is contained between this base label and an over-laminated cover sheet. The folded product information sheet is spaced inwardly from the outer edges of the base label. The over-laminated sheet is secured to the base label over the product information sheet and adheres to the base label between the outer edges of the base label and the product information sheet.
The foregoing structure forms a closed envelope containing the product information sheet, affixed flat on the surface of the brochure. (Presumably it could likewise be affixed on the surface of a product or product package.) The over-laminate sheet can have perforations on opposite sides of the product information sheet. To obtain access to the product information sheet, the user tears the over-laminate apart at the perforations and extracts the product information sheet, leaving the base layer and any undetached portions of the over-laminate attached to the primary substrate, in this case a promotional brochure. The base layer typically remains attached to the substrate, as does at least the peripheral part of the over-laminate, after the product information sheet has been extracted. Separation of the over-laminate at the perforations generally removes any structure that could hold the product information sheet to the base label, so the envelope is only useful until the product information sheet is first removed. Normally that is sufficient for a product information sheet with a promotional brochure because after review of the brochure, and optionally also the product information sheet, the brochure and information sheet are both usually discarded.
It may seem complicated to have a base layer, a product information sheet and a perforated over-laminate attached to the brochure or other substrate, when one might simply glue an edge of the product information sheet to the product. However, there are some structural advantages to having the folded information sheet captured in a flat package. In addition to preventing the information sheet from unfolding inadvertently, a continuous web of such flat packages can be made and the roll can be handled substantially the same as a roll of mailing labels. The flat packages can be fed from the roll onto the brochures, such that an adhesive bearing side of each package is placed against and adheres to the surface of an associated brochure.
Each flat package in U.S. Pat. No. 6,270,121, as described above, has two distinct sheets affixed together from opposite faces of the product information sheet. It is also possible to use one integral sheet in a similar manner, except to fold the integral sheet to form one of the edges of the flat package. That structure could potentially avoid the need for a glue joint at the fold, but without any adhesive would need some functionally similar attention (e.g., hot rolling along the edge) to form a crisp flat fold.
More complicated envelopes are also known, wherein there are additional web layers, glue joints that extend part way across the area of contact between web layers, joints that are intended to capture just an extreme edge of a product information sheet and so forth. However it would be advantageous if product of this type could be improved, potentially even to simplify them, without contributing to the complexity of their structure and use.
U.S. Pat. No. 5,587,222 discloses an exemplary label assembly that includes a removable multi-ply insert and is likewise complex. The assembly includes a label that has adhesive applied to one side, and a removable multi-ply insert attached to the label by at least one fastening strip. The fastening strip may be permanently secured to the label at an end, and secured to the label by a peelable adhesive at the other end. A multi-ply insert of this type might be reattached to the label, although with continued removal and reinsertion, the structural parts and adhesive relations could weaken.
There is a need for new and improved labels and methods for labeling of products whereby a removable item such as a folded product information sheet can be affixed to a product such as an advertising brochure, can capture and hold the removable item securely but permit it to be accessed readily without substantial damage to the underlying substrate, and that can be manufactured without excessive cost. The present invention is directed to these and other important ends.
SUMMARY OF THE INVENTION
These needs are solved according to an inventive concept by providing a way to apply an over-laminate sheet directly to the underlying substrate in a way that facilitates handling of the over-laminate sheet as a label, does not glue or at most only incidentally tacks the removable item, such as a folded product information sheet, to the substrate, and facilitates access to the inserted item by separating the over-laminate, without damaging the substrate, for example, due to pulling apart adhesively affixed layers.
In one aspect, the invention provides an insert label assembly having a substrate, an insert, and a substantially transparent oversheet. The oversheet is preferably but not necessarily rectangular, and has spaced edges straddling the insert. The insert is disposed between the substrate and the oversheet, and the oversheet is affixed to the substrate at least at two of the spaced edges.
The insert may be removable from between the substrate and the oversheet while the oversheet remains intact and/or affixed to the substrate. Alternatively the oversheet can be made to tear away. The insert can be a leaflet bearing text or images, which is apt for containing supplemental product information, such as warnings and detailed instructions for medicinal products, etc. In other embodiments, the insert can be a product or a device such as, for example, a sample of a consumer product contained in a packet and affixed to the assembly between the oversheet and the substrate.
In an embodiment wherein the oversheet is more or less rectangular in shape, namely having two pairs of opposing mutually perpendicular edges, the oversheet can be affixed to the substrate exclusively at one pair of the opposing edges, leaving one or both of the perpendicular pair edges unattached so as to form a pocket with one access edge or a banded-over retaining structure with two edges open. The oversheet can be an arbitrary shape, for example complementary with an arbitrarily shaped product, with the attached edges defining a whole or partial enclosure, a curve such as a U-shape with an open top edge and a closed U-shaped bottom edge, etc.
Conveniently, the oversheet is substantially rectangular in shape, and can have rounded corners. The oversheet has a pair of opposing side edges, a top edge, and a bottom edge, and is affixed to the substrate at the pair of opposing side edges. To improve the likelihood of retention of the insert, the oversheet can also be attached at the bottom edge. The top edge is not attached to the substrate, thereby providing an open-ended pocket.
To improve retention of the insert, a relatively light adhesive material can additionally be placed between the insert and the substrate or between the insert and the oversheet, or both. This tacking adhesive is limited in coverage area and adhesion force (tackiness) so that the insert is removably adhered to the substrate by the adhesive material, and there is little or no visible damage to the insert or to the substrate when the insert is removed.
A number of specific arrangements are possible wherein the insert is more or less securely adhered. Generally, design choices that improve the security of retention increase the need to tear the oversheet when removing the insert. This can be facilitated by perforating the oversheet in one or more defined areas such as spaced lines along opposite edge strips of the oversheet that are adhered to the substrate. The perforations are disposed between the adhered edge strips and a central area that is not adhered or provided with an active adhesive layer.
Another aspect of the invention is a method for manufacturing an insert label assembly, whereby the oversheet can be handled much like a mailing label, but when applied forms a partial pocket for neatly retaining a folded paper insert or the like. A substrate is provided, to which the insert will be affixed, and in a preferred finishing line application, a succession of substrates are fed along a conveyor line. A supply of inserts is likewise provided, for example in a feed magazine. Each insert has a back surface, a front surface, and at least three edges. In a preferred arrangement the insert is a folded paper information sheet, but other sorts of inserts such as product samples are also possible and useful.
The substrates are fed along a conveying path passing a feed outlet from the magazine, and each receives an insert from the magazine. One or more of the inserts are deposited directly against the substrate from one or more magazines, such that a back surface of the insert contacts the substrate. After placing the insert on the substrate, an oversheet is likewise placed onto the substrate, at least partly over the insert. The oversheet has a top surface and a bottom surface, and a portion of the oversheet extends beyond at least two of the edges of the insert. Thus the bottom surface of the oversheet is applied over the insert and extends beyond the edges of the insert, or straddles the insert, at edges of the oversheet that contact the substrate directly.
In preferred embodiments, the oversheet has a first adhesive material on its bottom surface facing toward the substrate and the insert. In a particularly preferred embodiment, the oversheet is a transparent plastic sheet taken from a roll of labels whereby the successive oversheets for successive inserts are lifted from a web by a label feeder and rested on and straddling over the insert.
The first adhesive material on the underside of the oversheet may be a permanent adhesive. The insert optionally is removably affixed to the substrate by a second adhesive material that is less permanent or at least less tacky.
In another preferred embodiment, the first adhesive on the bottom surface of the oversheet is applied substantially over the entire bottom surface of the oversheet when preparing the oversheet on a label web. However, in selected areas of each individual oversheet label or patch, specifically in a central area spaced from the edges, the first adhesive on the bottom surface of the oversheet is deactivated or “killed.” More particularly, the deactivated area can be chemically treated or coated so as to eliminate the tackiness of the adhesive, or to remove or to cover over the tacky adhesive, in a defined area to be disposed over the insert.
These and other embodiments of the invention will be apparent to those skilled in the art in view of the ensuing disclosure, the appended claims, and the drawings, wherein the same reference numbers have been used to identify corresponding items in the respective views. It should be appreciated, however, that in this description, a number of the terms employed to describe orientations or directions such as “top” and “bottom” and “upper” and “lower,” etc., are used for only convenience in describing the embodiments shown in the drawings being discussed. These terms are not intended to limit the invention to a particular orientation, or unless otherwise apparent, to exclude arrangements, including those having additional elements above a defined top or below a defined bottom, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a process for making insert label assemblies according to one embodiment of the invention.
FIG. 2 is a top view of a web of oversheets for use in making insert label assemblies according to one embodiment of the invention.
FIG. 3 is a cross-sectional view of an insert label assembly according to one embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention is described with respect to a preferred application for insert label assemblies wherein supplemental printed information is affixed to printed promotional stock as the substrate. This particular application, which should be regarded as a nonlimiting, is an advantageous type of assembly. However the invention is applicable to various situations wherein an article to be inserted and the substrate are supplied as a unit. In the example of supplemental printed information, the insert needs to be attached durably yet inexpensively, while facilitating the ability of the ultimate user to obtain access, when and if desired. Such insert label assemblies are useful in labeling products such as consumer products and the like. The insert assemblies allow inserts to be attached to the outside of such products, such as on their packaging materials, and removed without substantial difficulty by a user. The insert label assemblies are also useful for providing information to a potential user, such as a consumer or patient, apart from direct association with a supply of a particular product.
An insert assembly includes a substrate, a insert, and an oversheet. The substrate may be a product, a package for a product, or a substrate intended solely or substantially for use in connection with the insert such as, for example, a promotional brochure, poster or placard. Products for which the insert assembly is useful include consumer products, pharmaceutical products, products for use in a laboratory or manufacturing location and the like. The insert may be a leaflet bearing printed information such as information for a patient or a physician, e.g., dosage information, indications and contraindications, operating instructions, potential interaction warnings, or other text, as well as illustrations and/or diagrams.
In an alternative embodiment, instead of or in addition to an informational leaflet, the insert assembly can include a product sample or a product for purchase. Examples of products that may be provided in the assemblies instead of or in combination with a leaflet include pharmaceutical products such as one or more individual dosages of a medication; cosmetic products such as lotions, soaps, and shampoos; and miscellaneous products such as refrigerator magnets, pins or buttons, coins, etc. The product can be unwrapped or may be contained in a suitable container, such as, for example, an envelope, a packet such as a foil packet, a glass or plastic ampoule, or a bag.
It is possible to embody the assembly of the invention such that the insert is attached to the substrate in a way that permits the insert to be removed from the substrate without irreversibly altering or damaging the insert assembly, and potentially so that the insert can be replaced into the assembly after use. The insert can be supplementally affixed directly to the substrate, such a product package, by an adhesive. The insert and the substrate together can be attached to as a unit to a product container or other item, or distributed separately.
It is possible to arrange the assembly to permit the insert to be removed and replaced one or more times. For such removable attachment, a non-permanent adhesive material or a lightly tacky adhesive may be disposed on one surface of the insert, and the oversheet covering the insert can surround and enclose the insert only partially. Alternatively, a one-time use may be envisioned whereby after an initial access the insert and/or substrate is discarded. In that case, it is possible to permit the oversheet to become damaged in obtaining access to the insert.
For removable tacking attachment of the insert, whether or not reattachment of the insert to the substrate is desired, a non-permanent adhesive may be used. Suitable non-permanent adhesives include fugitive hot melts (temporary rubber cements), which do not cure and can affix two suitable surfaces together with a relatively low tackiness as compared to some other forms of more permanent adhesive. Thus, preferably, when the insert is removed from the assembly, the substrate is not damaged. In the context of a printed brochure as the substrate, “damage” is construed to mean any lingering visible effect from the adhesive, such as the pulling of fibers from the substrate, discoloration or the like, which generally are avoided by relying instead on the oversheet for retention of the insert.
The oversheet is dimensioned such that two or more margins or edge strips extend beyond the insert and are brought into contact with the surface of the substrate laterally adjacent to the insert. The oversheet extends over the substrate beyond the insert at least at one edge of the insert, preferably at two spaced substantially opposite edges straddling the insert, and optionally at three edges or all around the periphery of the insert. The size of the margins is not critical; within certain limits needed to affix the oversheet to the substrate and sufficiently to confine the insert.
At least certain of the margins contain an adhesive for affixing the oversheet to the substrate. These adhesive margins are sufficiently wide that an adequate quantity of adhesive can be deposited thereon to affix the oversheet to the substrate. The specific dimensions can vary with the size of the insert and the oversheet. For a typical folded insert, for example containing a folded manifold of two 8½ by 11 inch sheets printed on both sides and folded to a square of 2¾ inches on a side, two spaced margins of ½ to ¾ inch width can extend along the length of a rectangular oversheet that is rectangular and about 3 inches by 5 inches.
The width of the margins and the adhesive are preferably chosen to have the desired effect of either permitting the edge of the oversheet to be peeled up from the substrate or preventing the edge from being peeled up without tearing the oversheet. Either possibility can be provided. However, according to a preferred arrangement, the oversheet is intended to stay permanently affixed at the margins. The margins preferably are at least ⅛″ wide, and more preferably are between ¼″ to 1.0″ wide, or more.
The oversheet is affixed to the substrate, preferably by an adhesive that may be deposited onto the margins of the oversheet prior to the disposition of the oversheet over the insert. In some embodiments, the margins of the oversheet may be affixed to the substrate by a peelable adhesive, which may be re-sealable. In the preferred arrangement discussed, the margins of the oversheet are affixed to the substrate by a permanent pressure-sensitive adhesive or an activatable adhesive that is rendered operative by contact with a material on the substrate. An example of an activatable adhesive is an adhesive that becomes tacky and active, i.e., causes adhesion, when wet, such as the adhesives used on many business mailing envelopes.
Examples of suitable permanent adhesives for the marginal edges of the substrate are aqueous and non-aqueous adhesives, resins and similar compositions that remain tacky, volatile resins and compositions that dry or cure by chemical reaction, acrylates, epoxies, silicone and other sealants, etc.
In some embodiments, a portion of the oversheet is removable, and may be removed, for example, along with the insert. It is also possible to facilitate tearing away of the oversheet, e.g., by providing perforations along the margins between a portion adhesively affixed to the substrate and a portion spaced from the substrate by the insert or otherwise. It is generally desirable to minimize or prevent damage to the substrate by, for example, lifting of fibers from the paper stock, removal of colored coatings, inks or illustrations, or other visible effect on material that may be printed or otherwise appear on the substrate.
However, destructive removal of the oversheet may be desired to obtain access to the insert. In such embodiments, the oversheet is affixed to the substrate by an adhesive at the margins of the oversheet, so as to capture the insert. The oversheet includes a main body and at least two margins, of which at least one is attached along a perforated line to the main body of the oversheet. The main body of the oversheet can then be removed by a user separating the main body from the affixed margin at the perforated line, thus exposing the insert, while leaving the associated margin of the oversheet affixed to the substrate.
In assemblies including such an oversheet having perforably attached margins, the oversheet may have an adhesive substantially covering the bottom surface of the oversheet, including both the margins and the main body of the oversheet. The main body of the oversheet, which contacts the insert, can have “inactivated” adhesive thereon. Inactivated adhesives may be referred to by those skilled in the art as “killed adhesives,” and generally refers to an area at which an applied adhesive is no longer tacky. An adhesive can be reduced in tackiness or wholly inactivated as compared to its operative state, in known manner, depending on the nature of the adhesive. For example, a curable adhesive can be cured by application of the associated curing agent while not in contact with the substrate. An aqueous adhesive or one with a volatile carrier can be dried or evaporated when not in contact. Alternatively, any of these forms of adhesive can be coated to eliminate tackiness, for example by dusting the tacky area with talc or otherwise preventing adhesive contact.
In any event, according to a preferred arrangement, an uninterrupted adhesive layer preferably is applied substantially to the entire bottom surface of the oversheet, including the margins that are to be adhered to the substrate and also including the central area that is not to be adhered.
However, the adhesive in the central area is inactivated as described, and thus the oversheet can rest against the insert without substantial adherence or damage when separated.
For many embodiments, it is highly preferred that the insert be visible and identifiable as such through oversheet. Thus the oversheet preferably is a substantially transparent plastic sheet. By “substantially transparent” is meant that the insert over which the oversheet is disposed preferably is visible to the human eye through the oversheet and it the existence of printed text or images on the insert, if any, is discernable even if the text and images are not completely unobscured. In short, it is desirable for the insert to be sufficiently visible that the user can appreciate the nature of the insert, without the need for any supplemental instructional labeling on the substrate.
On the other hand, the oversheet need not be transparent or colorless or even translucent. The oversheet itself also could be printed. The oversheet preferably is made of a polymeric material that has sufficient flexibility and elasticity to be stretched over the insert and thus resiliently to bear down against the insert and to secure the insert against the substrate. In other embodiments, particularly in embodiments wherein an adhesive is present between the insert and the substrate, or less preferably between the insert and the oversheet, the oversheet may be made of a less stretchable polymeric material as polyester or oriented polypropylene.
Packages for which the insert assembly is useful include bottles, including glass and plastic bottles, cartons, cans, cylinders made of cardboard, paper, or metal, and tubes such as those commonly used for toothpaste and cosmetic products. Brochures and placards for use as substrates for the insert assemblies may be made of, for example, paperboard, laminated paperboard, with and without printing or other coatings, or plastic. Materials that are coated with a release material to which a given adhesive cannot attach, are obviously not preferred with that adhesive, and care should be given to choice of compatible materials for the substrate, adhesive and oversheet, as well as for any tacking adhesive for the insert, in known manner.
Leaflets for use as inserts according to the assemblies described herein are preferably in the form of a plurality of sheets or plies of a material that can be printed upon, particularly paper. The paper may be folded multiple times so that it assumes a configuration over which an oversheet may be placed and affixed. For example, the paper may be in booklet form, folded and bound together at the fold to form a spine of the booklet. Alternatively, the paper may be folded multiple times to form a number of panels or pages in an overlying relationship. Thus, the leaflet has two or more edges, preferably four edges, each of which may be independently folded, fixed as in a booklet spine, or free, i.e. unfolded. Preferably the leaflet when folded the leaflet is generally rectangular. Exemplary leaflet folding configurations suitable for use in the assemblies disclosed herein are described in U.S. Pat. Nos. 6,158,778 and 6,290,796.
The thickness of the leaflet is not critical; however, the practical upper limit to the thickness of the leaflet will be determined in part by the application for which the leaflet is intended. For example, if the leaflet is to be affixed to a cylindrical container such as a bottle, the leaflet is preferably sufficiently thin that it can conform to the shape of the container. A folded leaflet that is too thick may not be held in place sufficiently by the oversheet. A folded thickness from about ⅛ inch to about ⅜ inch may be advantageous. Commercially available sheet stock is suitable for use in making a leaflet.
Additionally, a leaflet containing many folded layers tends to fan open, particular for a time after initial folding, in the absence of a compressing force. One of the advantageous aspects of the oversheet according to the invention is that a certain amount of compression can be applied by pressing the oversheet over the insert on the substrate initially, because any tendency of the insert to fan open is transmitted into tension on the oversheet and is resisted after the margins of the oversheet are attached.
Product samples useful as inserts are preferably provided in a configuration that is adaptable to being affixed to substrate and covered with an oversheet. For example, product samples may be provided in an envelope, bag, or ampoule.
According to another aspect, the present invention concerns a novel method for making insert assemblies, particularly in that it is possible according to the invention to substantially simplify the complicated structures and handling steps needed to attach known envelope-like supplements to a substrate, by applying the envelope contents (the insert) directly to the substrate and holding it down using the oversheet techniques as described herein.
In a preferred embodiment, successive substrates such as promotional brochures, containers or the like are fed sequentially along a feed path to a feeder at which inserts are dispensed from a magazine directly onto the substrates. An exemplary substrate feeder for brochures is a comb wheel feeder, known to those skill in the art for transporting components from a first position to a second position for modification or processing. The comb wheel feeder may be mounted to dispense onto a conveyor belt or the like, whereby the fed brochures or other substrates are carried forward. When each substrate arrives at the dispensing point from the magazine of inserts, an insert is deposited onto the substrate. This can be accomplished by sensing the substrate mechanically or optoelectrically and feeding an insert, or simply as a matter of sequential conveyor indexing or timing wherein the inserts are incrementally fed at the same pitch that the brochures or other substrates are carried along the conveyor.
In the embodiment shown in FIG. 1, for example, the substrates are brochures fed along a horizontal conveyor belt to a point directly under a magazine that dispenses single inserts in sequence with incremental advance of a continuously moving conveyor belt. Other feeding and handling arrangements are possible, such as a conveyor that move in an indexing motion, substrates engaged by carriers or conveyor receptacles, and other specific arrangements that should be readily apparent.
Optionally, a spot of a mild adhesive, such as a Fugitive Hot Melt (mucilage rubber cement adhesive), may be deposited onto the substrate and/or the insert before the insert is deposited onto the substrate. This is useful as a temporary means of affixation, as well as a technique to retain the insert under the preferred form of oversheet, which does not enclose around all the sides of the insert and preferably only is attached to the substrate on two spaced marginal edges straddling the insert on opposite sides.
After the insert is deposited onto the substrate, preferably with a spot of fugitive hot melt for tacking, the oversheet is deposited onto the insert and substrate. The insert has at least three edges, and preferably has two pairs of edges, i.e. the insert is preferably rectangular in form and has four edges in two perpendicular spaced pairs. If the insert is a leaflet, and the leaflet has two or more plies, one of the edges of the leaflet is folded and the opposite edge tends to fan open. The folded edge preferably is the leading edge because the arrangement will be passed under compression rollers as it moves along the conveyor.
The oversheet has a top or outer surface, and a bottom or inner surface that contacts the substrate (at the margins of the oversheet) and the insert (in a middle part of the oversheet between the margins). The oversheet is deposited onto the insert such that the oversheet has a main body contacting the insert and one or more portions extending outside two of the edges of the insert and contacting the substrate. A portion of the oversheet that extends outside the edges of the insert is referred to herein as a margin, and preferably the oversheet has two margins that extend outside and straddle the insert, where the margins contact and adhere to the substrate. At least one of the margins preferably is connected to the main body of the oversheet along a perforation line. As discussed hereinabove, the main body and margins of the oversheets may have an adhesive on their bottom surface contacting the substrate, which adhesive has been deactivated or at least minimized in the area that contacts the insert.
After the oversheet is deposited onto the insert, pressure preferably is applied to secure the oversheet onto the substrate, to compress the insert if necessary, and generally to positively assemble the respective parts in their final arrangement. Pressure to secure the oversheet onto the substrate need only be applied substantially along the margins of the oversheet that bear against the substrate. However, additionally, pressure is preferably applied to the oversheet generally over its surface, including the margins and the central area, to compress the insert as well as the whole assembly. Such compression may be particularly desirable, for example, when the insert is a folded, multi-ply leaflet that tends to fan open. The pressure to secure the oversheet onto the substrate and/or the pressure to compress the insert may be provided by one or more rollers.
In a preferred embodiment, the oversheets are arranged in a manner similar to plastic labels and can be fed and applied over substrates and the inserts thereon using an automatic label applicator such as are available from Booth Manufacturing Co. t/a Autolabe, Fort Pierce, Fla. An advantageous form of label applicator employs a web of successively spaced labels on a carrier web or belt, for example plastic sheet labels on a paper stock web having a release coating. The carrier web is passed around the sharp bend of a reversing path at the point of application of the labels. The sharp bend causes the individual labels to be lifted from the web and dropped onto the substrate and the insert thereon. This stack, consisting essentially of a substrate (e.g., a glossy printed brochure), the insert resting on the substrate (e.g., a folded product information sheet), and the oversheet with the central body part laid over the insert and the adhesive margins residing directly over the substrate, is then rolled flat, permanently bonding the margins directly to the substrate.
A preferred embodiment for depositing the insert and oversheet onto a substrate is illustrated schematically in FIG. 1. A magazine of inserts 100 is located above belt 11 . Belt 11 transports substrate 12 in the direction shown. A insert 10 is deposited onto substrate 12 , optionally with a dab of fugitive hot melt to fix the insert in place on the substrate. Delivery roller 13 carries a web 15 of oversheets around detachment roller 24 , producing a sharp bend or fold 25 in the web 15 of oversheets. A top view of a web 45 of oversheets is shown in FIG. 2 . Oversheets 40 and 41 have margins 40 ′, 40 ″, 41 ′ and 41 ″. Margins 40 ′, 40 ″, 41 ′ and 41 ″ are affixed to web 45 by an adhesive (not shown) that is readily detachable, for example due to an appropriate release coating that prevents the adhesive bearing margins of the oversheets from adhering permanently to the web.
As the web passes around the bend or fold 25 , the leading edge of the oversheet 26 tends to continue along rather that to fold back with the web, and as a result the oversheet peels away from web 15 . The oversheet is thus deposited onto substrate 12 . Web 15 is carried to a web return roller 16 where it is accumulated for disposal. Substrate 12 is carried to a position beneath adhesive attachment rollers 17 , 18 , 19 , 17 ′, 18 ′ and 19 ′. In the illustrated embodiment three pairs of rollers are shown. However, the number of adhesive attachment rollers is not critical, and one pair of rollers may be used. The pairs of rollers are disposed such that the rollers contact and compress each adhesive bearing margin of oversheet 26 , thus permanently affixing the margins directly to the substrate a positions that straddle the insert. The adhesive attachment rollers help to secure oversheet 26 to substrate 12 , and particularly if the insert is fanning open, may initially be the cause for the margins to come into contact with the substrate. Substrate 12 bearing insert 10 and oversheet 26 is then carried to a position beneath compression roller 30 that generally compresses the assembly. Compressor roller 30 is optional, but is useful to compresses insert 10 and to tighten the assembly and better affix the oversheet margins to the substrates securely. The compression roller also eliminates unnecessary thickness in a stack of assembled insert-bearing substrates.
Thus as shown in FIG. 3 ( a ), before application of the oversheet and before compression, a leaflet 101 placed upon and preferably tacked to substrate 112 , even though folded, is somewhat expanded. In FIG. 3 ( b ), the leaflet 101 has been compressed by application of the oversheet (not shown) and, by roller pressure, such that the leaflet is substantially compressed, flat and captive under the oversheet, which is securely and compactly affixed to the substrate, enabling easy stacking and/or packing.
Various modifications, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims. | A substrate such as a promotional brochure or product container is provided with an insert holder. A preferably transparent an oversheet is attached to the substrate over an insert such as a folded product information sheet. The oversheet is affixed directly to the substrate by adhesive around a peripherally surrounding the insert, at lest on two opposite margins or edges straddling the insert. A zone is defined on the oversheet over the insert where the oversheet is nonadhesive. The oversheet can capture an inserted item, such as a folded product information sheet, which is intended to be extracted by a consumer by tearing away a portion of the oversheet or by laterally extracting the insert. The oversheet preferably is substantially clear and the edge strips are perforated. A process is disclosed wherein the oversheet provided on a label roll with a killed adhesive zone, and is applied on a production line using a label applicator and series of rollers. | 8 |
BACKGROUND
1. Field of the Invention
This invention relates to downhole drilling, and more particularly to apparatus and methods for transmitting data along a downhole drill string.
2. Description of the Related Art
For half a century, the oil and gas industry has sought to develop downhole telemetry systems that enable high-definition formation evaluation and borehole navigation while drilling in real time. The ability to transmit large amounts of sub-surface data to the surface has the potential to significantly decrease drilling costs by enabling operators to more accurately direct the drill string to hydrocarbon deposits. Such information may also improve safety and reduce the environmental impacts of drilling. This technology may also be desirable to take advantage of numerous advances in the design of tools and techniques for oil and gas exploration, and may be used to provide real-time access to data such as temperature, pressure, inclination, salinity, and the like, while drilling.
In order to transmit data at high speeds along a drill string, various approaches have been attempted or suggested. One approach that is currently showing promise is to incorporate a “network” of data transmission cable and other communication equipment into the drill string. Due to the length of drill strings, which may exceed 20,000 feet, such a network may require placing network “nodes” at selected intervals along the drill string. These nodes may act as repeaters to amplify the data signal and provide points of data collection along the drill string. Communication elements, such as magnetic couplers, may be incorporated into the ends of downhole tools to transmit data across the tool joints. Transmission lines, such as electrical cables, may be incorporated into the downhole tools to transmit data therealong.
Unfortunately, unlike conventional above-ground networks, a downhole network is constrained by the physical limitations of the downhole drill string. In particular, a downhole drill string is a linear structure, making it very difficult to build redundancy (and thereby reliability) into the downhole network. As a result, any break or malfunction in the data transmission path along the drill string may cause communication to be lost between the surface and downhole components. Because the drill string may include many hundreds of downhole components (e.g., sections of drill pipe, drill collar, bottom-hole assembly components, etc.), a single break or malfunction in any downhole component can break the communication path and cause the network to lose much if not all of its functionality.
In view of the foregoing, what are needed are apparatus and methods to provide multiple redundant paths of communication in a downhole network. Such apparatus and methods may be used to significantly improve the reliability of downhole communication networks.
SUMMARY
The invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available downhole networks. Accordingly, the invention has been developed to provide systems and methods to build redundancy into downhole networks. The features and advantages of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
In one aspect of the invention, an annular coupler for transmitting data across a tool joint may include a first coupler segment spanning a first portion of the circumference of the annular coupler. The annular coupler may further include a second coupler segment, electrically insulated from the first coupler segment, which spans a second portion of the circumference of the annular coupler. In selected aspects, the first and second portions do not overlap one another along the circumference. In certain aspects, the first and second coupler segments each span about fifty percent of the circumference of the annular coupler. Thus, each coupler segment may make up roughly half of the annular coupler.
In another aspect, a downhole tool in accordance with the invention may include an annular coupler installed in an end thereof. The annular coupler may include a first coupler segment spanning a first portion of the circumference of the annular coupler and a second coupler segment, electrically insulated from the first coupler segment, spanning a second portion of the circumference of the annular coupler. The first coupler segment may be coupled to a first transmission line to transmit data along the downhole tool. The second coupler segment may be coupled to a second transmission line to transmit data along the downhole tool.
In yet another aspect of the invention, a method for transmitting data across a tool joint may include installing an annular coupler in one of a primary and secondary shoulder of a downhole tool. Installing the annular coupler may include installing a first coupler segment in the primary or secondary shoulder that spans a first portion of the circumference of the annular coupler. Installing the annular coupler may also include installing a second coupler segment in the primary or secondary shoulder that spans a second portion of the circumference of the annular coupler. The first coupler segment may be electrically isolated from the second coupler segment. In selected aspects, the first coupler segment makes up about fifty percent of the circumference of the annular coupler and the second coupler segment makes up about the other fifty percent of the circumference of the annular coupler.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific aspects illustrated in the appended drawings. Understanding that these drawings depict only typical aspects of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:
FIG. 1 is a cross-sectional perspective view showing two transmission lines and a split-coil annular coupler incorporated into the pin end of a downhole tool;
FIG. 2 is a perspective view of multiple annular couplers connected by transmission lines;
FIG. 3 is perspective view of one aspect of a split-coil annular coupler in accordance with the invention;
FIG. 4 is a perspective cutaway view of a split-coil annular coupler installed in a mating surface of a downhole tool;
FIG. 5 is a perspective cutaway view of the split-coil annular coupler of FIG. 4 ;
FIG. 6 is a schematic view showing coupler segments rotationally aligned with one another; and
FIG. 7 is a schematic view showing coupler segments rotationally misaligned with one another.
DETAILED DESCRIPTION
It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of aspects of apparatus and methods of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected aspects of the invention.
The illustrated aspects of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the apparatus and methods described herein may be easily made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected aspects consistent with the invention as claimed herein.
FIG. 1 shows a pair of transmission lines 102 a , 102 b and a split-coil annular coupler 104 incorporated into the pin end 108 of a downhole tool 100 . In the illustrated aspect, the downhole tool 100 is a section of drill pipe 100 . However, the downhole tool 100 may also include other tubular components such as heavyweight drill pipe, drill collars, crossovers, mud motors, stabilizers, hole openers, sub-assemblies, under-reamers, drilling jars, drilling shock absorbers, network links, downhole measurement tools, or other downhole tools known to those of skill in the art.
The transmission lines 102 a , 102 b and annular coupler 104 provide multiple redundant paths of communication along the downhole tool 100 . Consequently, if communication is lost or interrupted on one transmission line 102 a , the other transmission line 102 b may still transmit data along the downhole tool 100 . Such a configuration may be used to provide multiple paths of communication in a downhole network, one example of which is disclosed in U.S. Pat. No. 7,041,908 to Hall et al. and entitled “Data Transmission System for a Downhole Component,” which is herein incorporated by reference in its entirety.
In the illustrated aspect of the invention, the annular coupler 104 is an inductive coupler 104 configured to transmit data across a tool joint as a magnetic signal. Two magnetically coupled annular couplers 104 (as would occur with two annular couplers 104 communicating across the tool joint) create a “transformer,” in this case an RF signal transformer. However, in other aspects, the annular coupler 104 may use other methods for transmitting data across the tool joint. For example, the annular coupler 104 may be an acoustic coupler, a fiber optic coupler, or an electrical coupler for communicating or transmitting a signal (i.e., an acoustic, optical, or electrical signal) across the tool joint.
In the illustrated aspect, the pin end 108 of the downhole tool 100 is shown. In this example, the pin end 108 is a double-shouldered design, which has been found to be particularly suitable for implementing an annular coupler 104 in accordance with the invention. One example of a double-shouldered downhole tool is described in U.S. Pat. No. 5,908,212 to Smith et al. and entitled “Ultra High Torque Double Shoulder Tool Joint.” Nevertheless, the annular coupler 104 is not limited to double-shouldered tool joints, but may be incorporated into tool joints having a wide variety of different configurations.
As shown, the annular coupler 104 is installed in a groove or recess formed in the secondary shoulder 106 of the pin end 108 of the downhole tool 100 . In other aspects, the annular coupler 104 may be installed in a primary shoulder or other mating surface of the downhole tool 100 . A corresponding annular coupler (not shown) may be installed in the box end of the downhole tool 100 . In selected aspects, the transmission lines 102 a , 102 b may be routed through holes (e.g., gun-drilled holes) formed in the pin end and box end respectively, since the wall thickness is these areas is typically greater. Where the wall thickness is thinner, such as along the length of the downhole tool 100 between the pin end and box end, the transmission lines 102 a , 102 b may be routed through the central bore 110 of the downhole tool 100 . In selected aspects, the transmission lines 102 a , 102 b may be held under tension to minimize movement of the transmission lines 102 a , 102 b within the central bore 110 , and to keep the transmission lines 102 a , 102 b against the wall of the central bore 110 .
Referring to FIG. 2 , a perspective view of multiple split-coil annular couplers 104 a - d, connected by transmission lines 102 a - d , is illustrated. A first set of annular couplers 104 a , 104 b and transmission lines 102 a , 102 b may be installed in a first downhole tool, and a second set of annular couplers 104 c , 104 d and transmission lines 102 c , 102 d may be installed in a second downhole tool physically coupled to (e.g., threaded into) the first downhole tool. A pair of annular couplers 104 b , 104 c may communicate with one another across the tool joint.
As shown, a pair of transmission lines 102 may communicate with each annular coupler 104 . Each transmission line 102 may communicate with a different electrically-isolated coupler segment 200 , as will be explained in more detail hereafter. For example, a first transmission line 102 c may communicate with a first coupler segment 200 a , and a second transmission line 102 d (which is electrically isolated from the first transmission line 102 c ) may communicate with a second coupler segment 200 b (which is electrically isolated from the first coupler segment 200 a ). In the event one of the couplers segments 200 a shorts out or ceases to function for some reason, the other coupler segment 200 b and transmission line 102 d may continue to function. In this way, redundancy may be built into the downhole network by providing multiple paths of communication through each downhole tool.
One significant advantage of the “split-coil” couplers 104 shown in FIG. 2 is that if a first coupler segment 200 a ceases to function, it is not likely to cause the second coupler segment 200 b to also cease to function. For example, if the coupler segments 200 a , 200 b were in close proximity to one another (such as two overlapping segments), a failure of one coupler segment 200 a could also cause the failure of the other 200 b . For example, a scrap of metal, pebble, or other material that interferes with and shorts out a first coupler segment 200 a would also likely short out the other coupler segment 200 b since it is in close physical proximity thereto. By dividing the annular coupler 104 into segments 200 a , 200 b , the segments 200 a , 200 b may be physically and electrically separated from one another to reduce the chance that a failure of one will cause the failure of the other.
Referring to FIG. 3 , one aspect of a split-coil annular coupler 104 in accordance with the invention is illustrated. In this aspect, the annular coupler 104 is divided into a pair of coupler segments 200 a , 200 b , although more coupler segments (and associated transmission lines) are also possible. In this aspect, each coupler segment 200 a , 200 b makes up about fifty percent of the circumference of the annular coupler 104 . Other ratios are possible and within the scope of the invention.
In the illustrated aspect, each coupler segment 200 a , 200 b includes half of a conductive coil 300 a , 300 b (i.e., together forming a “split coil”). Each coil 300 a , 300 b is partially surrounded by magnetically-conductive, electrically-insulating (MCEI) elements, which may be inserted into an annular housing 304 . The conductive coils 300 a , 300 b may be coupled to conductive straight portions 302 a , 302 b , which may be electrically coupled (by soldering, contact, or other means) to the transmission lines 102 . The other ends of the coils 300 a , 300 b maybe grounded. For example, an end 306 may be grounded by way of soldering, welding, or direct contact with the annular housing 304 (this makes a ½ turn coil that is a complete circuit). The annular housing 304 may be grounded by way of direct contact with the tool 100 . In certain aspects, the coils 300 a , 300 b and straight portions 302 a , 302 b may be pieces of wire that are bent or formed into the illustrated shapes. In certain aspects, the entire annular coupler 104 is preassembled before being installed in the downhole tool 100 .
Referring to FIG. 4 , a perspective, cross-sectional view of one aspect of a split-coil annular coupler 104 in accordance with the invention is illustrated. In selected aspects, the annular coupler 104 may include an annular housing 304 forming a trough. MCEI elements 400 may be placed within the trough. In certain aspects, the MCEI elements 400 are fabricated from a ferrite material or other material with similar electrical and magnetic properties. Similarly, the MCEI elements 400 may be formed in a U-shape that is sized and shaped to fit within the annular housing 304 . The annular housing 304 may provide a durable frame in which to house the relatively fragile MCEI elements 400 . The conductive coil 300 may be provided within the U-shaped MCEI elements 400 to carry electrical current. In selected aspects, the conductive coil 300 is coated with an electrically insulating material 402 . For example, the conductive coil 300 may be made of copper or silver-plated copper-clad steel, which may be insulated with varnish, enamel, or a polymer. In other aspects, the coil 300 is insulated with a tough, flexible polymer, such as high density polyethylene or polymerized tetrafluoroethane (PTFE).
As current flows through the coil 300 , a magnetic flux or field may be created around the coil 300 . The U-shaped MCEI elements 400 may contain the magnetic flux created by the coil 300 and prevent energy leakage into surrounding materials. The U-shape of the MCEI elements 400 may also serve to transfer magnetic current to a similarly shaped MCEI element 400 in an adjacent annular coupler 104 . Since materials such as ferrites may be quite brittle, the U-shaped MCEI elements 400 may be provided in segments 404 a , 404 b to prevent cracking or breaking that might occur using a monolithic piece of ferrite. In selected aspects, these segments 404 a , 404 b may be held together using a resilient material, such as an epoxy, a natural rubber, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), a fiberglass or carbon fiber composite, a polyurethane, or the like.
As was previously discussed, an annular recess 406 may be provided in a mating surface 408 of the downhole tool 100 , such as in the secondary shoulder 408 of the downhole tool 100 . The recess 406 may be positioned so as to lie substantially equidistant between the inner and outer diameter of the secondary shoulder or face. The annular coupler 104 may be inserted into and retained within the recess 406 . In selected aspects, the recess 406 may include a locking mechanism to enable the annular housing 304 to be retained within the recess 406 . For example, in one aspect, a locking mechanism may include a groove 410 or recess 410 formed within the larger recess 406 . A corresponding shoulder 412 may be formed along the annular housing 304 . This shoulder 412 may engage the groove 410 , thereby retaining the annular coupler 104 within the recess 406 .
In order to close any gaps between annular couplers 104 in the pin end and box end of downhole tools 100 making up a tool joint, an annular coupler 104 may be biased with respect to the mating surface 408 . That is, the annular coupler 104 may be urged in a direction 414 with respect to the mating surface 408 . In selected aspects, angled surfaces 416 , 418 of the recess 406 and the annular housing 304 , along with the diameters of the annular housing 304 and the recess 406 may provide a “spring force” in the direction 414 . This may be accomplished may making the diameter of the annular housing 304 slightly smaller than the diameter of the recess 406 and then pressing the annular housing 304 into the recess 406 until the shoulder 412 snaps into the groove 410 . The top surface of the annular coupler 104 may slit slightly above the mating surface 408 , but may travel downward into the recess 406 upon contacting a corresponding annular coupler 104 of an adjacent downhole tool 100 . The spring force may keep the annular couplers 104 in firm contact with one another, improving their ability to transmit a signal across the tool joint.
Referring to FIG. 5 , another cutaway view of the split-coil annular coupler 104 of FIG. 4 is illustrated. As shown, the annular coupler 104 includes an annular housing 304 , forming a trough, with multiple MCEI elements 400 residing in the trough. The MCEI elements 400 are U-shaped with a size and shape to fit within the annular housing 304 . A conductive coil 300 is routed through the U-shaped MCEI elements 400 . An electrically insulating material 402 is used to coat the conductive coil 300 . A shoulder 412 is formed along the inside diameter of the annular housing 304 to enable the shoulder 412 to engage a corresponding groove 410 in the annular recess of the downhole tool 100 .
Referring to FIGS. 6 and 7 , one advantage of the present invention is that communication may be maintained regardless of the “clocking” of the annular couplers 104 . For example, referring to FIG. 6 , where the annular couplers 104 a , 104 b are substantially aligned, a coupler segment 200 a of the annular coupler 104 a will be aligned with the coupler segment 200 c of the annular coupler 104 b . Similarly, a coupler segment 200 b of the annular coupler 104 a will be aligned with the coupler segment 200 d of the annular coupler 104 b . If one of the coupler segments 200 a , 200 c loses functionality, communication may nevertheless be maintained between the other coupler segments 200 b , 200 d . Similarly, if one of the coupler segment 200 b , 200 d loses functionality, communication may be maintained between the coupler segments 200 a , 200 c . In this scenario, most if not all of the signal power from the coupler segment 200 a will be transmitted to the coupler segment 200 c , and most if not all of the signal power from the coupler segment 200 b will be transmitted to the coupler segment 200 d.
On the other hand, where the annular couplers 104 a , 104 b are misaligned, the annular couplers 104 a , 104 b may still maintain communication. For example, referring to FIG. 7 , consider a case where a coupler segment 200 a of the annular coupler 104 a is misaligned with the coupler segment 200 c of the annular coupler 104 b , and a coupler segment 200 b of the annular coupler 104 a is misaligned with the coupler segment 200 d of the annular coupler 104 b . If a coupler segment 200 a loses functionality, communication may nevertheless be maintained between the coupler segments 200 b , 200 d . Communication may also exist between the coupler segment 200 b and the coupler segment 200 a of the annular coupler 104 b . The difference between this scenario and that illustrated in FIG. 6 is that power transmitted from the coupler segment 200 b will be split in some proportion between the coupler segments 200 a , 200 d . Thus, the annular couplers 104 a , 104 b may maintain communication regardless of the “clocking” between the annular couplers 104 a , 104 b . In either case ( FIG. 6 or 7 ), a drop in signal power (that would not prevent the network from functioning correctly) could be used as a warning that a tool joint has a failure in one of the two communication paths.
The present invention may be embodied in other specific forms without departing from its essential characteristics. The described aspects are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | An annular coupler for transmitting data across a tool joint may include a first coupler segment spanning a first portion of the circumference of the annular coupler. The annular coupler may further include a second coupler segment, electrically insulated from the first coupler segment, which spans a second portion of the circumference of the annular coupler. In selected aspects, the first and second portions do not overlap one another along the circumference. In certain aspects, the first and second coupler segments each span about fifty percent of the circumference of the annular coupler. Thus, each coupler segment may make up roughly half of the annular coupler. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my application Ser. No. 609,305 filed Sept. 2, 1975 and now abandoned. Reference is also made to my Patent No. 4,043,380, issued Aug. 23, 1977 on application Ser. No. 609,617 filed Sept. 2, 1975 as a continuation in part of my application Ser. No. 419,580 filed Nov. 28, 1973 now abandoned which is a continuation in part of my application Ser. No. 253,204 filed May 15, 1972 and now abandoned.
BACKGROUND OF THE INVENTION
It has been common practice for some time in the foundry industry to fabricate molds and cores, for use in casting metal parts, from commercial metal casting "plaster" which is a blend commonly comprising at least 50% gypsum plaster with the balance being primarily fibrous talc and some silica sand. Such molds and cores are conventionally used with a variety of metals which melt at temperatures substantially above the boiling point of water but below the melting point of gypsum, 2640° F., typical examples being aluminum and its alloys with melting points in the range of 1050°-1200° F., zim base alloys which melt around 900° F. and unleaded bronzes with a melting range of 1800°-1900° F.
In fabricating molds and cores for such uses, the commercial plaster is mixed with a large amount of water, for example an equal or greater amount of water, to produce a highly fluid suspension which is capable of completely filling even relatively complex patterns in the master mold or pattern. Then this large amount of water must be substantially completely eliminated, because any water which remains in the plaster can spoil a casting made therefrom, when it turns to steam upon contact with the molten metal at the elevated temperatures noted above, either by producing surface defects or by virtually exploding portions of the mold.
Drying of a plaster casting component by conventional methods is tedious and of unpredictable reliability in results, particularly if the component is complex or of substantial mass. One reason for these difficulties is that the gypsum component of the plaster normally retains a significant amount of water of crystalization, which cannot be eliminated without heating the entire component to a temperature greater than its calcining temperature of 270° F. This is a very time-consuming operation with a conventional baking furnace, which can easily require as much as 30 hours at 300° F., and even then, the probabilities are that a substantial proportion of a given plurality of components will crack or craze sufficiently to be unusable.
Attempts have been made to dry plaster casting components by exposure to microwave radiation in a microwave oven, on the premise that the known absorption capabilities of water for microwave radiation should make microwave heating an effective drying procedure for the plaster. Strangely, however, these attempts have not been successful, even when the mold or core is heated far beyond the normal 300° temperature obtained in a conventional oven, for example even as high as 600° F. While a mold or core dried in this manner appears to be completely dry, when it is then used for casting, sufficient additional water is given off by the plaster to spoil the majority of the castings. Additionally, heating to such high temperature ranges will usually cause cracks or crazing in a significant portion of the components which make them useless for casting purposes.
My above cross-referenced application discloses that casting components formed of commercial metal casting plaster can be dried very satisfactorily, very much more quickly than by conventional methods, and with minimal damage to the structure of the component itself and to its surfaces, if the wet-molded component is subjected to a two-stage microwave radiation treatment with an intermediate cooling step. More specifically, it appears that the water is effectively eliminated, i.e. the casting component is completely calcined, without loss of its strength or surface characteristics, when the microwave treatment is carried out only until the internal temperature of the component slightly exceeds 300° F., followed by cooling to a temperature of not more than 200° F., and then by a further microwave treatment which raises the temperature throughout the component to about 300° F.
The success of this procedure apparently derives from the fact that during the first microwave treatment, the free water throughout the casting component is driven off, but while the water of crystalization in the central zones of the component is caused to migrate to the surface zones, it is not driven off because the surface of the component is sufficiently cooled by evaporation, of the free water, and also by radiation of heat to the normally cold walls of a microwave oven, to prevent the surface temperature from reaching the calcining range except after such prolonged treatment and resultant high internal temperatures as will "dead burn" or destroy the strength of the plaster of the central zones of the component. The second microwave treatment after cooling causes the water to be driven off from the surface zones of the component before the surface has been cooled by evaporation, and also before the central zones of the component can be reheated to the point of damage.
SUMMARY OF THE INVENTION
The present invention provides a process for fabricating foundry casting components, i.e. molds and cores, from gypsum-containing plaster in accordance with which such components can be dried by a single stage microwave radiation treatment as satisfactorily as, and even more quickly than, by the method of my referenced application. This invention is based on the discovery that if such a casting component is subjected to microwave radiation while it is insulated by a medium which is pervious to both the radiation and to water vapor, but which substantially prevents heat radiation from the surface of the component, the water will be completely eliminated from the component without developing such high temperatures in the interior of the component as will dead burn the plaster. For example, the process of the invention has been performed completely satisfactorily when the microwave treatment is carried out while the casting component is substantially completely covered by glass fiber mats of the type commonly used in the insulation of domestic housing and the like.
When the process of the invention is carried out in this manner, the elimination of the water is essentially continuous until the casting component is completely calcined. This appears to result from the fact that with the heat prevented from radiating away from the component while the water vapor and steam are allowed to escape freely, the surfaces of the component remain hot enough for continuous driving off of water until the calcining operation is complete. This process can therefore be carried out successfully with multiple-part molds while the mold parts are closed, because the calcining operation is continuous and essentially uniform throughout the mold mass.
Whatever the scientific reasons may be, the significant result is that when a plaster casting component has been treated by microwave radiation as outlined above, it produces a perfect casting, free of the defects which commonly result from an incompletely dried plaster mold or core. Further, this advantageous result is obtained with the additional benefit that the time required is a minor fraction of the time necessary when a conventional baking oven is used. An even more important advantage is that plaster molds have been produced in this manner in much greater sizes and with much higher fidelity as to reproduction of detail than has previously been possible using conventional drying methods, with the further outstanding advantage that such molds have been produced with substantial freedom from the cracking and surface crazing which are common disadvantages of conventionally dried plaster molds, and especially without impairment of the strength of the components in the manner caused by the prolonged heating otherwise needed to effect comparably through drying.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An example of the type of product for which the invention offers special advantages is a plaster mold from which to make metal castings which will in turn be used to produce plastic parts or sheet material having intricate surface pattern characteristics, such as wood grain or the appearance of leather or fabric. Such plaster molds are desirably of relatively large size to provide correspondingly large working areas, and they are extremely difficult to produce by conventional methods because of the tendencies of large plaster molds to crack or craze during conventional drying treatment.
In the practice of the invention, molds of such characteristics are produced by the following steps:
1. Prepare a mold pattern having the desired surface texture to be produced, as by lining the bottom of the cavity with a wood grained pattern whose surface is to be reproduced;
2. Spray the surface of the pattern lightly with an oil or other conventional release agent;
3. Fill the mold cavity with the proper mixture of water and plaster, preferably using 40-50% dry plaster blend and 50-60% water;
4. Allow the plaster to set, which normally requires only about ten minutes;
These first four steps are conventional, and other conventional preliminary steps may be used. Thus if the final product is to be a female (negative) mold for producing multiple reproductions of an original piece, the mold pattern referred to in step 1 is commonly produced by a rubber-like commercial molding compound which is applied to the original piece and can then be peeled away as a negative reproduction of the original.
5. Remove the set plaster mold mass from the mold cavity and place it in a microwave oven;
6. Cover all exposed surface areas of the mass with glass fiber matting of a thickness of at least 1 inch;
7. Apply microwave radiation until the internal temperature of the mass is in the range of 350°-400° F.;
8. discontinue heating and the mold is now ready to use for casting the metal part therefrom.
Plaster molds produced as outlined above have been found to possess all necessary strength characteristics as well as high fidelity of detailed reproduction of the original pattern surface, free of cracks, crazing, and other surface and structural defects. The time necessary to dry a plaster mold mass of a size requiring 35 to 40 hours in a conventional oven is only 3 to 10 hours for the process of the invention. In addition, when similar plaster molds are attempted to be produced by conventional heating treatments, the rate of failure by reason of cracking or crazing often exceeds 50%. It is also significant that when a similar plaster mold was subjected to a single microwave treatment by which its temperature was raised far above 320° F., e.g. 600° F., it still retained an undesirable amount of water, and it also was wholly lacking in the necessary strength as compared with the product of the insulated microwave treatment of the invention.
While glass fiber matting insulation has proved highly satisfactory, as well as easy to use as described above, the one-inch thickness noted above is only an example of matting which is readily commercially available, and lesser thickness can also be used. It is also possible to use other types of insulation to prevent radiation of heat from the casting component so long as they will transmit microwave radiation and permit the escape of water vapor and steam from the component during the microwave treatment. For example, the insulation medium may comprise ceramic plates or other solid members of refractory material, such as bricks, capable of freely transmitting microwave radiation and which are located in closely spaced relation with the casting component to leave a narrow slot therebetween, such as a slot in the range of a few thousandths of an inch to perhaps a quarter-inch, the objective being to minimize convention current away from the component while permitting steam and water vapor to escape. With such an arrangement, the water vapor or steam readily escapes through the slot while the heat is reflected back into the surface zone of the component so that the desired dehydration of the component will continue until the plaster is completely calcined.
While the times and temperatures specified above are not critical, they typify the preferred range, and there are also some temperature guidelines which should be observed. The microwave treatment should continue until the mass is heated beyond the calcining temperature of gypsum, namely 270°, but if it is permitted to rise as high as 600° F., the internal strength of the mass will be effectively destroyed. As a practical matter of safety, therefore, it should not go significantly higher than 400°, and the range of 350°-400° provides a safe margin as well as effective results.
Highly satisfactory control over the operation of the invention has been established by means of an infrared thermal controller arranged to measure the temperature of the surface within a cavity in the component being dried. For example, if the sprue hole in a multiple-part mold is at a convenient location such that the infrared detector can use it for target purposes, this provides a convenient way of measuring when the surface of the cavity in the mold mass has reached the proper temperature. Alternatively, satisfactory results have been obtained by providing a blind target hole in the side of the mass, e.g. 2-3 inches in diameter and two inches in depth, and in this case, a hole should also be provided in the insulation in line with this target hole so that the infrared detector can measure that surface temperature of the bottom of the hole.
While the method herein described constitutes a preferred embodiment of the invention, it is to be understood that the invention is not limited to this precise method, and that changes may be made therein without departing from the scope of the invention. | Metal casting components, e.g. molds and cores, are produced from a compacted mass of plaster by microwave treatment while shielded by a heat insulating medium, e.g. glass fiber matting, which freely transmits microwave radiation as well as water vapor and steam. A casting component dried by this method is completely calcined, and the resulting component will promote cast reproduction of its surface pattern with maximum fidelity of detail. | 1 |
The present application is a continuation-in-part of application Ser. No. 08/624,773 filed on Mar. 29, 1996 (now abandoned.) entitled Method and Apparatus for Discovering Server Applications in a Network of Computer Systems by Allan B. Butt and Michael D. Day II, and commonly assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of networked systems and, in particular, to a method and apparatus for facilitating the management of networked devices.
2. Background Information
Networking of computing elements and, in particular, the implementation of client/server networks, wherein the client is the initiating node and the server is the responding node (i.e., not necessarily referring to a file "server" or an application "server"), are known. Examples of these networks include local area networks (LANS), wide area networks (WANS), global networks (Internet), and the networking of telecommunications devices (i.e., cellular networks, PCS networks, wireline telephony networks), and the like. Many of these networks comprise a variety of client computers having different processor architectures and Operating Systems (OS) using Transmission Control Protocol/Internet Protocol (TCP/IP), Internetwork Packet exchange (IPX), and User Datagram Protocol/Internet Protocol (UDP/IP), or other suitable networking protocols (cumulatively referred to as the Internet communication suite) to produce a seemingly transparent network. Although it may appear to an end-user that the network is seemingly indifferent to computer type (e.g., Intel®-based PC, a Macintosh, or a UNIX system), the useable interface to the network protocols providing the communication interface between the heterogeneous computer systems still rely on the host OS. Therefore, for each of the popular OS, a corresponding "flavor" of the Internet communication suite must be developed in order to network a host computer system operating with any of these OS.
Thus, despite this seemingly transparent operation, the reality is that these heterogeneous computer networks can be very cumbersome to manage and, consequently, expensive to maintain. While the standards-based communication protocols of the Internet communication suite (e.g., TCP/IP, UDP/IP, IPX) have facilitated the promulgation of such heterogeneous networks, those who manage these networks must duplicate a number of resources to account for a variety of processor architectures and corresponding OS disposed throughout the network. That is to say that the file management, processor communications and the interface to the network communication suite rely on the OS as the user interface to provide a functional computer system (at least from the perspective of the end-user). Accordingly, in most instances where the OS "hangs" (i.e., seemingly "freezes" in an unrecoverable state), the user is, in essence, locked out from the operational state of the computer and the only recourse is to restart the OS (e.g., by rebooting the computer).
Producers and consumers of computer systems have begun to quantify the costs associated with the purchase and maintenance of computer systems and, to some, the results are surprising. One generalization drawn from such study is that the initial cost of purchasing a computer system and software (regardless of size and complexity) is quite small compared to the cost of maintaining such systems. That is to say, the cost of system management, lost productivity due to computer/network downtime and the like are significantly higher than the initial cost of purchasing the hardware and software elements comprising the network.
It is not surprising then, that consumers of large networks of computing devices are placing more pressure on the computing industry to drive down the cost associated with the management and maintenance associated with computer systems, i.e., to reduce the total cost of ownership (TCO) associated with the purchase and maintenance of the computer systems. Despite their best efforts, however, prior art network management solutions (sometimes referred to as network management tools) to these problems have not had a significant impact on reducing the total cost of ownership.
While the introduction of these tools have improved the general state of network management, fundamental limitations in their effectiveness remain. An example of one such inherent limitation in prior art management tools is the fact that they rely on an operational operating system (OS) at the client computer. That is to say, the prior art network management tools are unable to interface with a "frozen" client computer, much less perform remote diagnostics and maintenance on a client computer in such a state. Rather, many of the prior art management tools created by third party developers merely generate usage statistics, or information readily available from networked computers (or the individual processors of the networked computers), i.e., they merely collect and provide commonly available information via a graphical user interface (GUI).
To further illustrate this limitation with an example, if a user calls a corporate help desk complaining of computer problems, and the network manager determines that the user's OS is "frozen", there is little the network manager can do remotely via the network management software. Consequently, the network manager is often relegated to the rather impotent suggestion of having the user "reboot" the computer and, consequently, losing all of the data stored in volatile memory (i.e., not saved on the hard drive).
Thus a need exists for a method and apparatus for facilitating the management of networked devices, unencumbered by the deficiencies and limitations commonly associated with the prior art.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, a network management service for facilitating the management of networked devices by network management applications (a.k.a., agents) is described. The network management service comprises an agent discovery service for discovering and registering remote management agents, and a file transfer service operative to send information to and receive information from remote systems.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
FIG. 1 is a block diagram illustrating an example network of computer systems incorporated with the teachings of the present invention;
FIG. 2 is a block diagram of a network management service incorporated with the teachings of the present invention;
FIG. 3 is an illustration of a simple file transfer datagram used to communicate between network management services;
FIG. 4 is a flow chart depicting the method steps for pushing a file from a client to a server utilizing the network management service of FIG. 2;
FIG. 5 is a flow chart depicting the method steps for pulling a file from a server to a client utilizing the network management service of FIG. 2;
FIG. 6 is an illustration of a remote execution datagram used to communicate between network management services;
FIG. 7 is a flow chart depicting the method steps of one example of remotely configuring an unconfigured client utilizing a network management service, in accordance with the teachings of the present invention;
FIG. 8 is a block diagram illustrating an example of an unconfigured client computer;
FIG. 9 is a block diagram depicting the method steps of FIG. 7 from a high-level network architecture view; and
FIG. 10 is a flow chart illustrating the method steps for enabling remote power management using the network management service of FIG. 2, in accordance with the teachings of the present invention.
DETAILED DESCRIPTION
In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well known features are omitted or simplified in order not to obscure the present invention. Furthermore, for ease of understanding, certain method steps are delineated as separate steps, however, these separately delineated steps should not be construed as necessarily order dependent in their performance.
Referring now to FIG. 1, a block diagram of an example network of computer systems incorporating the teachings of the present invention is depicted. In one embodiment, for example, network 100 is comprised of a plurality of computing elements, at least a subset of which include the teachings of the present invention. In particular, at least a subset of the computing elements comprising network 100 are disposed with an innovative network management service, incorporated with the teachings of the present invention, enabling an improved level of network manageability and interoperability independent of the myriad of operating systems that may reside within network 100. As will be described more fully below, the network management service incorporating the teachings of the present invention enables a network management application (also commonly referred to as network management agent, or NMA), for example, to interrogate and manipulate a client computer independent of the particular type of operating system (OS) resident on the client computer. In one embodiment, for example, a network management agent may initialize the network management service of the present invention to automatically populate a client computer located within network 100 with a new/updated operating system, and/or replaces an operating system on a client computer within network 100 that has become inoperative.
As depicted in FIG. 1, network 100 is shown comprising clients 102 and 104, and servers 106 and 108, interconnected to each other via network medium 120. In one embodiment, clients 102 and 104 are personal computer systems, while in an alternate embodiment, clients 102 and 104 are telecommunication network devices. As illustrated in FIG. 1, network medium 120 is intended to represent a broad category of networking infrastructure including network cables and their associated switching (routing), repeater, and/or delay elements, suitable for a high speed local area network (LAN), or a slower speed wide area network (WAN), or public network (i.e., Internet) implementations known in the art. Although certain computing elements of network 100 are labeled as servers 106 and 108 while other computing elements are labeled as clients 102 and 104, those skilled in the art will recognize that these labels are for the purpose of illustration and ease of understanding only. The term server includes but is not necessarily limited to a "file" server or an "application" server.
In one embodiment of the present invention, clients 102 and 104 include client application(s) 120 and 122, client operating system (OS) 130 and 132, network transport services 140 and 142 (sometimes referred to as the transport layer), operatively coupled as depicted. In one embodiment of the present invention, client 102 is shown further comprising network management service 150 incorporated with the teachings of the present invention. As will be discussed in greater detail below, a network management service (e.g., network management service 150) may be beneficially incorporated into each of the computing elements of network 100, however, as depicted in FIG. 1, a network management service need not be fully disposed in every client or server in order for network 100 to benefit from the present invention.
Continuing with FIG. 1, as illustrated, client applications 120 and 122 are intended to represent any number of a wide variety of applications, in particular, management applications such as Client Manager and Work Group Manager, available from Intel Corp., of Santa Clara, Calif. As depicted, client applications 120 and 122 rely on operating systems 130 and 132, respectively, to interface with network transport services 140 and 142 and, ultimately, with network medium 120. In one embodiment, as will be discussed in greater detail below, client application 120 may alternatively interface with network medium 120 via network management service 150 and network transport service 140 as shown.
Similarly, operating systems 130 and 132 are intended to represent a wide variety of operating systems common to a corresponding variety of computing platforms. Examples of such operating systems include the UNIX operating system, Windows™ based operating systems (e.g., Windows™ 3.1, Windows™ 95, Windows™ NT and Windows™ CE), the Macintosh™ and NeXTStep™ operating systems, and the like.
Network transport services 140 and 142 perform their conventional function of physically sending and receiving information over the network medium, as known in the art. In one embodiment the form of the information exchange is through a message packet. In one embodiment, for example, the message packet is a datagram, the structure of which will be discussed more fully below in FIG. 3. As illustrated, network transport services 140 and 142 are intended to represent a broad category of transport services known in the art. Examples of such network transport services include Internetwork Packet eXchange (IPX), User Datagram Protocol/Internet Protocol (UDP/IP), NetBEUI, NetBIOS over IP, NetBIOS over IPX, and the like.
In addition to clients 102 and 104, network 100 is also comprised of servers 106 and 108, which include server applications 160 and 162, server operating system 170 and 172, network transport services 180 and 182, and network management services 190 and 192 incorporating the teachings of the present invention, respectively. In an alternate embodiment, to be discussed more fully below, not all of the plurality of servers 106 and 108 need to have its own network management service. So long as a network management service is disposed within the network, the clients/servers of the network may benefit from some measure of the functionality that network management service provides.
As illustrated in FIG. 1, servers 106 and 108 include server applications 160 and 162, operating systems 170 and 172, and network transport services 180 and 182 each of which are intended to represent a broad category of applications, operating systems and network transport services known in the art. Consequently, they will not be discussed further. On the other hand, network management services (e.g., network management services 150, 190 and 192) incorporating the teachings of the present invention, comprise a plurality of services which enable, for example, network management applications to interact with network elements independent of the operating systems resident on those network elements.
Turning, then, to FIG. 2, a block diagram depicting one example of a network management service (i.e., network management service 200) is shown. In one embodiment of the present invention, network management service 200 may be beneficially incorporated into network 100 as, for example, network management service 150, 190 and/or 192. In one embodiment, network management service 200 is shown comprising agent discovery service 202, simple file transfer service 204 and remote execution service 206. In another embodiment of the present invention, network management service 200 may also include communication service 208 depicted in FIG. 2 with dashed lines. Each of the respective elements of network management service 200, and their corresponding communication protocols will be described more fully below. However, before describing these elements in further detail it should be noted that network management service 200 is an enabling technology. That is to say, network management service 200 enables a client to discover remote agents, communicate with remote agents, transfer files to and from remote computers, and remotely initiate local execution of applications on the client, independent of the particular type of operating system(s) operating on the client computer. Invocation of the services offered by the network management service may be accomplished in any number of approaches known in the art, e.g., application program interface(s) (API's).
Returning to the description of the elements of FIG. 2, network management service 200 includes agent discovery service 202. Agent discovery service 202 is the subject of the parent US Patent Application, identified above. In brief, agent discovery service 202 enables network management service 200 to discover and register remote agents, and allows local agents to be discovered and remotely registered. The remote agents may be agents residing on remote clients or remote servers. In one embodiment of the present invention, agent discovery service 202 initiates the discovery process by broadcasting a packet (or datagram) of information on network 100 via network medium 120. In the context of this implementation, the packet of information is referred to as a PING packet, i.e., the packet of information sent by agent discovery service 202 searching for remote agents. On behalf of remote agents disposed to discovery, discovery service of like kind, which may or may not be part of a network management agent, responds to the received PING packet with a similar packet of information, i.e., a PONG packet via network 100.
In one embodiment of the present invention, lists of remote agents discovered are maintained. In one embodiment, for example, local applications instruct network management service 200 to discover remote agents, while in an alternate embodiment, network management service 200 autonomously updates the discovered list. In addition, agent discovery service 202 of network management service 200 responds, in accordance with user preferences for the network element in which it resides, to PING packets of remote agents.
Another element of the network management service 200 of FIG. 2 is the simple file transfer service 204. In one implementation, files may be "pushed" (e.g., from client 102 to server 106) or "pulled" (e.g., from server 106 to client 102) using a pair of simple file transfer service 204 disposed in a client and a server, respectively. In an alternate implementation, simple file transfer service 204 unilaterally identifies and retrieves a file from a remote agent. In one embodiment, a listing (e.g., a directory) of the files available on the remote agent may be obtained by simple file transfer service 204, in addition to the files themselves. In one embodiment, simple file transfer service 204 will depict a directory of available files in a UNICODE format, requiring local agents to interpret the UNICODE listing and translate the UNICODE directory into a local format. In one embodiment of the present invention, communication for the simple file transfer service 204 is performed on dynamic IPX sockets and UDP/IP ports, while in alternate embodiments, a fixed socket/port may be assigned.
The communication protocol employed by simple file transfer service 204 uses a request/reply datagram sequence to accomplish the file transfer. For example, in one implementation, simple file transfer service 204 requests include cancel, close, execute, list, create, read, shutdown and write operations. In accordance with this example protocol, each request will be responded to with a reply. For example, a create request will be responded to with a create reply.
In accordance with this example protocol, a create request is used to obtain a file handle for a new file to be created on the server. A cancel request is used to abort or cancel any operation in process. In one embodiment, the cancel request does not elicit a reply. The close request is used to prematurely close a write request. The list operation is used to obtain a directory listing of files. The directory listing may contain a single file name or it may contain an iterative list of file names satisfying wild-card characters. In one embodiment, the read request/reply datagrams contain a status field which indicates to the simple file transfer service when the end of file (EOF) is reached. Similarly, the write request is used to "push" a file from the client to the server. In one embodiment, the write request/reply datagrams contain a status field which indicates to the simple file transfer service that the end of file (EOF) has been reached.
The shutdown request is used to log off, power off, reboot, "kill" or shutdown a remote server. In particular, the shutdown request contains an attribute field which specifies which of the above operations are to be performed with the issuance of the shutdown request. In one embodiment, the server will reply with a failed shutdown request if there are other clients using it. However, by utilizing the "kill" option of the shutdown request, the client forces the server to terminate all clients (with ample notification to the clients that the server is going down) and proceeds with the request. In accordance with the example protocol, the execute request is used to remotely initiate local execution of a specified process. In one embodiment of the present invention, the request/reply sequences take the form of a communication packet, or datagram. One example of a file transfer datagram is depicted in FIG. 3.
In accordance with the example file transfer datagram of FIG. 3, file transfer datagram 300 is depicted comprising header 302, version 304, packet type 306, dgram -- size 308, client -- data 310, server -- data 312, sequence field 314, status 316, file handle 318, I -- parm -- 1 320, I -- parm -- 2 322, data length indicator 324 and data 326. In this example file transfer datagram 300, header 302 includes a header identifying the transport service utilized. In one embodiment, for example, header 302 is the base transport layer header. Version field 304 indicates the file transfer protocol version. That is, the version of the datagram is compared to the version of the application, wherein the datagram packet is converted to the appropriate version, if necessary.
The packet type field 306 of file transfer datagram 300 indicates the request or reply type for the current packet. For example, packet type 306 will indicate whether the current request is an open, close, cancel, etc. The dgram -- size field 308 specifies the maximum packet size that can be accepted by the sender of the datagram (i.e., datagram 300). Consequently, any packet returned to the sender should not exceed this size. In addition, those skilled in the art will appreciate that each of the different transport layers support a different maximum datagram size, which should not be exceeded. Consequently, dgram -- size 608 contains the smaller of either the maximum datagram size of the sender, or the maximum datagram size of the base level transport layer employed. Client -- data field 310 indicates identification data from the client side. The server application places the contents of client -- data field 310 of a request packet into the client -- data field 310 for the corresponding reply packet. The data of the client -- data field 310 may be used, for example, to identify some instance data associated with the current packet session. Similar to client -- data field 310, is server -- data field 312 which contains information with regard to the server. Sequence field 314 is used to identify repeated request and reply packets.
With continued reference to the file transfer datagram of FIG. 3, status field 316 indicates the success or failure of a request. In one embodiment, for example, a zero indicates success, while a non-zero value represents some sort of error. File handle 318 may be found in all replies and in all requests except for an open or a create request (wherein the reply will include the file handle). I -- parm -- 1 320 and I -- parm -- 2 322 are optional fields in the datagram and may, in one embodiment of the present invention, be used for creation data and file size in the open reply. Data length 324 indicates the byte-length of the data field. Data 326, if present contains dynamic length data.
The contents of data field 326 depend on the packet type. For example, for a create packet type, data field 326 may contain the file specification, whereas for a read packet type, data field 326 may contain the read data. In the example implementation, all file transfer requests and replies use the same packet format. Not all fields are used by all requests or replies. In one embodiment, for example, when a field is not used in a particular request or reply, it is set to zero.
In accordance with this example implementation, FIG. 4 depicts a series of method steps wherein a file is pushed from a client to a server (e.g., client 102, server 106) through network management services. As depicted in FIG. 4, the process begins with a create request sent by client 102 to server 106 using file transfer service of the respective network management service or equivalent, step 402, wherein a temporary file is created on server 106 to store the pushed data. In one embodiment of the present invention, when the temporary upload file is created, a corresponding temporary file handle is created by simple file transfer service 204 of the server by which the temporary upload file is subsequently referred. Those skilled in the art will recognize that "a file handle is a [unique] `token` (number) that the system uses in referring to an open file" (Computer Dictionary, Second Edition, published by Microsoft Press, page 165 (©1994)). That is to say, the file handle binds the upload file to a particular network address, wherein the network address includes the client application's dynamic socket/port. It should be appreciated, then, that there may be only one file handle per network address active at one particular time (unless multiple network transport services-sockets/ports are available, i.e., a multiprocessing multi-communication channel system).
In one embodiment, the temporary upload file is created by simple file transfer service 204 of network management service 200 of the server in a non-volatile storage device on the server. In an alternate embodiment, simple file transfer service 204 of network management service 200 of the server may allocate space in a volatile storage device for the temporary upload file.
Once the temporary upload file has been created, i.e., on the server (e.g., server 106), the client opens the file which is to be uploaded and a write file transfer datagram is issued in step 404, wherein data is written from the file resident on client 102 to the temporary upload file created on server 106. The amount of data pushed with each write file transfer datagram is dependent upon the size of data field 326 of datagram 300. In step 406, a determination is made at client as to whether the end of the file to be pushed has been reached. If so, a close file transfer datagram is issued and the temporary upload file on the server is closed, step 408. If it is determined in step 406 that the end of the file to be pushed has not yet been reached, however, the process loops back to step 404, wherein another write file transfer datagram is issued and the next block of data is written from client 102 to the temporary upload file on server 106. The looping process (e.g., steps 404 and 406) continues until all of the data to be pushed has been written to the temporary upload file on server 106, whereafter a close file transfer datagram is issued and the temporary upload file is closed, step 408. Once the temporary upload file is closed, step 408, server 106 renames the temporary upload file with the filename designated in the create request and any other file with the same name is removed, step 410. If, however, a cancel request is issued prior to a close request, any previous file with the same name is preserved.
Similarly, in accordance with this example implementation, files may be pulled from a server to a client (e.g., from server 108 to client 104) employing simple file transfer service 204 of network management service 200 or equivalent, as depicted in FIG. 5. As illustrated, FIG. 5 depicts the method steps by which the simple file transfer service 204 of network management service 200 of a client "pulls" a file from server 108 to client 104. The method begins wherein simple file transfer service 204 of the client issues an open file transfer datagram, step 502, and in response simple file transfer service 204 of the server opens the source file located on the server (e.g., server 108). Concurrently, client 104 creates a temporary download file into which the data from the remote file will be read. Similar to the push process, client 104 creates a temporary download file, referenced via a file handle.
Once the remote file is opened, step 502, a read file transfer datagram is issued, wherein a block of data is read from the remote file into the temporary download file, step 504. The amount of data pulled in a single read file transfer datagram is limited only by the size allocated to data field 326 of file transfer datagram 300. Subsequently, in step 506, simple file transfer service 204 of the client determines whether the end of the remote file has been reached. If not, the method loops back to step 504, and the next block of data is pulled. If, however, the entire file has been pulled, simple file transfer service 204 of the client issues a close file transfer datagram to close the remote file, step 508. Once the close request has been issued, the file handle of the temporary download file is made permanent. If, however, a cancel request is issued prior to a close request, the remote file is closed and the temporary download file is removed (i.e., enabling client to reallocate memory allocated to the temporary download file).
In addition to its agent discovery service 202 and file transfer service 204 elements, network management service 200 of FIG. 2 includes remote execution service 206. Remote execution service 206 of network management service 200 is used to initiate remote execution of an application, as well as remotely initiate local execution of an application. In one embodiment remote execution services 206 disposed on a client and a server cooperate to facilitate a server to respond to a client (or vice versa, or among clients, or among servers) to initiate execution of a file. In one implementation, a communication protocol of datagrams is employed by remote execution service 206 to facilitate remote initiation of local execution of an application, or initiate remote execution of an application. One example of a datagram employed by remote execution service 206 is illustrated in FIG. 6.
FIG. 6 illustrates an example of a datagram communication packet suitable for use by remote execution service 206. As depicted in FIG. 6, remote execution datagram 600 is shown comprising header 602, version 604, packet -- type 606, dgram -- size 608, client -- data 610, server -- data 612, sequence 614, status 616, data -- length 618 and data field 620. Of particular interest is data field 620, wherein the executable filename and any command-line arguments (i.e., an argument list) are contained. In one embodiment of the present invention, each of the arguments within data -- field 620 are zero-terminated, and the argument list ends after an empty string (also zero-terminated). Thus, in accordance with this example implementation, an example of the information contained in data -- field 620 is depicted in example (1) below.
PBRUSH.EXE\0BITMAP.BMP\0\0 (1)
In an alternate embodiment, the data contained within data -- field 620 may be terminated with a carriage-return/line-feed, terminated by a null-string (0), as depicted below in example (2).
PBRUSH.EXE
BITMAP.BMP
0 (2)
The remote execution service 206, in the role of facilitator, upon receipt of remote execution datagram 600 checks for the presence of the executable file described in data -- field 620 and, if present, causes the file to be executed. Authorization services are incorporated into and are the responsibility of remote execution service 206. The authorization protocol will vary depending on the operating environment. In one embodiment, the execution of the applications will not begin until the network management service 200 has been shutdown. In another embodiment, network management service 200 may cause itself to be transferred to and executed on a remote computer.
Continuing with the description of remote execution datagram 600, header field 602 contains information related to the type of transport employed. In one embodiment, for example, header field 602 contains the transport layer header. Version field 604 contains the file transfer protocol version. The packet -- type field 606 of remote execution datagram 600 contains the request or reply type for this packet. The dgram -- size field 608 contains information as to the maximum packet size that can be accepted by the sender of remote execution datagram 600. Consequently, any packet returned to the sender of remote execution datagram 600 (i.e., a reply) should not exceed this size. As was the case for file transfer datagram 300, dgram -- size 608 contains the smaller of either the maximum datagram size of the sender, or the maximum datagram size of the base level transport layer employed.
In addition, remote execution datagram 600 includes client -- data field 610. In one embodiment, for example, client -- data field 610 is a four-byte field containing data from the client side. The remote execution service places the contents of client -- data field 610 of a request packet into the client -- data field 610 for the corresponding reply packet. The data of the client -- data field 610 may be used, for example, to identify some instance data associated with the current packet session. Similar to client -- data field 610, is server -- data field 612 which contains information with regard to the server. Sequence field 614 is used to identify repeated request and reply packets. Status field 616 of remote execution datagram 600 indicates the success or failure of a request. The data -- length field 618 indicates to the recipient of remote execution datagram 600 the length of the data field.
In addition to the above described elements of network management service 200, i.e., agent discovery service 202, simple file transfer service 204 and remote execution service 206, network management service 200 may beneficially include communication service 208. Network management service 190 employs communication service 208 to "translate" the information to/from the transport layer service.
In one embodiment, communication service 208 allows network management service 200 to function regardless of the underlying network transport protocol by abstracting the differences of the supported transport protocols (TCP/IP, IPX/SPX, etc.) into a set of common-denominator functions, and by establishing well-known port or socket addresses for communication service communications. For example, in one embodiment, communication service 208 establishes "listening addresses" for all of the supported transport protocols (identified above) and uses the agent discovery service 202 discovery protocol to make these listening addresses available to other instances of communication service 208 located throughout the network. Having established listening addresses for each supported transport protocol, and having made those addresses discoverable to communication service 208 of remote network management services (i.e., network management service 200), the network management service 200 of the server may then proceed to perform communications over the network, via communication service 208 without regard to any particular transport protocol supported by a particular client. In particular, communication service 208 on a server (e.g., server 108) knows which protocol(s) is(are) supported by communication service 208 on the client (e.g., client 104), and at which listening addresses those protocols are typically received.
Given the descriptions and example implementations above, one skilled in the art will appreciate that the innovative features of network management service 200 may be implemented in a number of alternate embodiments. In one embodiment, for example, network management service 200 may take the form of a plurality of software instructions stored in a machine readable format and executed by a computer. In an alternate embodiment, network management service 200 may be embedded in an Application Specific Integrated Circuit within a computer.
Having described the functional elements and protocols employed by network management service 200 in FIGS. 2-6 above, FIGS. 7-9 are provided as an example, and not limitation, of an example application of the innovative features of the network management service 200. In FIG. 7, a flow chart illustrating one example of a method for configuring an unconfigured client computer. For ease of understanding, the example application of FIGS. 7-9 will be described in the context of the elements of network 100. Accordingly, in the context of the example implementation, a network management application (e.g., application 160) executing on a server (e.g., server 108) through network management service 200 detects an unconfigured client computer (e.g., client 105) and, in accordance with the innovative features enabled by the network management service (e.g., network management service 192), configures the client for operation within network 100.
Before describing the method of FIG. 7 in detail, it may be helpful to review an example high-level architecture of an unconfigured client. FIG. 8 illustrates a block diagram of the high-level architecture of unconfigured client computer 800. The use of the term "unconfigured" may be a bit of a misnomer insofar as there is a rudimentary level of functionality that is assumed when a computer is shipped from a computer manufacturer. As depicted in the example architecture of FIG. 8, "unconfigured" client computer 800 includes hardware 802, hardware configuration data 804, basic input/output system (BIOS) 806, BIOS configuration data 808 and a rudimentary set of network boot instructions stored in non-volatile memory (e.g., a boot PROM) 810. In one embodiment, client computer 800 is client 105. Hardware 802 includes at least one processor, a memory subsystem, an input/output device, and a communications subsystem. In one embodiment, hardware 802 may also include such items as a mass storage device, a display, peripherals, and the like. Hardware configuration data 804 includes information necessary to interface elements of hardware 802. BIOS 806 provides basic input/output services. In one embodiment, BIOS 806 includes desktop management interface (DMI) services including special network manageability services, e.g., in accordance with Desktop Management BIOS Specification, version 2.0, dated Feb. 23, 1996. BIOS configuration data 808 includes configuration data for the hardware/I/O system. Boot instructions 810 provide a set of instructions executed at start-up which provide a nominal level of functionality to the computer. Boot instructions 810 are stored in a non-volatile memory such as a programmable read-only memory (PROM), and initiate execution of a rudimentary "operating system" (OS). In one embodiment, the rudimentary "OS" provides the computer with a rudimentary level of memory management, communication and file transfer capability to computer 800.
Returning to the example method of FIG. 7, the method of configuring an unconfigured client begins with step 702, wherein server 108 determines that client 105 is not executing an operating system. The means by which server 108 determines that client 105 does not have an operating system depends upon the configuration of client 105. For example, in one embodiment wherein client 105 is configured with network management service 200, the agent discovery service broadcasts PING datagrams looking for servers that can fully configure client 105. In an alternate embodiment, a network management service resident on server 108 broadcasts PING datagrams searching for unconfigured network clients, and client 105 responds to the PING datagram with an indication identifying client 105 as an unconfigured network client.
For the illustrated example, once it has been determined by management application 160 that client 105 is not populated with an operating system, management application 160 next determines whether client 105 is populated with a network management service. As described above, in one embodiment, agent discovery service 202 of network management service 192 issues a PING datagram on network medium 120 via network transport service 180, and awaits a reply (i.e., a PONG datagram). If, in step 704, it is determined that client 105 does not have a network management service, network management service 192 downloads a copy of network management service to client 105 via the rudimentary OS, in accordance with, for example, the method steps illustrated in FIG. 5, step 708. Once the download of a network management service has been completed in step 708, its execution is initiated, step 710.
Once a network management service has been downloaded to and executed on client 105 from network management service 192 in steps 706 and 708, or if in step 704 it was determined that client 105 was already enabled with a network management service, management application 160 determines the operating system requirements for client 105, step 710. In one embodiment, for example, this determination is made by ascertaining the type of processor resident in client 105. Having determined the operating system requirements of client 105, management application 160, via simple file transfer service 204 of network management service 192 downloads an appropriate operating system from server 106 to client 105, step 712. Once the download of the appropriate operating system has been completed in step 712, remote execution service 206 of network management service 192 of server 106 and the remote execution service of the newly downloaded network management service on client 105 are employed by management application 160 to remotely initiate execution of the newly downloaded operating system on the client, step 714. In one embodiment, for example, the remote execution service of network management service 192 of server 106 issues a remote execution datagram to the remote execution service of the downloaded network management service resident on client 105, identifying the AUTOEXEC.BAT file, with appropriate command line entries, thereby remotely initiating local execution of the operating system on client 105.
In addition to the download of a new, or an upgrade of an existing operating system, server 106 may utilize network management service 192 and the newly downloaded network management service on client 105 to download additional applications or agents to client 105, step 716. FIG. 9 illustrates a block diagram of the method steps depicted in FIG. 7 from a network perspective. In particular, FIG. 9 illustrates server 106 downloading a network management service to client 105 and subsequently utilizing the downloaded network management service to facilitate a network management agent to configure client 105 with an operating system and other applications/agents.
Another example of the innovative features enabled by the introduction of network management service 200 into a network is illustrated in FIG. 10. In particular, FIG. 10 illustrates the method steps wherein a server configured with network management service 200 facilitates remote initiation (i.e., "power up") of a network management service-enabled client computer that is in a power-off or "sleep" state (e.g., a low power state) to perform network management operations, and subsequently returns the client to its power state prior to the network management session. For ease of explanation, the method steps of FIG. 10 will be developed in the context of the network elements of FIG. 1.
The method begins, step 1002, with a network management agent identifying a client (e.g., client 102) that is the target of the management operation (i.e., the remote power-up operation) of the server (e.g., server 108). There are a number of methods by which the target client may be identified. In one embodiment, for example, network management agent 162 establishes a list of all network clients which are operating under a prior version of a particular operating system, which includes client 102 for this example. In accordance with the teachings of the present invention, rather than interrupting the computer services to a user of client 102 by immediately upgrading the clients operating system, network management agent 162 may make a log entry of the fact that the identified client needs defined network maintenance. Subsequently, when network management agent 162 "senses" that client 102 has been powered-off, network management agent 162 waits for a convenient maintenance period to perform such maintenance (e.g., after normal working hours).
Having identified the target client in step 1002, network management service 192 of the server is called upon to determine if client 102 is configured with a network management service. In one embodiment, network management service 192 sends a PING datagram to discover if client 102 is configured with a network management service, in accordance with the teachings above. If network management service 192 determines that client 102 is not populated with a network management service, network management service 192 populates client 102 with a network management service. In particular, with client powered-up, network management service 192 of the server pushes (i.e., downloads) a network management service from server 108 to client 102, step 1006, and remotely initiates local execution of the pushed network management service, step 1008, in accordance with the teachings of FIG. 5.
If, in step 1004, it is determined that client 102 is populated with a network management service (e.g., network management service 150), network management agent 162, through network management service 150, retrieves the last power state of client 102. In step 1010, network management agent 162 determines if the power state of client 102 is satisfactory to perform the desired operation, step 1012. If not, network management agent 162 issues a power state command through network management service 192 to network management service 150 to place client 102 in the necessary power state, step 1014.
Having issued the power state command in step 1014, or if in step 1012 it is determined that client 102 is in the proper power state to perform the desired operation, network management agent 162 performs the desired management function in step 1016. In accordance with the present example implementation, network management service determines that client is in a powered-down state, steps 1010, 1012, and issues the necessary power state command to enable at least a subset of the system components comprising client 102 (e.g., the computer, but not the monitor, printer, scanner, etc.), step 1014. Once client 102 has booted up, albeit running an old version of the OS, network management service initiates an OS upgrade, step 1016.
Having completed the desired network management operation in step 1016, network management agent 162 issues a power state command to network management service 150 through network management service 192 to place client 102 in the power state prior to the network management session, step 1018.
Those skilled in the art will appreciate that the innovative network management service provides a heightened level of network manageability and interoperability. As described above, the network management service is platform independent; that is, it will work in a myriad of computer processing environments. Insofar as the network management service 200 operates independently of any particular computer operating system, the introduction of a network management service 200 into a network (e.g., network 100) allows a network manager in a central location to not only monitor network statistics, but to interrogate and remotely manipulate remote clients. As alluded to earlier, network management service 200 is an enabling technology providing a new generation of network management applications with interoperable access to the most fundamental processes of the computer system.
Thus, alternative embodiments for a method and apparatus facilitating the management of networked devices have been disclosed. While the method and apparatus of the present invention has been described in terms of the above illustrated embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. For example, one skilled in the art will appreciate from the above description and example implementations that network management service 200 may be beneficially employed to perform a number of network functions heretofore unavailable in prior art network management tools. In addition, it has been shown that it is unnecessary for each of the computing elements within network 100 to incorporate network management service 200, for so long as it is available within the network, it may be downloaded and executed on an as needed basis. Thus, those skilled in the art will appreciate that the present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. Accordingly, the descriptions thereof are to be regarded as illustrative instead of restrictive on the present invention. | A network management service for facilitating the management of networked devices by network management applications (a.k.a., agents) is described. In a first embodiment, the network management service for facilitating the management of networked devices by network management applications (a.k.a., agents) comprises an agent discovery service for discovering and registering remote management agents, and a file transfer service operative to send information to and receive information from remote systems. | 7 |
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a continuation-in-part claiming priority under 35 U.S.C. §120 to U.S. app. Ser. No. 12/575,024, entitled System and Methods Using Fiber Optics in Coiled Tubing, filed Oct. 7, 2009, and which is a Continuation of 11/135,314 of the same title, filed on May 23, 2005, both of which are incorporated herein by reference in their entireties along with the Provisional Parent of the same title under 35 U.S.C. §119(e), App. Ser. No. 60/575,327, filed on May 28, 2004.
FIELD
[0002] Embodiments described relate to tools and techniques for delivering treatment fluids to downhole well locations. In particular, embodiments of tools and techniques are described for delivering treatment fluids to downhole locations of low pressure bottom hole wells. The tools and techniques are directed at achieving a degree of precision with respect to treatment fluid delivery to such downhole locations.
BACKGROUND
[0003] Exploring, drilling and completing hydrocarbon and other wells are generally complicated, time consuming, and ultimately very expensive endeavors. As a result, over the years, a tremendous amount of added emphasis has been placed on monitoring and maintaining wells throughout their productive lives. Well monitoring and maintenance may be directed at maximizing production as well as extending well life. In the case of well monitoring, logging and other applications may be utilized which provide temperature, pressure and other production related information. In the case of well maintenance, a host of interventional applications may come into play. For example, perforations may be induced in the wall of the well, regions of the well closed off, debris or tools and equipment removed that have become stuck downhole, etc. Additionally, in some cases, locations in the well may be enhanced, repaired or otherwise treated by the introduction of downhole treatment fluids such as those containing acid jetting constituents, flowback control fibers and others.
[0004] With respect to the delivery of downhole treatment fluid, several thousand feet of coiled tubing may be advanced through the well until a treatment location is reached. In man cases a variety of treatment locations may be present in the well, for example, where the well is of multilateral architecture. Regardless, the advancement of the coiled tubing to any of the treatment locations is achieved by appropriate positioning of a coiled tubing reel near the well, for example with a coiled tubing truck and delivery equipment. The coiled tubing may then be driven to the treatment location.
[0005] Once positioned for treatment, a valve assembly at the end of the coiled tubing may be opened and the appropriate treatment fluid delivered. For example, the coiled tubing may be employed to locate and advance to within a given lateral leg of the well for treatment therein. As such, a ball, dart, or other projectile may be dropped within the coiled tubing for ballistic actuation and opening of the valve at the end of the coiled tubing. Thus, the treatment fluid may be delivered to the desired location as indicated. So, by way of example, an acid jetting clean-out application may take place within the targeted location of the lateral leg.
[0006] Unfortunately, once a treatment application through a valve assembly is actuated as noted above, the entire coiled tubing has to be removed from the well to perform a subsequent treatment through the assembly. That is, as a practical matter, in order to re-close the valve until the next treatment location is reached for a subsequent application, the valve should be manually accessible. In other words, such treatments are generally ‘single-shot’ in nature. For example, once a ball is dropped to force open a sleeve or other port actuating feature, the port will remain open until the ball is manually removed and the sleeve re-closed.
[0007] As a result of having to manually access the valve assembly between downhole coiled tubing treatments, a tremendous amount of delay and expense are added to operations wherever multiple coiled tubing treatments are sought. This may be particularly the case where treatments within multilaterals are sought. For example, an acid jetting treatment directed at 3-4 different legs of a multilateral well may involve 6-8 different trips into and out of the well in order to service each leg. That is, a trip in, a valve actuation and clean-out, and a trip out for manual resetting of the valve for each treatment. Given the depths involved, this may add days of delay and tens if not hundreds of thousands of dollars in lost time before complete acid treatment and clean-out to each leg is achieved.
[0008] A variety of efforts have been undertaken to address the costly well trip redundancy involved in coiled tubing fluid treatments as noted above. For example, balls or other projectiles utilized for valve actuation may be constructed of degradable materials. Thus, in theory, the ball may serve to temporarily provide valve actuation, thereby obviating the need to remove the coiled tubing in order to reset or re-close the valve. Unfortunately, this involves reliance on a largely unpredictable and uncontrollable rate of degradation. As such, tight controls over the delivery of the treatment fluids or precisely when the coiled tubing might be moved to the next treatment location are foregone.
[0009] As an alternative to ball-drop type of actuations, a valve assembly may be utilized which is actuated at given pre-determined flow rates. So, for example, when more than 1 barrel per minute (BPM) is driven through the coiled tubing, the valve may be opened. Of course, this narrows the range of flow rate which may be utilized for the given treatment application and reduces the number of flow rates left available for other applications. In a more specific example, this limits the range of flow available for acid jetting at the treatment location and also reduces flow options available for utilizing flow driven coiled tubing tools, as may be the case for milling, mud motors, or locating tools. Thus, as a practical matter, operators are generally left with the more viable but costly manual retrieval between each treatment.
SUMMARY
[0010] A reversible valve assembly is disclosed for coiled tubing deployment into a well from an oilfield surface. The assembly includes a valve disposed within a channel of the assembly for reversibly regulating flow therethrough. A communication mechanism, such as a fiber optic line may be included for governing the regulating of the flow. The valve itself may be of a sleeve, ball and/or adjustable orifice configuration. Further, the valve may be the first of multiple valves governing different passages. Once more, in one embodiment first and second valves may be configured to alternatingly open their respective passages based on input from the communication mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front view of downhole coiled tubing equipment employing an embodiment of a surface controlled reversible coiled tubing valve assembly.
[0012] FIG. 2 is art enlarged cross-sectional view of the reversible coiled tubing valve assembly taken from 2 - 2 of FIG. 1 .
[0013] FIG. 3 is an overview depiction of an oilfield with a multilateral well accommodating the coiled tubing equipment and valve assembly of FIGS. 1 and 2 .
[0014] FIG. 4A is an enlarged view of a locator extension of the coiled tubing equipment signaling access of a leg of the multilateral well of FIG. 3 .
[0015] FIG. 4B is an enlarged view of a jetting tool of the coiled tubing equipment reaching a target location in the leg of FIG. 4A for cleanout.
[0016] FIG. 4C is an enlarged sectional view of the valve assembly of the coded tubing equipment adjusted for a fiber deliver application following the cleanout application of FIG. 4B .
[0017] FIG. 5 is a flow-chart summarizing an embodiment of employing a surface controlled reversible coiled tubing valve assembly in a well.
DETAILED DESCRIPTION
[0018] Embodiments are described with reference to certain downhole applications. For example, in the embodiments depicted herein, downhole cleanout and fiber delivery applications are depicted in detail via coiled tubing delivery. However, a variety of other application types may employ embodiments of a reversible coiled tubing valve assembly for a variety of different types of treatment fluids as described herein. Regardless, the valve assembly embodiments include the unique capacity to regulate fluid pressure and/or delivery for a given downhole application while also being adjustable or reversible for a subsequent application without the need for surface retrieval and manipulation.
[0019] Referring now to FIG. 1 , with added reference to FIG. 3 , a front view of downhole coiled tubing equipment 101 is depicted. The equipment 101 includes a reversible valve assembly 100 which, in conjunction with other downhole tools, may be deployed by coiled tubing 110 at an oilfield 301 . Indeed, the assembly 100 and other tools of the equipment 101 may communicate with, or be controlled by, equipment located at the oilfield 301 as detailed further below. The valve assembly 100 in particular may be utilized in a reversible and/or adjustable manner. That is, it may be fully or partially opened or dosed via telemetric communication with surface equipment.
[0020] A ‘universal’ valve assembly 100 , so to speak, with reversibility, may be employed to reduce trips into and out of a well 380 for fluid based treatments as indicated above. This capacity also lends to easier reverse circulation, that is, flowing fluids into and out of the well 380 . Further, this capacity also allows for utilizing the valve assembly 100 as a backpressure or check valve as needed. Once more, given that the valve assembly 100 operates independent of fluid flow, flow rates through the equipment 101 may be driven as high or as low as needed without being limited by the presence of the assembly 100 .
[0021] Telemetry for such communications and/or control as noted above may be supplied through fiber optic components as detailed in either of application Ser. No. 12/575,024 or 11/135,314, both entitled System and Methods Using Fiber Optics in Coiled Tubing and incorporated herein by reference in their entireties. However, other forms of low profile coiled tubing compatible telemetry may also be employed. For example, encapsulated electrically conductive line of less than about 0.2 inches in outer diameter may be utilized to provide communications between the valve assembly 100 and surface equipment.
[0022] Regardless, the particular mode of telemetry, the power supply for valve assembly 100 maneuvers may be provided through a dedicated downhole source, which addresses any concerns over the inability to transport adequate power over a low profile electrically conductive line and/or fiber optic components. More specifically, in the embodiment shown, an electronics and power housing 120 is shown coupled to the coiled tubing 110 . This housing 120 may accommodate a lithium ion battery or other suitable power source for the valve assembly 100 and any other lower power downhole tools. Electronics for certain downhole computations may also be found in the housing 120 , along with any communicative interfacing between telemetry and downhole tools, as detailed further below.
[0023] The coiled tubing 110 of FIG. 1 is likely to be no more than about 2 inches in outer diameter. Yet, at the same time, hard wired telemetry may be disposed therethrough as indicated above. Thus, the fiber optic or low profile electrically conductive line options for telemetry are many. By the same token, the limited inner diameter of the coiled tubing 110 also places physical limitations on fluid flow options therethrough. That is to say, employing flow rate to actuate downhole tools as detailed further below will be limited, as a practical matter, to flow rates of between about ½ to 2 BPM. Therefore, utilizing structural low profile telemetry for communications with the valve assembly 100 , as opposed to flow control techniques, frees up the limited range of available flow rates for use in operating other tools as detailed further below.
[0024] Continuing with reference to FIG. 1 , the coiled tubing equipment 101 may be outfitted with a locator extension 140 , arm 150 and regulator 130 for use in directing the equipment 101 to a lateral leg 391 of a well 380 as detailed below. As alluded to above, these tools 140 , 150 , 130 may be operate via flow control. More specifically, these tools 140 , 150 , 130 may cooperatively operate together as a pressure pulse locating/communication tool. Similarly, the equipment 101 is also outfitted with a flow operated jetting tool 160 for use in a cleanout application as also detailed below.
[0025] Referring now to FIG. 2 , an enlarged cross-sectional view of the valve assembly 100 taken from 2 - 2 of FIG. 1 is depicted. The assembly 100 includes a central channel 200 . The channel 200 is defined in part by sleeve 225 and ball 250 valves. In the embodiment shown, these valves 225 , 250 are oriented to allow and guide fluid flow through the assembly 100 . More specifically, for the depicted embodiment, any fluid entering the channel 200 from a tool uphole of the assembly 100 (e.g. the noted regulator 130 ) is directly passed through to the tool downhole of the assembly 100 (e.g. the noted locator extension 140 ). With added reference to FIG. 3 , a clean flow of fluid through the assembly 100 in this manner may take place as a matter of providing hydraulic support to the coiled tubing 110 as it is advanced through a well 380 in advance of any interventional applications.
[0026] However, depending on the application stage undertaken via the assembly, these valves 225 , 250 may be in different positions. For example, as depicted in FIG. 4C , the sleeve valve 225 may be shifted open to expose side ports 210 for radial circulation. Similarly, the ball valve 250 may be oriented to a closed position, perhaps further encouraging such circulation, as also shown FIG. 4C .
[0027] Continuing with reference to FIG. 2 , with added reference to FIG. 3 , the particular positioning of the valves 225 , 250 may be determined by a conventional powered communication line 275 . That is, with added reference to FIG. 1 , the line 275 may run from the electronics and power housing 120 . Thus, adequate power for actuating or manipulating the valve 225 or 250 through as solenoid, pump, motor, a piezo-electric stack, a magnetostrictive material, a shape memory material, or other suitable actuating element may be provided.
[0028] At the housing 120 , the line 275 may also be provided with interfaced coupling to the above noted telemetry (of a fiber optic or low profile electrical line). Indeed, in this manner, real-time valve manipulations or adjustment may be directed from an oilfield surface 301 , such as by a control unit 315 . As a result, the entire coiled tubing equipment 101 may be left downhole during and between different fluid flow applications without the need for assembly 100 removal in order to manipulate or adjust valve positions.
[0029] In one embodiment, the assembly 100 may be equipped to provide valve operational feedback to surface over the noted telemetry. For example, the assembly 100 may be outfitted with a solenoid such as that noted above, which is also linked to the communication line 275 to provide pressure monitoring capacity, thereby indicative of valve function.
[0030] It is worth noting that each valve 225 , 250 may be independently operated. So, for example, in contrast to FIG. 2 (or FIG. 4C ) both valves 225 , 250 may also be opened or closed at the same time. Further, a host of additional and/or different types of valves may be incorporated into the assembly 100 . In one embodiment, for example, the ball valve 250 may be modified with a side outlet emerging from its central passage 201 and located at the position of the sleeve valve 225 of FIG. 2 . Thus, the outlet may be aligned with one of the side ports 210 to allow simultaneous flow therethrough in addition to the central channel 200 . Of course, with such a configuration, orientation of the central passage 201 with each port 210 , and the outlet with the channel 200 , may be utilized to restrict flow to the ports 210 alone.
[0031] With specific reference to FIG. 3 , an overview of the noted oilfield 301 is depicted. In this view, the oilfield 301 is shown accommodating a multilateral well 380 which traverses various formation layers 390 , 395 . A different lateral leg 391 , 396 , each with its own production region 392 , 397 is shown running through each layer 390 , 395 . These regions 392 , 397 may include debris 375 for cleanout with a jetting tool 160 or otherwise necessitate fluid based intervention by the coiled tubing equipment 201 . Nevertheless, due to the configuration of the valve assembly 100 , such applications may take place sequentially as detailed herein without the requirement of removing the equipment 201 between applications.
[0032] Continuing with reference to FIG. 3 , the coiled tubing equipment 101 may be deployed with the aid of a host of surface equipment 300 disposed at the oilfield 301 . As shown, the coiled tubing 110 itself may be unwound from a reel 325 and forcibly advanced into the well 380 through a conventional gooseneck injector 345 . The reel 325 itself may be positioned at the oilfield 301 atop a conventional skid 305 or perhaps by more mobile means such as a coiled tubing truck. Additionally, a control unit 315 may be provided to direct coiled tubing operations ranging from the noted deployment to valve assembly 100 adjustments and other downhole application maneuvers.
[0033] In the embodiment shown, the surface equipment 300 also includes a valve and pressure regulating assembly, often referred to as a ‘Christmas Tree’ 355 , through which the coiled tubing 110 may controllably be run. A rig 335 for supportably aligning the injector 345 over the Christmas Tree 355 and well head 365 is also provided. Indeed, the rig 335 may accommodate a host of other tools depending on the nature of operations.
[0034] Referring now to FIGS. 4A-4C , enlarged views of the coiled tubing equipment 101 as it reaches and performs treatments in a lateral leg 391 are shown. More specifically, FIG. 4A depicts a locator extension 140 and arm 150 acquiring access to the leg 391 . Subsequently, FIGS. 48 and 4C respectively reveal fluid cleanout and fiber delivery applications at the production region 392 of the lateral leg 391 .
[0035] With specific reference to FIG. 4A , the locator extension 149 and arm 150 may be employed to gain access to the lateral leg 391 and to signal that such access has been obtained. For example, in an embodiment similar to those detailed in application Ser. No. 12/135,682, Backpressure Valve for Wireless Communication (Xu et al.), the extension 140 and atm 150 may be drawn toward one another about a joint at an angle θ. In advance of reaching the leg 391 , the size of this angle θ may be maintained at a minimum as determined by the diameter of the main bore of the well 380 . However, once the jetting tool 160 and arm 150 gain access to the lateral leg 391 , a reduction in the size of the angle θ may be allowed. As such, a conventional pressure pulse signal 400 may be generated for transmission through a regulator 130 and to surface as detailed in the '682 application and elsewhere.
[0036] With knowledge of gained access to the lateral leg 391 provided to the operator, subsequent applications may be undertaken therein as detailed below. Additionally, it is worth noting that fluid flow through the coiled tubing 110 , the regulator 130 , the extension 140 and the arm 150 is unimpeded by the intervening presence of the valve assembly 100 . That is, to the extent that such flow is needed to avoid collapse of the coiled tubing 110 , to allow for adequate propagation of the pressure pulse signal 400 , or for any other reason, the assembly 100 may be rendered inconsequential. As detailed above, this is due to the fact that any valves 225 , 250 of the assembly 100 are operable independent of the flow through the equipment 101 .
[0037] Continuing now with reference to FIG. 4B , an enlarged view of the noted jetting tool 160 of the coiled tubing equipment 101 is shown. More specifically, this tool 160 is depicted reaching a target location at the production region 392 of the leg 391 for cleanout. Indeed, as shown, debris 375 such as sand, scale or other buildup is depicted obstructing recovery from perforations 393 of the region 392 .
[0038] With added reference to FIGS. 1 and 2 , the ball valve 250 of the assembly 100 may be in an open position for a jetting application directed at the debris 375 . More specifically, 1-2 BPM of an acid based cleanout fluid may be pumped through the coiled tubing 110 and central channel 200 to achieve cleanout via the jetting tool 160 . Again, however, the ball valve 250 being in the open position for the cleanout application is achieved and/or maintained in a manner independent of the fluid flow employed for the cleanout. Rather, low profile telemetry, fiber optic or otherwise, renders operational control of the valve assembly 100 and the valve 250 of negligible consequence or impact on the fluid flow.
[0039] Referring now to FIG. 4C , with added reference to FIG. 2 , an enlarged sectional view of the valve assembly 100 is shown. By way of contrast to the assembly 100 of FIG. 2 , however, the valves 225 , 250 are now adjusted for radial delivery of a fiber 450 following cleanout through the jetting tool 160 of FIG. 4B . Delivery of the fibers 450 through the comparatively larger radial ports 210 in this manner may help avoid clogging elsewhere (e.g. at the jetting tool 160 ). The fibers 450 themselves may be of glass, ceramic, metal or other conventional flowback discouraging material for disposal at the production region 392 to help promote later hydrocarbon recovery.
[0040] Regardless, in order to switch from the cleanout application of FIG. 4B to the fiber delivery of FIG. 4C , the acid flow may be terminated and the ball valve 250 rotated to close off the channel 200 . As noted above, this is achieved without the need to remove the assembly 100 for manual manipulation at the oilfield surface 301 (see FIG. 3 ). A streamlined opening of the sleeve valve 225 to expose radial ports 210 may thus take place in conjunction with providing a fluid flow of a fiber mixture for the radial delivery of the fiber 450 as depicted. Once more, while the fluid flow is affected by the change in orientation of the valves 225 , 250 , the actual manner of changing of the orientation itself is of no particular consequence to the flow. That is, due to the telemetry provided, no particular flow modifications are needed in order to achieve the noted changes in valve orientation.
[0041] Referring now to FIG. 5 , a flow-chart is depicted which summarizes an embodiment of employing a surface controlled reversible coiled tubing valve assembly in a well. Namely, coiled tubing equipment may be deployed into a well and located at a treatment location for performing a treatment application (see 515 , 530 , 545 ). Of particular note, as indicated at 560 , a valve assembly of the equipment may be adjusted at an point along the way with the equipment remaining in the well. Once more, the equipment may (or may not) be moved to yet another treatment location as indicated at 575 before another fluid treatment application is performed as noted at 590 . That is, this subsequent treatment follows adjustment of the valve assembly with the equipment in the well, irrespective of any intervening repositioning of the equipment.
[0042] Embodiments described hereinabove include assemblies and techniques that avoid the need for removal of coiled tubing equipment from a well in order to adjust treatment valve settings. Further, valves of the equipment may be employed or adjusted downhole without reliance on the use of any particular flow rates through the coiled tubing. As a result, trips in the well, as well as overall operation expenses may be substantially reduced where various fluid treatment applications are involved.
[0043] The preceding description has been presented with reference to the disclosed embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. For example, embodiments depicted herein focus on particular cleanout applications and fiber delivery. However, embodiments of tools and techniques as detailed herein may be employed for alternative applications such as cement placement. Additionally, alternative types of circulation may be employed or additional tools such as isolation packers, multicycle circulation valves. Regardless, the foregoing description should not be read as pertaining to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope. | A valve assembly for reversibly governing fluid flow through coiled tubing equipment. Valves of the assembly may be directed by a telemetric line running from an oilfield surface. In this manner, valve adjustment and/or reversibility need not require removal of the assembly from the well in order to attain manual accessibility. Similarly, operation of the valves is not reliant on any particular flow rate or other application limiting means. As such, multiple fluid treatments at a variety of different downhole locations may take place with a reduced number of trips into the well and without compromise to flow rate parameters of the treatments. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a cutter for use in a double-pile loom.
In a double-pile loom, the top and the bottom ground fabrics are doubly woven and pile yarns are inserted therein. When these pile yarns are cut at the rear of the cloth fell and turned into piles, two separate cut warp pile fabric are simultaneously produced.
These kinds of pile fabrics are called wilton, moquette, velvet, plush etc.
As in an ordinary loom such as a plain-loom, the double-pile loom is comprised of warpletting-off apparatus, shedding apparatus, weft inserting apparatus, beeting apparatus, taking-up apparatus and so on.
However the double-pile loom is different from ordinary looms for weaving cotton or woolen fabric since it includes a pile cutting apparatus.
As regards the fabric woven by the ordinary loom, the appearance of a woven texture composed of warps and wefts intersecting each other is a decisive factor for determining the commercial value of the fabric. An uneven weft density or skew (wefts running not straight) is regarded as a defect.
In a pile fabric, woven texture composed of warps and wefts intersecting esch other are not apparent on the right side of the fabric and less influential upon the commercial value thereof but, instead, smoothness (evenness) of the pile-covered surface is an important factor decisive to the commercial value thereof. Roughness of this surface caused by pile lengh difference is considered a defect.
The degree of smoothness of pile-covered surface depends on whether the cutting apparatus operates regularly or not.
A cutting apparatus known in the prior art, has the structure as shown in FIGS. 1 through 4.
In the drawings, the reference numerals 18 and 19 indicate the ground texture of the top and the bottom fabrics composed of warps and wefts. The numeral 14 indicates pile yarns which are woven into the structure so as to stitch the ground texture 18 and 19 of the top and the bottom fabrics to each other. The numerals 2 and 3 indicate a rail supported in parallel with the cloth fell and a slider sliding on the rail 2 and provided with a cutter 4, respectively. The slider is driven to reciprocate in the space between the top and the bottom ground textures 18 and 19, respectively, by a drum 6, which turns in the right and the reverse directions synchronously with a picking motion, via rope 5.
The cutter edge 13 cuts a multitude of pile yarns 14 woven into the texture and stitching the top and the bottom ground textures 18 and 19, respectively, and arranged in a line weftwise for formation of piles 15 in line weftwise. At the same time, the ground textures 18 and 19 are separated from each other above and below. Two cut warp pile fabrics are thus formed--the top fabric 11 with the pile-covered surface on the lower side, and the bottom fabric 12 with a similar pile-covered surface on the upper side.
The numerals 9 and 10 denote stationary platelike blocks called scale for preventing the top and the bottom ground textures 18 and 19, respectively, from vibrating while the cutter 4 travels.
Usually, the number of pile yarns lined weftwise reaches thousands and the cutter edge 13 to cut these yarns in single stroke is susceptible to wear. As a countermeasure to such wear as above, a pair of grindstones 7 and 8 (7' and 8') directed upward and downward, respectively, are disposed near both edges of the fabric and energized by springs 16 (16') so that the obverse and the reverse sides of the running cutter edge 13 are ground by the grindstones during every reciprocation thereof.
To grind the cutter edge at a fixed angle from end to end thereof, grindstones 7 and 8 (7' and 8') must be under a fixed uniform pressure while touching the cutter edge from end to end thereof.
In other words, grindstones must be positioned and mounted on the loom so that the cutter edge is in point-contact with the grindstones under a fixed pressure. The grindstones surface in contact with the cutter edge must be curved in the lengthwise direction like the surface of a cone but straight in the transverse derection at any position from end to end thereof along the cutter running direction, and these conditions must be invariably maintained.
Such, performance however, is possible in theory but extremely difficult in practice.
Such problems as above involved in the prior art are summarized as follows:
(1) Pressing action by the weight of the downward directed grindstone 8 upon the cutter edge 13 is strong whereas that by the upward directed one 7 is weak. Accordingly, in consideration of the weight of the grindstones, the force of a spring 16 for the downward directed grindstone 7 and that of another spring 16' for the upward directed grindstone 8 must be weak and strong, respectively, for pressing both grindstones to the cutter edge 13 with the same degree of pressure. However, designing spring 16 and 16' to meet such requirement is difficult. Thus the cutter edge gradually varies in the shape while used such that, the obverse and the reverse sides (upside and downside) of the cutting edge lose angular therebetween, and a pile length difference is caused between both sheets of fabric in such a way that the pile length a of the fabric on one side to which the cutter edge is deviated is short whereas pile length b on the other side is long. Although the fabric having long piles can be correctly finished by shearing and adapted to conform to the standard, that having short piles cannot but be disposed of as rejected.
(2) By adjusting the positions of the scales 9 and 10 in the vertical direction for setting a path on which the cutter edge 13 runs at a middle position between the top fabric 11 and the bottom fabric 12, an inferior product having a length difference between piles 15 of the top fabric 11 and the bottom fabric 12 is prevented. However, such adjustment if performed every time required, gradually cause the middle position between the top fabric 11 and the bottom one 12 to deviate. In this case, a new cutter edge replacing the old one runs on an unexpected course, whereby a large pile length difference is caused between the top and the bottom fabrics, and a sharp step appear on the pile-covered surface of either sheet of the fabric correspondingly to the time of the replacement of cutter edge. Above all, in the case of moquette, since the pile length thereof a (b) is usually as short as 2 to 3 mm, the cutter edge, when deviated, may possibly eat into the ground texture 18 (19) on one side and produce an un-repairable defect.
(3) The cutter gradually becomes short since the edge thereof is always subjected to grinding by the grindstones. The edge 13' of a new cutter replacing the old one is located close to the cloth fell in length d anticipated to be worn out. Accordingly, althought one row of pile yarns lined weftwise will have been cut by one stroke of the cutter, two or more rows are unreasonably cut immediately after the replacement of cutters. Variation in cutting conditions as above causes a defect called weftwise streak on the pile-covered surface.
(4) Grindstones 7 and 8 are liable to be subjected to strong pressing to the cutter edge 13 due to the user's desire to obtain sharp cutting, however, extremely strong pressing causes the cutter edge 13 to be too sharp and prouce a burr on the edge 13, thereby reducing cutting ability. Moreover, the cutter edge thus deteriorated tears the pile yarns and causes an un-repairable hairy surface.
(5) A step-like rubbing mark gradually appears on the grindstones at the part rubbed by the cutter edge. When the cutter is replaced and positionally adjusted without replacing the transformed grindstones, transformation of the cutter edge, above all burr, is expedited. Therefore, even when either a cutter or a grindstone is worn and transformed, both of them must be replaced, or ground and adjusted correctly. However, grinding and adjustment of the worn grindstones requires a considerable level of skill and, in many cases, the worn grindstone is must be replaced by a new one.
(6) In the case of the fabric of high pile-density such as moquette, a pile length difference as small as 0.1 mm is regarded as a defect known as a stepped surface. Adjustment of the scales 9 and 10, grindstones 7 and 8, and cutter edge 13 requires a high level of skill and a considerable length of time. Further, as a matter of practice, the cutter edge must be ground and adjusted at intervals of about 30 min. during weaving. Therefore, the conventional cutting apparatus makes complete automation of the double-pile loom impossible, leaving the loom at a markedly low level of productivity.
(7) Trial operation is required after fine adjustment of the replaced cutter or grindstones and inevitably causes clumsily cut yarn.
(8) As described above, a step-like mark resulting from pile length difference as small as 0.1 mm is distinguished as a defect and this defect is inevitable even if a considerably high level of skill is applied to operation. Therefore, according to the prior art, the fabric is woven so as to be provided with piles slightly longer than those to be obtained in the finals in consideration of occurrence of such defect as above and then the piles are evenly cut by shearing to be conformable to the standard length.
Usually, the tip of pile in length as 0.3 to 0.6 mm is cut away by shearing. However, removal as much as 0.3 to 0.6 mm from the pile length of the short-pile fabric such as a moquette which ranges from 2 to 3 mm corresponds to a 15 or more percent loss of pile yarn. And, the pile yarn costs far higher than the warp and the weft yarns for the ground texture. Thus, loss of yarn in the shearing process adds greatly to the cost of products.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a double-pile loom of high operational efficiency which requires no adjustment in setting the cutter and the grindstone.
A second object of the present invention is to provide a double-pile loom not causing pile length difference between the top and the bottom sheets of pile fabric, breakage of the ground texture, weftwise streak on account of variation in cutting conditions, fuzzing on the pile-covered surface, and defects such as step-like mark on the pile-covered surface which may otherwise be caused in the trial operation thereof.
A third object of the present invention is to reduce the loss of pile yarns resulting from pile length difference between the top and the bottom sheets of pile fabric, breakage of the ground texture, weftwise streak resulting from variation in pile yarn cutting condition, fuzzing on the pile-covered surface, and step mark on the pile-covered surface caused in the trial operation of the loom.
A fourth object of the present invention is to economically provide a pile fabric of superior quality free from defects.
To fulfil the above objects, the inventors of the present invention have completed this invention after strenuous study and research into time loss in setting and adjusting the cutter and the grindstone as well as loss of pile yarns, apart from the conventional fixed concept of setting grindstones on the double-pile loom and of grinding the cutter during each reciprocation of the cutter.
The present invention comprises a cutter edge of single crystal sapphire, the cutter being used on the double-pile loom, fixed to a slider to slide on the rail in parallel with the cloth fell, and adapted to reciprocate crosswise in the space between the top and the bottom sheets of fabric synchronously with picking so as to cut pile yarns which stitch together the abovesaid two sheets of fabric for formation of piles.
A double-pile loom according to the present invention is characterized in that, first, none of grindstone to grind the cutter edge is provided therefor.
A second feature of the present invention is that single crystal sapphire in the shape of a sheet as thick as 0.4 mm is used as a cutter and a part of the periphery thereof is shaped arcuate and formed into an edge having an angle in the range of 5° to 31°.
Other objects and feature of the present invention will become more apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cutting apparatus on the conventional type double-pile loom;
FIG. 2 is a sectional view of a cutting apparatus taken at a yarn cutting position;
FIG. 3 is a partially sectional side view of the cutting apparatus taken at a position in which the cutteredge is ground;
FIG. 4 is a perspective view of conventionally used grindstone:
FIG. 5 a perspective view of a slider provided with a cutter as a first embodiment of the present invention;
FIG. 6 is a plan view of the cutter;
FIG. 7 is a side view of the cutter;
FIG. 8 is a perspective view of a slider provided with a cutter as a second embodiment of the present invention; and
FIG. 9 is a sectional view of the slider taken along the line X--X' in FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
According to this invention, a cutter edge to cut pile yarns is made of single crystal sapphire, and a grindstone to grind the cutter edge is not used.
The cutter may be in the shape of disk, in other words, may be a single crystal sapphire disk having a cutting edge at the entire periphery thereof. The cutter can be fixed to the slider after being bonded to a metal plate.
Single crystal sapphire is colorless and transparent, having characteristics such as specific gravity of 3.97, hardness of 2,300 kg/mm 2 in Vickers number, bending strength of 7,000 kg/cm 2 , compression strength of 30,000 kg/cm 2 , Young's modulus of 4,800,000 kg/cm 2 , specific heat of 0.18 cal/g ° C., which are without match among other mateials used in the conventional cutter in respect of mechanical strength, resistance to heat, anti-corrosiveness, resistance to chemical agents and resistance to wear.
In this way, single crystal sapphire used in the cutter according to the present invention is remarkably high in hardness, bending strength, resistance to corrosion, resistance to wear and so on, whereby too small degree of angle at the cutter edge is not proper and, at the same time, increased degree of angle is also not proper because cutting characteristic is decreased through the strength of the edge is increased.
From experiments in which cutters were prepared in such a way that the angle of cutter edge was varied very two degrees within the range from 5° to 31°, it was found important to fix the edge angle with in the range from 7° to 27°, preferably from 11° to 23°, for maintaining satisfactory cutting characteristics in the light of breakage of the cutter edge and eveness of the pile-covered surface.
Experiments on cutter edges made for trail with respect to meter ials thereof reveals that zerconia and alumina ceramics are not suitable since the pile-covered surface is not finished smooth.
A thin cutter vibrates during running and causes the pile-covered surface to be uneven. A thick cutter, on the other hand, is not suitable because of the difficulty in providing the edge therefor and the increase in resistance of pile yarns exerted thereto during movement.
As a trial, a 0.4 mm thick single crystal sapphire sheet cutter have an edge angle of 19° was used for weaving moquette with pile yarns of nylon which have hitherto to been liable to be a cause of unsatisfactory cutting, from it was confirmed that the cutting characteristic of the cutter was kept high even after weaving of about 40 pieces (each 50 meter long) of moquette.
Now, embodiments of the present invention wil be described.
FIGS. 5, 6, and 7 show a cutter 24 used in the first embodiment of the present invention. The reference numeral 20 indicates a slider provided with a dovetail groove 21 at the reverse side, and rotatably fitted onto the rail to be driven weftwise by the revolving drum through the rope.
The numeral 22 denotes a pressing plate fixed to the slider 20 with screws 23. The cutter 24 is clamped between the pressing plate 22 and the slider 20.
The cutter 24 is composed of a metal plate 25 and a 0.4 mm thick single crystal sapphire sheet 26. The single crystal sapphire cutting sheet 26 is bonded to the front side of the metal plate 25 with resin. The projecting end 28 of the cutting sheet 26 is in the shape of an arc and provided with an edge having an angle of 17° in the symmetrical configuration between the obverse and the reverse sides of the sheet.
For bonding the cutting sheet 26 to the metal plate 25, thermosetting resin such as epoxy resin or silver solder, which is free of rubber-like elasticity, is used.
The cutter 24 may be made up not only by bonding a cutting sheet 26 to a metal plate 25 as described above but also by composing a cutting sheet in one body includng a part corresponding to the metal plate 25.
FIG. 8 and FIG. 9 show a cutter used in a second embodiment of the present invention. The cutter 29 is a 0.4 mm thick disk made of single crystal sapphire and periphery 30 thereof is shaped into a cross-sectionally symmetrical cutting edge 31 having an angle of 17°. The cutter 29 is provided with a hole for a screw at the center thereof and fixed to the slider 35 with a nut 34 through washers 32 and 33.
The reference numeral 36 denotes a flat head screw to be screwed into the slider from the reverse side and idly inserted through the hole of the cutter 29. Therefore, the cutter edge 31 can be angularly shifted right and left by turning the cutter 29 after the nut 34 is loosened.
When using the cutter 24 having the edge cut away at both shoulder parts thereof and made arcuate at the front end, yarns are cut at approximately the same points on the edge during reciprocation of the cutter, whereby the cutter edge 27 is partially worn out and caused to lose cutting characteristic thereat.
However, the cutter 29 used in the second embodiment as shown in FIGS. 8 and 9 is circular, that is, a disk of a fixed diameter. Therefore, as far as the cutting sheet has an edge angle as described above (7° to 25°), even when cutting characteristic of a part of the edge is reduced, cutting is made possible by a slight turn of the cutter with the nut 34 and screw 36 loosened and by adapting another part of the cutter edge to touch the pile yarn. Thus, one piece of cutter 29 can be used dozens of times without being replaced or ground.
In conclusion, effects of the present invention are summarized as follows:
(1) The cutter edge is highly resistant to wear and the cutting characteristic is maintained for a long term. As a result, stoppage of the double-pile loom for grinding or adjusting the cutter and grindstones is not required, thereby significantly improving operation efficiency of the double-pile loom and enabling automation in weaving of the pile fabric.
(2) No adjustment is required in fixing the cutter and the grindstone, thus special skill is not required. Also the double-pile loom can be operated similarly to ordinary looms such as a plain loom.
(3) Deviation of the cutter position resulting from wear of the cutter edge is eliminated, that is, a distance e between the cloth fell and the cutter edge does not change, whereby simultaneous cutting of two or more rows of pile yarns lined weftwise possibly caused immediately after replacement of cutters is prevented. Thus, clumsy yarn cutting following the replacement of cutters never occurs.
(4) A pile length difference between the top and the bottom sheets of fabric is prevented from being caused by a burr, or backward or upward reflection of the cutter edge, whereby allowance of the pile yarn length prepared for weaving in consideration of poor cutting become unnecessary and the loss of pile yarns is entirely prevented, enabling saving of material cost in pile making.
(5) The cutter smoothly slides and is free of up-and-down vibration during running. The quantity of waste piles (minute chips) is minimized and brushing (removal of minute chips) prior to shearing is simplified since few minute chips stick to the pile-covered surface.
(6) Clumsy yarn cutting occurs far less frequently and shearing is simpified to a degree that only floating yarns are cut and removed, thereby reducing shearing frequency and raising efficiency in the finishing operation.
In this way, according to the present invention, productivity in weaving of the pile fabric is markedly raised. Particularly, shearing loss that has so far reached 39% of consumption of pile yarns is significantly reduced. The present invention, therefore, is very beneficial for cost saving in the production of pile fabric. | A cutter for a double-pile loom which cutter is fixed to a slider to slide on a rail in parallel with the cloth fell. The cutter is adapted to reciprocate crosswise in the space between the top and bottom sheets of fabric synchronously with picking to cut the pile yarns which stitch together two sheets of fabric to form piles. The cutter edge is made of a single crystal sapphire and is highly resistant to wear having its cutting characteristics maintained for a long term. Grindstones are not needed to maintain a sharpness of the cutter. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2009-060926, filed Mar. 13, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a sensor apparatus for detecting a positional relationship between two members arranged in opposed relation to each other, using a change in electrostatic capacitance between electrodes of the respective members and a method used for the sensor apparatus.
[0004] 2. Description of the Related Art
[0005] In recent years, a proximity sensor of electrostatic capacitance detection type has been proposed for detecting a proximity of an object (JP-A 2008-192319 (KOKAI)). In this sensor of electrostatic capacitance type, a first member constituting an object of detection and a second member of the sensor part have first and second electrodes, respectively, which are so arranged as to be opposed to each other. Of these electrodes, the one arranged on the first member is supplied with an electrical signal. The sensor detects a change in electrostatic capacitance between the first and second electrodes using the electrode arranged on the second member, thereby detecting a relative positional change of the members.
[0006] The sensor apparatus for detecting the proximity between two members is used for electronic devices such as a mobile phone. In the mobile phone, for example, the power consumption is required to be suppressed as far as possible to permit the use for a long time. In a conventional magnetic sensor apparatus, the positional relationship between a magnet and a Hall element. The magnet is arranged on a first member constituting an object of detection. The Hall element is arranged on a second member constituting a sensor part. In the process, the magnetic sensor apparatus detects a magnetic field from the magnet by driving the Hall element intermittently with a predetermined period. As a result, the power consumption of the sensor apparatus is suppressed and a waste of a battery power can be reduced.
[0007] As described above, if the electronic devices are required to suppress the power consumption, it is desirable for the sensor apparatus for detecting the proximity between two members to be operated intermittently so as to suppress the waste of the battery power. In the sensor apparatus of electrostatic capacitance detection type, however, the object of detection and the sensor part are operated independently of each other. This poses the problem that an attempt to operate the sensor apparatus intermittently fails to detect the relative positions of the members successfully due to the different intermittent operations between the object of detection and the sensor part.
[0008] As understood from the foregoing description, the intermittent operation of the sensor apparatus of electrostatic capacitance detection type harbors the problem that the relative positions of the members cannot be successfully detected in the case where the intermittent operation of the object of detection and that of the sensor part are different from each other.
BRIEF SUMMARY OF THE INVENTION
[0009] According to one embodiment of the present invention, there is provided a sensor apparatus for detecting a positional relationship between first and second members having first and second surfaces, respectively, comprising: a first electrode provided on the first surface of the first member; an applying unit configure to apply a charging signal periodically with a first cycle period to the first electrode so that first charges are induced on the first surface of the first member; a second electrode provided on the second surface of the second member to generate electrical detecting signals with the first cycle periods depending on second charges which are induced on the second surface due to the first charges held on the first surface and are changed with the first cycle period depending on a distance between the first and second surfaces; a selecting unit configured to select one of the first cycle period and a second cycle period which is different from the first cycle period, the first and second cycle periods being partially overlapped in respective segment periods; an output unit which periodically receives the electrical detecting signals from the second electrode, which allows parts of the electrical detecting signals to be output from the output unit during the segment periods, if the second cycle period is selected, and allows the electrical detecting signals to be output from the output unit with the first cycle in synchronized with the charging signals, if the first cycle period is selected; a comparator configure to compare an amplitude of the part of the electrical detecting signal or the electrical detecting signal from the output unit with a predetermined threshold value and generate a first comparison signal when the amplitude is not less than the predetermined threshold value and a second comparison signal when the amplitude is less than the predetermined threshold value, respectively; and a controller configure to generate, in response to the first comparison signal, a proximity signal which indicates the proximity of the first and second members, and to generate, in response to the second comparison signal, a non-proximity signal which indicates the non-proximity of the first and second members, wherein the selecting unit selects the second cycle period in response to the non-proximity signal, and selects the first cycle period in response to the proximity signal so that the proximity signal is continuously generated depending on the successive generation of the first comparison signals.
[0010] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
[0012] FIG. 1 is a diagram showing a configuration of a sensor apparatus according to a first embodiment of the invention;
[0013] FIG. 2 is a block diagram showing a functional configuration of the sensor apparatus of FIG. 1 ;
[0014] FIG. 3 is a diagram showing the relation between two types of clock signals generated in the sensor apparatus of FIG. 2 ;
[0015] FIG. 4 is a diagram showing the signals output from the component elements of the sensor apparatus of FIG. 2 ;
[0016] FIG. 5 is a flowchart of the process controlled by a controller for the switching operation of a switching unit;
[0017] FIG. 6 is a diagram showing an example of the application of the sensor apparatus of FIG. 1 to a mobile communication terminal; and
[0018] FIG. 7 is a diagram showing a specific example of the two types of clock signals.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A sensor apparatus according to embodiments of the invention is explained in detail below with reference to the drawings.
[0020] FIG. 1 is a schematic diagram showing a configuration of the sensor apparatus according to an embodiment of the invention. The sensor apparatus comprises a first sensor circuit 10 arranged on a first member 100 and a second sensor circuit 20 arranged on a second member 200 . The first and second members 100 , 200 have first and second surfaces which are arranged so as to be opposed to each other, and on which first and second electrodes 13 , 21 are provided. In the case where the members 100 , 200 come close to each other, the first electrode 13 of the first sensor circuit 10 and the second electrode 21 of the second sensor circuit 20 approach each other in opposed relation. The sensor apparatus detects a change in electrostatic capacitance between the first electrode 13 of the first sensor circuit 10 and the second electrode 21 of the second sensor circuit 20 . In this way, the sensor apparatus detects the relative positions of the members 100 , 200 , i.e. whether the members 100 , 200 are approaching or coming away from each other.
[0021] FIG. 2 is a block diagram showing the functional configuration of the sensor apparatus of FIG. 1 . In the first sensor circuit 10 , alternating current generated from an AC power supply 11 is supplied to the first electrode 13 through a first switch 12 . The first switch 12 is connected between the power supply 11 and the first electrode 13 for driving the first sensor circuit 10 intermittently. That is, the first sensor circuit 10 is operated while the first switch 12 is on so that the electrical signal is supplied to the first electrode 13 from the AC power supply 11 , and is not operated while the first switch 12 is off so that the electrical signal is prevented from being supplied to the first electrode 13 from the AC power supply 11 . The first switch 12 receives a first clock signal, i.e., a periodical switching signal, having a first cycle period T 1 from a clock unit 14 . In accordance with the first clock signal, the first switch 12 periodically permits the alternating current to be supplied from the AC power supply 11 to the first electrode 13 . Thus, the first electrode 13 periodically charges the surface portion of the member 100 , depending on an application of the supplied alternating current on the first electrode 13 .
[0022] The second sensor circuit 20 detects the change in electrostatic capacitance between the first and second electrodes 13 and 21 , and thus detects the relative positions of the first and second members 100 , 200 . The second electrode 21 is arranged on the surface of the member 200 . The electrode 21 induces, at the portion where it is arranged, charges corresponding to the charges held at the portion where the first electrode 13 is arranged. In the process, the charges induced by the electrode 21 change with the distance between the first and second electrodes 13 and 21 .
[0023] A second switch 22 is provided in the second sensor circuit 20 , for driving the second sensor circuit 20 intermittently. The second sensor circuit 20 is operated so as to sense electrical charges produced on a portion of the second surface on which the second electrode is provided, while the second switch 22 is on, and is prevented from being operated so as not to sense the electrical charges, while the second switch 22 is off. In the second sensor circuit 20 , an electrical signal is sensed as a voltage on the second electrode 21 which is produced based on the electrical charges induced on the second surface portion by the second electrode 21 . The sensed electrical signal is supplied to an amplifier (AMP) 23 through the second switch 22 which is switched based on one of the second and third clock signals, i.e., second and third periodical switching signals supplied from clock units 29 and 210 , respectively. The amplifier 23 amplifies the received electrical signal and outputs an amplified signal to a band-pass filter (BPF) 24 . The band-pass filter 24 filters the electrical signal to remove the noise component from the received electrical signal and outputs the electrical signal to a peak detector 25 . The peak detector 25 detects the peak level of the received electrical signal.
[0024] A comparator 26 receives the peak level signal from the peak detector 25 , and judges whether the amplitude level, i.e., the peak level of the peak level signal from the peak detector 25 is not less than a threshold value set in advance. In the case where the amplitude of the signal from the peak detector 25 is not less than the threshold value, the comparator 26 outputs the peak level signal to a controller 27 . In addition, in the case where the amplitude of the signal from the peak detector 25 is less than the threshold value, the comparator 26 outputs a signal of which the amplitude is zero to the controller 27 .
[0025] The controller 27 judges whether the first and second members 100 , 200 have approached each other or not, based on the output signal from the comparator 26 . In accordance with the judgment of a proximity of the first and second members 100 , 200 , the controller 27 generates a proximity signal indicating that the members 100 , 200 have approached each other. In accordance with the judgment of the non-proximity of the first and second members 100 , 200 , the controller 27 generates a non-proximity signal indicating that the members 100 , 200 have not approached each other. The proximity signal or non-proximity signal is supplied to a change-over unit 28 and to a device or devices in subsequent stages (not shown).
[0026] The change-over unit 28 is switched to one of the clock units 29 , 210 which is selected in response to the proximity signal or the non-proximity signal from the controller 27 , so that the clock signal from the selected one of clock units 29 or 210 to the second switch 22 . In the change-over unit 28 , upon reception of the non-proximity signal from the controller 27 , a second clock signal having a second cycle period T 2 is output from the second clock unit 29 and is supplied to the second switch 22 . In the case where the change-over unit 28 receives the proximity signal from the controller 27 , on the other hand, a third clock signal having the first cycle period T 1 is output from the clock unit 210 and is supplied to the second switch 22 .
[0027] Next, the relationship between the first clock signal having the first cycle period T 1 and the second clock signal having the cycle period T 2 is explained. FIG. 3 is a schematic diagram showing the relationship between the first clock signal having the first cycle period T 1 and the second clock signal having the second cycle period T 2 . The amplitude of the first and second clock signals are periodically changed between low and high levels at the different cycle periods T 1 and T 2 , as shown in FIG. 3 . However, as indicated by the circular portions in FIG. 3 , both of the two clock signals are periodically set to have the high levels in such a manner that a leading edge of the second clock signal is appeared in a period in which the first clock signal is maintained in the high level. Thus, the first and second clock signals have segment periods in which both signals are overlapped during a predetermined period of time. The predetermined period of time is sufficiently short as compared with, for example, the time taken to close the mobile phone. By using the clock signals of the period meeting this requirement, the sensor apparatus can perform the operation to detect the relative positions of the first and second members 100 , 200 at least once in the predetermined time period.
[0028] Next, the operation performed with the configuration described above is explained. FIG. 4 is a schematic diagram showing the signals output from the component elements of the sensor apparatus according to an embodiment of this invention. FIG. 5 is a flowchart showing the process executed by the controller 27 of FIG. 2 to control the operation of the change-over unit 28 .
[0029] First, the first switch 12 is operated in accordance with the first clock signal having the first cycle period T 1 from the clock unit 14 . Thus, the first electrode 13 is supplied with an alternating current in accordance with the first clock signal having the first cycle period T 1 .
[0030] The charges induced by the second electrode 21 produces a voltage to the second electrode 21 . The voltage is delivered as a sensing signal through the second switch 22 to the amplifier 23 in accordance with the second clock signal having the period T 2 from the clock unit 29 or the third clock signal having the first cycle period T 1 from the clock unit 210 . In the case where the first and second members 100 , 200 are not in proximity to each other, the charges induced at the portion where the second electrode 21 is arranged are so small that the amplitude of the electrical sensing signal supplied to the amplifier 23 is also small. In the case where the first and second members 100 , 200 are in proximity to each other, on the other hand, the charges induced at the portion where the second electrode 21 is arranged are so large that the amplitude of the electrical sensing signal supplied to the amplifier 23 is also large.
[0031] The electrical sensing signal supplied from the second switch 22 is amplified by the amplifier 23 , and after passing through the band-pass filter 24 , output to the peak detector 25 . The peak detector 25 detects the peak value of the electrical sensing signal from the band-pass filter 24 and outputs a peak level signal having a rectangular waveform.
[0032] The comparator 26 receives the peak level signal from the peak detector 25 , and outputs the peak level signal to the controller 27 in the case where the amplitude of the peak level signal is not less than the threshold value. On the other hand, the comparator 26 outputs the signal of which the amplitude is zero to the controller 27 in the case where the amplitude of the peak level signal is less than the threshold value.
[0033] The controller 27 judges whether the peak level signal from the comparator 26 is input when the leading edge of the second clock signal is appeared (step 51 ). In the case where the peak level signal from the comparator 26 is input to the controller 27 when the leading edge of the second clock signal is appeared shown by a time point t 2 in FIG. 4 (YES in step 51 ), the controller 27 judges that the first and second members 100 and 200 have approached each other (step 52 ). The controller 27 , upon judgment that the first and second members 100 , 200 are in proximity to each other, outputs a signal of a predetermined amplitude value (i.e. the proximity signal) to the change-over unit 28 and the devices in subsequent stages (step 53 ).
[0034] In the case where the signal of which the amplitude is zero from the comparator 26 is input to the controller 27 shown by a time point t 0 in FIG. 4 or the peak level signal is not input when the leading edge of the second clock signal is appeared shown by a time point t 1 in FIG. 4 (NO in step 51 ), the controller 27 repeats the flow of the judgment process shown in step 51 until the peak level signal from the comparator 26 is input to the controller 27 when the leading edge of the second clock signal is appeared.
[0035] The change-over unit 28 , upon reception of the proximity signal from the controller 27 , switches the connection to the third clock signal having the first cycle period T 1 output from the clock unit 210 , and supplies the third clock signal to the second switch 22 so that the second switch 22 is switched based on the third clock signal in synchronized with the charges held on the first electrode.
[0036] In the case where the first and second members 100 and 200 are in proximity to each other, the controller 27 judges whether the peak level signal from the comparator 26 is supplied iteratively in accordance with the first cycle period (step 54 ). If the controller 27 judges that the peak level signal from the comparator 26 is not supplied iteratively in accordance with the first cycle period shown by a time period t 3 in FIG. 4 (No in step 54 ), the controller 27 judges that the first and second members are not in proximity to each other (step 55 ). The controller 27 , upon judgment that the first and second members 100 and 200 are not in proximity to each other, stops outputting the proximity signal to the change-over unit 28 and the devices, and outputs a signal zero in amplitude (i.e. the non-proximity signal) to the change-over unit 28 and the devices (step 56 ). That is, the controller 27 continues to output the proximity signal from the time point t 2 until the time point t 3 .
[0037] The change-over unit 28 , upon reception of the non-proximity signal from the controller 27 , switches the connection to the second clock signal having the second cycle period T 2 input from the clock unit 29 , and supplies the second clock signal to the second switch 22 .
[0038] FIG. 6 is a schematic diagram showing an example of the application of the sensor apparatus according to an embodiment of the invention to a mobile communication terminal. The mobile communication terminal is presumed to be a mobile phone. In FIG. 6 , the first member 100 corresponds to the lower member of the mobile phone, and the second member 200 corresponds to the upper member of the mobile phone. The first electrode 13 of the first sensor circuit 10 is arranged in an electrode arrangement area 101 , and the electrode 21 of the second sensor circuit 20 in an electrode arrangement area 201 .
[0039] As long as the mobile phone is open, the first sensor circuit 10 is operated intermittently with the first cycle period T 1 and the second sensor circuit 20 is operated with the second cycle period T 2 . Once the mobile phone is closed, the sensor apparatus detects the proximity between the first and second members 100 , 200 by the process described above. In the case where the members are in proximity to each other, the intermittent operation of the second sensor circuit 20 is synchronized with that of the first sensor circuit 10 .
[0040] The first and second cycle periods T 1 and T 2 are determined taking the manual open/close operation of the mobile phone into consideration. Assuming it takes about 0.5 seconds to close the mobile phone manually, a sufficient period for detecting the open/close operation of the mobile phone is considered about 0.1 second. Also, in the case where the oscillation frequency of the AC power supply 11 is several tens of kHz to several hundred kHz, a pulse width is required to be 10 μsec to 1 msec to detect several wavelengths of the alternating current as an analog signal.
[0041] Specifically, the first clock signal having the first cycle period T 1 is periodically set to have the high levels of 10 μsec to 1 msec plurally during 0.1 second. The second clock signal having the second cycle period T 2 , even though not synchronized with the first clock signal, can be set in such a manner that the leading edge of the second clock signal is appeared in a period in which the first clock signal is maintained in the high level at least once in 0.1 second.
[0042] FIG. 7 is a diagram showing a specific example of the clock signals of the first and second cycle periods T 1 and T 2 . In this case, the oscillation frequency of the AC power supply 11 is set to 10 kHz. In FIG. 7 , the upper part of the diagram shows the first clock signal having the first cycle period T 1 of 10 msec and the pulse width of 100 μsec. In FIG. 7 , the lower part of the diagram shows the second clock signal having the second cycle period T 2 of 9 msec and the pulse width of 100 μsec. Even in the case where the first and second sensor circuits 10 , 20 are operated intermittently in different ways from each other, therefore, the relative positions of the first and second members 100 , 200 are detected at least once every 0.1 second.
[0043] As described above, according to the first embodiment, as long as the first and second members 100 , 200 are not in proximity to each other, the first sensor circuit 10 of the sensor apparatus is operated intermittently with the first cycle period T 1 , and the second sensor circuits 20 is operated intermittently with the second cycle period T 2 . The second cycle period T 2 is determined in such a manner that the leading edge of the second clock signal is appeared in a period in which the first clock signal is maintained in the high level during a predetermined time. In the case where the first and second members 100 , 200 are in proximity to each other, on the other hand, the sensor apparatus synchronizes the intermittent operation of the second sensor circuit 20 with the intermittent operation of the first sensor circuit 10 .
[0044] Even in the case where the cycle period of the intermittent operation is different between the first and second sensor circuits 10 and 20 , therefore, the relative positions of the first and second members can be detected at least once for every predetermined time. Also, as long as the first and second members 100 , 200 are in proximity to each other, the intermittent operation of the first sensor circuit 10 is synchronized with that of the second sensor circuit 20 , and therefore, the timing at which the first and second members 100 , 200 come away from each other can be detected with a high accuracy.
[0045] Therefore, the sensor apparatus according to this invention can detect the relative positions of the first and second members even in the case where the first member as the object of detection and the second member as the sensor part is operated intermittently with different periods.
[0046] Incidentally, this invention is not limited to the embodiment described above. According to the embodiment described above, for example, the first and second members 100 and 200 are judged to be in proximity to each other in the case where the leading edge of the second clock signal is appeared in a period in which the first clock signal is maintained in the high level. This invention, however, is not limited to such a configuration. For example, the same effect is produced as in the aforementioned embodiment by an alternative configuration in which the first and second members 100 , 200 are judged to be in proximity to each other as soon as the peak level signal is input from the comparator 26 . In such a case, the first and second cycle periods T 1 and T 2 are set in such a manner that a time periods in which the first and second clock signals are maintained in the high level are overlapped at least once for a predetermined time.
[0047] Also, according to the aforementioned embodiment, the first and second cycle periods T 1 and T 2 are different. By setting the first cycle period shorter than the second cycle period, the power consumption of the second sensor circuit 20 which consumes greater power when the two members are not in proximity to each other can be suppressed, thereby producing a higher power saving effect.
[0048] Further, according to the embodiment described above, the relative positions of the first and second members are detected based on the alternating current output from the AC power supply 11 . This invention, however, is not limited to such a configuration. For example, a DC power supply may be used in place of the AC power supply, in which case the relative positions of the first and second members can be detected as in the aforementioned embodiment.
[0049] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A sensor apparatus for detecting a positional relationship includes a first electrode, an applying unit applying a charging signal with a first cycle period to the first electrode, a second electrode, a selecting unit selecting the first or second cycle period which have overlapped segment periods, an output unit outputting electrical signals supplied from the second electrode with the first cycle period, if the first cycle period is selected, and parts of the electrical signals during the segment periods, if the second cycle period is selected, a comparator comparing an amplitude of the electrical signals with a threshold value and generating a first or second comparison signal and a controller generating a proximity and non-proximity signal in response to the first and second comparison signal, respectively, so that the selecting unit selects the first and second cycle period in response to the proximity and non-proximity signal, respectively. | 7 |
FIELD OF INVENTION
This discovery involves an improved methodology for detection of hepatitis B antigen in a human serum or plasma sample.
BACKGROUND OF THE INVENTION
Hepatitis B virus has been implicated to be the most probable etiologic agent for serum hepatitis or hepatitis of the long incubation variety. At least two distinct antigenic components have been found to be associated with hepatitis B virus. The first one, commonly known as hepatitis B surface antigen (HB s Ag) is present on the 20-nm spherical or filamentous form and 42-nm Dane particles. The other antigen designated as hepatitis B core antigen (HB c Ag) is found in the core of the 42-nm Dane particle. The antibodies for the two antigens are designated as anti-HB s and anti-HB c respectively. Blood or blood products containing hepatitis B virus can transmit Type B hepatitis following transfusion or parenteral inoculation. HB s Ag circulates in the blood of patients actuely or chronically infected with hepatitis B virus. Since the original studies on the detection of HB s Ag by immunodiffusion, several other methods have been developed for identification of this antigen. At present, radioimmunoassay for HB s Ag appears to offer superior sensitivity than immunodiffusion, complement fixation, counterelectrophoresis and rheophoresis techniques. However, sensitivity of either of these methods for detection of hepatitis B surface antigen has been found to be a major problem in the elimination of post-transfusion, Type B hepatitis.
The radioimmunoassay technique(s) for hepatitis B surface antigen available at the time of invention wherein either the inside of a test tube is coated with anti-HB s derived from guinea pigs or beads or beadlets consisting of polystyrene or polythylene polymers are coated with anti-HB s derived from either guinea pigs or human patients. A serum or plasma sample containing hepatitis B antigen when added to the tube, an antigen-antibody complex is formed. When such complex is contacted with the radioactively labeled anti-HB s , an additional complex is formed comprising of radioactive anti-HB s ; -HB s Ag;-non-radioactive anti-HB s . Any non-complexed radioactive antibody is removed by subsequent washing of the tubes or beads or beadlets. The extent of radiation emitted by such complex is determined and compared with the known control and thereby the presence or absence of hepatitis B antigen is determined.
The object of present invention is to modify the entire methodology including the processes involved so as to achieve better sensitivity and specificity for Hepatitis B antigen (both HB s Ag and HB c Ag), which would become more apparent in the following paragraphs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, an improved process is provided in this solid phase radioimmunoassay for production of reagents or components to be used in the identification of hepatitis B antigen in human serum or plasma. One improvement lies in the choice of material used for coating the antibody. The solid phase radioimmunoassay described earlier has utilized the interior of a tube for antibody coating (Kevin Catt, et al., Journal of Biochemistry, Volume 100, pages 31c-33c, 1966 and Science. Volume 158, page 1570, 1967; C. M. Ling, U.S. Pat. No. 3,867,517). An improvement in this procedure is achieved by utilizing commercially available imitation or cultured pearls for antibody adsorption. Another improvement involves an art of coating the pearls with a solution containing anti-HB s . The anti-HB s containing serum contains antibodies to two serotypes, ad and ay, of HB s Ag. Several methods are available to prepare antibody against HB s Ag in animals. The antibody is preferably produced in goats following serial inoculations of HB s Ag subtypes ad and/or ay. Commercially available pearls provide an excellent matrix for antibody attachment when used with a solution containing anti-HB s . The usage of pearls not only facilitates absorption of anti-HB s present in the solution, but also increases the specificity and thereby providing efficient detection of HB s Ag present in human serum or plasma. The size and the shape of these pearls could vary. However, spherical pearls of sizes ranging from 3 mm to about 8 mm are preferred. The number of pearls in one single reaction could also vary. However, one pearl of 6 mm size is preferred in a single reaction. These antibody coated pearls provide a solid matrix for this radioimmunoassay system.
The following examples will illustrate the details of the procedure.
EXAMPLE I
The pearls are coated by contacting them with a solution containing anti-HB s . The solution consists of an aqueous buffer consisting of 0.02 M to about 0.08 M Tris (hydroxy methyl) aminomethane-HCl at pH from 7.4 to about 8.8; calcium chloride at a concentration from 0 to about 300 micrograms per ml and optimum levels of antibody containing anti-HB s . A preservative, for example, sodium azide at concentrations from 400 micrograms to about 1,000 micrograms per ml may be added. The entire antibody solution is allowed to stand at 2° to about 8° C. for zero to about 24 hours. The entire solution could be filter sterilized using a 0.2 micron sterile filter. A typical suitable buffer is 0.02 M Tris-HCl buffer at pH 7.4 containing 300 micrograms per ml of calcium chloride and optimum levels of anti-HB s . The pearls are then coated with this solution. Approximately 17 ml ±0.5 ml of antibody solution is required for 100 pearls. The coating is achieved by incubating the pearls at 20° to about 37° C. with the above mentioned solution within 16 hours. At the end of the coating period the solution is removed and the pearls are washed with Tris-HC1 buffer (0.02 to about 0.08M, pH 7.4 to about 8.8) containing sodium azide at 400 micrograms per ml concentration. The remaining moisture content from the pearls is removed by lyophilization to a moisture content of less than 1%. The lyophilized pearls can be stored up to a period of six months at temperature of between -80° C. to about 8° C.
EXAMPLE II
HB s Ag (ad and/or ay) is purified from human plasma or serum by ultracentrifugation. The procedure in brief entails centrifugation of plasma or serum at 35,000 rpm for three (3) hours and thereby collecting the resultant pellet. The pellet is suspended in 0.02 M of Tris-HCl buffer at pH 7.4. The suspended virus is centrifuged on a 1.1 to 1.4 g/ml of Cesium chloride gradient at 35,000 rpm for 18 hours. The centrifuged virus is collected and centrifuged again in Cesium chloride at a density of 1.20 grams/ml at 35,000 rpm for 24 hours. The resultant virus peparation is resuspended in Cesium chloride at a density of 1.20 grams/ml and centrifuged again for 24 hours at 35,000 rpm. The virus so obtained is the purified preparation.
EXAMPLE III
Positive control in this technique consists of a heat inactivated HB s Ag preparation at a concentration of 1.0 micrograms/ml in a suspending solution. This solution consists of 1 part of sterile recalcified human plasma (negative for antinuclear antibodies, rheumatoid factor, syphilis, anti-HB s and any contaminating HB s Ag) and 2 parts of the sterile 0.02 M Tris-HCl buffer at pH 7.4 and sodium azide at a concentration of 1.0 milligrams/ml. The recalcified plasma is prepared by treating human plasma with 3.0% calcium chloride at a concentration of 1.0 ml of calcium chloride/30 ml of plasma. This entire mixture is incubated for 1 hour at 37° C. and thereafter frozen at -20° C. or lower. The contents are frozen and thawed 4 times, centrifuged and supernate filtered through a series of sterile filters ending through 0.2 micron filtration.
EXAMPLE IV
Negative control as used in this procedure is also a recalcified human plasma and is negative for antinuclear antibodies, rheumatiod factor, syphilis, anti-HB s and HB s Ag. Sodium azide at concentration 1.0 milligrams/ml may be added as a preservative.
EXAMPLE V
Antibody to hepatitis B surface antigen is labeled with a radioactive material. However, it is preferred to employ 125 I in the form of Na 125 I. This procedure of producing a radioactively ( 125 I) labeled anti-HB s is identified here as iodination and is essentially a modification of Hunter and Greenwood (Nature, Volume 194, page 495, 1962). The radioactively labeled antibody to HB s Ag is diluted to a final concentration of 0.4 to about 0.8 microcuries/ml using a radioactive antibody diluent. The diluent is prepared by diluting fetal calf serum 50:50 with Tris-HCl (0.02 M pH 7.4) and subsequently adding 10 ml of human serum (negative for antinuclear antibodies, rheumatoid factor, syphilis, anti-HB s and HB s Ag) to every 100 ml of diluted fetal calf serum. The diluent may be filter sterilized by filtering through 0.20 micron sterile filter. Sodium azide may be added as a preservative at a concentration of 1.0 milligrams/ml.
EXAMPLE VI
Serum or plasma may be assayed in this procedure. One pearl coated with anti-HB s is placed into a series of disposable tubes preferably glass. 0.2 ml of sample is placed in a tube. Likewise, negative control is added into six appropriately marked tubes and positive control in two appropriately marked tubes. The size of the tube or the volume of samples or controls are not important. However, it is preferred to use 0.2 ml of the controls or samples in 12 × 75 mm glass tubes, each containing individual pearls. The reaction time and temperature are variable but should be sufficient for an optimum antigen-antibody complex formation. Optimum reactivity is obtained at any time during the first 6 hours at 40° C.
At the end of the reaction, the entire reaction mixture is aspirated and the pearls are washed with water which may be distilled or deionized. The number of washings and the volume of wash solution are not important. Usually one wash with 2.0 to 3.0 ml of distilled or deionized water is sufficient.
Radioactive antibody to hepatits B surface antigen is subsequently added to each tube and the reaction continued for a time and temperature sufficient to form a non-radioactive antibody-antigen-radioactive antibody complex. Usually, 0.2 ml of radioactive antibody is added to each tube and the reaction is allowed to proceed for 1 hour at 40° C. The unreacted antibody is removed from each tube and the pearls washed again with distilled or deionized water to remove the remaining radioactive antibody. Usually two washings with 2.0 ml of wash solution are sufficient for this purpose, the only objective being to remove maximum proportions of unbound radioactive antibody without losing sensitivity or specficity. The amount of unbound radioactivity on each pearl is determined using a radioisotope counter capable of counting gamma radiation. In some instances the pearls may be transferred to clean glass or plastic tubes prior to counting to obtain better sensitivity. The extent of radiation emitted by the pearls from unknown sample or from positive control is compared by the extent of radiation emitted by the negative control treated pearls. The counts per minute (cpm) of unknown sample should be twice that of the average cpm of negative control for a HB s Ag positive reaction. The positive control cpm should always be at least twice the average cpm of negative control.
This procedure is simple and requires less manipulation.
However, it is apparent that many alterations could be made in the procedures and product without departing from the scope and concept of the invention. The description presented herein should be interpreted as illustrative and not in a limiting sense. | The presence of hepatitis B antigen in serum or plasma can be detected by this technique. Commercially available imitation or cultured pearls coated with antibody to hepatitis B antigen are first reacted with the sample and subsequently reacted with radioactively labeled antibody to hepatitis B antigen. Hepatitis B antigen present in the sample forms a complex consisting of non-radioactive antibody-antigen-and radioactive antibody. The radioactivity emanating from these complexes on pearls is measured. This is indicative of the extent of binding of radioactive antibody and thereby indicating the presence or absence of hepatitis B antigen in an unknown sample. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to German patent application 102 31 475.6, the subject matter of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The invention concerns a scanning microscope and an optical component.
BACKGROUND OF THE INVENTION
In scanning microscopy, a specimen is illuminated with a light beam in order to observe the reflected or fluorescent light emitted from the specimen. The focus of an illuminating light beam is moved in a specimen plane by means of a controllable beam deflection device, generally by tilting two mirrors, the deflection axes usually being perpendicular to one another so that one mirror deflects in the X direction and the other in the Y direction. Tilting of the mirrors is brought about, for example, by means of galvanometer positioning elements. The power level of the light coming from the specimen is measured as a function of the position of the scanning beam. The positioning elements are usually equipped with sensors to ascertain the present mirror position.
In confocal scanning microscopy specifically, a specimen is scanned in three dimensions with the focus of a light beam.
A confocal scanning microscope generally comprises a light source, a focusing optical system with which the light of the source is focused onto an aperture (called the “excitation pinhole”), a beam splitter, a beam deflection device for beam control, a microscope optical system, a detection pinhole, and the detectors for detecting the detected or fluorescent light. The illuminating light is coupled in via a beam splitter. The fluorescent or reflected light coming from the specimen travels back through the beam deflection device to the beam splitter, passes through it, and is then focused onto the detection pinhole behind which the detectors are located. Detected light that does not derive directly from the focus region takes a different light path and does not pass through the detection pinhole, so that a point datum is obtained which results, by sequential scanning of the specimen, in a three-dimensional image. A three-dimensional image is usually achieved by acquiring image data in layers, the track of the scanning light beam on or in the specimen ideally describing a meander (scanning one line in the X direction at a constant Y position, then stopping the X scan and slewing by Y displacement to the next line to be scanned, then scanning that line in the negative X direction at constant Y position, etc.). To allow the acquisition of image data in layers, the specimen stage or the objective is shifted after a layer has been scanned, and the next layer to be scanned is thus brought into the focal plane of the objective.
In many applications, specimens are prepared using a plurality of markers, for example several different fluorescent dyes. These dyes can be excited sequentially, for example with illuminating light beams that have different excitation wavelengths. Simultaneous excitation using an illuminating light beam that contains light of several excitation wavelengths is also common. European Patent Application EP 0 495 930 “Confocal microscope system for multi-color fluorescence,” for example, discloses an arrangement having a single laser emitting several laser lines. In practical use at present, such lasers are most often embodied as mixed-gas lasers, in particular as ArKr lasers.
Aberrations attributable to interference phenomena often occur in scanning microscopy. These interferences are usually caused by multiple reflections at various optical interfaces within the scanning microscope.
German Unexamined Application DE 100 42 114.8 A1 discloses a method for illuminating a specimen with light of a laser light source, preferably in a confocal scanning microscope. With the method, the coherence length of the laser light can be decreased so that troublesome interference phenomena in the image can be largely eliminated. If interference phenomena nevertheless do occur, they are to be influenced in such a way that they have no influence on detection. The method according to the invention is characterized in that the phase length of the light field is varied, using a modulation means, in such a way that interference phenomena in the optical beam path occur not at all, or only to an undetectable extent, within a definable time interval.
The method disclosed in the Unexamined Application is laborious in particular for high measurement speeds or images, and because of the special requirements in terms of illumination poses difficulties in terms of changing in the illuminating wavelength, or indeed illuminating with light containing multiple wavelengths.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a scanning microscope in which aberrations caused by troublesome interferences are avoided, and which at the same time allows a change in the illuminating light wavelength or detected light wavelength, or simultaneous illumination of the specimen with an illuminating light beam having several wavelengths, or simultaneous detection of detected light of several wavelengths, in largely error-free fashion.
The present invention provides a scanning microscope comprising an optical component, arranged in the beam path, that comprises a plane entrance surface through which a light beam bundle can be incoupled at an entrance angle, and a plane exit surface through which the light beam bundle can be outcoupled at an exit angle, whereby the optical component contains at least two elements that exhibit at least two different refractive indices; and the entrance angle and exit angle are different.
Another object of the invention is to provide an optical component that can be positioned in a beam path with no occurrence of troublesome interferences.
The invention also provides an optical component comprising at least two elements that exhibit at least two different refractive indices and that define a plane entrance surface through which a light beam bundle can be incoupled at an entrance angle and a plane exit surface through which the light beam bundle can be outcoupled at an exit angle, whereby the entrance angle is different from the entrance angle and whereby partial beam bundles divided from the light beam bundle by the optical element are sufficiently spatially separated from the light beam bundle that they do not interfere with the light beam bundle.
The invention has the advantage of making possible an improvement in image quality simultaneously with flexible usability in terms of the illuminating light wavelength and detected light wavelength.
In an embodiment, the light beam bundle is not deflected or is not substantially deflected by the optical component, so that the total deflection is less than 5 degrees. This has the advantage that the optical component can be introduced into the beam path in place of other optical elements that exhibit a largely continuous beam profile.
The exit angle is preferably identical for at least two wavelengths. In the interest of strict correctness, it should be clarified that the entrance angle and exit angle are angles of the light beam bundle with respect to the surface normal line.
In an embodiment, the interferences are avoided by placing the entrance and/or exit surface of the optical component obliquely, in which context the dispersion effect occurring because of the oblique placement can be compensated for by the fact that the optical component is achromatically corrected. In a particular embodiment, the optical component comprises at least two optical media each having a different refractive index, which can be embodied e.g. as wedges that preferably are combined into a double wedge. The properties and shape of the optical media, such as for example the refractive index, wedge angle, or thickness, are selected in such a way that a light beam bundle having different wavelengths follow the same optical axis after emergence from the optical component.
In another embodiment in which the light beam bundle comprises at least two portions of differing wavelengths, the invention has the particular advantage that portions of the light beam bundle of differing wavelengths extend collinearly after exiting from the optical component.
In an embodiment, the optical component is a beam splitter. The latter can additionally, for example, be provided for dividing a reference beam out of the illuminating light beam in order to measure, monitor, or control the current illuminating light power level, optionally in wavelength-specific fashion.
In another embodiment, the beam splitter serves to separate the illuminating light beam physically from the detected light beam. In this variant, in particular, the beam splitter can be embodied functionally as a beam splitter cube with no occurrence of the troublesome interferences.
In an embodiment, the optical component is a beam deflection device. The latter is preferably of monolithic configuration and can, for example, be embodied as a K-scanner. A K-scanner is known, for example, from German Unexamined Application DE 100 33 549.7 A1. In an embodiment, the beam deflection device is assembled from prisms that are arranged rotatably or pivotably. The prisms are preferably cemented to one another. The shape and optical properties of the prisms, in particular their refractive indices, angles, and passthrough lengths, are coordinated with one another in such a way that illuminating and/or detected light beams having differing wavelengths follow the same optical axis after emerging from the beam deflection device as in the conventional component, but without troublesome interferences.
In an embodiment, the optical component comprises at least two optical media each having a different refractive index, and an air gap can exist between the media. In a particular embodiment, the optical component contains a double wedge.
The optical component is preferably embodied in such a way that a light beam bundle comprises at least two portions of differing wavelength; and that the portions of differing wavelength extend collinearly after exiting from the optical component.
In an embodiment, the optical component contains an acoustooptical component. Acoustooptical components are known, for example, as acoustooptical filters. Mentioned here merely by way of example is German Unexamined Application 199 44 355.6 A1, which discloses a scanning microscope having an acoustooptical component for coupling in an illuminating light beam and coupling out a detected light beam.
In another embodiment, the scanning microscope is a confocal scanning microscope.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter of the invention is depicted schematically in the drawings and will be described below with reference to the Figures, identically functioning components being labeled with the same reference characters. In the drawings:
FIG. 1 shows a scanning microscope according to the present invention;
FIG. 2 shows a further scanning microscope according to the present invention;
FIG. 3 is a detail view of a beam splitter.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 schematically shows a scanning microscope according to the present invention that is embodied as a confocal scanning microscope. Illuminating light beam 5 coming from a light source 1 , which is embodied as a multiple-line laser 3 , strikes an optical component 7 that is embodied as a beam splitter 9 . Beam splitter 9 splits out from illuminating light beam 5 , in interference-free fashion, a reference light beam 11 that is detected using a reference detector 13 . Reference detector 13 generates an electrical reference signal, proportional in amplitude to the light power level of reference light beam 11 , that is transferred to a processing unit 15 for monitoring the illuminating light power level. Beam splitter 9 has an entrance surface 17 and an exit surface 19 , each of which illuminating light beam 5 strikes at an angle of incidence other than zero degrees. Beam splitter 9 is configured, in terms of its shape and its optical properties, in such a way that portions of illuminating light beam 5 of differing wavelength extend collinearly after exiting from optical component 7 . For that purpose, beam splitter 9 has a first element 21 and a further element 23 that are fitted to one another in cement-free fashion. Illuminating light beam 5 emerging from optical component 7 is focused by means of optical system 25 onto illuminating pinhole 27 . After passing through illuminating pinhole 27 , illuminating light beam 5 is directed by a beam splitter 29 to a gimbal-mounted scanning mirror 31 which guides illuminating light beam 5 through scanning optical system 33 , tube optical system 35 , and objective 37 and over or through specimen 39 . Specimen 39 is labeled with several fluorescent dyes. In the case of non-transparent specimens 39 , illuminating light beam 5 is guided over the specimen surface. With biological specimens 39 (preparations) or transparent specimens, illuminating light beam 5 can also be guided through specimen 39 . Detected light beam 41 proceeding from specimen 39 travels through objective 37 , tube optical system 35 , and scanning optical system 33 and via scanning mirror 31 to beam splitter 29 , passes through the latter, and after passing through detection pinhole 43 strikes a detector 45 , which is embodied as multiband detector 47 and generates electrical detected signals proportional to the power level of detected light beam 41 . These signals are forwarded to processing unit 15 and there correlated with the reference signal when image data are generated. The image data are transferred to a PC 49 which displays to the user, on its monitor 51 , an image of the specimen. According to the present invention, no troublesome interferences occur that might degrade the image quality.
FIG. 2 shows a further scanning microscope according to the present invention that is embodied as a confocal scanning microscope, having a light source 1 that emits a light beam 5 for illumination of a specimen 39 . Light beam 5 is focused onto an illumination pinhole 27 and is then reflected by a dichroic beam splitter 29 and a subsequent reflecting mirror 53 to an optical component 7 , namely a beam deflection device 57 , which guides light beam 5 through scanning optical system 33 , tube optical system 35 , and objective 37 and over or through specimen 39 . Detected light beam 41 proceeding from specimen 39 travels through objective 37 , via tube optical system 35 and scanning optical system 33 , and through beam deflection device 57 to dichroic beam splitter 29 , passes through the latter and detection pinhole 43 that follows, and lastly arrives at detector 45 , which is embodied as a photomultiplier. In detector 45 , electrical detected signals proportional to the power level of detected light beam 41 proceeding from the specimen are generated. The specimen is scanned in layers in order to generate from the detected signals a three-dimensional image of specimen 39 .
Beam deflection device 57 contains a rotatable deflection block 59 that is rotatable about first axis 85 . Deflection block 59 is constituted by a prism 61 and a polygonal glass block 63 which is similar to a prism, the hypotenuse surface being constituted by a first surface 65 and a second surface 67 that are at an angle to one another. First surface 65 forms exit surface 19 of optical component 7 . One short face of prism 61 is cemented onto second surface 67 . The other short face forms entrance surface 17 of optical component 7 . Illuminating light beam 5 always strikes entrance surface 17 and exit surface 19 of optical component 7 at an angle of incidence different from zero degrees. The hypotenuse surface of prism 61 constitutes a total reflection surface that deflects the illuminating light beam to glass block 63 . Illuminating light beam 5 is reflected two more times in glass block 63 by total reflection, and after leaving glass block 63 strikes a scanning mirror 69 that is rotatable about second axis 71 . By rotation of deflection block 59 about first axis 85 , light beam 5 is deflected perpendicular to the paper plane. Rotation of scanning mirror 69 about second axis 71 causes a deflection of light beam in the plane of the drawing. A galvanometer drive 73 , which moves deflection block 59 via arm 75 , is provided for rotation of deflection block 59 . Scanning mirror 69 is also driven by a galvanometer, which is not shown for the sake of clarity. The shape and optical properties of the deflection block are selected in such a way that illuminating light beams having different wavelengths follow the same optical axis after emerging from the optical component.
Certain optical elements for guiding and shaping the light beams are omitted from the Figure for better clarity. These are sufficiently familiar to one skilled in this art. With this variant as well, no troublesome interferences, and thus no aberrations or artifacts, occur.
FIG. 3 shows, as optical component 7 , a further beam splitter 55 for a scanning microscope that is usable in particular for separating the beam paths of an illuminating light beam 5 and a detected light beam 41 . The optical component has an entrance surface 17 and an exit surface 19 for illuminating light beam 5 .
The beam splitter comprises three glass modules differing in shape and optical nature, namely a first glass module 79 , a second glass module 81 , and a third glass module 83 . At the interface between the first and second glass modules, illuminating light beam 5 is reflected to exit surface 19 , which it strikes at an angle of incidence different from zero degrees. The shape and optical properties of glass blocks 79 , 81 , 83 are selected so that illuminating light beams having different wavelengths follow the same optical axis after emerging from the optical component. Detected light beam 41 strikes the third glass block on the same optical axis in the opposite direction, the exit surface functioning for the detected light beam as entrance surface, which it strikes at an angle of incidence different from zero degrees. The detected light beam passes through the optical component and leaves it through further exit surface 77 . The shape and optical properties of glass blocks 79 , 81 , 83 are selected so that both illuminating light beams 5 having different wavelengths and detected light beams 41 having different wavelengths respectively follow the same optical axis after emerging from the optical component. In the event that illuminating light beam 5 and/or detected light beam 41 respectively comprise portions having several wavelengths, those portions run in each case collinearly with one another even after passing through the optical component. Neither troublesome interferences nor troublesome spectral divisions occur.
The invention has been described with reference to a particular exemplary embodiment. It is self-evident, however, that changes and modifications can be made without thereby leaving the range of protection of the claims below. | An optical component is arranged in the beam path of a scanning microscope. The optical component has a plane entrance surface through which a light beam bundle can be incoupled at an entrance angle, and a plane exit surface through which the light beam bundle can be outcoupled at an exit angle, which is different from the entrance angle. The optical component contains at least two elements that exhibit at least two different refractive indices. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 12/112,478, filed Apr. 30, 2008, now U.S. Pat. No. 8,127,102, which relates to and claims priority from Japanese Patent Application No. 2008-046724 filed on Feb. 27, 2008, the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a storage system, a copy method, and a primary storage apparatus. The invention is particularly suitable for use in a storage system including a storage apparatus where plural virtual volumes are paired.
2. Description of Related Art
A storage apparatus includes a controller for controlling data I/O to/from the storage apparatus and a disk device having plural hard disk drives for storing the data. A storage apparatus is an apparatus in which plural hard disks are managed in a RAID (Redundant Array of Independent/inexpensive Disks) format. At least one logical volume is formed in a physical storage area provided by a number of hard disks.
There is technology called remote copy, which is designed to avoid, by duplicating data in another storage apparatus located in a distant place, disaster-related loss of data, or similar, in such a storage apparatus.
Remote copy is technology for transferring data in a copy source storage apparatus (hereinafter referred to as a “primary storage apparatus”) to a copy destination storage apparatus (hereinafter referred to as a “secondary storage apparatus”) located in a distant place, and storing the data in a disk device in the secondary storage apparatus. A technique relating to remote copy is disclosed in Japanese Patent Laid-open Publication No. 11-85408, with which data is copied between different storage apparatuses not via a host computer. With the remote copy technology, data can be duplicated to avoid loss of data.
In recent years, Japanese Patent Laid-open Publication No. 2003-015915 has disclosed a technique in which no logical volume with a fixed capacity is created from a storage area in hard disks, but a virtual volume is provided using plural logical volumes. Storage areas in logical volumes are dynamically allocated to that virtual volume. With this configuration, storage areas that are in actuality dispersed over plural storage apparatuses can be provided as a single volume to a host computer.
Pairs of those virtual volumes are set and data is copied from a primary virtual volume to a secondary virtual volume, thereby maintaining data reliability.
If remote copy is executed utilizing the above described virtual volume technique on a storage system including primary and secondary storage apparatuses, all data (including zero data) in a primary virtual volume is copied to a secondary virtual volume when setting a pair so that the content of those virtual volumes are consistent.
However, in this method the amount of traffic is large, so data transfer takes a long time. Therefore, the load on the storage system accompanying data transfer is a problem.
SUMMARY OF THE INVENTION
An object of the invention is to provide a storage system, a copy method, and a primary storage apparatus capable of reducing the load accompanying data transfer even in the case where remote copy is conducted when setting a virtual volume pair using the virtual volume technique in the storage system.
To achieve the above object, the invention provides a storage system for providing a primary logical volume formed with a storage area in plural hard disks, that includes a primary storage apparatus for storing data from a host computer in the primary logical volume, and a secondary storage apparatus connected to the primary storage apparatus, for providing a secondary logical volume for storing a copy of the data, the storage system comprising: a search unit for checking whether or not data exists in each primary slot area formed by partitioning a storage area in the primary logical volume into predetermined storage areas; a transmission unit for sending, if no data is held in the primary slot area, a notice indicating no data stored to the secondary storage apparatus; and a data write unit for writing, when the notice is received from the primary storage apparatus, zero data in the secondary slot area.
With that configuration, if data is not held in the primary logical volume when setting a pair, the primary storage apparatus only has to notify the secondary storage apparatus of no data being held, and the secondary storage apparatus writes zero data only. Accordingly, data transfer time and the load on the storage system accompanying data transfer is reduced.
The invention also provides a copy method for a storage system for providing a primary logical volume formed with a storage area in plural hard disks, that includes a primary storage apparatus for storing data from a host computer in the primary logical volume, and a secondary storage apparatus connected to the primary storage apparatus, for providing a secondary logical volume for storing a copy of the data, the method comprising: a search step for checking whether or not data exists in each primary slot area formed by partitioning a storage area in the primary logical volume into predetermined storage areas; a transmission step for sending, if no data is held in the primary slot area, a notice indicating no data stored to the secondary storage apparatus; and a data write step for writing, when the notice is received from the primary storage apparatus, zero data in the secondary slot area.
With that configuration, if data is not held in the primary logical volume when setting a pair, the primary storage apparatus only has to notify the secondary storage apparatus of no data being held, and the secondary storage apparatus writes zero data only. Accordingly, data transfer time and the load on the storage system accompanying data transfer is reduced.
The invention also provides a primary storage apparatus for providing a primary logical volume formed with a storage area in plural hard disks and storing data from a host computer in the primary logical volume, the primary storage apparatus comprising: a search unit for checking whether or not data exists in each primary slot area formed by partitioning the storage area in the primary logical volume into predetermined storage areas; and a transmission unit for sending, if no data is held in the primary slot area, a notice indicating no data held to a paired secondary storage apparatus.
With that configuration, if data is not held in the primary logical volume when setting a pair, the primary storage apparatus only has to notify the secondary storage apparatus of no data being held, and the secondary storage apparatus writes zero data only. Accordingly, data transfer time and the load on the storage system accompanying data transfer is reduced.
With the invention, only the data stored in the primary storage apparatus is transferred to the secondary storage apparatus when setting a pair, so the load on a storage system accompanying data transfer is reduced.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a hardware configuration for a storage system in an embodiment.
FIG. 2 is a conceptual diagram illustrating logical volumes in the embodiment.
FIG. 3 is a block diagram showing the content of shared memory in the embodiment.
FIG. 4 is a diagram showing a virtual volume management table in the embodiment.
FIG. 5 is a diagram showing a slot group management table in the embodiment.
FIG. 6 is a diagram showing a slot grid table in embodiment.
FIG. 7 is a diagram showing a slot table in the embodiment.
FIG. 8 is a diagram showing a pair setting table in the embodiment.
FIG. 9 is a diagram illustrating a bitmap table in the embodiment.
FIG. 10 is a flowchart showing processing for data transfer executed by a primary storage apparatus in a first pair setting in the embodiment.
FIG. 11 is a diagram showing transmission information in the case where copy data is sent in the embodiment.
FIG. 12 is a diagram showing transmission information used when a “data unallocated” message in the embodiment is sent.
FIG. 13 is a flowchart showing processing for data transfer executed by a secondary storage apparatus in a first pair setting in the embodiment.
FIG. 14 is a flowchart showing processing for data transfer executed by a secondary storage apparatus in a second pair setting in the embodiment.
FIG. 15 is a flowchart showing processing for quick format executed by a secondary storage apparatus in a second pair setting in the embodiment.
FIG. 16 is a flowchart showing processing for data transfer executed by a primary storage apparatus in a third pair setting.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An embodiment of the invention will be described below with reference to the drawings.
1. Storage System Configuration
Referring to FIG. 1 , numerical reference 1 represents the overall storage system in this embodiment. In the storage system 1 , a host computer 2 is connected to a primary storage apparatus 5 A via a network 3 , and the primary storage apparatus 5 A is connected to a secondary storage apparatus 5 B via a data copy network 4 .
In this embodiment, a storage apparatus that directly inputs/outputs data sent to/from the host computer 2 is referred to as a primary storage apparatus 5 A.
The host computer 2 is a computer device equipped with information processing resources such as a CPU and memory, and examples of the host computer 2 include a personal computer, a workstation, and a mainframe. The host computer 2 has information input devices such as a keyboard and a switch (not shown), and information output devices such as a monitor display and a speaker (not shown).
Examples of the network 3 and the data copy network 4 include a SAN (Storage Area Network), a LAN (Local Area Network), the Internet, a public line, or a dedicated line. If the network 3 is a SAN, data is communicated according to Fibre Channel protocol. If the network 3 is a LAN, data is communicated according to TCP/IP protocol. In this embodiment, the network 3 for connecting the host computer 2 with the primary storage apparatus 5 A is a SAN, and the other networks 3 and the copy network 4 are LANS.
The storage apparatus 5 has a disk unit 6 including plural hard disks 60 (HDD) and a controller unit 7 for managing the hard disks 60 in a RAID format. The suffixes “A” and “B” are omitted, except where the storage apparatuses have to be distinguished between.
The hard disks 60 are expensive, high-access performance disks such as SCSI disks, or inexpensive, low-access performance disks such as SATA disks or optical disks.
The controller unit 7 includes plural channel adapters 70 (referred to as “CHA” in the drawings), a switch 71 , shared memory 72 , cache memory 73 , plural disk adapters 74 (referred to as “DKA” in the drawings), and a service processor 75 (referred to as “SVP” in the drawings).
Each channel adapter 70 is a microcomputer system including a microprocessor 700 , memory (not shown), and a communication interface, and the like, and is provided with a port P for connection to a network. Each channel adapter 70 interprets various commands sent from the host computer 2 and executes the required processing. A network address (such as an IP address or WWN) for identifying each channel adapter 70 is allocated to the port P in the channel adapters 70 . With this configuration, each channel adapter 70 can individually serve as a NAS (Network Attached Storage).
The switch 71 is connected to the channel adapters 70 , the shared memory 72 , the cache memory 73 , and the disk adapters 74 . Data and commands are exchanged, via the switch 71 , between the channel adapters 70 , the shared memory 72 , the cache memory 73 , and the disk adapters 74 .
The shared memory 72 is memory shared by the channel adapters 70 and the disk adapters 74 . The shared memory 72 is used mainly for storing system configuration information, various control programs, and commands or similar sent from the host computer 2 . The tables and program stored in the shared memory 72 will be described later.
The cache memory 73 is also memory shared by the channel adapters 70 and the disk adapters 74 . The cache memory 73 is used mainly for temporarily storing data input to/output from the storage apparatuses.
The disk adapter 74 is a microcomputer system including a microprocessor 700 (not shown) and memory (not shown), and the like, and functions as an interface for controlling protocols used during communication with the disk unit 6 . Each disk adapter 74 is connected to a relevant disk unit 6 via, for example, a Fibre Channel cable, and exchanges data with that disk unit 6 in accordance with Fibre Channel protocol.
The service processor 75 is a computer device for maintaining the storage apparatuses 5 , and examples of the service processor 75 include a personal notebook computer. The service processor 75 is connected to the host computer 2 via the network 3 , and is able to receive data or commands from the host computer 2 .
The storage navigator 8 is a computer device operated for managing the storage apparatuses 4 , and examples of the storage navigator 8 include a personal computer. The storage navigator 8 sets storage apparatuses to be paired from among the plural storage apparatuses, sets a pair of virtual volumes V described later, and manages the association between a virtual volume V and a logical volume, which will also be described later. The storage navigator 8 may display the setting and management on a management screen 80 .
2. Logical Configuration for Hard Disks
In the storage system 1 in this embodiment, four disks in the hard disks 60 form a single RAID group. One or more logical volume(s) LU are defined in a storage area provided by the single RAID group.
A specific identifier LUN (Logical Block Number) is allocated to each logical volume LU. Data is input or output by specifying an address, which is a combination of the identifier and a specific number LBA (Logical Block Address) assigned to each block, which is a logical division of a logical volume.
FIG. 2 is a conceptual diagram showing a logical configuration for the hard disks 60 in the storage system 1 .
The logical volumes LU include virtual volumes V, which are logical volumes accessed by the host computer 2 , and real volumes R, which are associated with those virtual volumes V. Each storage area in the real volumes R is associated with a real storage area in the hard disks 60 . A pool area POOL is formed with plural real volumes R.
Storage areas are provided to the virtual volumes V by dynamically allocating, to the virtual volumes V, storage areas in the real volumes R in the pool area POOL. Since the virtual volumes V do not have physical presence of volumes, when data is stored in response to a write request or similar from a host computer 2 , a storage area in a real volume R included in a pool area POOL is reserved to store the data. If a read request from the host computer 2 is issued to an area that has reserved no storage area in a real volume R in the pool area POOL, the virtual volume V reads zero data from the pool area POOL to respond to the host computer 2 . Thus a volume having an arbitrary capacity that does not depend on the physical capacity can be provided to the host computer 2 by virtually creating a volume capacity of the virtual volume V.
Each storage area in the virtual volumes V and real volumes R is partitioned by a storage area referred to as a “slot S.” The virtual volumes V and the real volumes R are associated with each other in units of slots S. A slot S is a minimum storage area where the above described data is stored, and corresponds to the above mentioned block.
This embodiment aims at not only setting a pair of two virtual volumes V, but also setting a pair of a virtual volume V and a real volume R. A virtual volume V directly accessed by the host computer 2 is referred to as a “primary virtual volume V,” and a copy destination virtual volume V where data stored in the primary virtual volume PV (in actuality, data in a storage area in the hard disks 60 allocated to the primary volume PV) is copied is referred to as a “secondary virtual volume SV.”
A real volume associated with a primary virtual volume PV is referred to as a primary real volume PR, and a real volume associated with a secondary virtual volume SV is referred to as a secondary real volume SR.
Both the primary and secondary virtual/real volumes are described as virtual volumes V/real volumes R except where primary or secondary are specified.
3. Table Configuration
Various tables held in the storage system 1 will be described. The primary and secondary storage apparatuses 5 A and 5 B respectively hold each of the below tables. The suffixes A and B are not used except where the tables are specified.
First, FIG. 3 shows an example of various tables and a program stored in the shared memory 72 .
The shared memory 72 stores a virtual volume management table 720 , a slot group management table 721 , a slot grid table 722 , a slot table 723 , a pair setting table 724 , and a copy program 725 . In particular, the virtual volume management table 720 , the slot group management table 721 , the slot grid table 722 , and the slot table 723 are association information used to associate, aside from the pair setting, storage areas of a virtual volume V and a real volume R in a storage apparatus 5 . The copy program 725 is a program for having the storage apparatus 5 form a copy pair and execute copying.
3-1. Virtual Volume Management Table
The virtual volume management table 720 is a table where storage areas of virtual volumes and associated slot numbers are stored. The virtual volume management table 720 includes “virtual volume address” entries 7200 and “slot number” entries 7201 .
For example, as shown in FIG. 4 , the virtual volume management table 720 holds slot numbers “ 3 - 10 ,” which are associated with a virtual volume address “0x10.”
3-2. Slot Group Management Table
The slot group management table 721 is a table for managing plural slots by groups, and includes “slot number group” entries 7210 .
For example, the slot group management table 721 in FIG. 5 indicates that plural slots are managed in groups of fifty. Accordingly, the slot numbers “ 3 - 10 ” are managed in the first line of the slot group management table 721 .
3-3. Slot Grid Table
The slot grid table 722 is a table showing, in a grid, plural slot numbers respectively managed in each line in the slot group management table 721 .
For example, if slots are managed in groups of fifty in the slot group management table 721 , slots # 1 to # 50 are managed in one slot grid table 722 , and the subsequent slots # 51 -# 100 are managed in another slot grid table 722 . In the slot grid table 722 , a slot is associated with a virtual volume, “1,” which means “an allocated area,” is held. Meanwhile, if a slot is not associated with a virtual volume, “0,” which means “an unallocated area,” is held.
For example, in the slot grid table 722 in FIG. 6 , slot numbers “ 3 - 10 ” are unallocated areas (“ 1 ”).
3-4. Slot Table The slot table 723 is a table prepared for each slot number, and stores a real volume address allocated to an arbitrary slot number. The slot table 723 includes a “slot number” entry 7230 and a “real volume address” entry 7231 .
For example, the slot table 723 in FIG. 7 holds real volume address “0000,” which is allocated to slot number “ 3 .”
3-5. Pair Setting Table
The pair setting table 724 is a table for managing settings for pairs of copy source storage areas and copy destination storage areas. The pair setting table 724 includes “slot number” entries 7240 , “copy source address” entries 7241 , and “copy destination address” entries 7242 .
For example, the pair setting table 724 shown in FIG. 8 holds primary and secondary storage areas associated with slot number “ 3 .” Each of those primary and secondary storage areas is associated with address “0x10.”
3-6. Bitmap Table
The bitmap table M is management information that reflects the status of storage areas DS (hereinafter referred to as data storage areas DS) where data in real volumes R is stored, and is partitioned like a grid for management. The bitmap table M is a table used for real volumes that are not associated with virtual volumes V. A slot number is allocated to each entry in the grid of the bitmap table M. The bitmap table M is stored in a management storage area MS for storing management information about real volumes R. The bitmap table has been explained as being managed in units of slots, but may also be managed in units other than slots, such as pages or blocks in the virtual volumes.
For example, as shown in FIG. 9 , if data is stored in an arbitrary real volume R. “1” is stored in the slot number entries corresponding to the storage areas that store the data. If data is not stored, “0” is stored in the slot number entries corresponding to the storage areas that do not store data.
4. Processing for Data Transfer
Data transfer in this embodiment for pairs set between: a primary virtual volume PV and a secondary virtual volume SV (first pair setting), between a primary virtual volume PV a secondary real volume SR (second pair setting), and between a primary real volume PR and a secondary virtual volume SR (third pair setting) will be described below.
4-1. First Pair Setting
First, processing for data transfer in the case where a primary virtual volume PV and a secondary virtual volume SV are paired in the storage system 1 will be described. In this case, in the pair setting table 724 an address in the primary virtual volume PV is set as the copy source address, and an address in the secondary virtual volume SV is set as the copy destination address.
4-1-1. Processing for Data Transfer in Primary Storage Apparatus
Processing for data transfer in a primary storage apparatus shown in FIG. 10 is described. The data transfer in the primary storage apparatus 5 A is executed by a microprocessor 700 A in each channel adapter 70 A based on the copy program 725 .
After receiving a remote copy order from the host computer 2 or the storage navigator 8 A, the microprocessor 700 A refers to the bitmap table M and checks whether or not the first slot S in the primary virtual volume PV has already been allocated (S 1 ). In other words, the microprocessor 700 A checks whether or not data is stored in the primary real volume associated with the primary virtual volume PV. When doing so, the microprocessor 700 A checks whether or not the above described virtual volume management table 720 A, slot group management table 721 A, slot grid table 722 A, and slot table 723 A have been allocated to a copy target slot S.
If the microprocessor 700 A judges the copy target slot S as having already been allocated (S 1 : Yes), the data is stored in the primary real volume PR, so the microprocessor 700 A reads data from the address in the primary real volume PR associated with the primary virtual volume PV (S 2 ). The address in the associated primary real volume PR is searched for in the above described slot table 723 .
The microprocessor 700 A refers to the pair setting table 724 and sends the above read data to the pair target secondary virtual volume SV (S 3 ).
Information used when sending data to the pair target secondary virtual volume SV is shown in FIG. 11 . The transmission information SI 1 contains “operation code” SI 10 for notifying the secondary storage apparatus 5 B of an initial copy, “sub-information” SI 11 for notification of whether or not copy data exists, “address information” SI 12 about a copy source address, and “user data” SI 13 .
Since in step S 3 copy data is sent, “copy data exists” is registered as the “sub-information” SI 11 . In the “address information” SI 12 , the head slot number in the primary real volume PV, which is the position to start the copy, is held. “Data for 1 slot S” is registered as “user data” SI 13 .
Meanwhile, if the microprocessor 700 A judges the copy target slot S as being unallocated (S 1 : NO), data is not stored in the primary real volume PR, so the microprocessor 700 A sends, to the secondary storage apparatus 5 B, a “data unallocated” message, which indicates no data stored in the storage area (slot S) in the copy target primary virtual volume PV (S 4 ).
Information used when sending the “data unallocated” message to the pair target secondary virtual volume SV is shown in FIG. 12 . The transmission information SI 2 , which is the notification message for “unallocated data,” contains “operation code” SI 20 , “sub-information” SI 21 , and “address information” SI 22 , which is information on a copy source address.
In step S 4 , copy data is not sent; only a message is sent, so “no copy data” is held as the “sub-information” SI 21 . The head slot number in the primary real volume PV for which whether or not data is stored has been checked is held as the “address information” SI 22 .
Thus the microprocessor 700 A checks whether or not all slots S have been allocated (S 5 ). If not all slots S have been checked (S 5 : NO), the processing in steps S 1 to S 4 is repeated for the subsequent check target slots S.
After the allocation of all slots S has been checked (S 5 : Yes), the microprocessor 700 A terminates the processing for data transfer in the primary storage apparatus 5 A.
4-1-2. Processing for Data Transfer in Secondary Storage Apparatus
Next, processing for data transfer in the secondary storage apparatus 5 B shown in FIG. 13 will be described. The data transfer in the secondary storage apparatus 5 B is executed by a microprocessor 700 B in each channel adapter 70 B based on the copy program 725 .
First, if the microprocessor 700 B judges the data as having been received from the primary storage apparatus 5 A (S 10 : Yes), the microprocessor 700 B refers to the pair setting table 724 and searches for the copy target secondary virtual volume SV. After that, the microprocessor 700 B refers to the bitmap table M and checks whether or not each slot S in the above searched secondary virtual volume SV has already been allocated to a secondary real volume SR (S 11 ). In this step, the microprocessor 700 B checks whether or not the above described virtual volume management table 720 B, slot group management table 721 B, slot grid table 722 B, and slot table 723 B have been allocated to a copy target slot S.
If each slot S in the secondary virtual volume SV searched for by the microprocessor 700 B has not been allocated to a secondary real volume SR (S 11 : NO), no data is stored in the secondary real volume SR, so a data storage area DS is reserved in the secondary real volume SR (S 12 ). In this step, the microprocessor 700 B sets, in the virtual volume management table 720 B, the slot group management table 721 B, the slot grid table 722 B, and the slot table 723 B, the relationship between the above reserved storage area in the secondary real volume SR and the secondary virtual volume SV.
After that, the microprocessor 700 B writes the received data to the reserved data storage area DS in the secondary real volume SR (S 13 ), and terminates the processing for data transfer.
Meanwhile, if each slot S in the secondary virtual volume SV searched for by the microprocessor 700 B have already been allocated (S 11 : Yes), the microprocessor 700 B writes the received data to the data storage area DS in the associated secondary real volume SR (S 13 ), and terminates the processing for data transfer.
In step S 10 , if the microprocessor 700 B has not received data from the primary storage apparatus 5 A (S 10 : NO) but received a “data unallocated” message (S 14 :Yes), the microprocessor 700 B refers to the pair setting table 724 and searches for the copy target secondary virtual volume SV. After that, the microprocessor 700 B refers to the virtual volume management table 720 B, the slot group management table 721 B, the slot grid table 722 B, and the slot table 723 B, and checks whether or not each slot S in the above searched secondary virtual volume SV has already been allocated to a secondary real volume SR (S 15 ).
If each slots S in the secondary virtual volume SV searched for by the microprocessor 700 B has already been allocated (S 15 : Yes), the microprocessor 700 B writes zero data to the data storage area DS in the associated real volume SR (S 16 ) and terminates the processing for data transfer.
As described above, by setting primary and secondary virtual volumes V to be paired, the storage system 1 can create a virtual volume V having a capacity larger than the capacity of each real volume R. Accordingly, a large-capacity virtual volume V can be prepared in advance in consideration of the volume capacity that will increase in the future.
For an unallocated area in a primary virtual volume PV, the primary storage apparatus 5 A only has to transfer a “data unallocated” message to the secondary storage apparatus 5 B, so processing relating to data transfer for that allocated area in the secondary storage apparatus 5 B is unnecessary. Accordingly, as a whole, transfer time and processing time in the secondary storage apparatus 5 B is greatly reduced.
4-2. Setting of Second Pair
Next, processing for data transfer executed in the case where a primary virtual volume PV and a secondary real volume SR are paired in the storage system 1 will be described. In this case, in the pair setting table 724 , an address in the primary virtual volume PV is set as a copy source address, and an address in the secondary real volume SR is set as a copy destination address.
4-2-1. Processing for Data Transfer in Primary Storage Apparatus
As the processing for data transfer in the primary storage apparatus is the same as the processing in the above described steps S 1 -S 5 , an explanation has been omitted.
4-2-2. Processing for Data Transfer in Secondary Storage Apparatus
Next, processing for data transfer in the secondary storage apparatus 5 B shown in FIG. 14 will be described. The data transfer method in the secondary storage apparatus 5 B is executed by a microprocessor 700 B in each channel adapter 70 B based on the copy program 725 B.
First, if the microprocessor 700 B checks, from the transmission information SI 1 given from the primary storage apparatus 5 A, that data has been received (S 20 : Yes), the microprocessor 700 B refers to the pair setting table 724 B and searches for a copy target secondary real volume SR.
After that, the microprocessor 700 B writes the received data to the data storage area DS indicated by an address in the above searched secondary real volume SR (S 21 ), and terminates the processing for data transfer.
In step S 20 , if the microprocessor 700 B checks, from the transmission information SI 2 given from the primary storage apparatus 5 A, that data has not been received (S 20 : NO) but a “data unallocated” message has been received (S 22 : Yes), the microprocessor 700 B writes zero data to the data storage area DS indicated by an address in the above searched secondary real volume SR (S 23 ) and terminates the processing for data transfer.
As shown in FIG. 15 , the secondary storage apparatus 5 B may execute “quick format” processing. The “quick format” processing is processing for erasing data in a data storage area DS in the secondary real volume SR.
More specifically, in step S 20 , if the microprocessor 700 B checks, from the transmission information SI 2 given from the primary storage apparatus 5 A, that data has not been received (S 20 : NO) but a “data unallocated” message has been received (S 22 : Yes), the microprocessor 700 B erases data stored in the data storage area in the secondary real volume SR (S 24 ). When doing so, the microprocessor 700 B sets the target slot S in the bitmap table M stored in the secondary real volume SR to “0.”
After that, the microprocessor 700 B terminates the processing for data transfer.
As described above, since a virtual volume V is set as a primary volume and a real volume R is set as a secondary volume to form a pair, the primary storage apparatus 5 A only has to transfer, regarding an unallocated area in a primary virtual volume PV, a “data unallocated” message to a secondary storage apparatus 5 B. In addition, the secondary storage apparatus 5 B only has to write zero data to the data storage area DS in the above set pair, so processing relating to data transfer is unnecessary. Accordingly, as a whole, transfer time can be reduced.
4-3. Third Pair Setting
Next, processing for data transfer executed when in a primary real volume PR and a secondary virtual volume SV in the storage system 1 are paired will be described. In this case, in the pair setting table 724 , an address in a primary real volume PR is set as a copy source address, and an address in a secondary virtual volume SV is set as a copy destination address.
4-3-1. Processing for Data Transfer in Primary Storage Apparatus
Processing for data transfer in a primary storage apparatus shown in FIG. 9 will be described. The data transfer in a primary storage apparatus 5 A is executed by a microprocessor 700 A in each channel adapter 70 A based on the copy program 725 .
The microprocessor 700 A reads, after receiving a remote copy order from the host computer 2 or the storage navigator 8 A, the bitmap table M from a management storage area MS in the primary real volume PR, and checks whether or not the first copy target slot S in the primary real volume PR is “0” (S 30 ). More specifically, the microprocessor 700 A checks whether or not data is stored in the data storage area DS at the position of the first slot S.
If the microprocessor 700 A determines that the first copy target slot S is “0” (S 30 : Yes), the microprocessor 700 A sends a “data unallocated” message as transmission information SI 2 to the secondary storage apparatus 5 B (S 31 ).
Meanwhile, if the microprocessor 700 A determines that data exists in the data storage area DS corresponding to the first copy target slot S (S 30 : NO), the microprocessor 700 A reads data from that data storage area DS (S 32 ) and sends the above read data as the transmission information SI 1 to the secondary storage apparatus 5 B (S 33 ).
The microprocessor 700 A checks, for all slots, whether or not each slot S has been allocated (S 34 ). If not all slots S have been checked (S 34 : NO), processing in steps S 30 to S 33 is executed again on the subsequent check target slots S.
If the microprocessor 700 A has checked the allocation status of all slots S (S 34 : NO), the microprocessor 700 A terminates the processing for data transfer in the primary storage apparatus 5 A.
4-3-2. Processing for Data Transfer in Secondary Storage Apparatus
Since the processing for data transfer in the secondary storage apparatus are the same as the processing in above described steps S 20 to S 24 , an explanation has been omitted.
As described above, since a real volume R is set as a primary volume and a virtual volume R is set as a secondary volume to form a pair, the primary storage apparatus 5 A searches for an area in the primary real volume PR where data is not stored, and the primary storage apparatus 5 A only has to transfer, regarding the area where data is not stored, a “data unallocated' message” to a secondary storage apparatus 5 B. Since the secondary storage apparatus 5 B only has to write zero data to a data storage area DS in paired volumes, processing for data transfer is unnecessary and transfer time is reduced.
5. Advantage of this Embodiment
As described above, in this embodiment, when setting a pair only the data stored in a primary storage apparatus is transferred to a secondary storage apparatus. Accordingly, the load on the storage system accompanying data transfer is reduced.
The invention can be widely used in storage systems having one or more storage apparatus(es), or other types of storage systems.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised that do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A storage system having a primary storage apparatus for storing data from a host computer in a primary logical volume, and a secondary storage apparatus connected to the primary storage apparatus, for providing a secondary logical volume for storing a copy of the data, the storage system comprising: a search unit for checking whether or not data exists in each primary slot area formed by partitioning a storage area in the primary logical volume into predetermined storage areas; a transmission unit for sending, if no data is held in the primary slot area, a notice indicating no data stored to the secondary storage apparatus; and a data write unit for writing, when the notice is received from the primary storage apparatus, zero data in the secondary slot area. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a housing, preferably a hermetically sealing housing, a small-type refrigerating machine for receiving an electromotor and a piston-cylinder unit driven by the same for compressing a refrigerant guided via feed lines and discharge lines into the housing and into the piston of the piston-cylinder unit, with the housing being provided with at least one connecting element for fastening to a support plate, in accordance with the preamble of claim 1 .
DESCRIPTION OF THE PRIOR ART
[0002] Housings for this type of small-type refrigerating machines are well known. Such a housing is mounted during installation on a base plate arranged on the refrigerating machine. For mounting on the base plate, a connecting element is usually used which enables the fastening of the housing to the base plate.
[0003] Connecting elements consist of two fastening brackets for example, with the maker of the small-type refrigerating machine ensuring the mounting ability of the housing on a support plate or base plate of the refrigerating machine by providing a suitable configuration of the support element. Such a standardization concerning the fastening brackets relates especially to their outer distances and to the distances of the holes and hole diameters for receiving the fastening means such as screws. Four holes are usually provided for receiving the fastening means which have a distance of 170×70 mm from each other. With the help of the fastening brackets the small-type refrigerating machine is fastened to the support plate of the refrigerating machine. The fastening brackets of the small-type refrigerating machines are usually welded onto the housing.
[0004] Support plates are usually not separately produced for small-type refrigerating machines of smaller dimensions, but also for small-type refrigerating machines of larger configurations. The support plates thus usually have dimensions which are much larger than actually necessary for securely fastening the small-type refrigerating machines. This represents an unnecessary additional expenditure of required material since one needs to consider that small-type refrigerating machines of this kind are made in high numbers and said additional expenditure of material can therefore be considerable. Moreover, a large number of mounting parts is necessary which cause additional mounting work and costs.
[0005] Furthermore, there are sometimes difficulties in the operation of small-type refrigerating machines as a result of the occurring vibrations of the housing. Vibrations promote material fatigue and increased noise and reduce the bearing strength of the housing on the support plate. Although it is tried in accordance with the state of the art to prevent the transmission of vibrations onto the support plate with the help of vibration-damping elements in the holes for the fastening means, this measure however increases mounting work and the number of required components. Moreover, the currently used connecting elements have proven to be unfavorable concerning a reduction of the vibration transmission from housing to support plate and a reduction of the vibrations of the housing itself.
[0006] A fastening apparatus for hermetic compressors is known from WO 00/46504, with connecting elements being provided which can be coupled with deep-drawn parts arranged on the floor side of the housing. The connecting elements comprise flanged sections which are provided with bores and with which the connecting elements plus housing are mounted on a support plate.
[0007] A compressor housing is known from U.S. Pat. No. 4,964,786 which is fastened to a support plate by means of a cup-shaped connecting element. The connecting element is integrally made of elastic material and pressed with a web-shaped wall into a ring-shaped groove on the floor of the compressor housing where it is fastened additionally with a layer of adhesive. The planar, disk-like floor of the connecting element is subsequently also fastened by a layer of adhesive on the base plate.
[0008] It is the goal of the present invention to avoid the mentioned disadvantages and to ensure producing a connection between the housing and the support plate by means of a suitable configuration of the housing and the connecting element fastened to the same which reduces the need for material and the amount of mounting work and the number of components required for this purpose and thereby reducing the costs, and also allowing a technically simple reduction of the transmission of vibrations from the housing to the support plate and reduction of the vibrations of the housing. These objects are achieved by the characterizing features of claim 1 .
SUMMARY OF THE INVENTION
[0009] Claim 1 relates to a housing, preferably a hermetically sealing housing, a small-type refrigerating machine for receiving an electromotor and a piston-cylinder unit driven by the same for compressing a refrigerant guided via feed lines and discharge lines into the housing and into the piston of the piston-cylinder unit, with the housing being provided with at least one connecting element for fastening to a support plate. It is provided in accordance with the invention that in a direction of view perpendicular to the support plate the outermost dimensions of the housing protrude beyond the outermost dimensions of the at least one connecting element, and the connecting element or the imaginary shortest connecting line along the surface of the housing between the connecting elements in the case of several connecting elements encloses a surface area of the housing facing the support plate. The volume which is enclosed by the at least one connecting element and which receives the surface area of the housing facing the support plate is delimited by the support plate on its side opposite of the housing, which means that the surface area of the housing enclosed by the at least one connecting element faces directly to the support plate. The connecting element of a housing in accordance with the invention is provided with a considerably smaller configuration than the one according to the state of the art. Since also at least one connecting element or its imaginary connecting line encloses a surface area of the housing facing the support plate, it is also possible to follow an antinode line on the housing in the arrangement of the at least one connecting element in order to achieve advantageous vibration-damping effects, as will be explained below in closer detail.
[0010] Claim 2 provides that in a direction of view oriented parallel to the support plate, the at least one connecting element protrudes beyond the surface section of the housing which faces and is enclosed by the support plate. This enables simpler fastening of the at least one connecting element to the support plate and also ensures that after mounting the housing does not touch the support plate. As a result, vibrations from the housing are carried off only via the connecting element.
[0011] Claim 3 relates to a first embodiment, according to which precisely one connecting element is provided which is arranged as a support body in the shape of a cylinder or truncated cone and with a base surface in the shape of an annulus which encloses the surface area of the housing facing the support plate.
[0012] Claim 4 relates to a further embodiment, according to which precisely one connecting element is provided which is arranged as a cuboid support frame which encloses the surface area of the housing facing the support plate.
[0013] Claim 5 describes for both these embodiments a possibility for fastening the connecting element to the housing. In accordance with claim 5 , the at least one connecting element comprises at least one chamber with an opening facing the housing for receiving a holding element protruding from the housing.
[0014] A solution in analogy to claim 5 can also be used for fastening the connecting element on the support plate, as is proposed in claim 6 . In accordance with claim 6 , the at least one connecting element comprises at least one chamber with an opening facing the support plate for receiving a holding element protruding from the support plate.
[0015] One embodiment for the interaction between holding element and chamber as mentioned in claim 5 and 6 is proposed in claim 7 , according to which the opening of the at least one chamber forms a holding shoulder and the holding element comprises an undercut for latching into the holding shoulder.
[0016] A further possibility for fastening the connecting element to the support plate is proposed in claim 8 , according to which the at least one connecting element comprises a laterally arranged slit for receiving the free end of a holding bracket protruding from the support plate.
[0017] The arrangement of the housing in accordance with the invention also allows an alternative variant in accordance with claim 9 , according to which at least three connecting elements are provided which are arranged as support feet protruding axially from the housing, with the imaginary shortest connecting line between the support feet along the surface of the housing enclosing the surface area of the housing facing the support plate. At least three connecting elements are advantageous for the reason that a stable bearing of the housing on the connecting elements can be ensured with at least three connecting elements. The surface section of the housing facing the support plate can have the approximate shape of a spherical cap. According to claim 10 , two of the support feet can be arranged in the manner of pegs with a support plate each which can each be inserted into a breakthrough in the support plate, and the third support foot can be provided with a tab-like configuration which can be inserted into a further breakthrough in the support plate.
[0018] As a result of these different embodiments in accordance with the invention, an especially simple reduction of vibrations of the housing and their transmission from housing to support plate is achieved, such that in accordance with claim 11 the at least one connecting element is made at least partly of an elastomeric material or according to claim 12 the contact surface of the at least one connecting element with the housing is arranged in the region of antinodes of the overall system consisting of housing and connecting body, which antinodes correspond to usual operating states.
[0019] In accordance with claim 13 , the at least one connecting element can be formed on the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention is now explained in closer detail by reference to the enclosed drawings, wherein:
[0021] FIG. 1 shows a view of a housing for a small-type refrigerating machine with connecting elements in the form of two fastening brackets in accordance with the state of the art;
[0022] FIG. 2 shows a sectional view of a part of the configuration according to FIG. 1 along the cutting plane A;
[0023] FIG. 3 shows a schematic view of an embodiment of a connecting element in accordance with the invention with housing and support plate;
[0024] FIG. 4 shows the configuration according to FIG. 3 from below without the support plate;
[0025] FIG. 5 shows a sectional view of a part of the configuration according to FIG. 3 along the cutting plane B;
[0026] FIG. 6 shows a perspective view of a further embodiment of a connecting element in accordance with the invention with a housing and a support plate as seen from below;
[0027] FIG. 7 shows a front view of the configuration according to FIG. 6 ;
[0028] FIG. 8 shows a perspective view of the further embodiment of a connecting element according to FIG. 6 in accordance with the invention without the support plate;
[0029] FIG. 9 shows a perspective view of a further embodiment of a connecting element in accordance with the invention with a housing without support plate as seen from below;
[0030] FIG. 10 shows a perspective view of the further embodiment of a connecting element in accordance with the invention according to FIG. 9 as seen from above and with support plate;
[0031] FIG. 11 shows a front view of the configuration according to FIG. 10 ;
[0032] FIG. 12 shows a perspective view of a further embodiment of a connecting element in accordance with the invention with a housing and support plate;
[0033] FIG. 13 shows a sectional view of a part of the configuration according to FIG. 12 along the cutting plane C;
[0034] FIG. 14 shows the configuration of FIG. 12 from a different view;
[0035] FIG. 15 shows a view of the further embodiment of a connecting element in accordance with the invention according to FIG. 12 with a housing and support plate seen from below;
[0036] FIG. 16 shows a perspective view of a further embodiment of a connecting element in accordance with the invention with a housing and support plate, and
[0037] FIG. 17 shows a sectional view of a part of the configuration according to FIG. 16 along the cutting plane D.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] FIG. 1 shows a view of a housing 1 for a small-type refrigerating machine with connecting elements in the form of two fastening brackets 3 according to the state of the art ( FIG. 1 only shows one of the fastening brackets 3 ). The fastening brackets 3 are fastened to flange-like noses 4 of housing 1 by means of a welded connection for example, as is shown especially in FIG. 2 . Two vibration-damping support elements 2 are arranged on the two fastening brackets 3 , which support elements are finally fastened to the support plate or base plate of the refrigerating machine. The support plate is now shown in FIGS. 1 and 2 . It is clearly visible that several components are necessary for mounting the small-type refrigerating machine on the support plate or base plate of the refrigerating machine, thus leading to additional mounting work, need for material and mounting time. It can further be seen that the vibration damping of the oscillating housing 1 on the support or base plate of the refrigerating machine is not satisfactory, which promotes material fatigue and additional noise development. These disadvantages are to be avoided by an optimal mounting solution.
[0039] FIGS. 3 to 5 show an embodiment of making an improved connection between housing 1 and a support plate 5 which subsequently is fastened to the base plate of the refrigerating machine. The connection is made with the help of a connecting element which is arranged in this embodiment as a cylindrical support body 6 with an annular base. The support body 6 is fastened to the surface of housing 1 facing the support plate 5 and encloses a surface section of housing 1 facing the support plate. As is shown especially in FIG. 5 , the height of the cylindrical support body 6 is chosen in such a way that the lowermost point P of the housing 1 is slightly spaced from the support plate 4 , approximately 1 to 5 mm. An elastomeric material is preferably used for the support body 6 which has vibration-damping properties. The type of fastening of the support body 6 to housing 1 and the support plate 5 will be explained below in closer detail. FIGS. 3 to 5 show especially that the outermost dimensions of the housing 1 protrude beyond the outermost dimensions of the support body 6 in a direction of view oriented perpendicularly to the support plate 5 . The support body 6 can therefore be provided with a comparatively small configuration. The volume which is enclosed by the support body 6 and which receives the surface area of housing 1 facing the support plate 5 is delimited by the support plate 5 on its side opposite of housing 1 , so that the surface area of housing 1 enclosed by the support body 6 faces directly towards the support plate 5 . The overall height of the support body 6 is thus kept low.
[0040] Moreover, the positioning of the support body 6 is advantageously chosen in such a way that it is arranged on housing 1 in the region of antinodes of the overall system consisting of housing 1 and connecting body 6 , which antinodes correspond to usual operating states.
[0041] As an alternative to this, the support body 6 could also be arranged in the shape of a truncated cone and with an annular base surface. It is further possible that the support body 6 is not provided with an integral configuration, but is composed of mutually spaced annular segments which are arranged along a circumferential line of one of the surface sections of housing 1 facing the support plate 5 . In this case, an imaginary, very short connecting line can be drawn along the surface of housing 1 between the individual segments which enclose a surface area of housing 1 facing the support plate 5 . Such an embodiment would lead to additional material savings concerning the support body 6 .
[0042] A further embodiment for a connecting element in accordance with the invention is shown in FIGS. 6 to 8 . As has already been indicated above, the connecting element is provided with multi-part configuration, namely in the form of three support feet 7 , 8 , 9 which protrude axially from the housing 1 and which are subsequently fastened to a support plate 10 . The support feet 7 , 8 , 9 are situated within the outermost dimensions of the housing 1 in a direction of view oriented perpendicularly to the bearing plate 10 , with the imaginary shortest connecting line between the support feet 7 , 8 , 9 along the surface of the housing 1 enclosing a surface area of housing 1 facing the support plate 10 (see FIG. 8 ). The arrangement of said support feet can vary. In FIGS. 6 to 8 it is proposed that two of said support feet 8 , 9 are provided with a peg-like configuration and are provided with a preferably square support plate 11 which can be inserted into a respective breakthrough 12 of the support plate 10 . The third support foot 7 is provided with a tab-like configuration and engages in a further breakthrough 13 of the support plate 10 . In the course of mounting housing 1 on support plate 10 , the square support plates 11 are inserted into the breakthroughs 12 and tightly clamped with the help of the support foot 7 engaging in the breakthrough 13 . The support feet 7 , 8 , 9 can be formed or welded onto housing 1 . The support feet 7 , 8 , 9 can comprise sections for vibration damping which are made of an elastic material. As is shown especially in FIG. 7 , the height of the support feet 7 , 8 , 9 is chosen in such a way that the lowest point P of housing 1 is slightly spaced from the support plate 10 in the mounted state, e.g. 1 to 5 mm.
[0043] FIGS. 9 to 11 show a further embodiment of an improved connection between housing 1 and a support plate 14 , which subsequently will be fastened to the base plate of the refrigerating machine. The connection is made by means of a connection element which in this embodiment is arranged as a cuboid support frame 15 . The support frame 15 is fastened to the surface of housing 1 facing the support plate 14 and encloses a surface section of housing 1 facing the support plate 14 . As is shown especially in FIG. 11 , the height of the support frame 15 is chosen in such a way that the lowermost point P of housing 1 is slightly spaced from the support plate 14 , approximately 1 to 5 mm. An elastomer is preferably used for the support frame 15 , which elastomer has vibration-damping properties. FIGS. 9 to 11 also show that in a direction of view perpendicular to the support plate 14 the outermost dimensions of the housing 1 protrude beyond the support frame 15 , as a result of which the support frame 15 can be provided with a comparatively small configuration. Moreover, the positioning of the support frame 15 is advantageously chosen in such a way that it is arranged on the housing 1 in the region of antinodes of the entire system which consists of housing 1 and support frame 15 , which antinodes correspond to the usual operating states.
[0044] It is also possible that the support frame 15 is not provided with an integral configuration but is composed of mutually spaced cuboid segments. In this case, an imaginary shortest connecting line can be drawn along the surface of the housing 1 between the individual segments which encloses a surface area of the housing 1 facing the support plate 14 . Such a configuration would lead to additional savings in material concerning the support frame 15 .
[0045] The type of fastening of the support frame 15 to housing 1 and to support plate 14 can be made in such a way that two tabs 16 are punched out of the support plate 14 and are bent up perpendicular to the support plate 14 , the free end section 17 of which is then bent horizontal to the support plate 14 (see FIG. 10 ; merely one of the two tabs 16 is shown). Two holding brackets 27 are thus formed. The two tabs 16 extend parallel with respect to each other and correspond in respect of their distance to an outer dimension of the support frame 15 . The support frame 15 can therefore be inserted between the two tabs 16 . It comprises lateral slits 18 in which the horizontal end sections 17 of the tabs 16 engage. The housing 1 is thus already fixed in two spatial directions. In order to fix the housing 1 in the spatial direction parallel to the tabs 16 , a further tab 19 can be punched from the support plate 14 and can be bent up perpendicular to the support plate 14 which is oriented perpendicular to the tab 16 and rest tightly on the support frame 15 in the bent-up position. The housing 1 can thus be mounted in a simple and cost-effective manner on support plate 14 .
[0046] A similar procedure can also be chosen with such embodiments in which the connecting element is arranged as a cylindrical support body 6 according to FIGS. 3 to 5 . This will be explained below by reference to FIGS. 12 to 15 .
[0047] The type of fastening of the support body 6 to housing 1 and the support plate 5 can occur in an analogous manner in such a way that two tabs 20 are punched out of the support plate 5 and are bent up perpendicular to the support plate 5 , the free end section 21 of which is then bent horizontally to the support plate 5 (see FIG. 12 and FIG. 13 ). Two holding brackets 28 are thus formed. The two holding brackets 28 are arranged in such a way that they can come into engagement with the lateral slits 22 of the support body 6 . The support body 6 can therefore be pushed in the direction of the two holding brackets 28 , with the horizontal end sections 21 of the holding brackets 28 engaging in the slits 22 . In order to further fix the housing 1 to support plate 5 , a further tab 23 can be punched out of the support plate 5 and can be bent up perpendicular to the support plate 5 which in the bent-up position rests snugly on support body 6 . Said tab 23 is positioned relative to the holding brackets 28 in such a way that a movement of the support body 6 relative to the holding brackets 28 is suppressed. Housing 1 can thus be mounted in a very simple and cost-effective manner on the support plate 5 .
[0048] FIGS. 16 and 17 explain a further possibility of fastening the housing 1 or the connecting element 6 to the support plate 5 . As is shown especially in FIG. 17 , the support body 6 comprises a chamber 24 with an opening facing the support plate 5 . The support plate 5 is provided on its part with a holding element 25 which is received by chamber 24 . Preferably, the opening of chamber 24 forms a holding shoulder, so that an undercut 26 of the holding element 25 can latch into the chamber 24 .
[0049] One possibility for mounting the support body 6 or the support frame 15 on housing 1 is shown in FIG. 13 . The support body 6 or the support frame 15 comprises a chamber 29 with an opening facing the housing 1 . Housing 1 is provided on its part with a holding element 30 which protrudes in the axial direction and is received by chamber 29 . Preferably, the opening of chamber 29 forms a holding shoulder, so that an undercut 31 of the holding element 30 can latch into the chamber 29 . The holding element 30 can be formed on the housing 1 or welded onto the same.
[0050] The embodiment of the housing or the connecting element fastened to the same in accordance with the invention enables producing a connection between the housing and the support plate which reduces the amount of material and mounting work and the number of components required for this purpose, thus reducing the costs and also enabling a technically simple reduction of the transmission of vibrations from the housing to the support plate and a reduction of the vibrations of the housing. | A housing, preferably a hermetically sealing housing ( 1 ), a small-type refrigerating machine for receiving an electromotor and a piston-cylinder unit driven by the same for compressing a refrigerant guided via feed lines and discharge lines into the housing ( 1 ) and into the piston of the piston-cylinder unit, with the housing ( 1 ) being provided with at least one connecting element ( 6, 7, 8, 9, 15 ) for fastening to a support plate ( 5, 10, 14 ). It is provided in accordance with the invention that in a direction of view perpendicular to the support plate ( 5, 10, 14 ) the outermost dimensions of the housing ( 1 ) protrude beyond the outermost dimensions of the at least one connecting element ( 6, 7, 8, 9, 15 ), and the at least one connecting element ( 6, 7, 8, 9, 15 ) or its imaginary shortest connecting line along the surface of the housing ( 1 ) encloses a surface area of the housing ( 1 ) facing the support plate ( 5, 10, 14 ). The surface area of the housing ( 1 ) which is enclosed by the connecting element ( 6, 7, 8, 9, 15 ) faces the support plate ( 5, 10, 14 ) directly. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a compressor, in particular for an internal combustion engine, with a compressor wheel disposed in a compressor flow duct and a recirculation structure.
[0002] German patent publication DE 42 13 047 A1 discloses an exhaust gas turbocharger for an internal combustion engine which turbocharger comprises a compressor driven by an exhaust gas turbine. For increasing the compressor working range, the compressor is equipped with a characteristic-diagram stabilization means for displacing the surge limit and the fill limit of the compressor. The characteristic-diagram stabilization means consists of a bypass in relation to the compressor flow duct in the compressor casing, which bypass extends approximately parallel to the compressor flow duct and bridges the inlet area of the compressor wheel. The bypass has the function of a recirculation device, by means of which a part of the mass flow entering the compressor can be returned in the opposite direction to the general flow direction, with the result that the surge limit of the compressor is displaced in favor of a greater working range.
[0003] The fill limit can also be changed in order to increase the power of the compressor or of the motor. The flow cross section of the compressor flow duct is enlarged via the bypass, so that additional intake air can be supplied to the compressor. The fill limit is thereby displaced in the direction of greater mass flows.
[0004] The geometry of the bypass has a decisive influence on the formation of the re-circulation flow when the compressor is operating near the surge limit. For an improved return flow through the bypass, it was proposed, for example in U.S. Pat. No. 4,122,585, to provide an annular bypass flow structure surrounding the compressor wheel and having a multiplicity of flow passages which are distributed over the circumference and extend approximately tangentially in the swirling direction of the compressor wheel. Each flow passage extends axially over a portion of the compressor wheel and bridges the compressor-wheel inlet area, so that circulating combustion air can be returned axially, via the flow passages, into the region upstream of the compressor-wheel inlet.
[0005] One disadvantage of this device, however, is that the tangential swirl of the recirculation flow can be utilized only inadequately for forming and maintaining a circulating mass flow, because the flow ducts are closed on their radially outer sides and the mass flow flowing into the tangential flow ducts is deflected, at the end of the flow ducts, in the direction opposite to the compressor inflow direction.
[0006] It is the object of the present invention to provide a compressor, which can be operated in a wide operating range, by means of simple structural means.
SUMMARY OF THE INVENTION
[0007] In an air compressor, particularly for an internal combustion engine, which compressor has a compressor housing with a flow duct structure and a recirculation arrangement including a bypass structure for recirculation some of the air entering the compressor wheel, a recirculating ring is arranged in the bypass flow structure around the compressor wheel which ring has a plurality of flow passages distributed uniformly around its circumference with inflow orifices at the radial inner end in communication with the compressor flow duct and outflow orifice at the radial outer end in communication with a by-pass flow space.
[0008] It is thereby possible for the returned exhaust gas mass flow to be guided through the circulation ring radially from the inside outwards and to flow into the bypass flow space which surrounds the recirculation ring radially. The mass flow introduced into the recirculation device flows, under the influence of the centrifugal co-swirl flow, through the recirculation ring with a radial component, is subsequently collected in the annular bypass flow space and is finally returned axially into the compressor flow duct. There is no repulsion, which would detrimentally affect the co-swirl flow.
[0009] The recirculation ring may be designed as a separate component, which is to be inserted into the bypass. The recirculation ring is dimensioned such that a bypass flow space remains in the bypass which flow space surrounds the recirculation ring radially for receiving the returning mass flow.
[0010] In an expedient embodiment, the flow passages in the recirculation ring extend axially only over a portion of the axial width of the ring. The mass flow introduced into the recirculation ring is thereby prevented from flowing out axially at the axially closed side of the ring, thus necessitating an outflow with a radial component. The recirculation ring is expediently provided with flow passages, which are delimited on the opposite axial sides of the ring by wall portions, so that any axial inflow and outflow are prevented. As a result, flow turbulences can be avoided, and the co-swirl flow generated as a result of the rotation of the compressor wheel can be utilized optimally for the radial flow through the recirculation ring.
[0011] Advantageously, at least some of the flow passages extend rectilinearly, whereby manufacturing is simplified. Additionally or alternatively, however, it may also be expedient to make some or all of the flow ducts curved, wherein the curvature of the flow passages preferably follows the curvature of the compressor wheel. If both, rectilinear and curved, flow passages are provided, it may be advantageous, for the purpose of simplifying the production process, if the passages have a cross-section, which is constant over their length. It may also be expedient, however, to provide a flow cross-section, which narrows toward the radially outer end of the recirculation ring, whereby a nozzle effect is achieved for the recirculation flow.
[0012] The flow passages preferably extend in the swirling direction, the outflow orifice being arranged so as to be offset relative to the inflow orifice in the direction of the rotation of the compressor wheel. This results in the flow passages extending approximately tangentially with a radial component, so that the flow passages form an angle with the radial direction. In the case of a rectilinear design of the flow passages, the angle between the longitudinal axis of the flow passages and a tangent to the annular inside of the recirculation ring is advantageously about 20° to 60°. By contrast, with a curved flow passage, it may be expedient to provide the gradient of the flow passage in the region of its inflow orifice relative to the tangent to the annular inside of the recirculation ring with an inlet angle of 20° to 60° and the gradient in the region of the outflow orifice relative to a tangent to the annular outside of the recirculation ring with an outlet angle of between 10° and 50°. The outlet angle is smaller than the inlet angle, the outlet angle typically having a value of about 10° and the inlet angle a value of about 60°.
[0013] The invention will become more readily apparent from the following description of preferred embodiments, thereof shown, by way of example in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a sectional view of a compressor having a compressor wheel, which is surrounded by a recirculation ring,
[0015] [0015]FIG. 1 a is an enlarged sectional illustration of the recirculation ring of FIG. 1,
[0016] [0016]FIG. 2 is a view of the recirculation ring and the compressor wheel taken along the sectional line II-II of FIG. 1, the recirculation ring being partially cut away in order to show the rectilinearly designed flow passages,
[0017] [0017]FIG. 3 shows an illustration corresponding to that of FIG. 2, wherein however the flow passages are curved, and
[0018] [0018]FIG. 4 shows an illustration, corresponding to that of FIG. 1, of a compressor with a modified version of a recirculation ring.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] In the following description identical components are designated by the same reference symbols.
[0020] The compressor 1 illustrated in FIG. 1 and, in a detail, in FIG. 1 a , is part of an exhaust gas turbocharger of an internal combustion engine. It is driven by an exhaust gas turbine of the exhaust gas turbocharger, which turbine is arranged in the exhaust tract of the engine and is acted upon by the exhaust gases, which are under excess pressure. The compressor 1 , which in the exemplary embodiment is a radial compressor, is located in the intake tract of the internal combustion engine and compresses combustion intake air to an increased charge pressure with which the combustion air is fed to the combustion chambers of the internal combustion engine.
[0021] The compressor 1 comprises a compressor wheel 3 , which is arranged in a compressor flow duct 4 in a casing 2 of the compressor and which is driven by the turbine of the exhaust gas turbocharger via a shaft 5 . When the compressor 1 is in operation, combustion air is sucked into the compressor flow duct 4 in the direction of the arrow 6 , compressed to an increased charge pressure by the rotating compressor wheel 3 and conducted, via a diffuser 7 , in the direction of the arrow 8 into a spiral duct 9 in the casing 2 of the compressor. From there, the compressed air is normally conducted to a charge air cooler for cooling, and is then fed via the intake tract of the internal combustion engine to the engine inlet.
[0022] Located in the inflow region of the flow duct 4 near the compressor-wheel inlet end 10 is a recirculation device 11 , which makes it possible to recirculate combustion air sucked into the compressor flow duct 4 in a direction opposite to the main flow direction, identified by the arrow 6 , of the combustion air. In this way, the surge limit of the compressor can be displaced in favor of lower mass flows, so that the useful operating range of the compressor is increased. The recirculation device 11 surrounds the compressor wheel 3 annularly in the region near the inlet end 10 of the compressor-wheel. The recirculation device 11 of a bypass 12 and of a recirculation ring 13 which is arranged in the bypass 12 and which radially closely surrounds the compressor wheel 3 . Its main body projects axially beyond the compressor-wheel inlet end 10 by an amount Δx. The bypass 12 is formed in a half-sidedly open annular flange 14 , which delimits the space of the bypass axially inwardly and radially outwardly. The recirculation device 11 makes it possible for a partial mass flow of the sucked-in combustion air to flow back, according to the arrow 15 , out of a part of the compressor flow duct 4 , in which the compressor wheel 3 rotates, into an area of the inlet duct 4 just upstream of the compressor-wheel inlet end 10 . For this purpose, as a result of the flow swirl of the rotating compressor wheel 3 , a partial mass flow is first conducted radially outwardly through flow passages 16 in the recirculation ring 13 . Then, it is directed through the bypass 12 , where the partial mass flow is deflected in the axial direction and, finally, is returned, in the direction opposite to the main flow direction indicated by arrow 6 , into the flow duct 4 upstream of the inlet end 10 of the compressor wheel 3 .
[0023] By virtue of the red recirculation 13 projecting axially beyond the compressor-wheel inlet end 10 in the direction of the inflow orifice in the flow duct 4 by the amount Δx, some of the circulated partial mass flow can be returned radially inwardly into the flow duct 4 in the region of the projection. Since the flow passages 16 in the recirculation ring 13 are delimited axially at both axial ends, it is not possible, in this version, for the returned mass flow to escape axially.
[0024] As apparent from FIG. 2, a multiplicity of identical flow passages 16 are provided, distributed uniformly over the circumference of the recirculation ring 13 . The flow passages 16 extend radially through the recirculation ring 13 and have inflow orifices 17 on the radial inner side of the ring and outflow orifices 18 on the radial outer side of the ring. The inflow orifices 17 communicate with the flow duct, that is, the annular space around the compressor wheel 3 and the outflow orifices 18 communicate with the surrounding annular bypass 12 . The rectilinearly flow passages 16 have a constant cross section over their entire length. Each outflow orifice 18 of a flow passage 16 is arranged, offset relative to its inflow orifice 17 , in the direction of rotation 19 of the compressor wheel 3 , so that the flow passages 16 , extend tangentially with respect to a virtual circle enclosing the adjacent compressor wheel area. Each flow passage 16 forms, relative to a tangent to the radial inside of the recirculation ring 13 , an inflow angle α of about 25°. Each flow duct 16 forms, relative to a tangent to the radial outside of the recirculation ring 13 , an outflow angle γ, which is preferably larger than the inflow angle α and is about 40°.
[0025] In a particular embodiment of the invention, the rectilinear flow passages 16 become narrower in cross-section from the inflow orifice 17 to the outflow orifice 18 , so that a nozzle effect for the outwardly guided mass flow is achieved.
[0026] In another embodiment of a recirculation ring 13 as illustrated in FIG. 3, the flow passages 16 are curved, the direction of curvature coinciding with the direction of curvature of the compressor wheel. The compressor wheel and flow passages are oriented in the same direction. Each flow passage 16 has a constant cross section over its extent, however, a narrowing cross-section may be provided in order to achieve a nozzle effect. By virtue of the curved flow passages 16 , the inflow angle α, measured between the gradient of the flow duct 16 in the region of the inflow orifice 17 and a tangent to the radial inside of the recirculation ring, is larger than the outflow angle γ, measured between the gradient in the region of the outflow orifice 18 and a tangent in the region of the radial outside of the recirculation ring. In the exemplary embodiment shown, the inflow angle α is about 60° and the outflow angle γ is about 15°.
[0027] [0027]FIG. 4 shows a modified version of a compressor 1 with a recirculation ring 13 ′ as an integral part of the recirculation device 11 . The recirculation ring 13 ′ is axially flush with a compressor-wheel inlet end 10 of the compressor wheel 3 . In contrast to the recirculation ring of FIG. 1, in this case, first flow passages 16 1 and second flow passages 16 2 , arranged offset in parallel in two axial planes, are distributed uniformly over the circumference of the recirculation ring 13 ′. The flow passages 16 2 adjacent to the compressor-wheel inlet end 10 are open axially in the direction of the entrance of the compressor flow duct 4 , so that the partial mass flow returned through the second flow passages 16 2 can be returned both radially outwards and axially into a portion of the flow duct 4 upstream of the compressor wheel 3 . First flow passages 16 1 and second flow passages 16 2 are separated by an axial partition 20 , with the result that direct gas exchange between the first and second flow passages 16 1 and 16 2 is prevented and an outflow, directed solely radially outwardly from the first flow passage 16 1 is achieved. Both the first flow passage 16 1 and the second flow passages 16 2 may otherwise be designed in the above-described way, as stated with regard to FIGS. 1 to 3 .
[0028] The above-described compressor may also be a component, which is driven mechanically by the internal combustion engine and the drive power of which is derived indirectly or directly from the crankshaft of the internal combustion engine. Alternatively to this, a motor drive, in particular an electric motor drive, is also possible. In the case of a mechanical or motor drive, an exhaust gas turbine may be dispensed with.
[0029] The above-described statements also apply in a similar way to compressors, which are used independently of internal combustion engines. | In an air compressor, particularly for an internal combustion engine, which compressor has a compressor housing with a flow duct structure and a recirculation arrangement including a bypass structure for recirculation some of the air entering the compressor wheel, a recirculating ring is arranged in the bypass flow structure around the compressor wheel which ring has a plurality of flow passages distributed uniformly around its circumference with inflow orifices at the radial inner end in communication with the compressor flow duct and outflow orifice at the radial outer end in communication with a by-pass flow space. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a screw hone assembly adapted for use in the honing of a gear manufactured by the gear cutting by forming process, the gear cutting by generating process or other like process.
The purpose of the gear honing is to improve the smoothness or flatness and dimensional accuracy of the tooth surface of the gear, following the shape thereof.
2. Description of the Prior Art
As shown in FIG. 7, the prior art screw type hone 1 includes a hone body 2 comprising a resilient material such as a mixture of urethane rubber and epoxy resin and white alundum grains (hereinafter referred to as the WA grains) mixed therein. As such a polymeric material has insufficient bending or tensile strength, however, there is a fear that the threaded portion may break upon receipt of impacts caused by, e.g., collision or concentrated load. Especially in the case of a screw type hone having a smaller module, the dedendum of the threaded portion is apt to break.
In order to obviate these problems and improve the honing function of the prior art screw type hone 1, it has been proposed to use cubic system boron nitride grains (the CBN grains) in the hone body 2, said grains having a greater harness and exhibiting the most satisfactory honing property with respect to steel materials in comparison with the WA grains. However, such proposal has a disadvantage that the hone body 2 wears out in an earlier stage thanks to the extremely excellent durability of the CBN grains, resulting in earlier escape thereof. Thus, the CBN grains have not effectively been used in the prior art.
Accordingly, the present invention contemplates providing longer service life by using a grain binder formed of a material other than resilient materials such as urethane rubber and epoxy resin, thereby giving rigidity to the overall threaded portion.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a screw type hone assembly for the honing of a gear, having a rigid threaded portion which permits the hone assembly to be used for a very extended period of time without causing breakage thereof during use.
Another object of the present invention is to provide a screw type hone assembly for the honing of a gear, which is adapted to be mounted on the rotating shaft of a honing apparatus such that it is movable in the axial and radial directions relative to the rotating shaft.
A further object of the present invention is to provide a screw type hone assembly for the honing of a gear which can easily be attached to or detached from the rotating shaft of a honing apparatus, and replaced by another screw type hone assembly.
A still further object of the present invention is to provide a screw type hone assembly for the honing of a gear which satisfactorily follows the tooth surface of the gear and makes it more smooth.
A still further object of the present invention is to provide a screw type hone assembly for the honing of a gear, which is designed such that, when a honing grain layer is formed only on the surface of the threaded portion, a suitable binder can optionally be selected for the grains used.
Other objects of the present invention will become obvious from an understanding of the following description of preferred embodiments, and are specified in the appended claims. Numerous advantages not referred to herein will also become apparent to those skilled in the art by carrying out the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one example of a honing apparatus which is adapted to hone a gear using the screw type hone assembly according to the present invention;
FIG. 2 is a partially enlarged, longitudinal section of the screw type hone assembly according to the first embodiment of the present invention, which is mounted on the rotating shaft of a honing apparatus;
FIG. 3 is a partially enlarged, longitudinal semi-section of the screw type hone assembly according to the second embodiment of the present invention, which is mounted on the rotating shaft of a honing apparatus;
FIG. 4 is a cross-sectional view of the screw type hone assembly of FIG. 3;
FIG. 5 is a partially enlarged, longitudinal section of the screw type hone assembly according to the third embodiment of the present invention;
FIG. 6 is a cross-sectional view of the screw type hone assembly of FIG. 5; and
FIG. 7 is a longitudinal section of the prior art screw type hone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, there is shown a first embodiment according to the present invention. In this embodiment, a screw type hone indicated by reference numeral 11 is constructed as follows: that is to say, the honing assembly shown in FIG. 1 is provided on its rotating shaft 41 with a cylindrical sleeve 12 which is firmly clamped between a flange portion 51 and a sleeve 50 to avoid axial movement thereof. The cylindrical sleeve 12 is supported by a key groove 42 in such a manner that it can rotate integrally with the rotating shaft 41. The sleeve 12 has at one end a flange retaining portion 13 formed as an integral piece and around the other end a threaded portion 14. Two nuts 15 threadedly fitted over the threaded portion 14 then permit a retaining ring 16 having virtually the same shape as that of the retaining portion 13 to be tightly secured on a stepped portion 17 of the sleeve 12. Receiving grooves 18 and 18, 19 and 20 in an annular form are provided in the outer peripheries of the opposite ends of the sleeve 12, the retaining portion 13 and the retaining ring 16, respectively. These grooves 18 and 18, 19 and 20 are fitted therein with solid or hollow support rings 21 and 21, 22 and 23 formed of a resilient material such as urethane rubber and having a circular shape in section.
The sleeve 12 is fitted on the periphery with a screw type hone body 24 in the substantially cylindrical form and made of a rigid material such as metals, plastics or the like. The hone body 24 is held in place by a key groove 25 such that it can rotate integrally with the sleeve 12, and is resiliently supported on the inner periphery and the right and left end faces by the retaining rings 21 and 21, 22 and 23. Consequently, the hone body 24 can freely move in the axial and radial directions of the rotating shaft 41.
The hone body 24 includes a spirally threaded portion 61 comprising threads 26 formed integrally with the body 24 and a honing grain layer 27 deposited on the surface of the threads 26 and consisting of a honing stone composed of a hard binder and grains. Accordingly, the overall threaded portion 61 possesses rigidity.
The honing grain layer 27 is deposited on the threads 26 such that the CBN grains or diamond grains having a grain size of about Nos. 60-600 according to the JIS specification are open to view. The grain layer 27 may have an optional thickness that is not critical, and may contain a suitable binder in dependence upon the kind and purpose of the grains used. It will be understood that, when use is made of a honing stone of the CBN grains, it is possible to coat the grains on the threads 26 by using a resin or metal bond as the binder.
Reference will now be made to the operation of the screw type hone 11 thus arranged.
As shown in FIG. 1, the screw type hone 11 is fixedly mounted on the rotating shaft 41 of the honing assembly, and a gear 44 is placed on a gear-mounting shaft 43. In order to make a mating engagement between the hone and the gear, a back-lash may be exerted on them. The screw type hone 11 is then rotated by a motor 45, so that the gear 44 turns correspondingly. With a suitable amount of braking exerted on the gear 44 in this state, the threaded surface of the screw type hone 11 comes into slide contact with each tooth surface of the gear whereby the tooth surface is honed. In the meantime, a screw rod 48 is rotated through a belt 46 and a pulley 47 by a motor (not illustrated), so that a table 49 supporting the gear 44 reciprocates in the axial direction of the gear 44, whereby the overall tooth surface is honed. After the motor 45 is reversed to effect reversal of the hone 11, the same operation as aforesaid is repeated to accomplish honing of the entire tooth surface of the gear 44.
In this embodiment, the threaded surface of the hone body 24 having the honing grain layer 27 is adapted to effect facing following the tooth surface of the gear 44, since the hone body 24 is resiliently supported through the support rings 21 and 21, 22 and 23 formed of a resilient material. This ensures that the tooth surface is more smooth and free from mars or damages such as dents.
During the foregoing honing operation, escape of the honing grains caused by abrasion of the hone body 24 is avoided more effectively in comparison with the prior art resilient hone. This is because the honing grain layer 27 is formed by depositing grains such as the CBN grains onto the surface of the hone body 24 formed of a rigid material with the aid of a hard binder. Accordingly, it is possible to make effective use of the grains such as the CBN grains.
In addition, another hone body having a threaded portion 61 with a different module or a honing grain layer 27 with a different grain size may easily be substituted for the hone body 24 by making two nuts 15 loose for removal thereof, since the body 24 and the sleeve 12 are separately provided in the hone according to the present invention. When honing is effected with a gear having a different module or rough-machining and honing are carried out with the same gear, only the replacement of the hone body 24 may be performed with no need for the removal of the sleeve 12 and the like, thus rendering prompt honing possible.
A second embodiment of the present invention will now be explained with reference to FIGS. 3 and 4.
In the second embodiment, the retaining portion 13 of the sleeve 12 and the retaining ring 16 are integrally provided on the outer peripheries with a pair of cylindrical portions 28 and 29 which extend inwardly in the face-to-face relation to the hone body 24. Both cylindrical portions 28 and 29 are provided in the inner peripheries with grooves 30 and 31, respectively, for receiving therein support rings 32 and 33 similar to the aforesaid support rings 21, 22 and 23. These support rings 32 and 33 are adapted to come into resilient contact with the outer periphery of the hone body 24 and support it. In this embodiment, the hone body 24 is formed with threads 26 having a smaller module, and is divided into several or tens of segments 34 extending in the axial direction thereof, as shown in FIG. 4. The spacing 71 between the adjacent segments 34 is such that each segment is movable in the axial and radial directions of the rotating shaft 41 (e.g., about 0.1 mm).
In this embodiment, the rotation of the sleeve 12 is transmitted to the respective segments 34 through the resiliently frictional force produced by the support rings 21, 22, 23, 32 and 33, although there is no key groove between the sleeve 12 and the hone body 24.
Sine the hone body 24 is divided into several or tens of segments 34 in the second embodiment as mentioned above, the hone body 24 follows the tooth surface of a gear 44 in a more satisfactory manner during the honing. As a result, the segments 34 are susceptible to experience resilient and incremental movement, following the tooth surface of the gear 44. This makes the tooth surface of the gear 44 more smooth.
A third embodiment of the present invention will now be explained with reference to FIGS. 5 and 6.
In the third embodiment, the support rings 32 and 33 located on the outside of the hone body 24 in the second embodiment are omitted and the remaining support rings 21 and 21, 22 and 23 are formed into a hollow shape. The segments 34 forming the hone body 24 are then provided on the inner peripheries with a guide projections 35 extending in the axial direction of the rotating shaft 41 as integral parts. The sleeve 12 is correspondingly provided in the outer periphery with a plurality of guide grooves 36 adapted to receive therein the guide projections 35. The guide grooves 36 have a length somewhat longer than that of the guide projections 35, so that the segments are movable in the axial and radial directions.
It should be noted that, in order to put the segments 34 in an outwardly urged state, suitable resilient members such as coil springs may be placed between the bottom surfaces of the guide grooves 36 and the insides of the guide projections 35. The spacing 71 between the adjacent segments 34 fulfills the same function as attained in the second embodiment.
As regards other action and function, the second and third embodiments make further improvements in the first embodiment.
While the hone body 24 is resiliently movable in the axial and radial directions of the rotating shaft 41 in the foregoing embodiments, it will be understood that the hone body may be movable in either one direction without departing from the present invention. Even with such an arrangement, the hone body 24 fulfills the same function as discussed in the foregoing since it can escape according to the tooth surface.
In addition, the sleeve 12 may be omitted; in this case, the support rings 18 are attached directly on the outer periphery of the rotating shaft 41, and are detachably or fixedly provided on the outer peripheries with the hone body 24.
As stated in the foregoing, the present invention renders it feasible to prevent breakage of the threaded portion of the screw type hone and escape of honing grains, thereby making improvements in the durability and service life thereof.
As it is apparent that a wide variety of different embodiments may be provided without departing from the spirit and the scope of the present invention, the invention is not limited to such specific embodiments, and is restricted by the appended claims alone. | The present invention provides a screw type hone assembly for the honing of gears manufactured by the gear cutting by forming process, the gear cutting by generating process or other like process. The hone assembly comprises a cylindrical sleeve mounted on the rotating shaft of a honing device and a hone body resiliently supported on the sleeve such that it is movable in the axial and radial directions thereof. The hone body includes spiral threads composed of a rigid body and a honing grain layer deposited thereon. The honing grain layer contains hard grains. The screw type hone assembly can easily be attached to or detached from the rotating shaft, and can readily be replaced by another screw type hone. | 1 |
RELATED APPLICATIONS
This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/166,573, filed Jun. 10, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to step systems for aerobic and cardio-vascular activities.
2. Description of the Prior Art
By way of background, a popular form of cardio-vascular training is aerobic stepping. An aerobic step workout is performed by stepping on and off a raised, level step platform. The steps are choreographed, usually performed to music, and leader-driven by an instructor in a class setting or on videotape for home exercise. Workout intensity is largely dependent on the step platform height. Presently, step platforms require a user to suspend the workout while an adjustment to height is made. This is disruptive. Additionally, a user who is becoming fatigued and who should probably lower the step height will not do so, and instead will continue the workout, allowing for the possibility of over fatigue and potential miss-step. Another drawback of existing level step platforms is the great amount of load placed on the knee joint while performing the step up to the level platform. To step up on a level platform, the leg is moved forward by hip flexion. At the same time, the foot is brought up to a position above the level platform by knee flexion. Once the foot is on the platform it has a surface from which to push off. The hip and knee joints go into extension to move the body up against gravity. This places the knee joint under a substantial compression load. Further, most aerobic or cardiovascular activity such as stepping will cause the participants to perspire. This perspiration has a tendency to pool on the level step platform, creating the potential for injury by slipping on the surface.
SUMMARY OF THE INVENTION
The foregoing problems are solved and an advance in the art is obtained by a novel step exercising system for an aerobic step workout comprising a portable inclined step ramp. The ramp is sloped towards a user such that the user can step onto the ramp at various height levels, thereby easily regulating the degree of intensity of the workout. There is no need to suspend the workout to perform a height adjustment, as is the case when using a level aerobic step platform. There is also reduced stress on the knee joint.
In exemplary embodiments of the invention, the ramp is configured to define a front portion, a back portion, an upper workout surface portion, and an underside portion. The incline of the ramp can be provided in various ways, with adjustable legs or other incline members being preferred so that the incline of the ramp can be altered. The legs can be permanently or removably attached to the underside portion of the ramp proximate to the back portion thereof. In addition, adjustable legs can also be mounted to the front portion of the ramp so as to allow the overall height of the ramp to be varied. The ramp can also have one or more additional features, such as a radiussed leading edge on the ramp's front portion for contacting an independent support surface. Further, the ramp can be formed with grooves that channel perspiration from the upper work surface portion of the ramp and serve to visually divide the ramp into multiple workout areas, such as a central workout area and two lateral workout areas. Each workout area can be color-coded so as to allow a user to follow a choreographed routine. The front of the center workout area may be recessed relative to the lateral workout areas so as to facilitate easier access to all workout areas by the user. The upper workout surface portion is preferably configured with a non-slip surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying Drawings, in which:
FIG. 1 is a front perspective view showing a first embodiment of a step exercising system constructed in accordance with the invention;
FIG. 2 is a rear perspective view of the step exercising system of FIG. 1 ;
FIG. 3 is a side elevation view of the step exercising system of FIG. 1 ;
FIG. 4 is a detailed perspective view of an exemplary height adjustable incline member for the step exercising system of FIG. 1 ;
FIG. 5 is a front perspective view showing a second embodiment of the step exercising system constructed in accordance with the invention;
FIG. 6 is a side elevation view showing the step exercising system of FIG. 5 ;
FIG. 7 is a front perspective view of the step exercising system of FIG. 1 in use;
FIG. 8 is a front perspective view showing a third embodiment of the step exercise system constructed in accordance with the invention;
FIG. 9 is a top plan view of the step exercise system of FIG. 8 ;
FIG. 10 is a side elevation view of the step exercise system of FIG. 8 ;
FIG. 11 is a rear elevation view of the step exercise system of FIG. 8 ;
FIG. 12 is a front elevation view of the step exercise system of FIG. 8 ;
FIG. 13 is a bottom plan view of the step exercise system of FIG. 8 ;
FIG. 14 is a close-up fragmentary view of an adjustable leg of the step exercise system of FIG. 8 ;
FIG. 15 is a cross-sectional view of the adjustable leg, taken along line 15 — 15 of FIG. 14 , showing the leg in a retracted position;
FIG. 16 is a cross-sectional view of the adjustable leg, taken along line 16 — 16 of FIG. 14 , showing the leg in an extended position;
FIG. 17 is an exploded, perspective view of the adjustable leg of the step exercise system of FIG. 8 ;
FIG. 18 is a cross-sectional view of the adjustable leg, showing the spring resistance means; and
FIG. 19 is a cross sectional view, taken along line 19 — 19 of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A step exercising system for an aerobic workout will now be described by way of exemplary embodiments shown by the drawing figures, in which like reference numerals indicate like elements in all of the several views.
Turning to FIGS. 1–3 , a step exercising system 2 in accordance with a first exemplary embodiment of the invention is shown at rest on a support surface S (see FIG. 3 ), such as a floor. The step exercising system 2 includes a portable inclined aerobic step ramp 10 , whose overall configuration is best shown in FIGS. 1 and 2 . It will be appreciated that the ramp 10 can be made of any suitable material capable of supporting a person stepping thereon. Examples include but are not limited to plastics such as ABS (acetyl butyl stylrene), polyethylene or the like. The ramp 10 can be formed with such materials using a blow mold technique, pressure forming, or injection molding. As an alternative to plastic, other material such as metal (e.g. aluminum) could be used to form the ramp 10 .
Although shown as being semi-circular in shape, the ramp 10 may be constructed in various configurations, depending on design preferences. Such shape variations notwithstanding, the ramp will generally define a front portion 12 adapted to face a user and a back portion 14 that lies away from the user. The ramp 10 will further define an upper workout surface portion 20 and an underside portion 22 . As can be seen in FIG. 3 , the back portion 14 is positioned at a height which is above the front portion 12 relative to the support surface S, such that the upper workout surface portion 20 is inclined toward the person at a constant angle during use. Moreover, the leading edge 24 of the front portion 12 preferably rests on the support surface S, so as to facilitate easy stepping onto the ramp 10 . The ramp 10 will preferably be constructed such that the incline of the upper workout surface portion 20 has about a 10–30 degree angle relative to the support surface S. An angle of incline less than about 10 degrees will be too small to facilitate an adequate workout, and an angle greater than about 30 degrees will be too large to enable the user to step securely up onto the ramp 10 and will tend to hyper extend the achilles tendon. It will be appreciated that the inclined configuration of the ramp can be provided in various ways. In FIGS. 1–3 , the incline is provided by mounting incline members in the form of adjustable legs 26 to the underside portion 22 , proximate to the back portion 14 . Other types of incline members could also be used, such as non-adjustable legs, frames, blocks, or otherwise. Another alternative would be to form the ramp 10 as a wedge-shaped structure in which the back portion 14 is thicker than the front portion 12 .
The legs 26 in the ramp embodiment of FIGS. 1–3 can be made of any suitable material capable of supporting a person, including plastics as described above, and metals. The legs 26 can be attached to the underside portion 22 in any suitable fashion. For example, if the ramp 10 is molded, the legs 26 , or a portion thereof, could be integrally formed with the ramp 10 during the molding process so as to be built-in to the ramp 10 . Other alternatives include attachment by welding, bolting, threading or the like, depending on whether the legs are to be permanently or removably attached to the ramp 10 .
The legs 26 are constructed with a height adjustable feature so that the incline angle of the ramp 10 can be altered. FIG. 4 illustrates one example of a leg 26 having height adjustment capability. As shown in FIG. 4 , the leg 26 comprises an inner tubular member 31 that is slidably disposed within, and surrounded by, an independent outer tubular member 33 that is attached to the ramp 10 . The inner tubular member 31 is thus capable of telescoping from the outer structure 33 , allowing for a change in length of the leg 26 . The inner tubular member 31 may be secured in position relative to the outer tubular member 33 in various ways.
In FIG. 4 , the outer tubular member 33 is constructed with a slotted opening 35 and the inner tubular member 31 is constructed with a protruding pin member 37 that is received in the slotted opening 35 . The slotted opening 35 includes two horizontal channels 41 connected by a vertical channel 43 . To adjust the length of the leg 26 (thereby adjusting the height and incline of the ramp 10 ), the inner tubular member 31 is rotated so that the pin member 37 can be slid from a fixed point 45 in one of the horizontal channels 41 , then through the vertical channel 43 of the slotted opening 35 , and to another fixed position 47 in the other horizontal channel 41 . Note that additional horizontal channels 41 can be provided depending on the number of height adjustments desired. Other adjustment arrangements could also be used, including pins inserted through holes in the inner tubular member 31 and outer tubular member 33 .
The legs 26 can further be mounted with a slip-resistant tip 49 at the end, which rests on the support surface S. The tip 49 may be made of any suitable slip-resistant material, including but not limited to silicone rubber, high friction plastic, or otherwise. As best shown in FIG. 4 , the front portion 12 of the ramp 10 may be constructed with a radius on the leading edge 24 . The radius enables the leading edge 24 to contact the support surface S without damaging it, as might be the case from a squared edge. The radius also facilitates ramp angle changes by allowing the leading edge 24 to contact the support surface at various locations. In addition, the radius provides a friendlier contact surface with a user.
Turning now to FIGS. 5 and 6 , a second embodiment of the ramp 10 is shown wherein the underside 22 mounts adjustable legs 52 proximate to the front portion 12 of the ramp 10 . The adjustable legs 52 directly contact the support surface S and enable the leading edge 24 to be positioned above the support surface rather than resting directly thereon. This allows a user to intensify the workout by having a higher initial starting point for the workout.
As can be seen in any of FIGS. 1–2 and 5 , and as further illustrated in FIG. 7 , the upper workout surface portion 20 of the ramp 10 comprises grooves 54 that divide the surface into visually distinct workout areas. The grooves 54 can be formed in a variety of ways. If the ramp 10 is formed as a single unit, the grooves 54 can be formed therein during the fabrication process or thereafter in subsequent processing. Alternatively, the grooves 54 could be defined by fabricating the ramp 10 as separate sections that are suitably fastened together such that a space is formed between adjacent sections to define the grooves 54 .
In the embodiments of FIGS. 1–3 and 5 , the grooves 54 divide the upper workout surface portion 20 into three visually distinct workout areas, namely, a center workout area 55 and two distinct side workout areas 56 adjacent to the center workout area 55 . Other configurations in which the number and arrangement of workout areas is different could also be used. To further visually differentiate the workout areas 55 and 56 , and to enable a user to follow a step workout choreographed to different workout areas, the workout areas 55 and 56 can be color-coded.
The workout areas 55 and 56 are also preferably constructed with a non-slip surface configuration. The non-slip configuration could be provided by suitably texturing the upper workout surface portion 20 in its initial construction. Alternatively, the non-slip configuration can be provided by a separate material that is directly applied to the workout areas 55 and 56 after initial construction, as by spraying, brushing, or adhering. Examples include, but are not limited to, textured paints, rubber coatings, or various inserts or stickers made of rubber, sand paper, or other materials. Note that the center workout area 55 is constructed with a recess 59 at the front portion 12 of the ramp 10 . The recess 59 is adapted to enable a user easier access to the two side workout areas 56 such that the user may contact a side workout area 56 without stepping over the center workout area 55 , as will now be described.
FIG. 7 shows the ramp 10 as it would be used during a typical workout. It is assumed that the ramp 10 includes plural workout areas as described above. First, a user 70 can predetermine the overall incline of the ramp 10 by adjusting the length of the legs 26 (when included in the ramp's construction). Next, the ramp is placed on the support surface S with the leading edge 24 in direct contact with the support surface S (or above the support surface S if the ramp 10 is so constructed and the user desires such a setup). The ramp 10 remains in this constant position throughout the workout. The user 70 stands facing the ramp 10 proximate to the leading edge 24 of the front portion 12 . The user 70 steps on and off the various workout areas 58 of the upper work surface portion 20 of the ramp 10 as dictated by a choreographed workout. Throughout the workout, the user 70 can vary the height of each step by choosing a point (e.g. 81 , 82 , or 83 ) of contact on the ramp 10 and thereby modifying the intensity of the workout.
Referring to FIGS. 8–19 , a third embodiment of the portable inclined aerobic step ramp 110 of the present invention includes a plurality of adjustable legs 126 affixed to an underside portion 122 and are preferably disposed adjacent to a peripheral edge 113 of the underside portion 122 .
The underside portion 122 is preferably substantially parallel to an upper workout surface portion 120 of a main body 111 of the portable inclined aerobic step ramp 110 ; and is spaced a distance from the upper workout surface portion 120 . The portable aerobic step ramp 110 may be formed in a hollow configuration such that a gap 115 exists between an interior surface 117 of the upper workout surface portion 20 and an interior surface 119 of the underside portion 122 (see FIGS. 15 and 16 ).
The adjustable legs 126 preferably include a fixed, outer tubular member 133 and an inner tubular member 131 which is telescopically, slideably received within the outer tubular member 133 . An attachment flange 150 is integrally formed with or otherwise affixed to the outer tubular member 133 . The attachment flange 150 extends radially outwardly from the outer tubular member 133 and is preferably permanently affixed to the underside portion 122 of the main body 111 by bolts, or other suitable attachment means.
Preferably, the attachment flange 150 is affixed to the outer tubular member 133 intermediate upper and lower ends 152 , 154 of the outer tubular member 133 such that the upper end 152 of the outer tubular member 133 extends into the gap 115 between the interior surfaces 117 , 119 of the upper workout surface portion 120 and the underside portion 122 . Also, the upper end 152 of the outer tubular member 133 abuts or is disposed in close proximity to the interior surface 117 of the upper workout surface portion 120 , such that, during periods of high loads, the adjustable legs 126 can provide support directly to the upper workout surface portion 120 .
Protruding pin members 137 extends radially outwardly from the inner tubular member 131 , substantially perpendicular to a longitudinal axis of the inner tubular member 131 , preferably on two opposed sides of the inner tubular member 131 . The protruding pin members 137 may be formed from a threaded sleeve and two threaded bolts.
The outer tubular member 133 includes slotted openings 135 into which the protruding pin members 137 extend. The slotted openings 135 are located on opposite sides of the outer tubular member 133 and are preferably separated by 180 degrees. Preferably, one of the slotted openings 135 is aligned to be easily visible by a user.
Each slotted opening 135 includes an upper angled portion 156 , a middle longitudinal portion 158 and a U-shaped lower portion 160 . The U-shaped lower portion 160 includes a first longitudinal section 162 (which is connected to the middle portion 158 ), a center, circumferential section 164 , and a second longitudinal section 166 . The second longitudinal section 166 has a closed end 168 , which is aligned with a closed end 170 of the upper angled portion 156 of the slotted opening 135 .
The middle longitudinal portion 158 , and the first and second longitudinal sections 162 , 166 of the U-shaped lower portion 160 are preferably aligned substantially parallel to a longitudinal axis of the inner tubular member 131 . The outer circumferential section 164 of the U-shaped lower portion 160 is preferably aligned substantially perpendicular to the longitudinal axis of the inner tubular member 131 (i.e., parallel to the circumference thereof).
The upper angled portion 156 of each of the slotted openings 135 includes a closed end 172 which is aligned with the closed end 168 of the second longitudinal section 166 on a line which is substantially parallel to the longitudinal axis of the inner tubular member. The upper angled portion 156 is preferably disposed within the main body 111 .
The upper angled portion 156 extends downwardly from a closed end 172 to the middle longitudinal portion 158 at an angle that is oblique to the longitudinal axis of the inner tubular member 131 , preferably at an angle of about 45 degrees from the longitudinal axis of the inner tubular member 131 .
As depicted in FIG. 15 , each adjustable leg 126 has a retracted supporting position in which the protruding pin member 135 is disposed adjacent the closed end 172 of the upper angled portion 156 of the slotted opening 135 . As depicted in FIG. 16 , each adjustable leg 126 has an extended supporting position in which the protruding pin member 135 is disposed adjacent the closed end 168 of the second longitudinal section 166 of the U-shaped lower portion 160 of the slotted opening 135 . It can be appreciated that when the adjustable leg 126 is in either of the retracted and extended positions, the upward movement of the adjustable leg 126 is prevented.
To articulate the adjustable leg 126 from the extended to the retracted position, the inner tubular member 131 is further extended to a point where the protruding pin member 137 is disposed in a bottom of the second longitudinal section 166 . Then, the inner tubular member 131 is rotated relative to the outer tubular member 133 such that the protruding pin member 137 is disposed in a bottom of the first longitudinal section 162 . Then, the inner tubular member 131 is urged to retract it further into the outer tubular member 133 until the protruding pin member 137 reaches a bottom of the upper angled portion 156 .
Further retraction of the inner tubular member 131 into the outer tubular member 133 causes the inner tubular member 131 to rotate as the protruding pin member 137 passes along and is guided by the upper angled portion 156 until the adjustable leg 126 is in the retracted position. It can be appreciated that when the inner tubular member 131 is in the retracted position, it is in the same rotational orientation relative to the outer tubular member 133 as when in the extended position.
Thus, the upper angled portion 156 serves to automatically properly align the inner tubular portion 131 when in the retracted position. This facilitates the movement of the leg into the extended position, which is desirable since the inner tubular member 131 is disposed within the main body 111 and is not visible to the user. As described in further detail below, this rotational alignment serves to properly align the slip resistant tip 149 attached to the inner tubular member 131 .
Referring to FIG. 10 , preferably, the longitudinal axes of the inner and outer tubular members 131 , 133 are aligned substantially perpendicular to the underside portion 122 of the main body 111 of the portable inclined aerobic step ramp 110 . A contact surface 180 of the slip resistant tip 149 is aligned substantially parallel to the support surface S when the adjustable leg 126 is in either the retracted or extended positions. Thus, the contact surface 180 is aligned at an angle that is oblique to the longitudinal axis of the inner tubular member 131 . Preferably, each contact surface 180 is substantially planar and comprises a substantial portion of a bottom surface of the associated adjustable leg 126 . Also, preferably the contact surfaces 180 of each of the adjustable legs 126 are substantially co-planar with one another (and with the support surface S) when the adjustable legs 126 are simultaneously in either the retracted or extended position.
Preferably, the configuration of the inner and outer tubular members 131 , 133 at each of the adjustable legs 126 are substantially identical, except for the length of the inner tubular members 131 . It can be appreciated that the inner tubular portions 131 of adjustable legs 126 located closer to the front portion 112 of the main body 111 are shorter than those located further away.
Referring to FIG. 18 , preferably, each adjustable leg 126 includes means to resist free movement of the inner tubular member 131 relative to the outer tubular member 133 while permitting a user to adjust the leg. Preferably, the inner tubular member 133 includes a through hole 184 through which a contact pin 186 of a resistance spring 188 protrudes. The resistance spring 188 is disposed within the inner tubular member 131 . The contact pin 186 is biased against the outer tubular member 133 and the resulting friction creates a resistance to movement of the inner tubular member 131 . The resistance spring 188 has a substantially V-shaped portion which contacts the inner tubular member 131 opposite the through hole 184 .
Referring to FIGS. 2 and 19 , the center and side workout areas 55 , 56 preferably include non-slip panels 190 , 194 formed of resilient material. The non-slip panels 190 , 194 preferably have textured upper surfaces 196 , 198 . The lower surfaces 200 , 202 of each non-slip surface 190 , 194 preferably have elongated recessor channels 206 disposed at substantially regular intervals and aligned substantially parallel to the front portion 112 of the main body 111 . It can be appreciated that material above the channels 206 is thinner than the material intermediate the channels 206 . When subject to load, the resilient, non-slip panels deflect downwardly. The upper surface of the non-slip panels in the area above the channels 206 deflect a greater amount than the areas intermediate the channels 206 . Under load, this provides substantial resistance to slippage. While not under load, the upper surface of each non-slip panel is substantially planar (except for any texture thereof). The substantially planar non-loaded configuration of the upper surface allows perspiration to drain unimpeded from the surface, prevents the undesirable build up of dirt on the surface and allows the surface to be cleaned more effectively.
Accordingly, a system for an aerobic step workout has been disclosed. While various embodiments of the invention have been shown and described, it should be apparent that many variations and alternative embodiments could be implemented in accordance with the teachings herein. It is understood, therefore, that the invention is not to be in any way limited except in accordance with the spirit of the appended claims and their equivalents. | A step exercising system for an aerobic step workout is constructed as a portable inclined step ramp. The ramp is sloped towards a user such that the user can step up onto the ramp at various heights, thereby regulating the degree of intensity of the workout without having to suspend the workout to adjust the step height, as is the case when using a conventional aerobic step having a raised level platform. | 0 |
RELATED APPLICATION
This application claims priority to and the benefit of U.S. provisional patent application Ser. No. 61/505,696, filed Jul. 8, 2011, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates generally to the digestion of solid waste. More particularly, in certain embodiments, the invention relates to apparatus and methods for decomposing organic matter into biogas and compost.
BACKGROUND OF THE INVENTION
The degradation of organic matter is a process that occurs aerobically and/or anaerobically in nature by the complex interaction of a multitude of microorganisms. Controlled more or less industrialized methods have been known for a long time and referred to as composting for aerobic processes and fermentation, bio-methanisation, or simply anaerobic digestion (AD), for the anaerobic processes. AD processes may be divided into two principle steps: hydrolysis and methanogenesis.
The two processes of composting and AD have been developing independently over the last many years. Composting as a way to produce compost for fertilization and soil improvement has been thoroughly described many places. Likewise, one-stage, two-stage, or multi-stage AD methods have been developed on the basis of the most varied developments. In addition to wet AD developed from liquid-manure and wastewater treatment, dry AD is also practiced.
The principle of the two-step, two-stage AD was described for the first time by Ghosh in 1978. In this process, wastes are percolated in an anaerobic reactor. The percolation water is subsequently fermented to biogas in a methane reactor. The method was further developed and patented by Rijkens and Hofank (U.S. Pat. No. 4,400,195) in the 1980s for organic wastes. The method was converted twice to practice, to the ANM method in Ganderkesee and to the Prethane-Rudad method in Breda. Tests were conducted by Wellinger and Suter in the 1980s with solid manure, and by Widmer with market and meatpacking wastes. In the latter case, the percolator was also driven in an aerobic environment.
The newest plants, which have been developed according to this method (for residual wastes) are the ISKA® percolation method in Sansenheck, and the BIOPERCOLAT® method (DE 198 46336 A1). Here, the waste is hydrolyzed in a percolator after a mechanical pretreatment (for example, sieving, metal separation). The percolator is therefore equipped with a stirring mechanism, so that the wastes are continually transported through the reactor. After a residence time of 2 to 3 days, the percolate is discharged free of water and ready for further treatment or depositing in a layer. The percolation water is fermented anaerobically to biogas in a methane reactor after separation of sand and fibers. The water that is cleaned in this way is directly used as percolation water or is used after another cleaning (e.g., for removing nitrogen).
Large amounts of organic solid wastes are produced in many towns and cities all over the world, and treatment methods are often limited by solids handling requirements for adequate sterilization of these large amounts of heavy, solid waste. Accordingly, there is a need for improved systems and methods for digestion and composting of solid wastes with limited solids handling requirements.
SUMMARY OF THE INVENTION
A system is presented for solid waste treatment that does not require moving the solid fraction of the waste between different stages of the process. Only initial loading of the waste and final unloading of the solids after sanitization is needed.
In one embodiment, organic waste is loaded into a chamber that resembles a garage. After filling, the door is closed and anaerobic conditions are created. Anaerobic methane extraction takes place for a period of time (e.g., from 1 to 4 weeks), after which an aerobic composting process begins in the same chamber. The organic waste remains in place and oxygen (e.g., in air) is forced into the chamber for an additional period of time (e.g., from 2 to 4 weeks). At the conclusion of the aerobic composting phase, the process yields a rough compost product that is stable and pathogen free. The rough compost can be further processed and blended to create high value engineered soils. There is no requirement to handle raw, post-methane extraction digestate prior to composting. The biogas produced has a high methane content, e.g., about 70% or more, compared to about 55-60% using other processes. The biogas also has lower concentrations of VOC's, siloxane, and other contaminants.
The system employs dry anaerobic digestion in which bacterial hydrolysis—that is, the leaching out of fatty acids from the organic solid waste—is physically separated from methane generation. A series of hydrolysis and methane generation (gasification) stages are conducted for a period of time (e.g., from 1 to 4 weeks) under anaerobic conditions with the solid waste in a waste processing tank operating at ambient (e.g., atmospheric) pressure. Percolate liquid is recirculated through a grating at or near the base of the waste processing tank during the hydrolysis stage. The percolate is pumped into a biogas reactor tank in which methane and/or other biogases are produced, then filtered, degassed percolate is pumped back to the waste processing tank. After hydrolysis and gasification is completed, the waste processing tank becomes a composter, such that air flows through the solid waste, through the grating at the base, then passes through a biofilter before being released into the atmosphere. After composting, the solid waste is sufficiently sanitary for removal and may be safely disposed or used as a byproduct.
During all three stages—hydrolysis, gasification, and composting—the waste processing tank remains closed. No solid waste is moved, and only fluids and air circulates between the process module and the gas reactor in a closed system. The system design insures that the processes of hydrolysis, percolation, methane generation, and composting are separate and occur rapidly and efficiently. There is no need for inoculation using earlier processed material to start fresh batches, thereby insuring full traceability of the waste. The process is self-sustaining and there is no need for heating to start the process, allowing for a high energy efficiency. A wide variety of organic waste types may be processed, for example, municipal waste; industrial, commercial, and institutional waste; garden waste; and sewage sludge.
Thus, in one aspect, the invention relates to a system for decomposition of organic matter into biogas and compost, the system including: a waste processing tank into which solid organic waste is loaded and in which hydrolysis and composting takes place at separate times, with composting of the solid organic waste taking place during a separate stage after hydrolysis is completed, wherein the waste processing tank comprises a drain at or near its base, the drain allowing flow of percolation liquid out of the waste processing tank during the hydrolysis stage, the drain also serving as a vent through which air flows into and/or out of the solid organic waste in the waste processing tank during the composting stage; a spraying system configured to spray percolate liquid onto the solid organic waste in the waste processing tank during the hydrolysis stage, wherein the percolate liquid comprises fatty acids leached from the solid organic waste and wherein the percolate liquid is recycled from the base of the waste processing tank during the hydrolysis stage; and a biogas reactor tank into which the percolate liquid from the waste processing tank is pumped for generation of biogas under anaerobic conditions during a gasification stage. In certain embodiments, the waste processing tank is configured to operate at ambient pressure during the hydrolysis stage, the composting stage, or both. In preferred embodiments, the waste processing tank is configured to operate under anaerobic conditions during the hydrolysis stage.
In certain embodiments, the system further includes a biofilter through which air from the waste processing tank passes prior to discharge to the atmosphere during the composting stage. In certain embodiments, the system further includes a filter configured to separate solids from the percolate liquid.
In certain embodiments, the system includes at least two waste processing tanks connected in parallel. In certain embodiments, the waste processing tank includes an acid-resistant lining or coating. The biogas reactor tank is preferably gas-tight. The system may also include a heater for heating the percolate liquid either in the biogas reactor tank or outside the biogas reactor tank (for later introduction back into the tank after heating). In certain embodiments, the biogas reactor tank includes a sump to separate sediment and/or particles from the percolate liquid.
In preferred embodiments, the system further includes a liquid process tank into which percolate liquid from either the biogas reactor tank, the waste processing tank, or both flows prior to being pumped to the spraying system for spraying onto the solid organic waste in the waste processing tank during the hydrolysis stage. In certain embodiments, there is one liquid process tank for every waste processing tank. In certain embodiments, there is at least five waste processing tanks (e.g., each with their own associated liquid process tank), for every biogas reactor tank (there may be one or more biogas reactor tanks in the system). In certain embodiments, percolate liquid from both the biogas reactor and the waste processing tank flows into the liquid process tank prior to being pumped to the spraying system for spraying onto the solid organic waste in the waste processing tank during the hydrolysis stage. The system may further include a filter tank configured to separate solids from the percolate liquid before the percolate liquid enters the liquid process tank.
Elements of other aspects of the invention can be applied to this aspect of the invention as well.
In another aspect, the invention relates to a method for decomposition of organic matter into biogas and compost, the method including the steps of: (a) loading solid organic waste into a waste processing tank; (b) during one or more series of hydrolysis and gasification stages: (i) spraying percolation liquid over the solid organic waste in the waste processing tank during a first (and/or subsequent) hydrolysis stage in which bacterial hydrolysis takes place; (ii) optionally recirculating the percolation liquid after it passes through the solid organic waste in the waste processing tank during the first (and/or subsequent) hydrolysis stage; (iii) pumping percolation liquid into a biogas reactor tank for generation of biogas during a first (and/or subsequent) gasification stage; (iv) pumping percolate liquid out of the biogas reactor tank following the first (and/or subsequent) gasification stage, for spraying over the solid organic waste in the waste processing tank during a second and/or subsequent hydrolysis stage; and (c) following all hydrolysis and gasification stages, ventilating the waste processing tank for composting of the solid organic waste under aerobic conditions.
In certain embodiments, the series of hydrolysis and gasification stages is carried out for a period of from 1 to 4 weeks (e.g., for about 21 days) before the composting stage begins. In certain embodiments, methanogenesis takes place in the biogas reactor tank during the gasification stage. In preferred embodiments, the hydrolysis and gasification stages take place under anaerobic conditions. In certain embodiments the one or more hydrolysis stages (and/or the gasification stage(s)) take place under atmospheric pressure. Hydrolysis generally takes place at the same time as gasification, but the processes occur in different tanks.
In certain embodiments, the percolation liquid is passed through a filter tank configured to separate solids from the percolate liquid, then the filtered liquid is transported into a liquid process tank where it mixes with liquid from the biogas reactor tank before being recirculated via spraying over the solid organic waste in the waste processing tank. In certain embodiments, the percolation liquid enters a process tank where it mixes with liquid from the biogas reactor tank before being recirculated via spraying over the solid organic waste in the waste processing tank.
In certain embodiments, the method comprises flooding the waste processing tank with percolation liquid at least once during the hydrolysis stage.
In certain embodiments, the temperature of the organic solid waste in the waste processing tank reaches at least 60° C. during at least part of the composting stage. In preferred embodiments, the method further includes the step of passing air through a biofilter after it has passed through the solid organic waste in the waste processing tank during the composting stage. In certain embodiments, the solid organic waste in the waste processing tank has been sanitized by the end of the composting stage.
The description of elements of the embodiments above can be applied to this aspect of the invention as well.
In another aspect, the invention relates to a dual-purpose drain assembly for transport of percolate from a process module during a digestion stage and for ventilation of the process module during a composting stage of a waste processing system, the drain assembly including one or more rails through which a plurality of conduits are drilled, wherein each of the conduits has (i) a first end facing the process module containing solid waste being processed and (ii) a second end facing a pipe through which liquid percolate flows out of the process module during hydrolysis and through which air flows into the process module during composting, wherein the first end has a width or diameter smaller than the second end's. In certain embodiments, the first end has a diameter (or width) no greater than 90% of that of the second end. In certain embodiments, the ratio of the diameter of the first end to the diameter of the second end is about 0.75.
In certain embodiments, each of the rails has a notch, and two or more of such notched rails form a shelf for supporting a removable plate (e.g., stainless steel plate) that prevents the solid waste in the waste processing module from entering the pipe. In certain embodiments, the pipe is a conduit formed in a concrete base below the process module.
Elements of other aspects of the invention can be applied to this aspect of the invention as well.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
While the invention is particularly shown and described herein with reference to specific examples and specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
FIG. 1 is a schematic drawing of an apparatus for digestion and composting of solid waste, highlighting components involved in the hydrolysis and methanogenesis stages, in accordance with an embodiment of the invention.
FIG. 2 is a schematic drawing of an apparatus for digestion and composting of solid waste, highlighting components involved in the composting stage, in accordance with an embodiment of the invention.
FIG. 3 is a schematic drawing of an apparatus for digestion and composting of solid waste, highlighting components involved in the hydrolysis and methanogenesis stages, in accordance with an embodiment of the invention.
FIG. 4 is a schematic drawing of an apparatus for digestion and composting of solid waste, highlighting components involved in the composting stage, in accordance with an embodiment of the invention.
FIG. 5 is a schematic drawing of views of a dual-purpose drain assembly for transport of percolate from a process module during a digestion stage as well as for ventilation of the process module during a composting stage, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
It is contemplated that apparatus, devices, systems, methods, and processes of the claimed invention encompass variations and adaptations developed using information from the embodiments described herein. Adaptation and/or modification of the devices, systems, methods, and processes described herein may be performed by those of ordinary skill in the relevant art.
Throughout the description, where apparatus, devices and systems are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are apparatus, devices and systems of the present invention that consist essentially of, or consist of, the recited components, and that there are processes and methods according to the present invention that consist essentially of, or consist of, the recited processing steps.
It should be understood that the order of steps or order for performing certain actions is immaterial so long as the invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
It is contemplated that methods, systems, and processes of the claimed invention encompass scale-ups, variations, and adaptations developed using information from the embodiments described herein. The processes and methods described herein may be performed using reactor equipment that is known to those of ordinary skill in the art, including, without limitation, for example, batch reactors, plug-flow reactors, continuously-stirred tank reactors, packed-bed reactors, slurry reactors, fluidized bed reactors, and columns. The processes described herein may be conducted in batch, semi-continuous, and/or continuous operation, or adapted therefor. It is also contemplated that methods, systems, and processes of the claimed invention may include pumps, heat exchangers, and gas-, liquid-, and/or solid-phase material handling equipment known to those of ordinary skill in the art.
The mention herein of any publication, for example, in the Background section, is not an admission that the publication serves as prior art with respect to any of the claims presented herein. The Background section is presented for purposes of clarity and is not meant as a description of prior art with respect to any claim.
In certain embodiments, the invention relates to a method for converting organic matter into biogas and compost. The organic matter may be sorted and mixed with green structure, introduced in a process module, where percolate, recycled in a process tank, washes out nutrients (e.g., volatile fatty acids). Excess percolate may be pumped through a coarse filter to a reactor tank where the anaerobic digestion takes place. Biogas produced in the reactor tanks may be transported to utilization. Degassed percolate may then be returned to the process tank for washing out additional nutrients from the organic matter.
In another embodiment, after a period of time, and when the pH reaches a specified value, the percolation process is stopped, an air-intake is opened, and through the drain system, used for percolation, air is drawn through the organic matter to initiate the composting process. After compositing, the process modules are emptied, and the material is left in open bays for after maturation, until it is sorted and the final soil improvement products ready for market.
In certain embodiments, the two-stages (AD and composting) are combined with a time-dependent and physical split of the AD process in hydrolysis and methanogenesis. For example, in a first process cycle, percolation of dry organic matter causes hydrolytes (such as volatile fatty acids, etc.) to be extracted, and the percolate (the wet fraction) is delivered to a biogas reactor tank for methanogenesis. In one embodiment, the hydrolysis takes place under anaerobic conditions. Hydrolysis may be accomplished in the solid phase, followed by methanogenesis in the wet phase, followed by methanogenesis in the solid phase, and finally composting of the dry phase.
In certain embodiments, AD and composting are achieved using specialized process modules (PM) and a methane reactor (MR). In one embodiment, a mixture of structure and organic matter is loaded into the PMs, and one or more gates to the PMs are closed. Run off (i.e., percolate) containing hydrolytes from the PM may be delivered to a process tank (PT) prior to transfer to the MR.
In certain embodiments, degassed liquid from the MR is returned to the PT, from which it may be sprayed onto the organic matter in the PM. The percolate from the PM may be fed back to the process tank, through a drain in the bottom of the PM. In one embodiment, the process module is operated under anaerobic conditions during percolation. Excess percolation liquid, now containing hydrolytes, may be fed through a coarse filter, and introduced into the MR, where the methanogenesis takes place. Separation of fresh and degassed percolate may take place using a principle of leveling in the reactor tank. Percolate may be continuously taken out of the MR and heated in a heat exchanger.
When the pH of percolate coming out of the process module has reached a defined level, and the solid fraction in the PM has been inoculated by methanogenic bacteria, the methanogenesis may start in the PM. After a period of time, the methane production or accumulation in the PM is stopped. In one embodiment, for example, an air intake is opened and a fan starts to draw air (including oxygen) through the organic matter still contained and enclosed in the process modules. During this portion of the process, when composting takes place, the process module is operated under aerobic conditions. In another embodiment, the air is introduced or extracted through the same drain as that the percolation fluid passes through during percolation.
The introduction of air may start a composting process of the organic matter in the process modules. In certain embodiments, this causes the temperature to increase, and a sanitization process will take place. Further, water may evaporate from the organic matter, thereby reducing the moisture content. After leaving the organic matter, the air may be fed through a biofilter and an optional scrubber for elimination of odors.
In certain embodiments, when the temperature of the organic matter in the process module has reached a defined level, or the composting process has taken place for a specific period of time, the fan is stopped. At this point, a door or gate the process module may be opened, and the degassed and composted organic matter may be taken out of the process module. The organic matter may then be left outside in open bays for after maturation, before final screening and mixing for compost or soil improvement products.
In certain embodiments, a decomposing method for organic matter is provided in which an amount of biogas is formed according to need. An anaerobically driven process module may be loaded with a mixture of structure and organic matter. In one embodiment, a percolation liquid is sprayed onto the organic matter, led through the bottom of the process module to a process tank, from where is again sprayed on the organic matter. In another embodiment, excess percolation liquid is passed through a coarse filter into a reactor tank, where it is fermented to biogas. The degassed percolate may be fed back to the process tank.
The decomposing methods described herein are advantageously based on a simple and robust process. In this way, control of the biogas formed according to need is made possible, and a biogas requirement, for example, for conversion to electrical energy or production of heat at peak times or times of low demand, can be controlled accordingly. While control of biogas production may not be provided or may be provided only in constricted periods for adapting to consumption in known plants, a rapid adaptation to the current requirement can be provided with the decomposing method, in accordance with an embodiment of the invention.
All substances originating from living organisms may be considered to be biogenic materials, including, in particular, the following: bio-wastes, lawn cuttings, curbside clippings, garden clippings, bio-solids, industrial waste, food waste, household waste, agricultural waste, kitchen waste, renewable resources, and similar materials.
Since, in certain embodiments, hydrolysis and methanogenesis are physically and time-wise separated, the biogas contains low concentration of sulphur, and silicas, thus cleaning of H 2 S and SiO x is not necessary when applying the biogas for heat and power production in an IC engine.
In one embodiment of the invention, the construction of the bottom of the process module, used for percolate discharge and air exhaust, is performed in a manner so blocking does not occur. In this way, the design may ensure that percolate and air always have free passage during operation.
As mentioned, in certain embodiments, the atmosphere is anaerobic during percolation and aerobic during composting. It is further possible to insulate or even heat the PMs. For example, the temperature in the process module may be approximately 38° C. under percolation and 70° C. during composting.
In certain embodiments, all of the liquid in the system is pumped through one circuit. The percolation liquid leaving the reactor tank, as degassed percolate, may be discharged discontinuously and replaced with fresh, hydrolyte rich liquid. In this way, a concentration of foreign matter in the circuit may be avoided. In another embodiment, substances that sink and/or float are separated in the reactor tank in a sump, equipped with a pump that is able to remove sludge.
In certain embodiments, methanogenesis of the percolate to biogas is conducted by means of bacteria. In this case, the methanogenesis may be conducted with the participation of a bacterial matrix of several bacterial strains. The methane reactor can be heated; for example, it can be heated by taking out a slipstream of liquid and heating the liquid in a heat-exchanger before it is introduced again into the reactor tank. In this way, a constant temperature can be maintained in the biogas reactor. The temperature within the biogas reactor may be, for example, between about 38° C. or 55° C.
In addition, in certain embodiments, the an apparatus is provided that includes at least one process module, a process tank, a filter tank, and a reactor tank. The process module may be equipped with at least one pump and one fan. The methane reactor tank can be, for example, CSTR, UASB, or another type for AD. Compared previous systems, because the process step of methanogenesis occurs in the MR, overfeeding is much less likely to occur and it is easier to control and/or measure.
Preferably, in one embodiment, the biogas plant includes at least five parallel-connected process modules. In this case, the percolation liquid may be sprayed continuously or discontinuously over the organic matter. Spraying may be performed by a separate pump for each process module through a specially designed spraying system, depending on the material used. For example, a separately operable liquid circuit may be formed for each process module. A connection between one or more individual percolators may be used to inoculate the organic matter with specific species of bacteria.
The use of at least two percolators, in some embodiments, has the advantage that a loading and unloading of solid materials is possible at any given time. In addition, the substrate specific residence time in each process module can be controlled individually.
Due to acids that may be formed during the decomposition process, the process modules are preferably acid-resistant. In certain embodiments, the percolation liquid dissolves the acids and/or other materials that form, and/or the percolation liquid is enriched with hydrolytes that can be easily transformed to methane.
In one embodiment, the process modules have a special designed bottom. During percolation, the bottom of the process modules is used to perform a solid-liquid separation, where the separated percolation liquid collects under the drain and is sprayed continuously or discontinuously in the circuit over the organic matter by means of pumps. Excess percolation liquid may be pumped into the buffer tank with appropriate filling level, and from there into the biogas process reactor. During composting, the bottom of the process tanks may be used for air discharge, after the air has passed through the organic matter. The temperature in the process modules may be approximately 38° C. The process modules may be insulated and/or heated.
In certain embodiments, the AD is provided by means of added and/or immobilized bacteria, which are continuously prevailing and produced in the methane reactor. The methane reactor tank may be essentially gas-tight and/or may function according to a reactor principle that is common to wastewater technology. For example, the reactor tank may be an Up-flow Anaerobic Sludge Bed (UASB-sludge bed), a solid bed reactor, and/or a Continuously Stirred Tank Reactor (CSTR). A solid bed biogas reactor tank can be, for example, operated as a plug flow reactor, so that both the residence time in the process module as well as the residence time in the biogas reactor tank can be defined and controlled.
In certain embodiments, the biogas includes methane (CH 4 ) [e.g., 50-85 vol. %], carbon dioxide (CO 2 ) [e.g., 15-50 vol. %], as well as oxygen, nitrogen, and trace gases (including hydrogen sulfide). A biogas with a high methane fraction of between about 65 and about 80 vol. %, or more, may be produced with the decomposing method according to the invention.
Among other things, the biogas can be used directly for heating purposes or, by means of a block-type thermal power system (IC engine, Fuel Cell, Turbine), for the coupled production of electricity and heat, or it can be upgraded for introduction in pipeline systems or used for vehicle fuel. In various embodiments, the gas is produced by anaerobic digestion of organic matter.
To increase the biogas yield, co-materials (for example, renewable resources or wastes from the food industry) can be used. The AD and composted organic matter can subsequently be evaluated as high-value fertilizer for agricultural use.
In certain embodiments, during the methanogenesis, a slipstream of the percolate leaves the reactor tank, is heated in a heat exchanger or other heating device, before being reintroduced in the reactor tank. In this way, a constant temperature can be maintained in the biogas reactor tank. The temperature in the biogas reactor tank may be between about 38° C. and about 55° C. In certain embodiments, the temperature in the biogas reactor tank is about 38° C., or about 55° C.
An accumulation of the most varied substances in the percolate can be avoided, as a mechanism in the bottom of the reactor tank (e.g., a sump) allows particles to be continuously or frequently removed from the process.
FIG. 1 depicts an apparatus 20 for digestion of solid waste, in accordance with an embodiment of the invention. In one embodiment, the process tank 1 operates at ambient pressure. Liquid percolates through organic matter in the process tank 1 and exits through a draining system (a grating) 3 at the bottom. The percolate is collected in a process tank 5 , then pumped to a spraying system 2 back into the process tank 1 with a pump 4 . Excess percolation liquid is pumped into a filter tank 6 by another pump 8 , where it is filtered, then is pumped into a biogas reactor tank 9 . Degassed percolation liquid is discharged from the biogas reactor tank 9 and returned to the process tank 5 .
Process modules 1 are constructed as a type of “garage” or container, with an acid-resistant lining. The process modules 1 are configured such that they are charged by the usual technological means (for example, with wheel loaders). A bottom of the process modules 1 includes a drain system 3 so that a solid-liquid separation can occur. The drain system 3 is designed and constructed to prevent blocking or clogging. The process modules 1 may operate at ambient pressure.
The percolation liquid is drained or percolated through organic matter and exits the process modules 1 through the draining system 3 at the bottom of the process modules 1 . The percolate is collected in process tanks 5 , from which it is pumped to a spraying system 2 in the process modules 1 . The spraying system 2 continuously or discontinuously sprays the liquid over the organic matter in the process modules 1 by means of pumps 4 .
During operation of the apparatus 20 , the percolation liquid dissolves the acids, volatile fatty acids, and other substances from the solid organic waste bed. As a result, the percolation liquid is enriched with easily digestible substances.
From the process tanks 5 , excess percolation liquid is pumped via pumps 8 into filter tanks 6 having an appropriate filling level. The filter tanks 6 are equipped with a coarse filter where bigger pieces (e.g., large solids) can be separated from the liquid stream.
From there, the percolation liquid is pumped in a gas-tight manner into a biogas reactor 9 by means of pumps 8 . The biogas reactor 9 functions according to a reaction principle that is common for wastewater technology (e.g., UASB, CSTR, sludge bed, solid bed reactor). Inside the biogas reactor 9 , the percolation liquid is digested rapidly into exiting biogas 13 , containing mainly CH 4 and CO 2 . The degassed percolation liquid is discharged from the biogas reactor 9 and returned to the process tanks 5 using pumps 7 .
FIG. 2 depicts an apparatus for composting solid waste, in accordance with an embodiment of the invention. After the hydrolysis and methanogenesis stages depicted in FIG. 1 , the conditions in the process modules 1 shifts from anaerobic (with percolation) to aerobic, as air is introduced. In the depicted embodiment, air intakes 10 mounted on top of the process modules 1 are opened and pumps 11 start to draw air continuously or discontinuously (e.g., intermittently) through the already percolated organic matter. After passing through the organic matter, the air is discharged through a biofilter 12 , where odors are scrubbed (e.g., using microorganisms) from the air.
FIG. 3 and FIG. 4 are analogous to FIG. 1 and FIG. 2 , respectively, with minor changes in the process streams during the hydrolysis/methanogenesis stages (methanization process) depicted in FIG. 3 . In FIG. 3 , percolate that passes through the drain 3 at the bottom of a process module 1 first passes through a filter tank 6 prior to entry into the process tank 5 . The filter tanks 6 are equipped with a coarse filter where bigger pieces (e.g., large solids) can be separated from the liquid stream. Degassed percolation liquid from the biogas reactor tank 9 is also discharged to the process tanks 5 , e.g., using pumps. Thus, the process tanks 5 collect percolate from the process modules 1 as well as liquid recycled from the biogas reactor tank 9 , as depicted in FIG. 3 . Liquid from a process tank 5 is pumped to a spraying system 2 in one or more process modules 1 ( FIG. 3 depicts one process tank 5 per process module 1 , but alternative embodiments may have multiple process modules 1 sharing a single process tank 5 ). The spraying system 2 continuously or discontinuously sprays the liquid over the organic matter in the process modules 1 by means of pumps 4 . FIG. 3 depicts two process modules 1 —each with associated process tank 5 and filter tank 6 —for every biogas reactor tank 9 . However, there may be many process modules 1 for a given biogas reactor tank 9 . For example, in various embodiments, a plant may have at least 5, 10, 15, or 20 process modules 1 for a given biogas reactor tank 9 .
After the hydrolysis and methanogenesis stage depicted in FIG. 3 , the conditions in the process modules 1 shifts from anaerobic to aerobic, as air is introduced. FIG. 4 depicts this aerobic composting stage, where the same process modules 1 through which percolate flowed in the hydrolysis/methanogenesis stage are used for aerobic treatment of the organic waste, thereby obviating transport of the solids to another vessel. In the depicted embodiment, air intakes 10 mounted on top of the process modules 1 , as shown in FIG. 4 , are opened and pumps 11 start to draw air continuously or discontinuously (e.g., intermittently) through the already percolated organic matter. After passing through the organic matter, the air is discharged through a biofilter 12 , where odors are scrubbed (e.g., using microorganisms) from the air.
Exemplary Embodiment
An example implementation of the system depicted in FIG. 3 and FIG. 3 is described in this section. In this example, the system produces biogas by anaerobic digestion of solid waste material (e.g., municipal waste) over a period lasting from one to four weeks. The de-gasified material is then decomposed through aerobic decomposition into a rich black soil, a process which takes an additional two to four weeks. The system allows control of the biological processes while avoiding over-engineering of the technical facilities.
The municipal waste is weighed and registered, after which it is unloaded in a reception area where the quality and pureness of the material is assessed. Surface fluid from the reception area is led through an oil separator and a sand collector to a receiving tank, then pumped to sewer.
The solid municipal waste is then handled and pre-treated using mobile equipment such as front loaders, feed mixers and drum screens. Non-organic components such as plastic, metal, and the like are separated out for incineration. The remaining waste is treated in a drum screen filter. The filtered-out fraction is transported to incineration while the ‘clean’ fraction is mixed with structure material such as wood branches and rough garden waste in a feed mixer. In this example, approximately 2 kg of structure material is used for every 10 kg of waste. The mixed material is front loaded into the process modules 1 . When full, each module 1 is closed by bolting the gas tight door shut.
Biogas is produced in two phases—hydrolysis and methanogenesis. Hydrolysis takes place in the process modules 1 , e.g., 600 m 3 concrete boxes or vessels, where each module 1 is fitted with sprinklers 2 and ventilations systems 10 . The organic waste in the closed process module is irrigated with percolate from the process tank 5 . This percolation draws out the fatty acids from the waste and the acidic percolate is then used for gas production in the reactor tank 9 . The hydrolysis in the process module 1 runs for a period from two to four weeks.
Methane is produced in a gas tight reactor tank 9 (e.g., 1,500 m 3 membrane-covered concrete container), which is also used for gas storage. The fluids (percolate) from the hydrolysis in the process modules 1 are led to the reactor tank 9 where they feed the methanogenesis. Addition of percolate is controlled by the pH value in the reactor tank. The pH in the tank should be from about 7 to about 7.5 for good gas production. The process in the reactor tank 9 may take place without stirring, or with only light stirring. The reactor tank 9 design may simply be a modification of bio-gasification tanks used for livestock manure on farms.
The two processes—hydrolysis and methanogenesis—are thus handled in physically separate containers, and the interface between the two containers is a separate process tank 5 (e.g., a 6 m 3 vessel). Process control is performed in the process tank 5 and all related installations, including valves, pumps, fans, and the like, can be established in or around the process tank. This allows there to be no electrical installations in the process modules 1 or the reactor tank 9 . In preferred embodiments, there is one process tank 5 connected to each process module 1 . A plant that employs this system may have, for example, twenty process modules 1 , each with a corresponding process tank 5 , placed next to or opposite each other, and two reactor tanks 9 , thus, in this example, 5 process modules 1 for every biogas reactor tank 9 .
From the reactor tank 9 , the biogas can be led to a biogas motor that produces electricity supplied to the electricity grid and heat which is used internally in the system. The internal heating system can transfer heat from the biogas motor to the reactor 9 , offices, etc. Alternatively, the biogas can be captured and upgraded to higher methane content and fed to a natural gas system. A gas control unit measures gas flow and quality in the gas pipes, expressed by methane content, CO 2 content, and O 2 content. In addition to methane, CO 2 may be captured as well. The plant may be equipped with an emergency gas exploitation unit (e.g., gas flare) to exploit gas in the event of a biogas motor breakdown or during repair.
Once the hydrolysis is complete, pathogenic microorganisms are removed from the material in a sanitation step where the temperature in the process module is raised to a minimum of 70° C. and for a minimum of one hour. After purification, the waste in the process modules 1 can be converted to compost in the composting stage.
The composting process, depicted in FIG. 4 , is activated by forced aeration of the now de-gasified waste, at which time composting begins and pH rises. The aeration may be performed by opening a pneumatic controlled damper 10 in the roof of the process module 1 , thereby allowing atmospheric air into the module 1 . Each process module 1 has its own air intake 10 . The air is sucked out through the drainage bottom 3 via canals in the floor of the process module 1 using a fan placed outside the process module 1 .
Composting will generally run for two to four weeks in the process module 1 , after which the compost is stable and can be moved to open curing boxes for final composting without odor problems. The ventilation system transports air through the compost mass and sucks out process air to an air cleaning system 12 . Process air cleaning is used to break down and clean odor components, such as ammonia. The air may be cleaned in a simple open surface biofilter or, if required, it can be wasted in a scrubber and subsequently cleaned in a biofilter. If the plant is equipped with a scrubber, then a water recycling system may be established to minimize water use.
FIG. 5 is a schematic drawing of views of an exemplary dual-purpose drain assembly 3 for transport of percolate from a process module 1 during a digestion stage as well as for ventilation of the process module 1 during a composting stage. The exemplary dimensions shown are in millimeters. Reference 200 is a bottom view of a rail 201 , with funnels 202 through which percolate runs from the module (side A) to a pipe 204 (side B) during the digestion stage (hydrolysis/methanogenesis) and through which air flows from the pipe 204 (side B) to the module (side A). The funnels 202 have a conical shape, with the narrow end 204 facing the process module 1 and the wide end 206 facing the pipe 204 . This design has been found to help prevent clogging of the funnel 202 with biomass in the process module 1 . In certain embodiments, the ratio of the diameter at the narrow end 204 to the diameter at the wide end 206 is about 0.75. In certain embodiments, the ratio is no greater than about 0.90.
Reference 208 is a side view of a rail 201 from the process module 1 side (side A), showing the narrow end 204 of the funnels 202 . Reference 210 is a side view of the rail 201 from the pipe side (side B), showing the wide end 206 of the funnels 202 . Reference 212 is a ground view of the rail 201 showing pre-fabricated shelves 214 which hold a steel plate 216 , and reference 218 is a ground view of the rail 201 showing pre-fabricated screw holes 220 for screws 221 that bolt the rail 201 to the concrete 222 .
Reference 224 is a top view of the rail 201 . This view shows the pre-fabricated screw holes 220 for the screws 221 that bolt the rail 201 to the concrete 222 , and the prefabricated shelf 214 that holds the steel plate 216 . Dotted lines represent the funnels 202 described above.
Reference 230 is a ground view of the drainage system. Rails 201 are on either side of a pipe 204 . The rail may be made from polyethylene PEHD LF 1000, for example. Funnels 202 are drilled through the rails 201 to allow liquid percolate to flow from the process module 1 to the pipe 204 during the hydrolysis stage, and to allow flow of air from the pipe 204 to the process module 1 during the composting stage. A screw 221 bolts the rail 201 directly into the concrete 222 .
Percolate flows from the process module 1 into the pipe 204 , and from there is transported to the filter tank 6 , process tank 5 , and then biogas reactor tank 9 during the hydrolysis/methanogenesis stage. Furthermore, during the composting stage, air flows through the pipe 204 and into the process module 1 via the funnels 202 . A steel plate 216 (e.g., 6 mm-thick stainless steel) tops the pipe 204 and compost lies on top of the steel plate 216 . The steel plate 216 prevents compost/waste in the process module 1 from falling directly into the pipe 204 . The plate 216 is held in place by a shelf 214 fabricated into the rails 201 . The shelf 214 allows the plate 216 to be easily removed for cleaning of the pipe 204 when composting is complete and the solid material has been removed from the process module 1 .
EQUIVALENTS
While the invention has been particularly shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | This invention relates generally to systems and methods for digestion of solid waste that simplify solids handling. In certain embodiments, anaerobic methane extraction takes place for a period of time (e.g., from 1 to 4 weeks), after which an aerobic composting process begins in the same chamber. The organic waste remains in place and oxygen (e.g., in air) is forced into the chamber for an additional period of time (e.g., from 2 to 4 weeks). At the conclusion of the aerobic phase, the process yields a rough compost product that is stable and pathogen free. The rough compost can be further processed and blended to create high value engineered soils. | 8 |
TECHNICAL FIELD
[0001] The present invention is generally directed to a technique for drive current stabilization and, more specifically, to a technique for drive current stabilization of an automotive ignition system.
BACKGROUND OF THE INVENTION
[0002] Frequently, modern automotive ignition systems have controlled an ignition coil current by modulating a control terminal, e.g., a gate, of a switching device, e.g., an insulated-gate bipolar transistor (IGBT), which provides a current path for a primary winding of an ignition coil. In such automotive ignition systems, it has generally been desirable for the current in the primary winding of the ignition coil to increase as quickly as possible, limited by an impedance of the primary winding, to a predetermined desired coil current limit level. Further, when the coil current limit level has been reached, it has generally been desirable for the coil current to smoothly transition to a steady-state value, with minimal oscillation during the transition.
[0003] In a typical automotive ignition system, when an IGBT is used as the switching device, a designed current of approximately 500 uA has been used to quickly charge a gate capacitance of the IGBT and raise an IGBT gate voltage above a turn-on gate threshold of the IGBT. However, when the IGBT gate capacitance is charged to a maximum voltage level, as typically determined by an ignition control integrated circuit, the gate voltage can be maintained with significantly less current than the current initially required to quickly charge the IGBT gate capacitance. After the gate is fully charged, the lower IGBT gate current requirement continues while the primary winding current is increasing to the desired coil current limit level. When the coil current limit level is reached, the IGBT gate voltage is reduced in an attempt to maintain a constant primary winding current.
[0004] In a typical automotive ignition system, the decrease in the IGBT gate voltage has been achieved through the use of a closed-loop feedback circuit, i.e., a gate control current limit circuit. When the IGBT gate voltage is reduced, a gate drive current source that is providing the IGBT gate charging current has generally increased its output current due to changes in the current source bias conditions. Thus, in order to reduce the IGBT gate voltage, the gate control current limit circuit has been required to sink the additional current. As mentioned above, in operation, the input current draw is at a maximum during the initial charging of the IGBT gate and subsequently reduces during the time that the primary winding current is increasing to the current limit level. Finally, the current draw again increases when the gate control current limit circuit reduces the IGBT gate voltage to control the primary winding current.
[0005] In input-powered automotive ignition systems, a supply current is provided from an associated control unit, through a series resistor that is either internal or external to the ignition control integrated circuit. Unfortunately, the fluctuation in the supply current provided by the control unit, through the series resistor, causes a proportional voltage fluctuation to the gate drive current source. This voltage fluctuation, under some input conditions, causes the gate control current limit circuit to repeatedly change from an open-loop condition (IGBT fully on) to a closed-loop condition (IGBT gate voltage controlled). This voltage oscillation, in turn, causes an undesired oscillation in the primary winding current.
[0006] What is needed is a drive current stabilization circuit that substantially maintains a constant current output from a current source that is driving a control terminal of a switching device that controls a primary winding current of an ignition coil, irrespective of the state of a current limit control loop.
SUMMARY OF THE INVENTION
[0007] The present invention is generally directed to a technique for drive current stabilization. According to one embodiment of the present invention, a drive current is received that includes a control current that is provided to a control terminal of a switch, a current limit input current that is provided to a current limit circuit associated with the switch and a stabilization current. The switch carries a load current responsive to the magnitude of a control signal on the control terminal. The magnitude of the control current is monitored and the magnitude of the stabilization current is increased responsive to a decrease in the magnitude of the control current to substantially maintain the magnitude of the drive current.
[0008] According to another aspect of the present invention, the magnitude of the stabilization current is reduced responsive to an increase in the magnitude of the current limit input current to substantially maintain the magnitude of the drive current. According to a different aspect of the present invention, the switch is one of an insulated-gate bipolar transistor (IGBT) or a field-effect transistor (FET).
[0009] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0011] FIG. 1 is an electrical diagram, in block and schematic form, of an exemplary automotive ignition system that implements a drive current stabilization circuit constructed according to one embodiment of the present invention;
[0012] FIGS. 2A-2B are graphs depicting waveforms of a primary winding current of an ignition coil for a prior art automotive ignition system and an automotive ignition system that implements a drive current stabilization circuit constructed according to one embodiment of the present invention, respectively;
[0013] FIGS. 3A-3B are graphs depicting waveforms of a drive current for a prior art automotive ignition system and an automotive ignition system that implements a drive current stabilization circuit constructed according to one embodiment of the present invention, respectively;
[0014] FIGS. 4A-4B are graphs depicting waveforms of a supply voltage for a prior art automotive ignition system and an automotive ignition system that implements a drive current stabilization circuit constructed according to one embodiment of the present invention, respectively; and
[0015] FIG. 5 is an electrical schematic of a relevant portion of an exemplary automotive ignition system that implements a drive current stabilization circuit constructed according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] According to one embodiment of the present invention, a drive current stabilization circuit for an automotive ignition system is disclosed that maintains a constant current output from a current source that drives a control terminal, e.g., a gate, of a switch, e.g., a field-effect transistor (FET) or insulated-gate bipolar transistor (IGBT), that controls a current through a primary winding of an ignition coil. The present invention is generally applicable to drive current stabilization for automotive ignition systems that are input-powered, as well as automotive ignition systems that are battery-powered. Further, it is contemplated that the present invention is applicable to other environments where a switch is utilized to provide a current path for a coil or other load.
[0017] As is shown in FIG. 1 , an automotive ignition system 100 includes a primary winding Lp of an ignition coil that is coupled between a battery B+ and a switch S 1 , e.g., a FET or an IGBT. An output terminal, e.g., an emitter, of the switch S 1 is coupled to ground through a sense resistor Rs. A gate control current limit circuit 108 is coupled across the sense resistor Rs. The circuit 108 monitors a voltage developed across the resistor Rs to determine a magnitude of the current flowing through the primary winding Lp. The circuit 108 acts to limit the current through the primary winding Lp, when the current reaches a desired level. A control unit 102 provides an electronic spark timing (EST) signal V 1 to a gate drive current source 104 and a gate control current limit circuit 108 , via a resistor Rsource, e.g., a 470 Ohm resistor. The gate drive current source 104 provides a drive current I 1 to a drive current stabilization circuit 106 , constructed according to one embodiment of the present invention. The drive current stabilization circuit 106 provides a current limit input current I 3 to an input of the gate control current limit 108 and a control current I 2 to a gate of the switch S 1 . The drive current stabilization circuit 106 , as required, sinks a stabilization current I 4 to substantially maintain a magnitude of the drive current I 1 .
[0018] As is discussed above, in prior automotive ignition systems, which have not included the drive current stabilization circuit 106 , a drive current I 1 has been split between a current limit input current I 3 , which was used by the gate control current limit circuit 108 , and a control current I 2 , which was used to charge the IGBT gate capacitance and turn on the switch S 1 . After the gate capacitance of the switch S 1 was charged, the current I 2 would cease flowing and, thus, the current I 1 would decrease. This reduction in current would then cause the voltage V 1 to increase. When the current through the sense resistor Rs had increased to a desired current limit level, the current I 3 would increase to reduce the IGBT gate voltage. The increase in the current I 3 would then cause an equal increase of the current I 1 and, thus, the voltage V 1 would decrease. It should be appreciated that this voltage change was generally undesirable as it can cause oscillation in the primary winding Lp current.
[0019] However, in automotive ignition systems that implement the drive current stabilization circuit 106 , designed according to the present invention, when the current I 2 decreases, the stabilization current I 4 increases by an approximately equal amount. In this manner, the drive current I 1 remains substantially constant (e.g., within +5 percent) and, as such, the voltage V 1 also remains substantially constant. According to one embodiment, the gate control current limit circuit 108 , the drive current stabilization circuit 106 and the gate drive current source 104 are integrated within an ignition control integrated circuit 107 .
[0020] FIGS. 2A, 3A and 4 A depict exemplary waveforms of an ignition primary current, the drive current I 1 current and the V 1 voltage, respectively, as a function of time, for a prior art automotive ignition system. FIGS. 2B, 3B and 4 B depict exemplary waveforms of the ignition primary current, the drive current I 1 current and the V 1 voltage, respectively, as a function of time, for an automotive ignition system including a drive current stabilization circuit 106 constructed according to the present invention. As is evident from comparing the signals of FIGS. 3A and 3B , the drive current I 1 is significantly more constant during IGBT gate capacitance charging, when the gate is fully charged and when the gate voltage is reduced by current limit control. As is also evident from comparing the signals of FIGS. 4A and 4B , the voltage V 1 is substantially more constant, when the gate is fully charged, as well as when the gate voltage is reduced by the current limit control.
[0021] With reference to FIG. 5 , transistor level circuit implementation of the drive current stabilization circuit 106 is depicted in relationship to related components of an ignition control integrated circuit (IC) of an automotive ignition system. Transistors Q 100 to Q 109 and resistors R 100 to R 103 form a reference current generator known as a ‘Delta Vbe generator’. As is well known to one of ordinary skill in the art, the ‘Delta Vbe generator’ is a standard building block and has a reference current (Iref) defined by the following equation:
Iref = Vt * Ln ( N ) Rdvbe
where Vt is the thermal voltage defined by k*T/q, k is Boltzman's constant, T is the temperature in degree Kelvin and q is the electronic charge; N is the ratio of the emitter areas used to develop the Delta VBE current, i.e., transistors Q 105 to Q 108 , and in the disclosed implementation N is set equal to 9; and Rdvbe is the resistance chosen to establish a magnitude of the reference current Iref and corresponds to the value of resistor R 102 . The reference current Iref is used to drive a current mirror rail, which drives other circuits necessary for operation of the ignition control integrated circuit (IC), along with the gate drive current.
[0022] In one embodiment, due to the relative emitter areas of the transistor Q 100 and the transistor Q 3 and the values of the resistors R 100 , R 3 and R 4 , the gate drive current I 1 is approximately eight times the Iref current. As is shown, the gate charging drive current I 1 is provided from a collector of the transistor Q 3 . When the drive current I 1 is initially turned on, the switch S 1 gate voltage is low and rises as a gate capacitance of the switch S 1 is charged. The current I 1 , supplied from the collector of the transistor Q 3 , is used by the gate control current limit circuit 108 or to charge the gate capacitance of the switch S 1 . At this point, the current I 4 is approximately equal to zero as transistors Q 2 and Q 6 are turned off. The transistor Q 2 remains off as long as its emitter voltage is no more than approximately 0.6 Volts greater than its base voltage. The emitter voltage of the transistor Q 2 tracks the gate voltage of the switch S 1 and its base voltage is defined by the following equation:
Q 2 base voltage= V 1−[( I ref* R 100)+ Vbe of the transistor Q 100]
[0023] While the switch S 1 gate capacitance is charging, the base voltage of the transistor Q 2 is higher than its emitter voltage and, as such, the collector of the transistor Q 2 does not provide current to turn on the transistor Q 6 . It should be appreciated that the transistors Q 100 , Q 1 , Q 4 and Q 5 and resistors R 100 , R 1 and R 2 create two current mirrors that discharge and maintain a low state on the base of the transistor Q 6 , when the transistor Q 2 is off. These current mirrors are configured to create a current that is a reduced version of the reference current Iref. It is desirable that this current be relatively small, e.g., a few microamperes, which allows the drive current stabilization circuit to become active when the base voltage of the transistor Q 2 is only slightly below the emitter voltage of the transistor Q 2 . This occurs when the transistor Q 3 approaches saturation and the collector voltage of the transistor Q 3 approaches the base voltage of the transistor Q 3 . When the transistor Q 3 approaches saturation, its base current increases, thereby creating an additional voltage drop across the resistor R 3 , lowering the base voltage of the transistor Q 2 relative to its emitter voltage.
[0024] It should be appreciated that if the transistor Q 3 is allowed to be driven deep into saturation, the overall current draw of the component will reduce as the current output of the transistor Q 3 decreases. However, according to the present invention, the transistor Q 2 begins to conduct current when the transistor Q 3 begins to saturate. When the current conducted by the transistor Q 2 overcomes the pull-down current of the transistor Q 5 , the transistor Q 6 begins to turn on and the voltage at the collector of the transistor Q 3 is maintained, which keeps the transistor Q 3 from being driven into hard saturation. This eliminates the undesired change in the collector current of the transistor Q 3 .
[0025] The current I 2 that was previously charging the switch S 1 gate capacitance is now diverted to ground, via the transistor Q 6 . As such, the drive current I 1 remains substantially unchanged. When the ignition coil primary winding current limit is reached, the gate control current limit 108 increases the current I 3 to reduce the switch S 1 gate voltage. As this reduces the voltage at the emitter of the transistor Q 2 , the current flow from the collector of the transistor Q 2 is stopped and the transistor Q 6 is turned off, which ends the current I 4 flow. In this manner, the overall current I 1 is relatively unchanged since the current I 4 that was flowing through the transistor Q 6 is now used by the gate control current limit 108 .
[0026] Accordingly, a drive current stabilization circuit has been described herein that enhances drive current stabilization, which reduces undesired oscillation in a current carried by a primary winding of an ignition coil of an automotive ignition system.
[0027] The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. | Drive current stabilization is achieved through the management of a drive current. The drive current may include a control current that is provided to a control terminal of a switch, a current limit input current that is provided to a current limit circuit associated with the switch and a stabilization current. The switch carries a load current responsive to a control signal on the control terminal. The magnitude of the control current is monitored and a magnitude of the stabilization current is increased responsive to a decrease in the magnitude of the control current to substantially maintain a magnitude of the drive current. | 5 |
FIELD
[0001] The present disclosure relates to accumulators for hydraulic fluid systems and more particularly to combination spring biased and gas filled accumulators for hydraulic fluid systems.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
[0003] Accumulators which are essentially pressurized fluid storage devices are common components of hydraulic fluid systems. They serve two related functions in such systems. On one hand, when a supply pump is operating, they function as a reservoir or storage site for excess pumped fluid resulting simply from pumped fluid volume exceeding system fluid consumption. On the other hand, when a supply pump is not operating or system fluid consumption exceeds pumped volume, the accumulator supplies pressurized fluid until the pump re-starts, supplies pressurized fluid while the pump restarts or until pump output exceeds fluid consumption. Thus, accumulators maintain and create both desired fluid pressure and flow in a hydraulic fluid system, improve the match between the instantaneous volume of fluid supplied by the pump and the instantaneous volume of fluid consumed by the system and thereby improve system operation.
[0004] Accumulators are a common component of many automatic transmission configurations in which selective flows of hydraulic fluid are utilized to manipulate spool valves and operate actuators, clutches and brakes to sequentially engage desired speed or gear ratios. The majority of automatic transmission accumulators take two forms: a super-atmospheric gas charged accumulator and a spring biased accumulator. In the first design, one face of a free piston in a cylinder is acted upon by the hydraulic fluid and the adjacent region defines a fluid storage volume; the opposite face of the piston and adjacent volume is charged with, for example, super-atmospheric pressurized nitrogen. The compressed (and compressible) gas provides a fluid spring against which the hydraulic fluid acts. The spring biased accumulator replaces the gas with a mechanical compression spring which biases the piston and maintains the pressure of the hydraulic fluid.
[0005] Notwithstanding their popularity, these devices each have shortcomings. For example, given the operating pressures of automatic transmissions, the most practical size gas filled accumulator will, as noted above, include a gas charged to a pressure above atmospheric pressure. Over the life of the accumulator, this pressurized gas will slowly leak out, rendering the accumulator without optimal functionality. This slow change will slowly but inexorably affect the operation of the transmission where there may not be enough fluid storage volume for operations such as re-engaging the clutches for engine start—stop vehicle launches. The alternative to a super-atmospheric pressure charged accumulator is an atmospheric pressure charged accumulator but this choice results in a much larger accumulator which is especially undesirable given the current trend toward highly efficient packaging. A spring accumulator is also generally larger than a gas filled accumulator and thus suffers from the same packaging related problems. Though size may appear to be a minor issue, it is a major issue and has major consequences in automotive component design. Thus, there is a need for an efficiently packaged accumulator for use in hydraulic systems such as those in automatic transmissions.
SUMMARY
[0006] The present invention provides a compact fluid accumulator which both stores a relatively large amount of fluid and provides good fluid pressure stability. The accumulator includes a piston slidably disposed in a cylindrical housing having a fluid inlet/outlet at one end which communicates with a first chamber and one face of the piston. Engaging the opposite face of the piston, and disposed in a second chamber, is a compression spring. The second chamber is filled with a gas which is at atmospheric pressure when the accumulator is relaxed. When pressurized hydraulic fluid begins to fill the first chamber, the piston moves against the pressure of the spring and gas in the second chamber. The accumulator of the present invention is especially suited for engine start—stop applications.
[0007] The present invention thus provides an accumulator having the small size of a gas filled accumulator without the leakage problem of a super-atmospheric gas charged chamber—the extra force being provided by the compression spring.
[0008] It is thus an object of the present invention to provide an accumulator for a hydraulic fluid system.
[0009] It is a further object of the present invention to provide an accumulator for a hydraulic fluid system of an automatic transmission.
[0010] It is a still further object of the present invention to provide an accumulator for a hydraulic control system of an automatic transmission.
[0011] It is a further object of the present invention to provide an accumulator having a piston disposed in a cylindrical housing.
[0012] It is a further object of the present invention to provide an accumulator having a cylindrical housing with an inlet/outlet at one end.
[0013] It is a further object of the present invention to provide an accumulator having a piston biased by both a compression spring and gas disposed in a cylindrical housing.
[0014] It is a further object of the present invention to provide an accumulator having a piston biased by both a compression spring and gas disposed in a cylindrical housing and adapted to engine start—stop applications.
[0015] It is a further object of the present invention to provide a compact accumulator having a piston biased by both a compression spring and gas.
[0016] Further objects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0017] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0018] FIG. 1A is a diagrammatic view of a hydraulic fluid supply system incorporating a fluid accumulator according to the present invention;
[0019] FIG. 1B is a fragmentary, diagrammatic view of a portion of a hydraulic fluid supply system incorporating a fluid accumulator according to the present invention which is especially suited to engine start—stop applications;
[0020] FIG. 2A is an enlarged, side view of a fluid accumulator according to the present invention in an unfilled state;
[0021] FIG. 2B is an enlarged, side view of a fluid accumulator according to the present invention in a filled state; and
[0022] FIG. 3 is a multiple plot graph presenting the performance of a prior art gas filled accumulator at three different temperatures and the performance of an accumulator according to the present invention at the same three temperatures.
DETAILED DESCRIPTION
[0023] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0024] With reference to FIG. 1A , a typical and representative hydraulic fluid supply system is illustrated and generally designated by the reference number 10 . The hydraulic fluid supply system 10 may find application in, for example, vehicular automatic transmissions and numerous other devices having hydraulic control and hydraulic operating systems. The hydraulic fluid supply system 10 typically includes a sump 12 which is disposed at the lowest region of a housing (not illustrated) or other device or fluid containment component. Typically, a filter 14 is disposed in the sump 12 which filters the hydraulic fluid passing from the sump 12 to a suction line 16 to remove foreign particulate matter. The suction line 16 is in fluid communication with a suction or inlet port 18 of a hydraulic pump 20 . Typically the pump 20 will be a positive displacement pump such as a vane pump (illustrated), a gear pump or a gerotor pump. The pump 20 also includes a pressure or outlet port 22 which communicates with a first pressure line 24 . If desired, the supply system 10 may include a blow-off or pressure relief valve 28 . The pressure relief valve 28 is pre-set at a pressure limit and when that pressure limit is exceeded in the pressure line 24 , the pressure relief valve 28 opens, reducing the pressure in the first pressure line 24 , and, typically, returning hydraulic fluid to the sump 12 .
[0025] The first pressure line 24 is also in fluid communication with a filtration assembly 30 . The filtration assembly 30 includes a second particulate filter 32 , typically having finer filtration media and pores than the sump filter 14 . Also contained in the filtration assembly 30 and in fluid parallel with the second filter 32 is a flow bypass valve 34 . The flow bypass valve 34 is pre-set at a pressure differential and when this pressure differential is exceeded, due to flow restriction or plugging of the second filter 32 , the flow bypass valve 34 opens to allow hydraulic fluid to flow around the second filter 32 , thereby avoiding starving the supplied hydraulic system of hydraulic fluid.
[0026] A second pressure line 36 communicates with the outlet of the filtration assembly 30 and an inlet of a one-way or ball check valve 38 . The ball check valve 38 allows hydraulic fluid flow from the filtration assembly 30 into the rest of the hydraulic system but prevents reverse flow from the system back into the filtration assembly 30 and other upstream components.
[0027] The outlet of the ball check valve 38 communicates with a fluid accumulator 40 and a main fluid supply line 42 which may optionally include a fluid pressure sensor or similar transducer 44 which provides a signal indicative of the pressure of the hydraulic fluid in the fluid supply line 42 to associated control equipment (not illustrated).
[0028] Referring now to FIG. 1B , a portion of a hydraulic fluid supply system 10 ′ incorporating a fluid accumulator 40 according to the present invention, which is specific to engine start—stop applications, is illustrated. The components illustrated in FIG. 1B are associated with and in communication with the main fluid supply line 42 and reside generally on the right side of FIG. 1A . In communication with the main fluid supply line 42 is a flow restricting orifice 46 which, in turn, communicates with another one-way or ball check valve 48 A which is configured to permit fluid flow toward a hydraulic line 49 and the accumulator 40 but prevent reverse flow. The accumulator 40 in this application is the same as the accumulator 40 in FIG. 1A , includes a piston 58 and a spring 70 and is further described below. Also in fluid communication with the accumulator 40 and the hydraulic line 49 is a solenoid valve 50 . The solenoid valve may be electrically energized to open and provide fluid communication and flow therethrough out of the accumulator 40 to an additional one-way or ball check valve 48 B. The additional check valve 48 B is configured to permit fluid flow toward the main supply line 42 but prevent reverse flow.
[0029] Referring now to FIGS. 1A , 1 B, 2 A and 2 B, the fluid accumulator 40 includes a generally cylindrical housing 52 having an inlet/outlet port 54 which communicates with the fluid supply line 42 in FIG. 1A and the hydraulic line 49 in FIG. 1B . The housing 52 defines a cylinder 56 having the piston 58 which divides the cylinder 56 into a first, fluid chamber 62 and a second, gas chamber 64 on the opposite side or face of the piston 58 . The piston 58 defines a circumferential channel or groove 66 which receives an O-ring seal 68 which provides a fluid tight seal between the piston 58 , the wall of the cylinder 56 and between the chambers 62 and 64 . An additional groove 66 and O-ring seal 68 may be utilized in the piston 58 , as well as other seal types, if desired. Additional glide rings may be incorporated if deemed necessary. Typical oil storage volumes of the accumulator 40 in automatic transmission hydraulic systems will be less than about 0.3 liters.
[0030] Disposed within the second, gas chamber 64 is the compression spring 70 . The compression spring 70 may take many forms and have a spring constant (rate) that varies significantly depending upon the particular application and system pressure. In applications such as vehicular automatic transmissions, spring constants (rates) in the range of about 20 newtons/meter to about 28 newtons/meter have been found suitable and a nominal value of 24 newtons/meter has been found preferable. Additionally, the compression spring 70 is preloaded for automatic transmission service to between about 600 and 650 newtons and a nominal value of 622 newtons has been found preferable. Other spring rates and preloads of the compression spring 70 are within the purview of the present invention and can vary significantly from the values recited above based upon the application, system operating pressure and other design criteria. Preferably, as well, the compression spring 70 is a coil spring, as illustrated, although helical (spiral) springs or stacked spring washers or Belleville springs, for example, and other spring configurations may be utilized.
[0031] In FIG. 2A , the accumulator 40 is presented in a relaxed state with essentially no hydraulic fluid in the first, fluid chamber 62 . In this case, the second, gas chamber 64 is filled with a gas, essentially at atmospheric pressure having a volume V 1 . Depending upon design and application parameters, there may or may not be a preload on the compression spring 70 . In FIG. 2B , the accumulator 40 is presented with a full fluid charge and the piston 58 has translated a full stroke to its travel limit. Now the first, fluid chamber 62 is at its maximum volume and is fully filled with pressurized hydraulic fluid. The second, gas chamber 64 is at its minimum volume V 2 , determined by the stack of the compression spring 70 . The general equation for the instantaneous pressure of the accumulator 40 which essentially represents a force balance on the piston 58 is
[0000]
P
2
=
P
1
(
V
1
V
2
)
(
k
-
1
)
(
V
1
V
2
)
+
K
(
D
)
+
B
π
(
R
)
2
[0000] where P 1 is the initial pressure in the second, gas chamber 64 , P 2 is the final pressure of the hydraulic fluid in the first, fluid chamber 62 , V 1 is the initial volume of the second, gas chamber 64 , V 2 is the final volume of the second, gas chamber 64 , K is the spring constant of the compression spring 70 , D is the displacement of the piston 58 from its relaxed position illustrated in FIG. 2A and its energized position illustrated in FIG. 2B , B is the preload of the compression spring 70 and R is the radius of the piston 58 .
[0032] Referring now to FIG. 3 , a multiple plot graph illustrates the performance of a prior art gas charged accumulator and an accumulator 40 according to the present invention having both a compression spring and gas charge. Both accumulators define the same interior volume. The graph plots hydraulic fluid volume along the horizontal (X) axis and hydraulic fluid pressure along the vertical (Y) axis. The three lower plots 80 A, 80 B and 80 C present data from a prior art accumulator having only a gas charge at 20° C., 80° C. and 120° C., respectively. The three upper plots 82 A, 82 B and 82 C present data from a combination spring and gas filled accumulator 40 according to the present invention also at 20° C., 80° C. and 120° C., respectively. Note that a gas charged accumulator has a usable volume of only 126 cc whereas the accumulator 40 according to the present invention has a usable volume of 199 cc. As a general observation, the accumulator 40 according to the present invention, with the same stored hydraulic fluid volume, operates and provides a higher pressure at essentially all operating conditions when compared to the accumulator having only a gas charge.
[0033] The foregoing description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention and the following claims. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A compact fluid accumulator both stores a relatively large amount of fluid and provides good fluid pressure stability. The accumulator includes a piston slidably disposed in a cylinder having a fluid inlet/outlet at one end which communicates with a first chamber and one face of the piston. Engaging the opposite face of the piston, and disposed in a second chamber, is a compression spring. The second chamber is filled with a gas which is at atmospheric pressure when the accumulator is relaxed. When pressurized hydraulic fluid fills the first chamber, the piston moves against the pressure of the spring and gas in the second chamber. The present invention thus provides an accumulator having the relatively small size of a gas filled accumulator without the leakage problem of a super-atmospheric gas charge—the extra force being provided by the compression spring. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to an electric vehicle having a battery unit and a motor.
BACKGROUND ART
[0002] According to an electric vehicle disclosed in Japanese Laid-Open Patent Publication No. 09-309343 (hereinafter referred to as “JP 09-309343 A”), a battery cluster 20 is disposed below a driver seat 6 (FIG. 2).
[0003] A vehicle 1000 disclosed in U.S. Patent Application Publication No. 2006/0096797 (hereinafter referred to as “US 2006/0096797 A1”) has a first battery pack 1900 that is a 12-volt lead storage battery, and a second battery pack 2000 that is a lithium ion battery ([0032], [0033]). The first battery pack 1900 is disposed in an engine compartment ([0033]). The second battery pack 2000 is provided beneath the base of a front passenger seat 1120 of the vehicle 1000 ([0034]).
[0004] According to an electric vehicle disclosed in Japanese Laid-Open Patent Publication No. 08-002405 (hereinafter referred to as “JP 08-002405 A”), a lead battery 25 is disposed above a fuel tank 24, and a sodium-sulfur battery 28 is disposed behind a partition 27 (FIG. 4, FIG. 5, [0011], [0012]).
[0005] According to U.S. Patent Application Publication No. 2007/0089442 (hereinafter referred to as “US 2007/0089442 A1”), a rear air-conditioning unit 2000 and a battery pack 3000 are provided on a floor panel 4000 and below an upper back panel 5000 (FIG. 1, [0052]). The battery pack 3000 is substantially in the shape of a rectangular parallelepiped (FIGS. 1 and 2).
[0006] According to a vehicle 1 disclosed in U.S. Patent Application Publication No. 2011/0132676 (hereinafter referred to as “US 2011/0132676 A1”), the front side of a battery 12 that supplies electric power to a motor 11 is disposed forwardly of a dash panel 18, and the rear side of the battery 12 is disposed in a tunnel 22 that extends in a longitudinal direction of the vehicle (Abstract, FIGS. 1 and 2).
SUMMARY OF INVENTION
[0007] The above documents propose various layouts with respect to battery units such as batteries, etc. However, there is still room for improvement in the proposed layouts. For example, according to JP 09-309343 A, since the battery cluster 20 is disposed below (immediately below) the driver seat 6 (FIG. 2), a limitation is imposed on efforts to lower the position of the driver seat 6 itself. Therefore, it is difficult to lower the center of gravity of the overall vehicle while the vehicle is being driven, thus leading to roll-axis moments or the like that impede efforts to enhance driving performance.
[0008] According to the vehicle 1000 disclosed in US 2006/0096797 A1, the second battery pack 2000 is provided beneath the base of the front passenger seat 1120 of the vehicle 1000 (FIG. 2, FIG. 3, [0034]). Consequently, the vehicle 1000 has the same limitations or restrictions as the vehicle disclosed in JP 09-309343 A.
[0009] According to JP 08-002405 A, the lead battery 25 and the sodium-sulfur battery 28 are disposed in the positions shown in FIGS. 4 and 5 of the reference. For example, the lead battery 25 and the sodium-sulfur battery 28 are located in relatively higher positions compared to the seated position of the passenger. Therefore, it is difficult to lower the center of gravity of the overall vehicle while the vehicle is being driven, leading to roll-axis moments or the like that impede efforts to enhance driving performance.
[0010] According to US 2007/0089442 A1, the battery pack 3000, which is in the shape of a rectangular parallelepiped, is disposed on the floor panel 4000 and below the upper back panel 5000 and the rear air-conditioning unit 2000 (FIG. 1). In particular, FIG. 1 of US 2007/0089442 A1 shows that the front part (left side of FIG. 1) of the upper back panel 5000 is inclined along a rear seat back 1010, whereas the battery pack 3000 is disposed in an uninclined position. Therefore, a dead space is created on a front side (left side in FIG. 1) of the battery pack 3000 between the battery pack 3000 and the upper back panel 5000.
[0011] According to US 2011/0132676 A1, the front side of the battery 12 is disposed forwardly of the dash panel 18, and the rear side of the battery 12 is disposed in a tunnel 22 that extends in the longitudinal direction of the vehicle (see Abstract, and FIGS. 1 and 2). Consequently, there is a tendency for the battery 12 to impair occupant comfort in the vehicle, or to present obstacles to efforts to make the vehicle compact.
[0012] The present invention has been made in view of the aforementioned problems. An object of the present invention is to provide an electric vehicle, which enables at least one of driving performance, compactness, and occupant comfort to be improved.
[0013] According to the present invention, there is provided an electric vehicle having two seats, including a battery unit, a motor configured to drive a rear wheel, and motor mounts disposed behind the battery unit and supporting the motor securely in place. The electric vehicle further comprises a rear partition defining a passenger compartment behind a rear surface of an occupant seat, wherein the rear partition includes a slanted portion, which is inclined progressively rearward of the electric vehicle in an upward direction, the battery unit has at least a portion disposed along the slanted portion of the rear partition, the battery unit has a lower end disposed below a hip point of an occupant, and the motor mounts are disposed such that an upper portion of the battery unit and a portion of the motor mounts overlap each other in a vertical direction of the electric vehicle as viewed transversely across the electric vehicle.
[0014] According to the present invention, the lower end of the battery unit is disposed below the hip point, thereby making the center of gravity of the electric vehicle lower, as compared with a situation in which the lower end of the battery box is disposed above the hip point. Consequently, it is possible for the center of gravity of the electric vehicle to be positioned close to the hip point in the vertical direction. Thus, the occupant of the vehicle is given a feeling of oneness with the electric vehicle and a nimble sense of maneuverability when driving the electric vehicle. Further, assuming that the hip point can be lowered, the height of the electric vehicle can also be lowered, resulting in a reduction in air resistance and thereby minimizing fuel consumption or electric power consumption.
[0015] According to the present invention, in addition, the rear partition includes the slanted portion, which is inclined progressively rearward of the electric vehicle in an upward direction, and at least a portion of the battery unit is disposed along the slanted portion of the rear partition. Consequently, it is possible to locate the battery unit close to an occupant seat in the longitudinal direction of the electric vehicle. In addition, the motor mounts are disposed such that an upper portion of the battery unit and a portion of the motor mounts overlap each other in a vertical direction of the electric vehicle as viewed transversely across the electric vehicle (e.g., the upper portion of the battery unit and the portion of the motor mounts overlap each other as viewed in plan). Thus, the motor mounts and the motor fixed to the motor mounts can be located close to the occupant seat in the longitudinal direction of the electric vehicle. Stated otherwise, the amount of dead space behind the rear partition can be reduced. Consequently, the electric vehicle can be made compact, or the space in the passenger compartment can be increased by the reduced dead space, thereby enhancing occupant comfort.
[0016] The battery unit may be disposed outside of the passenger compartment, and the battery unit may have a portion fixed to the rear partition. In this manner, it is possible to increase the rigidity of the rear partition (as well as the vehicle body) by taking advantage of the rigidity of the battery unit itself.
[0017] The battery unit may supply electric power to the motor. In addition, the battery unit, the motor, and an inverter configured to control supply of electric power from the battery unit to the motor may be disposed in one space. Normally, the motor, the battery unit, and the inverter are high-voltage devices, respectively. By disposing such high-voltage devices close to each other, electric power efficiency can be increased.
[0018] The inverter may be disposed behind the battery unit and above the motor. When disposed in this manner, the motor, the battery unit, and the inverter are housed in a compact fashion.
[0019] The battery unit may be constructed integrally with the inverter. In accordance with this feature, it is possible to dispense with electric power cables that interconnect the battery unit and the inverter.
[0020] The battery unit may include a cover, and the cover may be installed in a direction that is the same as a direction in which the inverter is installed. In accordance with this feature, the process of installing the inverter and operations to connect electric wires thereto can be facilitated.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a side elevational view, partially omitted from illustration, of an electric vehicle according to an embodiment of the present invention;
[0022] FIG. 2 is a plan view, partially omitted from illustration, of the electric vehicle;
[0023] FIG. 3 is a bottom view, partially omitted from illustration, of the electric vehicle;
[0024] FIG. 4 is an enlarged fragmentary perspective view, partially omitted from illustration, of the electric vehicle;
[0025] FIG. 5 is a rear elevational view, partially omitted from illustration, of the electric vehicle;
[0026] FIG. 6 is a perspective view of a motor and portions around the periphery thereof;
[0027] FIG. 7 is an enlarged fragmentary plan view, partially omitted from illustration (including a battery box), of the electric vehicle;
[0028] FIG. 8 is an enlarged fragmentary side elevational view, partially omitted from illustration, of the electric vehicle;
[0029] FIG. 9 is an enlarged fragmentary plan view illustrating a supporting structure for the battery box;
[0030] FIG. 10 is an enlarged fragmentary side elevational view showing a modified rear partition;
[0031] FIG. 11 is an enlarged fragmentary side elevational view showing a first modification of the battery box according to the embodiment; and
[0032] FIG. 12 is an enlarged fragmentary side elevational view showing a second modification of the battery box according to the embodiment.
DESCRIPTION OF EMBODIMENTS
A. Embodiment
1. Description of Overall Arrangement
[1-1. Overall Arrangement]
[0033] FIG. 1 is a side elevational view, partially omitted from illustration, of an electric vehicle 10 (hereinafter also referred to as a “vehicle 10 ”) according to an embodiment of the present invention. FIG. 2 is a plan view, partially omitted from illustration, of the electric vehicle 10 . FIG. 3 is a bottom view, partially omitted from illustration, of the electric vehicle 10 . FIG. 4 is an enlarged fragmentary perspective view, partially omitted from illustration, of the electric vehicle 10 . FIG. 5 is a rear elevational view, partially omitted from illustration, of the electric vehicle 10 . The vehicle 10 , which is an electric car (battery car) in a narrow sense, includes a motor 12 and an electric power system 14 having a battery box 16 (battery unit). As described later, the vehicle 10 may be another type of electric vehicle apart from an electric car, insofar as the motor 12 is included therein.
[0034] The vehicle 10 is a two-seater vehicle in which a driver seat 20 and a front passenger seat 22 , each functioning as an occupant seat, are disposed adjacent to each other in a transverse direction of the vehicle, i.e., in the direction of arrows Y 1 and Y 2 in FIG. 2 , etc. As described later, aside from a two-seater vehicle, the vehicle 10 may be another type of vehicle (as to the number of seats thereof). Although the vehicle 10 is a right-hand drive vehicle, the vehicle 10 may be a left-hand drive vehicle.
[1-2. Motor 12 ]
(1-2-1. Overview of Motor 12 )
[0035] The motor 12 serves as a drive source for generating a driving force F for the vehicle 10 , and in the present embodiment, the motor 12 drives the rear wheels 24 r . The motor 12 , which comprises a three-phase AC brushless motor, generates a driving force F for the vehicle 10 on the basis of electric power supplied from the battery box 16 . In addition, the motor 12 regenerates electric power (regenerative electric power Preg) [W] in a regenerative mode, and outputs the regenerative electric power Preg to the battery box 16 in order to charge the battery box 16 . The motor 12 may also output the regenerative electric power Preg to a 12-volt system or to various accessories, not shown. The motor 12 is combined integrally with a gearbox and is disposed coaxially with shafts 26 for the rear wheels 24 r.
(1-2-2. Layout of Motor 12 )
[0036] FIG. 6 is a perspective view of the motor 12 and portions around the periphery thereof. FIG. 7 is an enlarged fragmentary plan view, partially omitted from illustration (including the battery box 16 ), of the electric vehicle 10 . As shown in FIGS. 1 through 7 , the motor 12 is fixed to a subframe 32 by motor mounts 30 a through 30 c (hereinafter referred to collectively as “motor mounts 30 ”).
[0037] The motor mounts 30 a through 30 c according to the present embodiment include three motor mounts, i.e., a left front mount 30 a , a right front mount 30 b , and a rear mount 30 c . However, the motor mounts 30 a through 30 c are not limited to this description, insofar as the motor mounts 30 a through 30 c are capable of supporting the motor 12 .
[0038] As shown in FIGS. 1 , 2 , and 6 , etc., the left front mount 30 a and the right front mount 30 b as well as a portion of the battery box 16 overlap each other as viewed in plan, i.e., along the direction of arrows Z 1 and Z 2 .
[1-3. Electric Power System 14 ]
(1-3-1. Overview of Electric Power System 14 )
[0039] The electric power system 14 supplies electric power to the motor 12 and is charged with regenerative electric power Preg from the motor 12 . In addition to the battery box 16 , the electric power system 14 includes a motor controller 40 and a battery controller 42 .
(1-3-1-1. Battery Box 16 )
(1-3-1-1-1. Overview of Battery Box 16 )
[0040] FIG. 8 is an enlarged fragmentary side elevational view, partially omitted from illustration, of the electric vehicle 10 . The battery box 16 includes a plurality of battery modules 50 , a battery tray 52 , a first battery cover 54 , and a second battery cover 56 . Although the battery box 16 basically is in the shape of a rectangular parallelepiped, as shown in FIG. 4 , etc., the battery box 16 has a recess in which the motor controller 40 is disposed. The battery box 16 is disposed in the same space as the motor 12 and the motor controller 40 (including an inverter 90 , to be described later). The battery box 16 is constructed integrally with the motor controller 40 (see FIG. 4 , etc.).
(1-3-1-1-2. Battery Modules 50 )
[0041] Each of the battery modules 50 , which serve as battery units, is an electric energy storage device (energy storage) including a plurality of battery cells, which may comprise lithium ion secondary cells, nickel hydrogen secondary cells, or capacitors. According to the present embodiment, each of the battery modules 50 comprises lithium ion secondary cells. Further, in the present embodiment, each of the battery modules 50 is substantially in the shape of a rectangular parallelepiped. A non-illustrated DC/DC converter may be connected between the battery modules 50 and the motor controller 40 (inverter 90 ) for stepping up or stepping down the output voltage of the battery modules 50 or the output voltage of the motor 12 .
(1-3-1-1-3. Battery Tray 52 )
[0042] The battery tray 52 is a plate-like support member made of metal or plastic that supports the battery modules 50 . As shown in FIG. 8 , each of the battery modules 50 is fixed to the battery tray 52 by bolts 58 .
(1-3-1-1-4. First Battery Cover 54 , Second Battery Cover 56 )
[0043] The first battery cover 54 and the second battery cover 56 are members made of plastic or metal that cover the battery modules 50 and the battery tray 52 . The first battery cover 54 is fixed to the battery tray 52 on a front side of the battery tray 52 and is oriented in the X 2 direction, and the second battery cover 56 is fixed to the battery tray 52 on a rear side of the battery tray 52 and is oriented in the X 1 direction. The first battery cover 54 and the second battery cover 56 are fixed to the battery tray 52 by non-illustrated bolts.
(1-3-1-1-5. Layout of Battery Box 16 )
[0044] FIG. 9 is an enlarged fragmentary plan view illustrating a supporting structure for the battery box 16 . As shown in FIG. 1 , etc., the battery box 16 has a lower end E 1 , which is disposed in a position below a hip point P 1 of a driver 60 as an occupant. The hip point P 1 is represented by a center (design value) of the hip of an occupant (including the driver 60 ).
[0045] According to the present embodiment, the lower end E 1 of the battery box 16 is disposed in a position, which lies below not only the hip point P 1 , but also a lower end E 2 (design value) of the hip of the driver 60 .
[0046] As shown in FIGS. 1 and 4 , etc., the battery box 16 is inclined along a rear partition 72 of a metallic main frame 70 of the vehicle 10 , such that an upper portion of the battery box 16 is positioned more rearwardly (rightwardly in FIG. 1 ) than a lower portion of the battery box 16 .
[0047] The rear partition 72 is a partition (a so-called bulkhead) that defines a passenger compartment 74 , and is disposed at a position behind rearward sides of the driver seat 20 and the front passenger seat 22 . As shown in FIGS. 1 and 4 , etc., the rear partition 72 includes a slanted portion 76 , which is inclined progressively rearward in an upward direction.
[0048] As shown in FIG. 4 , etc., the battery box 16 is fixed to the rear partition 72 and along the slanted portion 76 by a left side bracket 80 a and a right side bracket 80 b . Thus, the battery box 16 is disposed on an outer side of the passenger compartment 74 .
[0049] The battery box 16 is fixed to areas of the rear partition 72 , which comprise stiffened members 78 a , 78 b that are increased in rigidity due to having a substantially rectangular cross-sectional shape. The lower stiffened member 78 a is disposed on the slanted portion 76 , whereas the upper stiffened member 78 b is not disposed on the slanted portion 76 . The upper stiffened member 78 b may also be disposed on the slanted portion 76 .
[0050] The phrase “along the slanted portion 76 ” does not necessarily imply that the front surface of the battery box 16 lies parallel to the slanted portion 76 , but rather, implies that the front surface of the battery box 16 is of a shape more likely to protrude forwardly toward a lower part of the slanted portion 76 than if the front surface of the battery box 16 were to extend in a strictly vertical direction.
[0051] As shown in FIG. 9 , the battery box 16 is fixed in position by a left upper bracket 82 a , a right upper bracket 82 b , and a stiffener bracket 84 . More specifically, as shown in FIG. 9 , the left upper bracket 82 a and the right upper bracket 82 b , which are of a bent shape, have respective ends that are fixed to front portions (around central pillars 87 ) of an upper back panel 86 , respective other ends that are fixed to suspension damper housings 88 , and respective centers that are fixed to the battery tray 52 .
[0052] As shown in FIG. 9 , the stiffener bracket 84 is of a straight shape, one end of which is fixed to the left upper bracket 82 a , and another end of which is fixed to the right upper bracket 82 b . The stiffener bracket 84 increases the stiffness of a linkage that is provided between the suspension damper housings 88 , thereby preventing the battery box 16 from wobbling.
[0053] The battery box 16 can be installed from below the main frame 70 . To permit the battery box 16 to be installed in this manner, the main frame 70 has an opening 89 defined in a bottom surface thereof for allowing the battery box 16 to pass therethrough. A lower cover, not shown, is disposed below the battery box 16 in order to protect the battery box 16 , etc., from mud and water splashing up from the road.
[0054] The left upper bracket 82 a , the right upper bracket 82 b , and the stiffener bracket 84 are illustrated only in FIG. 9 , and have been omitted from illustration in the other figures.
(1-3-1-2. Motor Controller 40 )
(1-3-1-2-1. Overview of Motor Controller 40 )
[0055] The motor controller 40 serves to control electric power that is exchanged between the motor 12 and the battery box 16 , and includes an inverter 90 (see FIG. 5 ) and a non-illustrated electronic control unit. An electric power cable (a so-called three-phase cable) is connected between the motor 12 and the motor controller 40 .
(1-3-1-2-2. Layout of Motor Controller 40 )
[0056] As shown in FIGS. 2 and 4 , etc., the motor controller 40 (inverter 90 ) is fixed to a left side of the second battery cover 56 behind the second battery cover 56 . The motor controller 40 (inverter 90 ) is combined integrally with the battery box 16 (see FIG. 4 , etc.). The motor controller 40 is fixed to the second battery cover 56 by non-illustrated bolts or the like, for example. As shown in FIG. 4 , etc., the motor controller 40 (inverter 90 ) is disposed in the same space as the motor 12 and the battery box 16 .
(1-3-1-3. Battery Controller 42 )
(1-3-1-3-1. Overview of Battery Controller 42 )
[0057] The battery controller 42 serves to control electric power that is exchanged between the battery box 16 and a non-illustrated external power supply. The battery controller 42 includes a charger and an electronic control unit, neither of which are shown.
(1-3-1-3-2. Layout of Battery Controller 42 )
[0058] As shown in FIGS. 2 and 4 , etc., the battery controller 42 is fixed to a right side of the second battery cover 56 behind the second battery cover 56 . The battery controller 42 is constructed integrally with the battery box 16 , and is disposed adjacent to the motor controller 40 (see FIG. 4 , etc.). The battery controller 42 is fixed to the second battery cover 56 by non-illustrated bolts or the like, for example. As shown in FIG. 4 , etc., the battery controller 42 is disposed in the same space as the motor 12 , the battery box 16 , and the motor controller 40 (inverter 90 ).
2. Advantages of the Present Embodiment
[0059] In the foregoing manner, according to the present embodiment, as described above, the lower end E 1 of the battery box 16 (battery unit or cell cluster) is disposed below the hip point P 1 , thereby making the center of gravity of the vehicle 10 lower compared with the lower end E 1 of the battery box 16 , which is disposed above the hip point P 1 . Consequently, it is possible to position the center of gravity of the vehicle 10 close to the hip point P 1 . Hence, the occupant of the vehicle 10 is given a feeling of oneness with the vehicle 10 and a nimble sense of maneuverability when driving the vehicle 10 . Further, assuming that the hip point P 1 can be lowered, the height of the vehicle 10 can also be lowered, resulting in a reduction in air resistance and thereby minimizing electric power consumption.
[0060] According to the present embodiment, in addition, the rear partition 72 includes the slanted portion 76 , which is inclined progressively rearward in an upward direction, and the battery box 16 is disposed along the slanted portion 76 . Therefore, it is possible to locate the battery box 16 close to the driver seat 20 and the front passenger seat 22 (occupant seats) in the longitudinal direction of the vehicle 10 . In addition, the motor mounts 30 a , 30 b are disposed such that an upper portion of the battery box 16 and the motor mounts 30 a , 30 b overlap each other in the vertical direction of the vehicle 10 as viewed transversely across the vehicle 10 (more specifically, the upper portion of the battery box 16 and a portion of the motor mounts 30 a , 30 b overlap each other as viewed in plan). Therefore, it is possible to position the motor mounts 30 a , 30 b as well as the motor 12 that is supported thereon close to the driver seat 20 and the front passenger seat 22 (occupant seat) along the longitudinal direction of the vehicle 10 . Stated otherwise, the amount of dead space behind the rear partition 72 can be reduced. Consequently, the vehicle 10 can be made compact, or the space in the passenger compartment 74 can be increased by the reduced dead space, thereby enhancing occupant comfort.
[0061] According to the present embodiment, the battery box 16 is disposed outside of the passenger compartment 74 , and includes a portion that is fixed to the rear partition 72 (see FIGS. 4 , 9 , etc.). In this manner, it is possible to increase the rigidity of the rear partition 72 (as well as the vehicle body) by taking advantage of the rigidity of the battery box 16 itself.
[0062] According to the present embodiment, the battery box 16 supplies electric power to the motor 12 , and the motor 12 , the battery box 16 , and the inverter 90 are disposed in the same space (see FIG. 4 , etc.). Normally, the motor 12 , the battery box 16 , and the inverter 90 are high-voltage devices, respectively. By disposing such high-voltage devices close to each other, electric power efficiency can be increased.
[0063] According to the present embodiment, the inverter 90 is disposed behind the battery box 16 and above the motor 12 (see FIGS. 2 , 4 , etc.). When disposed in this manner, the motor 12 , the battery box 16 , and the inverter 90 are housed in a compact fashion.
[0064] According to the present embodiment, the battery box 16 is constructed integrally with the motor controller 40 (inverter 90 ) (see FIG. 4 , etc.). In accordance with this feature, it is possible to dispense with electric power cables that interconnect the battery box 16 and the inverter 90 .
[0065] According to the present embodiment, the second battery cover 56 is installed in a direction that is the same as the direction in which the motor controller 40 (inverter 90 ) is installed (see FIG. 4 , etc.). In accordance with this feature, the process of installing the inverter 90 and operations to connect electric wires (not shown) thereto can be facilitated.
B. Modifications
[0066] The present invention is not limited to the above embodiment, but may employ various arrangements on the basis of the disclosure of the present description. For example, the following arrangements may be employed in the present invention.
[0000] 1. Electric Vehicle 10 (Object to which the Present Invention is Applied)
[0067] In the above embodiment, the vehicle 10 is a two-seater type of vehicle. However, the vehicle 10 may be of any type (as to the number of seats), insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a through 30 c ) and the battery box 16 , or the positional relationship between the rear partition 72 and the battery box 16 . For example, the vehicle 10 may be a one-seater, a three-seater, or a four-seater type of vehicle or the like. Stated otherwise, the number of seats on the vehicle 10 may be one or three or more.
[0068] In the above embodiment, the battery box 16 (battery unit) is mounted on the electric vehicle 10 , which is a battery car in a narrow sense. However, from the standpoint of the layout of the motor 12 and the battery box 16 , the present invention is applicable to other uses. For example, the present invention may be applied to other types of electric vehicles 10 (e.g., a hybrid vehicle having a non-illustrated engine as a drive source in addition to the motor 12 , or a fuel cell vehicle).
2. Motor 12
[0069] In the above embodiment, the motor 12 comprises a three-phase AC brushless motor. However, the motor 12 is not limited to such a motor. Although the motor 12 is a brushless motor in the above-described embodiment, the motor 12 may be a brush motor.
[0070] In the above embodiment, the motor 12 is used to drive the rear wheels 24 r . However, the motor 12 may be used to drive front wheels 24 f , insofar as the battery box 16 (battery unit) can be inclined and the motor mounts 30 a through 30 c can be placed in a space below the inclined battery box 16 . From the same standpoint, the motor 12 need not necessarily be a motor that is used to drive wheels, but may be a motor for use in any of other devices (e.g., an air compressor or an air conditioner that is mounted in the vehicle 10 ). Alternatively, the motor 12 may be a motor that is used in various apparatus such as industrial machines (e.g., manufacturing apparatus, machine tools, or elevators), home electric appliances (e.g., washing machines, cleaners, air conditioners, or refrigerators), or the like.
3. Motor Mounts 30
[0071] In the above embodiment, the motor 12 is supported on three motor mounts 30 a through 30 c . However, insofar as the motor 12 can be supported, the number of motor mounts 30 is not limited to three.
[0072] In the above embodiment, the front motor mounts 30 a , 30 b and an upper portion of the battery box 16 overlap each other as viewed in plan (see FIGS. 1 , 2 , 7 , etc.). However, from the standpoint of effectively utilizing the space below the slanted portion 76 of the rear partition 72 and around the lower portion of the battery box 16 , the front motor mounts 30 a , 30 b and the upper portion of the battery box 16 need not necessarily be superposed, insofar as the motor mounts 30 a , 30 b can be disposed such that the upper portion of the battery box 16 (battery unit) and the motor mounts 30 a , 30 b overlap each other in the vertical direction (the direction of arrows Z 1 and Z 2 ) of the vehicle 10 , as viewed transversely (in the direction of arrows Y 1 and Y 2 ) across the vehicle 10 . Stated otherwise, the front motor mounts 30 a , 30 b may be positioned laterally of the battery box 16 (along a transverse direction across the vehicle 10 ) as viewed in plan.
4. Electric Power System 14
[4-1. Battery Box 16 (Battery Unit, Cell Cluster)]
[0073] In the above embodiment, the battery box 16 is used as a battery unit or a cell cluster. However, other battery units may be used insofar as the battery units function as an electric power supply source. For example, a fuel cell stack may be used as a battery unit. If a fuel cell stack is used, the fuel cell stack may be inclined in the same manner as with the battery box 16 .
[0074] In the above embodiment, the lower end E 1 of the battery box 16 is disposed below the hip point P 1 and the lower end E 2 of the hip of the driver 60 . However, insofar as the lower end E 1 of the battery box 16 is disposed below the hip point P 1 , the lower end E 1 of the battery box 16 may be disposed above the lower end E 2 of the hip.
[0075] In the above embodiment, the battery box 16 is disposed outwardly of the rear partition 72 (see FIGS. 1 , 4 , etc.). However, insofar as the battery box 16 (battery unit or cell cluster) is disposed along the slanted portion 76 of the rear partition 72 , the battery box 16 may be disposed inwardly of a rear partition 72 a , as shown in FIG. 10 .
[0076] In the above embodiment, the battery box 16 includes the battery modules 50 , which are disposed on both sides (front and rear sides, in terms of the orientation of the vehicle 10 ) of a principal plane of the battery tray 52 (see FIG. 8 , etc.). However, the battery modules 50 are not limited to such a layout, insofar as the battery box 16 or the battery modules 50 can be disposed along the slanted portion 76 of the rear partition 72 .
[0077] FIG. 11 is an enlarged fragmentary side elevational view showing a battery box 16 a according to a first modification of the battery box 16 (battery unit or cell cluster) of the above-described embodiment. The battery box 16 a comprises a plurality of battery modules 50 , which are inclined and stacked in a plurality of layers. The battery box 16 a is disposed along the rear partition 72 , thereby making it possible to reduce the amount of dead space behind the rear partition 72 .
[0078] In the above embodiment and the modification shown in FIG. 11 , the battery box 16 , which is basically in the shape of a rectangular parallelepiped, is inclined (see FIG. 1 , etc.). However, the battery box 16 is not limited to such an inclined layout, insofar as the battery unit can be disposed along the slanted portion 76 of the rear partition 72 . For example, the battery modules 50 may be stacked in a plurality of layers, with the front ends of the battery modules shifted more rearwardly in higher layers.
[0079] FIG. 12 is an enlarged fragmentary side elevational view showing a battery cluster 130 according to a second modification of the battery box 16 (battery unit or cell cluster) of the above-described embodiment. The battery cluster 130 comprises a plurality of battery modules 50 disposed in a stepped pattern. The battery cluster 130 is disposed along the rear partition 72 , thereby making it possible to reduce the amount of dead space behind the rear partition 72 .
[0080] In FIG. 12 , each of the battery modules 50 is shifted in a stepped pattern. However, only a portion of the battery modules 50 may be shifted in this manner. For example, two lower battery modules 50 in FIG. 12 may be kept in the same position along the longitudinal direction (the direction of arrows X 1 and X 2 ).
[0081] In the above embodiment, the battery box 16 is supported at upper and side regions thereof. More specifically, the battery box 16 is supported by the left side bracket 80 a , the right side bracket 80 b , the left upper bracket 82 a , the right upper bracket 82 b , and the stiffener bracket 84 (see FIGS. 4 , 9 , etc.). However, insofar as the battery box 16 can be supported in place, the present invention is not limited to such a supporting structure. For example, the battery box 16 may be supported only at an upper region or on side regions thereof. Alternatively, in addition to or in place of the regions referred to above, the battery box 16 may be supported at other regions (e.g., a lower region) thereof.
[0082] In the above embodiment, the battery box 16 supplies electric power to the motor 12 . However, insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a , 30 b ) and the battery box 16 , in addition to the motor 12 , the battery box 16 may be used to supply electric power to other components apart from the motor 12 . Alternatively, the battery box 16 may be configured so as not to supply electric power to the motor 12 , but only to supply electric power to other components apart from the motor 12 .
[0000] [4-2. Motor Controller 40 and Battery Controller 42 ] In the above embodiment, the motor controller 40 including the inverter 90 and the battery controller 42 are disposed on an outer side of the second battery cover 56 . However, concerning the layout of the battery box 16 , the motor controller 40 and the battery controller 42 are not limited to the above layout. For example, as shown in FIG. 11 , the battery controller 42 (and the motor controller 40 ) may be disposed above the battery box 16 a.
[0083] In the above embodiment, the inverter 90 is disposed behind the battery box 16 and above the motor 12 (see FIGS. 2 , 4 , etc.). However, insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a , 30 b ) and the battery box 16 , the inverter 90 need not necessarily be disposed in the aforementioned layout. For example, the inverter 90 may be disposed above the battery box 16 a.
[0084] In the above embodiment, the motor controller 40 (inverter 90 ) is constructed integrally with the battery box 16 (battery unit), without any cables being interposed between the motor controller 40 and the battery box 16 . However, insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a , 30 b ) and the battery box 16 , cables may be provided if desired. Similarly, in the above embodiment, the battery controller 42 is constructed integrally with the battery box 16 (battery unit), without any cables being interposed between the battery controller 42 and the battery box 16 . However, cables may be provided if desired.
[0085] In the above embodiment, the motor 12 , the battery box 16 (battery unit), the motor controller 40 (inverter 90 ), and the battery controller 42 are disposed in the same space (see FIG. 4 , etc.). However, such a layout is not necessarily required, insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a , 30 b ) and the battery box 16 . For example, the motor controller 40 (inverter 90 ) and the battery controller 42 may be disposed in a space that differs from the space in which the motor 12 and the battery box 16 (battery unit) are installed.
[0086] In the above embodiment, the second battery cover 56 is installed in a direction that is the same as the direction in which the motor controller 40 (inverter 90 ) and the battery controller 42 are installed. However, such an arrangement is not necessarily required, insofar as attention is focused on the positional relationship between the motor 12 (motor mounts 30 a , 30 b ) and the battery box 16 .
5. Other Features
[0087] In the above embodiment, the battery box 16 is disposed along the slanted portion 76 of the rear partition 72 , and the motor mounts 30 a , 30 b are disposed in the space behind the battery box 16 . In addition, the motor 12 for driving the rear wheels 24 r is supported on the motor mounts 30 a through 30 c . However, insofar as the battery box 16 (battery unit) is inclined, and any one of the motor mounts 30 a through 30 c is disposed in a space beneath the battery box 16 , the same layout may be employed on the front side of the vehicle 10 .
[0088] In the above embodiment, the rear partition 72 serves as part of the main frame 70 . However, the rear partition 72 may be provided separately from the main frame 70 , insofar as the rear partition 72 can function as a partition that defines the passenger compartment 74 . | An electric vehicle wherein at least part of a cell unit is provided along an inclined part of a rear dividing wall. A bottom end of the cell unit is positioned lower than the hip point of a passenger. As seen from the vehicle-width direction, motor mounts are positioned so that the top part of the cell unit and part of the motor mounts overlap in the vertical direction of the electric vehicle. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly-assigned copending U.S. patent application Ser. No. ______ (Attorney Docket No. 96470/NAB), filed herewith, entitled METHOD OF PREVENTING DAMAGE TO A PHOTOCONDUCTOR, by Pitas et al.; the disclosure of which is incorporated herein.
FIELD OF THE INVENTION
[0002] The present invention relates to electrophotography in general, and in particular to a replacement cartridge for an electrophotographic printer.
BACKGROUND OF THE INVENTION
[0003] Electrophotographic equipment utilizes sensitive components that must be routinely serviced by either dedicated service personnel or by the end user. Many of these components are easily damaged unless care is exercised during replacement. In some instances, it is considered imprudent to depend upon an individual exercising care as a step in carrying out critical operation. This is especially important when the risk of error is high, and the cost and machine down-time associated with error is great.
[0004] A primary component requiring frequent replacement within an electrophotographic print engine is the photoreceptive member. The function of the photoconductor is to provide a means of developing an image and transferring that image to paper. The photoreceptive member is coated with photosensitive material which is essential to operation of electrographic printers. The photosensitive material is easily scratched and can be damaged by exposure to ambient light if handled imprudently. This type of damage creates unacceptable image quality defects in the transferred image.
[0005] In close proximity to the receptive member are many components that support the imaging of the photoconductor. These components can scratch or abrade the photoreceptive member during replacement. There is a need to eliminate the potential for damage to the photoreceptive member.
SUMMARY OF THE INVENTION
[0006] Briefly, according to one aspect of the present invention an in situ replacement cartridge for an electrophotographic printer includes a rigid, cylindrical photoreceptive member; a housing for retaining and attaching the photoreceptive member to the printer; and a removable shield surrounding the photoreceptive member.
[0007] The invention and its objects and advantages will become more apparent in the detailed description of the preferred embodiment presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an cross-section of a replacement cartridge according to the present invention.
[0009] FIG. 2 is a cross-section of a replacement cartridge in an electrophotographic printer.
[0010] FIG. 3 is a perspective view of the replacement cartridge shown in FIG. 2
DETAILED DESCRIPTION OF THE INVENTION
[0011] An electrophotographic printer includes all components necessary to accomplish the task of printing an image on paper. A printer is comprised of various subassemblies which perform specific functions.
[0012] An imaging module in the printer consists of components to enable printing of a single color image. Multiple modules may be assembled to enable the printing of multiple color images. FIG. 1 shows details of a typical printing module 31 , which may be assembled with other imaging modules to enable printing multiple colors.
[0013] Primary charging subsystem 210 uniformly electrostatically charges photoreceptor 206 of photoreceptive member 111 , shown in the form of an imaging cylinder. Charging subsystem 210 may include a grid 213 having a selected voltage, or may be in the form of a roller with conductive properties.
[0014] Additional necessary components provided for control may be assembled around the various process elements of the respective printing modules. Meter 211 measures the uniform electrostatic charge provided by charging subsystem 210 , and meter 212 measures the post-exposure surface potential within a patch area of a latent image formed from time to time in a non-image area on photoreceptive member 206 .
[0015] Image writer 220 is used to expose photoreceptive member 206 and may be a light emitting diode (LED) array or other similar mechanisms or laser. Toning unit 225 , comprising elements 226 and 227 is used to develop the latent image created by image writer 220 on photoreceptive member 206 . Cleaning unit 230 removes residual toner from photoreceptive member 206 after transfer of the image to secondary receiver (not shown). Other meters and components may be included.
[0016] Within the imaging module 31 , periodic replacement of critical components is necessary to ensure proper function. It may be desired to cluster multiple components to enable simultaneous replacement.
[0017] Referring to FIG. 2 , shown here with a change in form, for the present invention a replacement cartridge 200 within imaging module 31 is created consisting of a photoreceptive member 206 , cleaning unit 230 , and charger 210 . These components are assembled into a cartridge and held in place with a plastic housing 233 . Further, protective guards 231 a and 231 b are applied to the module, which serve to prevent damage to the photoreceptive member 206 . The replacement cartridge slides into the electrophotographic printer with guides 232 a and 232 b. Guides 232 a and 232 b are attached to the printer and help mount and align the replacement cartridge in the proper position.
[0018] Because of the proximity of subsystems that interface with module 31 and with replacement cartridge 200 , it is necessary to have large areas of the photoreceptive member open during use. During insertion into the print engine, these open, unprotected areas could be damaged either mechanically or by light exposure. Therefore it is necessary to protect the photoreceptive member 206 from damage, either from extraneous light, fingerprints, or mechanical scrapes. The protective guards 231 a and 231 b, also referred to as a removable shield, slide in place in grooves within the replacement cartridge housing. These removable shields 231 a and 231 b stay in place when the cartridge is installed in the printer, and are removed by sliding out of the housing to the front of the equipment after the replacement cartridge 200 is in place in the printer.
[0019] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention.
PARTS LIST
[0000]
31 module
111 photoreceptive member
200 replacement cartridge
206 photoreceptive member
210 subsystem
211 meter
212 meter
213 grid
220 image writer
225 toning unit
226 element
227 element
230 cleaning unit
231 a protective guards (removable shield)
231 b protective guards (removable shield)
232 a guide
232 b guide
233 plastic housing | An in situ replacement cartridge ( 200 ) for an electrophotographic printer includes a rigid, cylindrical photoreceptive member ( 206 ); a housing ( 233 ) for retaining and attaching the photoreceptive member to the printer; and a removable shield ( 231 a, 231 b ) surrounding the photoreceptive member. | 6 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates generally to attaching articles to the roof of a structure, and more particularly to a height adjustable mount for attaching articles to the roof of a structure.
[0003] 2. Background of the Invention
[0004] There are many situations in which it is necessary or desirable to attach articles to the roof of a structure. These articles may be photovoltaic (a.k.a. solar) panels, photothermal panels, heating equipment, air conditioners, satellite dishes, and so on. Attachment is commonly accomplished by the use of one or more mounts which attach to the roof, and either provide mounting hardware for the article(s) or accept mounting hardware for the article(s). These mounts are usually designed so as to minimize leakage of water or other elements through the roof.
[0005] One issue encountered when mounting an article or articles on a roof is alignment. Most roofs or other structures are not truly flat or straight, whether by design or by imperfections, warping, or simple wear and tear. It is frequently desirable to attach articles to a roof such that they lay flat, and the unevenness common to roofs makes this challenging. Most mounts do not easily adjust the height between the article and the roof and thus do not solve this problem. Additionally, it may be desirable to mount articles at different heights even if the roof is flat or straight. Most mounts do not allow the article(s) to be mounted at various heights as may be advantageous for a specific installation of articles.
[0006] Another issue encountered when mounting an article or articles on a roof is the need to use a standard rack in addition to whatever mounts have been chosen for the particular installation. That is to say that usually when one installs articles on a roof the articles themselves must be installed in a rack/frame and this rack/frame is then attached to the roof via the mounts.
[0007] It is thus a first object of the present application to provide a height adjustable mount for attaching an article or articles to a roof structure.
[0008] It is a further object of the present application to provide a mount which provides a plurality of discrete heights between the roof and the article.
[0009] It is a further object of the present application to provide a mount which provides easy and repeatable selection of a specific height between the roof and the article.
[0010] It is a further object of the present application to provide a mount which includes built in cable guides.
[0011] It is a further object of the present application to provide a mount which does not require the use of a standard rack but instead employs the edge of the article as the structural element that is attached to the mount.
[0012] It is a further object of the present application to provide a mount that allows simple and easy height adjustment such that an installation of an article or articles may be quickly and easily adjusted/aligned for ascetics.
[0013] It is a final object of the present application to provide a mount for attaching an article or articles to a roof structure, which minimizes potential leakage through the roof.
[0014] These and other objectives, advantages, features, and aspects of the present invention will become apparent as the following description proceeds. To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter more fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but several of the various ways in which the principles of the invention may be employed.
SUMMARY OF THE INVENTION
[0015] The present application presents a height adjustable mount for attaching an article to a roof. This mount improves upon existing mounts by allowing a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article to be mounted. The heights may be independently selected, thereby allowing adjustability to compensate for the uneven nature of many roofs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing aspects and many of the attendant advantages of the invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the attached charts and figures, wherein:
[0017] FIG. 1 is a perspective view of a preferred embodiment of the mount;
[0018] FIG. 2 is a side view of a preferred embodiment of the mount;
[0019] FIG. 3 is a perspective view of the top portion of a preferred embodiment of the mount;
[0020] FIG. 4 is a side view of the top portion of a preferred embodiment of the mount;
[0021] FIG. 5 is a side view of the top portion of a preferred embodiment of the mount;
[0022] FIG. 6 is a perspective view of a preferred embodiment of the base of the mount;
[0023] FIG. 7 is a top view of a preferred embodiment of the base of the mount;
[0024] FIG. 8 is a side view of a preferred embodiment of the base of the mount along cut-line A-A of FIG. 7 ;
[0025] FIG. 9 is a series of side views of the mount;
[0026] FIG. 10 is a perspective view of an alternative embodiment of the base of the mount;
[0027] FIG. 11 is a top view of an alternative embodiment of the base of the mount;
[0028] FIG. 12 is a side view of an alternative embodiment of the base of the mount along cut-line A-A of FIG. 11 ;
[0029] FIG. 13 is a side view of a preferred embodiment of the mount including an embodiment of article attachment hardware;
[0030] FIG. 14 is a side view of a preferred embodiment of the mount including an embodiment of article attachment hardware;
[0031] FIG. 15 is an exploded side view of a preferred embodiment of the mount including an embodiment of article attachment hardware;
[0032] FIG. 16 is a perspective view of an alternative embodiment of the base;
[0033] FIG. 17 is a side view of the alternative embodiment of the base shown in FIG. 16 ;
[0034] FIG. 17 b is a side view of the alternative embodiment of the base shown in FIG. 16 ;
[0035] wherein the alternative embodiment is attached to a post in partial view;
[0036] FIG. 17 c is a side view of the alternative embodiment of the base shown in FIG. 16 ; wherein the alternative embodiment is attached to a post;
[0037] FIG. 18 is a perspective view of an alternative embodiment of the base;
[0038] FIG. 19 is a perspective view of an alternative embodiment of the base;
[0039] FIG. 20 is a perspective view of an alternative embodiment of the mount shown attached to a tile roof and holding an article;
[0040] FIG. 21 is a perspective view of a preferred embodiment of the mount shown attached to a shingled roof and holding an article;
[0041] FIG. 22 is a perspective view of a plurality of a preferred embodiment of the mount shown attached to a shingled roof and holding two articles;
[0042] FIG. 23 is a perspective view of an alternative embodiment of the mount;
[0043] FIG. 24 is a side view of an alternative embodiment of the mount;
[0044] FIG. 25 is a top view of an alternative embodiment of the mount;
[0045] FIG. 26 is a perspective view of an alternative embodiment of the mount which includes an integrated cable guide;
[0046] FIG. 27 is a top view of an alternative embodiment of the mount which includes an integrated cable guide;
[0047] FIG. 28 is a side view of an alternative embodiment of the mount which includes an integrated cable guide;
[0048] FIG. 29 is a side view of an alternative embodiment of the mount which includes an integrated cable guide;
[0049] FIG. 30 is a perspective view of an alternative embodiment of the mount;
[0050] FIG. 31 is a perspective view of an alternative embodiment of the base;
[0051] FIG. 32 is a top view of the alternative embodiment of the base first shown in FIG. 31 ;
[0052] FIG. 33 is a side view of the alternative embodiment of the base first shown in FIG. 31 ;
[0053] FIG. 34 is a side view of the alternative embodiment of the base first shown in FIG. 31 ;
[0054] FIG. 35 is a side view of an alternative embodiment of the base;
[0055] FIG. 36 is a perspective side view of the alternative embodiment of the base first shown in FIG. 35 ;
[0056] FIG. 37 is a side view of the alternative embodiment of the base first shown in FIG. 35 ; and
[0057] FIG. 38 is a perspective view of the alternative embodiment of the base first shown in FIG. 35 .
DETAILED DESCRIPTION OF THE INVENTION
[0058] The following description is presented to enable a person of ordinary skill in the art to make and use various aspects and examples of the present invention. Descriptions of specific materials, techniques, and applications are provided only as examples. Various modifications to the examples described herein will be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the examples described and shown, but is to be accorded the scope consistent with the appended claims.
[0059] The present application presents a height adjustable mount for attaching an article to a roof. This mount allows a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article mounted thereto.
[0060] Turning first to FIG. 1 , a perspective view of a preferred embodiment is shown. The preferred embodiment mount 1 comprises a base 100 and a top portion 200 , which interlock at a plurality of discrete heights. In a preferred embodiment the top portion 200 is between six and eleven inches long, however, in alternative embodiments the top portion may longer than eleven inches or shorter than six inches. As will be clear from the following figures and description, the top portion slides over the base via interlocking components, preferably protrusions and/or recesses. After the top portion has been slidingly interlocked with the base as shown in FIG. 1 , the top portion may be secured in place by use of a bolt (not shown) placed through bolt hole 201 . In a preferred embodiment bolt hole 201 is a clearance hole on one side and a ¼×20 tap on the other. In alternative embodiments the bolt hole may be clearance on both sides, or may take any suitable form known in the art which will accept a bolt or other fastening member. The upstanding member 101 of the base has a corresponding blot slot 103 (see briefly, FIG. 6 ) to allow the bolt to secure the base and the top portion together. In an alternative embodiment a wire guide may also be attached to the mount via the bolt and bolt hole, such an embodiment is shown in FIGS. 26-29 . For the purposes of this application, the upstanding member is generally planer in shape and in a preferred embodiment projects substantially vertically from the base, substantially vertically meaning for the purposes of this application with fifteen degrees of vertical. In alternative embodiments the upstanding member need not project substantially vertically, but may instead project at other angles. For the purposes of this application generally planer is taken to mean that the object in question is substantially longer and/or wider than it is thick.
[0061] Returning to FIG. 1 , in most embodiments, base 100 comprises an attachment portion 120 . In a preferred embodiment the attachment is a roof attachment portion 120 as shown, and which is configured to attach to a roof with one or more fasteners. In other embodiments the attachment may be accomplished by other structures. Also shown in FIG. 1 is cover 121 , which in a preferred embodiment slides over the roof attachment portion 120 of the base 100 . In other embodiments, the cover may take any form known in the art such as but not limited to plugs. In yet other embodiment no cover is present at all. In the preferred embodiment the base attached to a roof with a flashing 600 (not shown in FIG. 1 ).
[0062] In a preferred embodiment the base and the top portion are made of a metal, and more particularly aluminum. In other embodiments the base and top portion may be made of any suitable material known in the art including but not limited to metal, plastic, ceramic, and composite. The base and top may be made of different materials.
[0063] Turning now to FIG. 2 , a side view of a preferred embodiment is shown. As may be seen clearly in this view, the upstanding portion 101 comprises a plurality of height adjustment protrusions 102 and/or height adjustment recesses (not labeled). In a preferred embodiment these height adjustment protrusions and/or recesses are of a regular ridge and recess form as shown in FIG. 2 . In alternative embodiments the height adjustment protrusions/recesses may take any form known in the art, provided it allows the base and top portion to interlock at one of a plurality of heights.
[0064] In a preferred embodiment, the top portion comprises a vertical channel 202 , each side of which comprises height adjustment protrusions and/or recesses 203 configured to interlock with the height adjustment protrusions and/or recesses 102 of the upstanding member 101 at a plurality of discrete positions achieving varying heights between the base and the top portion, and thereby varying heights between the roof and the article. It is noted, and will be further illustrated below, that the top portion may interlock in two orientations with the base. In other words the upstanding member 101 can flip-flop and attach either direction. Note that the upstanding member may be thought of as a base height adjustable interlocking means.
[0065] It is important to note that in the preferred embodiment the recesses may be conceptualized as the space between the protrusions. In an alternative embodiment the protrusions may be thought of as the portions of material between the recesses. The terminology is effectively interchangeable, but one terminology may be preferable over the other depending upon the manufacturing process employed to create the base and top portion.
[0066] In a preferred embodiment, in order to allow the top portion to slide and interlock with the upstanding member in either of two orientations the height adjustment protrusions/recesses disposed on the upstanding member are configured such that each protrusion on one side of the upstanding member is vertically aligned with a recess on the opposite side of the upstanding member, and visa-versa.
[0067] At the upper end of top potion 200 is a receiver track 204 for receiving an inverted bolt and thereby the article attachment hardware. In a preferred embodiment the receiver track 204 is sized to receive a 5/16 inch inverted bolt, however, it should be readily understood that the receiver track may be sized to receive a different size bolt, or may be replaced entirely with any structure known in the art and which is capable of receiving article attachment hardware, or of directly mounting an article. Also at the upper end of top portion 200 is a screw race 205 configured to accept accessories such as but not limited to a ground clip or a cap.
[0068] Turning to FIGS. 3 , 4 , and 5 , a perspective view, and two side views of the top portion 200 of a preferred embodiment is shown. In this preferred embodiment the upper end of top portion 200 comprises friction ridges 206 running longitudinally on top of the receiver track 204 shown best in FIG. 2 . These friction ridges 206 aid in securing an article to the top portion. In alternative embodiments these friction ridges may take any form known in the art such as ridges running perpendicular to those shown in the FIG. 3 , surface texture, or may be omitted entirely.
[0069] Turning to FIGS. 6 , 7 , and 8 , a perspective view, and two side views of the base of a preferred embodiment is shown. It is noted that FIG. 8 shows a side view along cut line A-A in FIG. 7 . The base comprises bolt slot 103 , which corresponds to bolt hole 201 in the top portion. As may be seen the bolt slot 103 extends vertically through most of the upstanding member 101 and allows the top portion and the base to be secured together at one of a plurality of heights after the top portion is slid over and interlocked with the upstanding member at one of a plurality of discrete positions. In this preferred embodiment the attachment portion 120 comprises two roof attachment holes 122 , which in this preferred embodiment are dimensioned to be coupled with a flashing (not shown) and to then accept one screw driven into the roof (one screw per hole). These screws anchor the base to the roof, and the flashing ensures that water doesn't leak through the roof. After the base is anchored to the roof, the cover 121 (see FIG. 1 ) is slid over the attachment portion 120 to further prevent water from leaking through the roof. In alternative embodiments there may be only a single roof attachment hole 122 , or the roof attachment holes may be replaced with any structure known in the art which would serve to anchor the base to the roof. Similarly, the screws may be replaced with any fastener known in the art such as but not limited to bolts.
[0070] Turning to FIG. 9 , a series of side views of the mount are shown. These side views illustrate how the top portion 200 and the base 100 (not labeled in this Fig.) may be slid together and interlocked at a plurality of discrete heights. Note that the top portion may be slid together and interlocked with the base in one of two orientations, and each of the two orientations allows for different discrete heights to be achieved. In all embodiments the top portion and the base may be slid together and interlocked at a minimum height, at a maximum height, and at a plurality of discrete heights between the minimum and maximum height. In all embodiments the maximum height is less than twice the minimum height. In all embodiments the maximum height is technically achieved when the top portion is interlocking with one of the upstanding member's protrusions, however, due to stability concerns the preferred minimum number of upstanding member protrusions interlocked is 3, as shown in Position 6.0.
[0071] Another way to conceptualize the various heights between the roof and the top of the receiving track sets a minimum height as H=1 unit height. The mount may then be configured at any of a plurality of discrete heights H n where 1≦H n <2. Here, and in practice, the number of discrete configurations has no upper limit.
[0072] Turning to FIGS. 10 , 11 , and 12 , a perspective view, and two side views of the base of an alternative embodiment is shown. Note that FIG. 12 shows a side view along cut-line A-A of FIG. 11 . As may be seen, this alternative embodiment of the base differs in that it includes a single roof attachment hole.
[0073] Turning to FIG. 13 , a side view of a preferred embodiment of the base 100 , top section 200 , and a first embodiment of article attachment hardware 300 is shown. As may be seen an inverted bolt (not labeled) has been slid into receiver track 204 (not labeled), and article attachment hardware 300 has been secured to the bolt and the top section by a nut.
[0074] Turning to FIG. 14 , a side view of a preferred embodiment of the base 100 , top section 200 , and a first embodiment of article attachment hardware 300 is shown. Article attachment hardware comprises a lower section 302 and an upper section 301 . Lower section is secured to the top portion 200 by the bolt passing through lower section 301 and a nut on the bolt. Lower section and upper section interlock at one a plurality of discrete heights by use of periodic protuberances/recesses disposed on a surface of the lower section and corresponding periodic protuberances/recesses disposed on a surface of the upper section configured to interlock with those on the lower section. These protuberances/recesses may take any form known in the art such as but not limited to a comb, dovetail design, or more creative jigsaw puzzle-type shapes. The lower and upper sections 302 and 301 may attach to each other by any other means known in the art such as but not limited to fasteners and adhesives. In alternative embodiments the upper and lower sections 302 and 301 may be replaced with a single piece article attachment hardware.
[0075] In this first embodiment article attachment hardware 300 comprises a clamping portion 303 configured to overlay and exert pressure towards the top portion 200 on an article 500 . The pressure exerted by the clamping portion 303 on the article 500 is sufficient to securely hold the article to the top portion 200 , and thereby attach the article to the mount, and thereby to the roof. This first embodiment of article attachment hardware is suitable to attach a top portion to a single article.
[0076] Turning to FIG. 15 , an exploded side view of a preferred embodiment of the base 100 , top section 200 , and a second embodiment of article attachment hardware 400 is shown. In this embodiment the article attachment hardware 400 comprises a securing piece 401 , which has a hole to slide onto the bolt, and is then secured with a nut. Fully assembled, the bolt will be slid into the receiving track as shown in FIGS. 13-14 , and the nut will be tightened urging the securing piece 401 towards the top portion 200 . This embodiment of article attachment hardware is suitable for attaching a top portion to two articles. Each side of the securing piece 401 will exert pressure on an article and thereby secure it to the top portion, and thereby to the mount and roof.
[0077] It is to be appreciated that the first and second embodiments of article attachment hardware are but two of many possible embodiments, and that the articles may be secured to the top portion by any means known in the art such as but not limited to directly bolting the articles to the top portion.
[0078] Turning to FIGS. 16 and 17 , a side view and a perspective view of an alternative embodiment of the base is shown. This embodiment allows the base to be mounted onto the top of a post while adding little height to the overall mounting system. FIGS. 17 b and 17 c expand on this embodiment by showing depicting said attachment to a post (not labeled).
[0079] Turning to FIG. 18 , a perspective view of an alternative embodiment of the base 100 is shown. In this embodiment the roof attachment portion has been removed and instead the base includes a simple bolt slot through which any appropriate fastener (such as but not limited to screws and bolts) may be driven to attach the base to a roof.
[0080] Turning to FIG. 19 , a perspective view of an alternative embodiment of the base is shown. In this embodiment the upstanding member has been incorporated onto a roof mounting hook which is commonly used worldwide. The upstanding member may be attached to nearly any standard mount or hook to allow for height adjustable mounting of an article(s).
[0081] Turning to FIG. 20 , a perspective view of an alternative embodiment of the mount is shown attached to a tile roof and holding an article. In this embodiment the upstanding member is attached to a base configured to slide up and under a roof tile. As may be seen in this figure, each base/top portion pair has been slid together and interlocked at a different height so as to account for roof unevenness. Note that while only single article is shown for clarity, the article attachment hardware as shown is configured to hold two articles, one as shown, and one extending towards the bottom of the figure.
[0082] Turning to FIG. 21 , a perspective view of a preferred embodiment of the mount is shown attached to a shingled roof and holding an article. In this embodiment each base is attached to the roof with a flashing 600 intermediate the base and the roof. The flashing slides up and under the shingles on the roof and prevents leakage of water through the roof. As may be seen in this figure, each base/top portion pair has been slid together and interlocked at a different height so as to account for roof unevenness. Note that while only a single article is shown for clarity, the article attachment hardware as shown is configured to hold two articles, one as shown, and one extending towards the bottom of the figure.
[0083] Turning to FIG. 22 , a perspective view of a plurality of a preferred embodiment of the mount is shown attached to a shingled roof and holding two articles. In this embodiment each base is attached to the roof with a flashing 600 intermediate the base and the roof. The flashing slides up and under the shingles on the roof and prevents leakage of water through the roof.
[0084] One feature of the mount which is shown clearly in FIGS. 20-22 is that the article(s), in this case solar panels, are attached directly to the mount and do not require a standard rack. The mount simply attaches directly to the edge of the article(s), and that edge acts as the structural member. This feature of the mount saves time and money when installing an article or articles on a roof as a standard rack need not be purchased or installed.
[0085] Turning to FIGS. 23-25 , a perspective view, a top view, and a side view of an alternative embodiment of the mount is shown. This embodiment differs from the above-disclosed embodiments in that the upstanding member has height adjustment protrusions and/or height adjustment recesses on only a single side of the upstanding member. This embodiment also differs from the above-disclosed embodiments in that the top portion comprises a single vertical surface configured to slide and interlock with the upstanding portion of the base. This single surface comprises height adjustment protrusions and/or height adjustment recesses configured to interlock with those on the upstanding portion of the base. The top portion also comprises a bolt hole as disclosed above to secure the top portion to the base after they have been interlocked.
[0086] Turning to FIGS. 26-29 , a perspective view, a top view, and two side views of an additional alternative embodiment of the mount is shown. This embodiment differs from the above disclosed embodiments in that the mount further comprises a wire guide attached to the base via the bolt and bolt hole. The wire guide may comprise a conduit, channel, or other suitable structure for securing and organizing wires.
[0087] Turning to FIG. 30 a perspective view of an alternative embodiment of the mount is shown. This embodiment differs from the above-disclosed embodiments in that the two roof attachment holes have been reoriented such that the mount would attach to the rafter of a roof 90 degrees offset from the above-disclosed embodiments. This may be desirable depending upon the design of the roof the mount and the article(s) are being attached to.
[0088] Turning to FIGS. 31-34 , a perspective view, a top view, and two side views of an alternative embodiment of the base is shown. This embodiment differs from the above-disclosed embodiments in that the roof attachment holes configured to accept screws driven into a roof have been removed and replaced with a single attachment hole configured to accept a screw driven into the side of a structure. This base could be used for example if it was advantageous to attach the base to the edge of a roof.
[0089] Another embodiment similar to the embodiment shown above is depicted in FIGS. 35-38 . In this embodiment the base is replaced with an alternative base that allows for tilting adjustments to be made to the upstanding portion.
[0090] Although the invention has been shown and described with respect to certain embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of the specification. In particular, with regard to the various functions performed by the above-described components, the terms (including any reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent) even though not structurally equivalent to the disclosed component which performs the functions in the herein exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one embodiment, such feature may be combined with one or more other features of other embodiments as may be desired or advantageous for any given or particular application. | The present application presents a height adjustable mount for attaching an article to a roof. This mount improves upon existing mounts by allowing a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article to be mounted. The heights may be independently selected, thereby allowing adjustability to compensate for the uneven nature of many roofs. | 5 |
This application is the U.S. national phase under 35 U.S.C. 371 of International Application No. PCT/BR2007/000318 filed 21 Nov. 2007, which designated the U.S. and claims priority to Application No. BR P10605484-6 filed 21 Nov. 2006; the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention generally relates to the isolation of certain toxins from the venom of the spider Phoneutria nigriventer and the use of those toxins as inhibitors of the function of ionic channels. In particular, the present invention relates to the use of the spider Phoneutria nigriventer venom toxins and their isoforms as blockers of calcium channels in the central nervous and neuromuscular systems of organisms, including humans.
BACKGROUND OF THE INVENTION
Movement of calcium ions across cell membranes is a critically important event in the normal functioning of excitable tissues such as vascular smooth muscle, cardiac muscle, and the central nervous system. Influx of calcium ions through specialized channels in the cell membrane regulates the release of substances such as hormones and neurotransmitters.
Drugs that interfere with calcium influx in neurons are used in the treatment of the pain. In the treatment of hyperalgesia and alodinia it has been suggested that drugs that block calcium channels are more effective in the treatment of the pain than antagonists for individual receptors as NMDA, BK1, NK2 and CGRP. This advantage is due to the fact that calcium channel blockers do not develop tolerance as morphine does and they interfere with the release of neurotransmitters involved in nociception. With the exception of an omega-conotoxin ziconotide, disclosed in WO 9954350, and isolated from the snail Conus magnus no other drug with sufficient specificity or potent effect on the diverse forms of pain is known.
Patent document U.S. Pat. No. 6,489,298 relates to contulakin-G, analogs thereof and uses thereof in the native form or cDNA in formulations with application in pain processes associated with thrombosis, gastrointestinal disorders, analgesia, ulcers, tumors.
In WO02079236, an alpha-conotoxin peptide is used in the treatment or prevention of pain, in recovery from nerve injury, and in the treatment of painful neurological conditions. Alpha-conotoxin peptides are also described as being useful for muscle relaxation and neuromuscular blocking agents, in U.S. Pat. No. 6,268,473.
Technologies related to spider toxins are also found in the prior art. Document EP1161951 describes the toxin of spider Selenoscomia huwena , the peptide of which can be applied parenterally or topically in the treatment of pain and inhibition of calcium channel activity.
Patent document U.S. Pat. No. 5,281,693 discloses methods and compositions with the use of oligonucleotides obtained from the toxin of spider Agelenopsis aperta , for blocking Ca2 + channels, and their use in the treatment of neurological disorders.
More common is the use of morphine and derivatives thereof with wide application in the treatment of nociceptive processes and analgesia procedures. However, its efficacy is for a short period of time, requiring new doses. In view of new technologies with a large spectrum of action and duration, the possibility of developing tolerance to the medication reduces its application.
As already mentioned above, the movement of calcium ions regulates contraction of heart muscle and vascular smooth muscle in the wall of the blood vessels. Abnormal influx of calcium ions has been reported to play a role in the pathogenesis of various cardiovascular disorders (e.g. anoxic/ischemic heart disease, cardiac arrhythmias) and drugs capable of blocking the movement of calcium through calcium channels have been used for treatment of pain, cardiac arrhythmias, coronary artery diseases, cardiopathy and stroke.
The current used drugs, however, have non-specific physiological effects and varying tissues specificities that can lead to undesirable side-effects in patients. Moreover there are several known subtypes of calcium channels with varying physiological actions and no drug that specifically bocks certain of these subtypes is known.
Phα1β was more effective to inhibit pain without causing severe side effects as those observed with ω-conotoxin zicononotide. This toxin-induced antinociception caused on the animals side effects such as serpentine tail movements, body shaking and allodynia that were not observed with analgesic doses of Phα1β.
Phα1β injected intrathecally has a potent and longer antinociceptive effect on the inflammatory phase of formalin test than ω-conotoxin ziconotide. Thus the analgesic effect of Phα1β lasted for a longer period of time than that observed for ω-conotoxin ziconotide.
The spinal dose-response curves showed that Phα1β displayed lower ED 50 values for inhibiting the inflammatory phase of formalin test, than that observed with ω-conotoxin ziconotide.
In the nervous system, calcium influx into the presynaptic nerve terminal via calcium channel is a necessary prerequisite for the release of chemical neurotransmitter at synapses and thus for the proper functioning of these synapses. Lowering the extracellular calcium is routinely used by neurophysiologist to reduce or abolish synaptic transmission in isolated pieces of nervous tissue.
ω-conotoxin ziconotide and Phα1β caused inhibition of the capsaicin-induced increase of [Ca 2+ ] i , which plays an important role in neurotransmitter release, by blocking N-type calcium channels on neuronal pre-synaptic membrane.
Phα1β presented higher efficacy than ω-conotoxin ziconotide to inhibit capsaicin-induced release of glutamate from nerve ending spinal cord of rats.
Most important, the antinociceptive effects of Phα1β were observed using doses that were around 15 times lower than those associated with side-effects (DT50).
The recombinant form of Phα1β expressed in E. coli was capable to repeats the antinociceptive effects of the native toxin.
Phα1β may have a superior efficacy profile for relief of persistent pathological pain states than ω-conotoxin MVIIA.
Phα1β also showed higher efficacy than conotoxins against pain induced on the hot plate test. On this model of pain, Phα1β elevates thresholds, increasing significantly the latency period to 3, 4, 5, 6 and 24 hours after its administration In contrast, morphine only produced a significant effect that was initiated faster, but only lasted for up to 5 hours, a shorter time.
It has not been possible, however, specifically to affect synaptic transmission in vivo in the central nervous system (CNS) by manipulating the function of neuronal calcium channels. With the exception of the omega-conotoxin ziconotide isolated from the venom of the marine snail no drug with sufficient specificity or potent effects on CNS calcium channels is known. Phα 1B may have the same properties of omega-conotoxin ziconotide without having the side effects observed for omega-conotoxin ziconotide.
Abnormal influx of calcium is thought to be very important in the pathogenesis of several CNS disorders, including anoxic/ischemic (stroke) damage, epilepsy, and the neuronal death associated with chronic epilepsy. Again, the paucity of chemical agents that potently and specifically block CNS calcium channels has impeded the development of an effective drug therapy for these prevalent neurological problems.
Thus, it would be a very considerable improvement in the art if it were possible to develop chemical agents that specifically and potently block calcium channel function in the CNS. In particular it would be advancement in the art to provide a specific blocker of particular subtypes of calcium channel. Similarly it would be advancement in the art to provide a specific blocker of calcium channels in the CNS.
Such chemical composition and methods for their use are disclosed and claimed below.
OBJECTS OF THE INVENTION
The present invention is related to the isolation, identification and use of spider Phoneutria Phα 1B and other toxins contained within these venoms. In particular the present invention is related to the isolation and use as calcium channel blockers of certain toxins from spider venom.
As discussed above, calcium channels are intimately involved in pain and brain disorders. Calcium influx affects the diverse forms of pain, cerebral disorders and contraction of cardiac muscle and vascular smooth muscle. Similarly, calcium influx into nerve cells is required for the release of chemical neurotransmitter substances at synapses and, therefore, for the normal functioning of the nervous system. Calcium influx into nerve cells is also involved in mediating certain electrical responses of those cells. Abnormal calcium influx into cells is associated with disturbs of nociception, cardiovascular and brain ischemia.
The present invention is related to obtaining toxins from the spider Phoneutria nigriventer that have specific and potent blocking effects on calcium channels within the organism and thus are effective in the treatment of the pain, stroke and cardiovascular arrhythmias.
Within the scope of the present invention, spider venom of Phoneutria nigriventer is obtained by electrical stimulation. The electrical stimulation of the spider cause release of the venom and suction is used to collect the released venom. This assures that impurities, which have traditionally been contained within spider venoms obtained by conventional techniques are eliminated.
Spider venoms are known to be a complex mixture of enzymes, peptide toxins, nucleotides, free amino acids, and other molecules. As a result, in order to obtain useful spider toxins it is necessary to separate the various components of the whole spider venom. According to one embodiment of the present invention, whole venoms are fractionated by gel filtration on columns of Sephadex G-50 Superfine and Superose 12HR, and reverse phase FPLC on C 2 /C 18 (PEP-RPC) and C 1 /C 8 (PRO-RPC) columns. It will be appreciated, however, that any type of fractionation technique or other technique may be useful to obtain the toxins from the spider Phoneutria nigriventer necessary for use in the present invention.
A group of specific spider Phoneutria nigriventer toxins has been isolated and used extensively in the context of the present invention.
The aggressive South American “armed” or solitary wandering spider P. nigriventer occurs in north Argentina, Uruguay, Paraguay, Central- and South East Brazil. Specimens found in Montevideo, Uruguay, and Buenos Aires, Argentina have probably been introduced by shipments of fruit. The classification is Spider (animal group), Ctenidae (family) and Phoneutria (genus).
The primary specific toxin Phα 1B which falls within the scope of the present investigation has been isolated from the venom of the spider Phoneutria nigriventer . In particular, a relative high molecular weight toxin that suppresses synaptic transmission in the vertebrate central nervous system by blocking calcium channels suppressing the pain.
Phα 1B has been identified by amino acid sequencing techniques as a 55-amino acid peptide. The toxin has the sequence described on FIG. 1 . The composition has molecular weight of 6017.
The coding sequence that produces the Phα 1B toxin was cloned by PCR, the “polymerase chain reaction” technique described by Saiki et al. (See R. K. Saiki et al., “Primer-directed enzymatic amplification of DNA with a thermostable DNA polymerase”, Science 239, 487 (January 1988).
In order to clone the coding sequence of the toxin four primers were prepared. Information about their sequence is presented in Table 1. Two overlapping oligonucleotides, S 1 and AS 1 contained most of the coding region and were used as template for the amplification. Amplification was obtained using primers S-Eco and AS-PsT. These primers are specific for the 5′ and 3′ regions of the coding region and contained recognition sites for the restriction enzymes Eco RI and PstI respectively, in order to facilitate the cloning step. Primer S-Eco also contained a sequence encoding for a recognition site for the protease Factor Xa to allow that the recombinant Phα 1B protein be cleaved from any added N-terminal tag after purification without adding any vector-derived residues to the protein.
The coding region was amplified by PCR, the product purified, digested and cloned in an appropriate vector. Restriction fragment analysis and DNA sequencing were used to confirm that the cloned product contains the complete coding sequence of Phα 1B . The sequence of the fragment to be cloned and the analysis of the translated peptide are presented in Table 2. The cloned fragment encodes a peptide identical to the mature Phα 1B , present in the venom of the Phoneutria nigriventer spider. Cloning of the coding sequence responsible for the production of Phα 1B facilitates the production of the toxin by using recombinant DNA techniques and may result in the ability to genetically engineer different organisms, such as bacteria, yeast or plants to produce the toxin.
TABLE 1
Primers used for PCR amplification (SEQ ID
NOS: 2 to 5, respectively) of the
coding sequence of the toxin Phα 1B
Name
Sequence
Size
S-Eco
5′-AAT TGA ATT CAT CGA GGG AAG GGC TTG
39
CAT CCC GCG TGG-3′
AS-Pst
5′-AAT TCT GCA GTT AAG CTT TTT TAC ATT
39
TTT CTT TTT TAC
S1
5′-CAT CCC GCG TGG TGA AAT TTG CAC CGA
80
TGA CTG TGA ATG CTG CGG CTG TGA CAA CCA
ATG TTA TTG CCC GCC GGG TTC CT-3′
AS1
5′ TTT CTT TTT TAC GGT TAC AAA AAT ATT
80
TAT TTG CAT GTG CAC ACG AGC ATT TAA AGA
TAC CCA GCG AGG AAC CCG GCG GG-3′
TABLE 2
Nucleotide sequence (SEQ ID NO: 6) of the
DNA fragment to be cloned and amino acid
sequence (SEQ ID NO: 7) of toxin Phα 1B
GCT TGC ATC CCG CGT GGT GAA ATT TGC ACC GAT GAC
TGT GAA TGC TGC GGC
ALA CYS ILE PRO ARG GLY GLU ILE CYS THR ASP ASP
CYS GLU CYS CYS GLY
TGT GAC AAC CAA TGT TAT TGC CCG CCG GGT TCC TCG
CTG GGT ATC TTT AAA
CYS ASP ASN GLN CYS TYR CYS PRO PRO GLY SER SER
LEU GLY ILE PHE LYS
TGC TCG TGT GCA CAT GCA AAT AAA TAT TTT TGT AAC
CGT AAA AAA GAA
CYS SER CYS ALA HIS ALA ASN LYS TYE PHE CYS ASN
ARG LYS LYS GLU
AAA TGT AAA AAA GCT TAA
LYS CYS LYS LYS ALA *
Analysis of the translated peptide sequence indicated a protein having a molecular weight of approximately 6,017 Daltons with 12 cysteine residues.
Phα 1B is found to block transmission in central nervous system cells by blocking calcium currents. It is particularly noteworthy that Phα 1B is not acutely toxic to the cells tested and does not affect the electrical excitability of the neurons themselves. Thus Phα 1B effects are not produced by acute cytotoxic action. Simply stated, CNS transmission is blocked without damaging the cells involved. In experiments using rats, Phα 1B reduces the pain without any side effect contrary to that observed with morphine.
It is a primary object of the present invention to provide calcium channel blockers and methods for their use which have specific and identifiable therapeutic effect on an organism without any side effect.
Another object of the present invention is to provide calcium channel blockers which affect the central nervous system.
It is another object of the present invention to provide calcium channel blockers for use as research tools and for use in the clinical setting.
It is also an object of the present invention to identify the amino acid sequence of Phα 1B toxin responsible for blocking synaptic transmission in the central nervous system.
It is a similar object of the present invention to clone a synthetic gene responsible for production of the Phα 1B toxin that blocks synaptic transmission.
Other objects of the present invention will become apparent upon reading the following detailed description and appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the peptide sequence (SEQ ID NO: 1 at the bottom and SEQ ID NO: 7 at the top) of the toxin isolated from Phoneutria nigriventer.
FIG. 2 refers to a schematic drawing representing the procedures employed in cloning a synthetic a gene responsible for production of Phα 1B .
Using the amino acid sequence data obtained as described above, a synthetic gene responsible for the production of the mature Phα 1B protein was designed (see nucleotide sequence in Table 2) and the procedures for its cloning were delineated. Both DNA strands of the gene are represented graphically in step (a), being the sense strand represented in red and the antisense strand in blue. The codons responsible for each amino acid in the synthetic gene were chosen using the E. coli codon preference, which is presented in Table 3. It is noteworthy that the possible number of sequences available to produce a 55-peptide is very large, due to the fact that some of the amino acids can be produced by up to six different codons.
TABLE 3
E. coli codon preference (adapted from Granthan et al.,
Nucleic Acids Research 9(1): 43-74 (1981))
Bacteria
all
E. coli
other
expression
(29)
(25)
(4)
high (13)
weak (16)
ARG
CGA
4
3
8
0
CGC
21
21
20
17
24
CGG
4
4
9
0
8
CGU
30
30
26
44
18
AGA
5
5
6
1
9
AGG
2
2
1
0
4
LEU
CUA
3
2
7
0
5
CUC
8
8
5
2
12
CUG
47
47
47
58
39
CUU
9
8
18
3
15
UUA
9
7
21
3
14
UUG
7
7
6
3
10
SER
UCA
8
8
9
1
13
UCC
13
13
12
16
10
UCG
9
9
5
3
14
UCU
17
17
23
28
9
AGC
9
9
13
10
9
AGU
8
7
12
1
13
THR
ACA
5
5
6
4
6
ACC
21
22
13
22
20
ACG
9
10
7
1
16
ACU
20
21
16
32
11
PRO
CCA
7
7
6
5
9
CCC
5
4
8
1
8
CCG
18
19
12
22
15
CCU
5
5
7
5
6
ALA
GCA
31
31
28
43
21
GCC
21
20
26
13
27
GCG
24
23
28
21
26
GCU
38
37
44
65
16
GLY
GGA
5
4
9
2
7
GGC
29
29
32
32
27
GGG
7
6
10
1
11
GGU
30
33
14
45
19
VAL
GUA
20
21
16
32
11
GUC
10
9
13
7
12
GUG
17
17
14
14
19
GUU
26
28
18
34
20
LYS
AAA
45
46
38
62
31
AAG
17
18
12
19
15
ASN
AAC
26
25
31
39
15
AAU
11
10
19
3
18
GLN
CAA
14
13
19
8
18
CAG
29
29
27
28
29
HIS
CAC
10
9
11
8
11
CAU
15
16
14
10
20
GLU
GAA
36
37
29
39
33
GAG
17
18
17
10
23
ASP
GAC
28
27
33
36
22
GAU
25
25
30
16
33
TYR
UAC
13
12
14
14
12
UAU
13
14
4
5
19
CYS
UGC
6
6
6
5
7
UGU
5
5
4
1
8
PHE
UUC
17
18
11
15
19
UUU
18
18
18
5
29
ILE
AUA
5
5
8
2
8
AUC
31
32
25
42
22
AUU
24
24
27
17
30
MET
AUG
22
22
20
19
25
TRP
UGG
11
12
5
5
16
Four oligonucleotides were designed in order to generate the synthetic gene and are represented as arrows in step (b). The oligonucleotide sequences are presented in Table 1. The sense oligonucleotide S1 contains the nucleotides encoding residues 3 through 28 of the mature Phα 1B . The antisense oligonucleotide AS1 overlaps with S1 and contains the nucleotides encoding residues 25 through 50. S1 and AS1 were used as template of the synthetic gene in the PCR reaction (see details in FIG. 2 ). Two other oligonucleotides were designed to be used as primers for the PCR reaction. The sense primer S-Eco contains the nucleotides encoding residues 1 through 6 . The additional sequence AATTGAATTCATCGAGGGAAGG (SEQ ID NO: 2 from 1 to 22) was added at the 5′ end of primer S-Eco. This sequence contains an EcoRI restriction site (underlined) followed by a sequence encoding a protease Factor Xa recognition site (double underlined). The antisense primer AS-Pst contains the nucleotides encoding residues 47 through 51 followed by an additional sequence that contains a stop codon and a PstI restriction enzyme site (CTGCAG).
These four oligonucleotides were used in a PCR reaction to produce the synthetic Phα 1B gene (step c—see details in FIG. 2 ). PCR is well documented in the literature, including the citation set forth above. Essentially, PCR allows the production of a selected DNA sequence when the two terminal portions of the sequence are known. The synthetic gene was amplified over multiple cycles, as it is taught in PCR procedure. In this particular case amplification is going to take place over 40 cycles in order to assure maximum amplification.
The synthetic gene produced was digested with the appropriate restriction enzymes and cleaved at the engineered restriction site (step d). The digested gene sequence can then be cloned into an appropriate vector using conventional techniques, analyzed and sequenced. This step is illustrated at (e).
FIG. 3 shows a schematic drawing representing the initial steps during PCR amplification.
For this application, PCR amplification was prepared using two overlapping oligonucleotides as template (oligonucleotides S1 and AS1, shown in red and blue respectively; nucleotide sequences shown in Table 1) and two amplification primers (S-Eco and AS-Pst; shown as yellow-red and green-blue respectively; nucleotide sequences shown in Table 1). The four oligonucleotides were incubated with the appropriate amount of the four deoxynucleotides and the thermostable DNA polymerase and subjected to 40 cycles in a programmable heat block. Each cycle consists of denaturing the DNA at 94° C. for 2 minutes, annealing the primers for 1 minute at 55° C., and then extending the primers at 72° C. for 1 minute.
During the first cycle of the PCR amplification, the two overlapping template oligonucleotides anneal and the thermostable DNA polymerase extends these sequences generating a double stranded DNA that contains most of the synthetic Phα 1B gene.
In the second cycle, the double stranded DNA generated in the first cycle was used as template. The strands are separated (94° C. for 2 minutes), the amplification primers anneal (55° for 1 minute) and the polymerase replicates the strands (72° C. for 1 minute). Note that in this cycle, the newly synthesized strand is longer than the template strand due to the additional sequences present at the 5′ end of the amplification primers (indicated by yellow and green boxes).
The full-length Phα 1B gene sequence flanked by restriction enzyme sites was first obtained in the third cycle. Complete strands are indicated by (*). From then on the number of complete sequences was increased exponentially as indicated in the fourth cycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As discussed above, the present invention is related to new and unique calcium channel blockers, methods for their isolation, and methods of application of such molecules. In particular the present invention relates to the use of isolated toxins obtained from the venom of the spider Phoneutria nigriventer and their use as specific calcium channels blockers.
It has been found within the scope of the present invention that certain spider venoms may selectively act on the central nervous system. More particularly, it has been found that spider venoms can have specific activities on calcium channels with specific and identifiable therapeutic effect on the organism.
An additional benefit of the present invention is that the isolated toxins act without significant cytotoxicity and side effects. Thus the toxins block the channels without destroying the cells within the systems in which they are active. Additionally, the toxins of the present invention generally act without affection axonal conduction within the nervous system. It will be appreciated, therefore, that only calcium channels are affected by the toxin that acts on central nervous system.
I—Techniques for Isolation of Venom
To avoid impurities within the spider venom and the isolated toxins, the spider venom that was used for the tests, described below was electrically milked from the spiders using a method which employs safeguards to prevent contamination of the venom by abdominal regurgitate or hemolymph.
Once the spider venom is obtained it is further purified using gel filtration chromatography or other related technique. In addition, it is frequently desirable that the final fractionation of the spider venom be performed by high performance liquid chromatography (HPLC).
Thus, using the technique of electrically milking the spider coupled with gel filtration chromatography and high performance liquid chromatography it is possible to obtain purified and usable spider toxins. It will be appreciated, however, that other equivalent technique may also be employed and used.
II—Specific Toxin within the Scope of the Invention
While it will be appreciated that additional toxins may also fall within the scope of the present invention, the following relates to the identification and isolation of specific toxin which has been found to have the characteristics required for a usable calcium channel blocker as described above. In addition, a synthetic gene responsible for the production of the toxin is being cloned.
Using the techniques described above relating to the collection of the venom, a toxin has been isolated from Phoneutria nigriventer spider having a molecular weight of approximately 6017 and the following peptide sequence described on FIG. 1 . It has been found that Phα 1B blocks synaptic transmission, the influx of calcium on depolarized terminal and the release of excitatory neurotransmitter, glutamate.
Intrathecally administration of Phα 1B in rats produced antinociception verified by formalin and hot plate tests. In these experiments the antinociceptive effect of Phα 1B was higher than that induced by morphine. The IC 50 for the antinociceptive effect of Phα 1B was 50.2 pmol and the maximal inhibition was obtained with a dose 87.2 pmol. The antinociceptive effect of Phα 1B lasts up to 24 hours. Even at this concentration the toxin does not induce any side and adverse effects in the injected rats.
The toxin blocks the mammalian calcium channels expressed in HEK cells and whole-cell patch-clamp measurements shows that the Phα 1B reversibly inhibited the N-type calcium channels with an IC 50 of 122 nM.
In summary the toxin exhibited measurable preference for N-type channels among the HVA Ca 2+ channels and the blockade of this channel is reversible. It has been shown that blockade of N-type calcium channels has pharmacological utility to treat pain and intratrathecal injection of low doses on of the toxin on the range of pmoles blocks pain transmission.
III—Comparison with Other Calcium Channel Blockers.
Receptor- and voltage-activated calcium channels are of fundamental importance in the survival and function of virtually all cell types. Entry of calcium through such channels regulates a variety of cellular activities including contraction of cardiovascular muscle and the release of neurotransmitters. There are presently three major known classes of organic calcium channel blockers, as opposed to inorganic blockers such as lanthanum or manganese. The organic calcium channel blockers include: phenylalkylamines such us verapamil, benzothiazepines such as diltiazem and dihydropyridine such as nifedipine.
The current available organic calcium channel blockers have pronounced action on heart and vascular smooth muscle, although relative selectivity for these two types of tissues varies among these compounds. A second notable feature of these agents is that, although they will bind to brain tissues, they have either no effect or a relatively minor effect on the function of neurons in CNS, particularly when compared to their striking effects on hearth and vascular smooth muscle.
The Phα 1B toxin derived from Phoneutria nigriventer venom has properties that very clearly distinguish it from the currently available calcium channel blockers. Phα 1B toxin acts primarily, if no exclusively, on neuronal calcium channels as opposed to heart or vascular smooth muscle calcium channels. This tissue selectivity is opposite to that seen in the compounds mentioned above.
In view of the importance of calcium and calcium channels to the function of neurons, there are a variety of potential applications of compounds within the scope of the present invention. Calcium influx through channels mediates neurotransmitter release and modulates neuronal excitability. Selective blockers of neuronal calcium channels, therefore, could modify neuronal excitability by effects on both presynaptic and postsynaptic calcium channels.
Accordingly, appropriate calcium channel blockers could be used in treatment of several neurological disorders that are thought to involve excessive neuronal excitation: e.g. stroke, traumatic head injury, epilepsy, and neurodegenerative disorders such as Huntington's disease and Alzheimer's disease.
Furthermore appropriate calcium channel blocker could be used in the treatment of the pain and on its diverse forms.
IV—Amino Acid Sequencing
Phα 1B was further analyzed in order to determine the amino acid sequence. The venom was obtained from Phoneutria nigriventer spiders using the techniques described herein. Active fractions of the venom were pooled and subject to separation on columns of Sephadex G 50 Superfine and Superose 12HR and reverse phase FPLC on C 2 /C 18 (PEP-RPC) and C 1 /C 8 (PRO-RPC) columns. The sequence of the toxin, FIG. 1 , was performed using a model 477A automatic pulse liquid phase protein sequencer employing a standard Edman degradation sequenator program.
The results of the amino acid sequences analysis of Phα 1B toxin yielded 55-amino acid peptide, FIG. 1 . The peptide has a molecular weight in the range of 6017. The sequence of the peptide as identified by the procedure is:
Recombinant Expression
Provision of a suitable DNA sequence encoding the desired protein permits the production of the protein using recombinant techniques is well known in the art. The coding sequence can be obtained by retrieving a cDNA or genomic sequence from a native source of the protein or can be prepared synthetically using the accurate amino acid sequence from the nucleotide sequence of the gene. When the coding DNA is prepared synthetically, advantage can be taken of known codon preferences of the intended host.
Expression systems containing the requisite control sequences, such as, promoters, and preferably enhancers and termination controls, are readily available and known in the art for a variety of hosts.
Thus the desired proteins can be prepared in both prokaryotic and eukaryotic systems, resulting, in the case of many proteins, in a spectrum of processed forms. The most commonly used prokaryotic system remains E. coli , although other systems such as B. subtillis and Pseudomonas could also be used. Suitable control sequences for prokaryotic systems include both constitutive and inducible promoters including the lac promoter, the trp promoter, hybrid promoters such as tac promoter, and the lambda phage P 1 promoter. In general, foreign proteins may be produced in these hosts either as fusion or mature proteins. When the desired sequences are produced as mature proteins the sequence produced may be preceded by a methyonine which is not necessarily removed. Moreover, constructs may be made wherein the coding sequence for the peptide is preceded by an operable signal peptide which results in the secretion of the protein. When produced in prokaryotic hosts in this matter, the signal sequence is removed upon secretion.
A wide variety of eukaryotic hosts is also now available for production of recombinant foreign proteins. As in bacteria, eukaryotic hosts may be transformed with expression systems which produce the desired protein directly, but more commonly signal sequences are provided to effect the secretion of the protein. Eukaryotic systems have the additional advantage that they are able to process introns which may occur in the genomic sequences encoding proteins of higher organisms. Eukaryotic systems also provide a variety of processing mechanisms which result in, for example, glycosylation, oxidation or derivation of certain acid residues, conformational control, and so forth.
Commonly used eukaryotic systems include yeast, insect cells, mammalian cells, avian cells and cells of higher plants. Suitable promoters are available which are compatible and operable for use in each of these host types as well as are termination sequences and enhancers. As above, promoters can be either constitutive of inducible. For example, in mammalian systems, the MTII promoter can be induced by the addition of heavy metal ions.
The particulars for the construction of expression systems suitable for desired hosts are well known to those in the art. For recombinant production of the protein, the DNA encoding it is suitably ligated into the expression system of choice, and the system is then transformed into the compatible host which is then cultured and maintained under conditions wherein expression of the included gene takes place. The protein thus produced is recovered from the culture, either by lysing the cells or from the culture medium as appropriate.
A “mutation” in a protein alters its primary structure (relative to the commonly occurring or specifically described protein) due to changes in the nucleotide sequence of the DNA which encodes it. These mutations specifically include allelic variants. Mutational changes in the primary structure of a protein result from deletions, additions or substitutions. Such changes involving only 3 or less amino acid residues are generally preferred. A “deletion” is defined as a polypeptide in which one or more internal amino acid residues are absent. An “addition” is defined as a polypeptide which has one or more additional internal amino acid residues as compared to the wild type. A “substitution” results from the replacement of one or more amino acid residues by other residues. A protein “fragment” is a polypeptide consisting of a primary amino acid sequence which is identical to a portion of the primary sequence of the protein to which the polypeptide is related.
Preferred “substitutions” are those which are conservative, i.e., wherein a residue is replaced by another of the same general type. As is well understood, naturally-occurring amino acids can be subclassified as acidic, basic, neutral and polar, or neutral and nonpolar. Furthermore, three of the encoded amino acids are aromatic. It is generally preferred that encoded peptides differing from the native form contain substituted codons for amino acids which are from the same group as that of the amino acid replaced.
The protein of the invention (Phα 1B ) can be made recombinantly. Because of the variety of post-translational characteristics conferred by various host cells, various modifications for the naturally-occurring protein will also be obtained. A “modified” protein differs from the commonly occurring protein as a result of post-translational events which change the glycosylation or lapidation pattern, or the primary, secondary, or tertiary structure of the protein.
It should be further noted that if the protein herein (Phα 1B ) is made synthetically, substitutions by amino acids which are not encoded by the gene may also be made. Alternative residues include, for example, phenylglycine, citrulline, methionine sulfoxide, cyclohexyl alanine, ornithine and hydroxyproline.
Example 1
A synthetic cDNA coding the mature Phα 1B was cloned. The procedure can be outlined as follows:
1—Oligonucleotides containing the coding sequence for the mature Phα 1B toxin were synthesized.
2—The oligonucleotides were used in PCR reactions to produce the complete coding sequence for the mature Phα 1B flanked by restriction endonuclease sites.
3—The PCR amplified product was analyzed and isolated.
4—The PCR product was digested with appropriate enzymes, cloned and sequenced.
Step #1:
Two oligonucleotides were designed to be used as template for the PCR reaction. A sense oligonucleotide corresponding to residues 3 through 28 of the mature Phα 1B (coding strand) and an overlapping antisense oligonucleotide corresponding to residues 25 through 50. Two other oligonucleotides were designed to be used as primers of the PCR reaction. The sense primer contained an Eco RI restriction enzyme site (GAATTC), followed by a sequence encoding a protease Xa recognition site (ATCGAGGGAAGG) (SEQ ID NO: 2 from 11 to 22) and nucleotides encoding residues 1 through 6. The antisense primer contained an PstI restriction enzyme site (CTGCAG) followed by an stop codon and nucleotides encoding residues 55 through 47. Primers were designed using the E. coli codon preference and were synthesized by IDT—Integrated DNA Technologies. Oligonucleotide sequence is presented in Table 1.
Step #2:
Primer directed enzymatic amplification of DNA with a thermostable DNA polymerase was initially described by Saiki et al. (Science, 239: 487 (1988)). For our application, the amplification reaction is going to contain the sense and antisense template oligonucleotides in a 0.1 μM concentration, the amplification primers in a 1 μM concentration, 250 μM of each deoxynucleotide triphosphate and 2 units of the thermostable recombinant Taq polymerase. The reaction was run in a programmable heat block manufactured by BioRad (USA). It was started by denaturing the DNA at 94° C. for 2 minutes, annealing the primers for 1 minute at 55° C., and then extending the primers at 72° C. for 1 minute. This cycle was repeated 40 times. After the final cycle, the samples were chilled at 4° C.
Step #3:
The PCR reaction was run on a 1.5% agarose gel in Tris/borate/EDTA (TBE) buffer in the presence of ethidium bromide. The gel was photographed and the band corresponding to the full length PCR (200 bp) was cut from the gel and purified using the QIAquick™ Gel Extraction kit (Qiagen, USA) to remove unincorporated primers.
Step #4:
The PCR product is then going to be digested with the restriction enzymes EcoRI and PstI (Invitrogen, USA), utilizing the restriction sites contained in the sense and antisense primers. The vector, pMAL-c2X (NewEngland BioLabs), is also going to be digested with EcoRI and PstI to generate sites specific for directional cloning. Vector and insert were ligated and transformed into competent E. coli strain DH5-α. Bacterial colonies were screened by PCR and candidate colonies were further characterized by sequencing mini-prep DNA using commercially available external primers.
Example 2
A spider toxin within the scope of the present invention was isolated from Phoneutria nigriventer spider. The identification of the specie provided in the Instituto de Ciencias Biológicas, UFMG, Belo Horizonte, MG, Brazil. Phoneutria nigriventer spiders were electrically milked using a method that employs safeguards to prevent contamination of the venom by abdominal regurgitate or hemolymph. The venom was fractionated by gel filtration chromatography on columns of Sephadex G-50 Superfine and Superose 12HR and reverse phase HPLC using Vydak C-18. The fractions were tested for the inhibition of glutamate release and calcium uptake in the synaptosomes. The column was eluted with a gradient of 0 to 40% (v/v) acetonitrile in 0.1% TFA over 180 min at a flow rate of 10 ml/min. Elutions was monitored by absorbance detection at 216 nm. Peaks were collected manually, dried down, stored at −20° C. in siliconized Eppendorf tubes and then reconstituted with saline solution. For gel electrophoresis SDS-PAGE was carried out using 22% gels. Gels were stained with Coomasssie Blue. High resolution propionic acid/urea was performed as described in the literature. Examination of the toxin by SDS-PAGE revealed their apparent molecular weight but more accurate estimates were obtained by subjecting the proteins to the Biolon time of flight plasma desorption mass spectroscopy method which yielded value of 6017,9. The toxin was bath-applied to stimulated synaptomes preparation. It was found that the toxin blocked the stimulated release of glutamate and the uptake of 45 Ca 2+ in synaptosomes and by intratechal injection reduces the pain in rats without any side effect contrary to the observed with morphine.
Example 3
Male and female specimens of the spider were collected in the regions of Santa Barbara and Mariana, respectively, both in the State of Minas Gerais, Brazil. Venom from live adult spiders was obtained by electrical stimulation of the fangs. The venom was immediately transferred to siliconized glass tubes in ice, diluted with the same volume of distilled water and centrifuged at 4000 g to remove insoluble materials and debris. The supernatant was lyophilized and stored at −18° C. Aliquots of 25-30 mg of lyophilized venom were dissolved in 2 ml of aqueous 0.1 trifluoroacetic acid (TFA) and centrifuged at 4000 g for 10 min to remove insoluble materials. The brownish yellow supernatant was applied to preparative column (2.2×25 cm) of Vidac C4 equilibrated with 0.1 TFA in water (solvent A). Solvent B was 100% acetonitrile containing 0.1 TFA. The column was eluted with a flow rate of 5 ml/min with the following gradient system: 0 to 20 min, 100% A; 20 to 30 min, 0-20% B, 30-110 min, 20-40% B; 110-130 min, 40-50% B; 130-150 min 50-70% B. The presence of peptides or proteins in the eluate was detected by measuring the UV absorption at 214 nm. Fractions containing peptides were collected manually and lyophilized. The lyophilized fractions from the preparative reverse phase HPLC(RP-HPLC) were then dissolved in 2 ml of 10 mM sodium phosphate buffer pH 6.1 and subjected to ion-exchange FPL on a column (6.4 mm×30 mm) of Resource™ S equilibrated in the same buffer. A small number of fractions from the preparative RP-HPLC step which were not well resolved by using cation exchange chromatography were fractionated on anion exchange HPLC column of Synchropak AX-300 using linear gradient of 0-0.5 M NaCl in 10 mM Tris-HCl buffer pH 8.6 at a flow rate of 1 ml/min. The venom components obtained from these cation and anion exchange FPLC and HPLC steps were desalted and further purified by RP-FPLC or RP-HPLC on analytical columns of PepRPCTM, Vydac C8 or C18 using gradients of acetonitrile in 0.1 TFA. The purity of all fractions obtained was examined by PAGE and mass spectroscopy on ES-Q-TOF spectrometer equipped with an electrospray ionization source. The amino acid sequences of the S-pyridyl-ethylated intact. The results of amino acid and sequence analyses of Phα 1B are described on FIG. 1 .
Example 4
The Phα 1B toxin purified by the described procedure was tested on whole-cell patch clamp recordings performed on HEK cells transfected with cDNA coding for one type of calcium channels. The toxin produced a reversible block of all four HVA calcium channels subtypes (L, N, P/Q and R) but the inhibition was most potent and effective on N-type (al b) calcium channel.
Pretreatment with Phα 1B by intratechal bolus injection showed that the toxin blocks the acute, cronic and neurogenic pain. In the heat pain model the antinociceptive effect of the Phα 1B lasts 24 h.
The toxin so obtained was tested for its ability to block neurotransmitter release on in vitro synaptosome preparations from brain cortical slices. The toxin blocked the release of glutamate induced by K+ depolarization
It will be appreciated that the present invention provides the ability to effectively block specific channels using the toxin. Similarly, specific channel blocker with activity on the central nervous system may have the potential to treat various neurological disorders. It has been found, for example that these channel blockers may act as a treatment of pain. In addition, channel blockers of the type disclosed in the present invention may also be used in treatment of stroke, traumatic head injury and degenerative central nervous system diseases such as Huntington disease and cardiac arrhythmias.
In summary, it can be seen that the method and compositions of the above invention accomplish the objectives set forth above. In particular, the present invention provides calcium channel blockers which can be used as research tools or in a clinical setting. In particular, the spiders of the present invention can be used as calcium channel blockers in the central nervous system.
According to the present invention the toxin may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the inventions is therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Methods and compositions for blocking calcium channels with a spider toxin from Phoneutria nigriventer are provided. For easy identification the toxin will be sometimes generally referred to as Phα-1B herein. The toxin comprises a 55-amino acid sequence having a molecular weight of approximately 6,017. This Phα-1B spider toxin was found to block calcium channels within the nervous system. The synthetic gene responsible for producing this toxin has been designed and cloned. This gene and/or its derivative provide a mechanism by which the toxin can be produced using recombinant DNA expression technologies. The present invention further relates to methods of treating neurological diseases and pain by applying the isolated and identified toxins. The toxin Phα-1B may provide beneficial effects on pain and certain neurological conditions including seizures, ischemic- hypoxic, CNS damage, and neurodegenerative disorders. It was also found that the toxins are effective as tags in probing calcium channels. | 0 |
TECHNICAL FIELD
The invention relates to a device for gluing the tail end of a reel or log of wound web material, of the type comprising: conveying means for moving the reel; unwinding means for unwinding the tail end of the web material; a dispenser of glue for applying a glue to the web material of the reel; and means for rewinding the reel after the glue has been applied. More particularly, the invention relates to a device of the above type in which the glue is applied to a portion Of material still wound on the reel and onto which the tail or outer end is then rewound.
Such devices are commonly used in the paper converting industry, wherein large paper coils (parent rolls) are unwound and rewound to form reels or logs of smaller diameters. The tail end of these reels is glued after rewinding and the reels are thereafter subject to further operations, such as cutting along planes perpendicular to the reel axis, in order to produce toilet paper rolls, all purpose wipers rolls, kitchen rolls or the like.
STATE OF THE ART
Various kinds of reel gluing devices exist, and, purely by way of illustration, those disclosed in, for example, U.S. Pat. No. 4,475,974, U.S. Pat. No. 4,963,223, EP-A-0 481 929 and U.S. Pat. No. 5,242,525 may be indicated. In all currently known gluing devices, and in particular in those disclosed in the patents cited above, the unwinding of the tail end of the web material before gluing takes place is achieved by holding the reel in an unwinding position and striking said reel with blasts of air emitted by nozzles in suitable positions and orientations. These blasts of air lift the tail end of the reel and open it onto a supporting surface. The reel is then made to rotate in order partly to rewind the tail end so that a predetermined and limited length of web material remains on the supporting surface. Once this has been done it is necessary to transfer the reel with the tail end in this position to the glue dispenser. In conventional gluing devices, disclosed for example in U.S. Pat. No. 4,963,223 or in U.S. Pat. No. 4,475,974, the reel is transferred by translationally moving a pair of rolls on which the reel is supported and, integrally with said rolls, the surface on which the tail end has been unwound. This is necessary because the glue is dispensed through nozzles directly onto the tail end which is then rewound onto the reel. In order to considerably simplify the gluing process, EP-B-0 481 929 discloses a novel gluing process, in which once the tail end has been unwound from the reel, the reel is rolled over a slit through which the glue is dispensed. This makes it possible to achieve major simplifications and to greatly reduce maintenance, if not eliminate it altogether.
The present invention relates to a tail sealer using the same method as disclosed in EP-B-0 481 929, with a modified glue dispenser.
DISCLOSURE OF THE INVENTION
Basically, the device according to the invention comprises a glue dispenser which includes a glue container with at least one upwardly oriented slit from which glue is dispensed, wherein inside said container a moving member is positioned, which is cyclically immersed in the glue and moved toward the upwardly oriented slit in order to apply the glue on the reel which rolls over said slit.
In a particularly advantageous embodiment, said container is upwardly closed by a rolling surface on which the reels to be glued are made to roll, said surface being provided with said at least one upwardly oriented slit.
According to an embodiment of the invention, the movable member is formed by a transversely extending, substantially rectilinear bar. Said movable member may be provided with an upwardly oriented concave surface, in which the glue is collected.
Further advantageous features of the invention are set forth in the appended claims.
The invention also relates to a method for gluing the outer end of a web material wound on a reel, wherein: the outer end of the web is unwound or detached from the reel by a predetermined extent; the glue is applied on a region of the web material which is still wound up on the reel by rolling said reel, with the outer end being unwound therefrom, along a rolling surface and over a slit from which the glue is dispensed; and the outer end is rewound on the reel while the reel is rolling along the rolling surface. While the reel is rolling over the upwardly oriented slit, glue is dispensed therefrom by a movable member which is cyclically immersed into a glue container to pick up a certain amount of glue.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more clearly from a perusal of the description and enclosed drawing, the latter showing a practical, non-limiting embodiment of the invention. In the drawing:
FIG. 1 shows a side view of the device according to the invention;
FIG. 2 shows an enlarged side view and partial longitudinal section of the glue dispensing area of the device;
FIG. 3 shows a cross section according to line III--III in FIG. 2; and
FIG. 4 shows a modified embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The device according to the invention comprises an entry chute 1, on which the reels L arrive in succession from a re-reeling machine positioned upstream of the device, and not shown. In the accompanying figures the reels L are of the type having a central winding core, but it is obvious that the working of the device of the present invention will not be changed if it is used for gluing reels that have no central winding core.
The numeral 3 indicates a feeder rotating about an axis A, which transfers one reel at a time from the chute 1 to a supporting and conveying surface indicated as a whole by the numeral 5. Downstream of the feeder 3, the surface 5 comprises an aperture from which the upper surface of an unwinding roll 7, rotating about a fixed axis marked B, projects slightly. Downstream of the unwinding roll 7 (which in the example illustrated rotates anticlockwise) is a vacuum space 9 leading down underneath the surface 5. Positioned downstream of the mouth of the space 9 is the glue dispenser, indicated 11 as a whole. The dispenser is positioned underneath a dispensing aperture or slit 155 formed along the supporting and conveying surface 5. The latter then continues towards the reel discharge area where there are collecting means (not shown) which take the glued reels and transfer them to the cutting machine which cuts up the individual reels into a plurality of rolls of predetermined height.
Above the supporting and conveying surface 5 is an assembly 15 suspended by a chain 16 at a height that can be adjusted to suit the dimensions of the reels L for the purposes indicated below. The assembly 15 carries a pair of rolls 17, 19 around which a flexible drive 21, consisting of one or a series of belts or the like travels. The flexible drive 21 has a lower half 21I that runs approximately parallel with the reel supporting and conveying surface 5. The distance from the lower half 21I to the surface 5 is adjustable by means of a system comprising a handwheel 23 and a speed-reducing mechanism 25, by means of which the assembly 15 can be moved vertically, guided laterally by means of rolls 27 and relevant tracks. The handwheel 23 and the speed-reducing mechanism 25 may also be replaced by a geared-down motor or the like.
Between the upper and lower halves of the flexible drive 21 is a pressure roll 29 mounted on a unit 31 which in turn is supported by links 33, 35 connected to a spring-loaded member 37 which pushes the pressure roll 29 down against the lower half 21I of the flexible drive 21. The unit 31 has a slot 31A along which the pressure roll 29 can be positioned in order to alter its position relative to the glue dispenser 11.
Communicating with the vacuum space 9 is a vacuum box 51 connected to a vacuum line (not shown). The vacuum box 51 extends across approximately the entire width of the device, at right angles to the plane of the figures, and has an opening or a plurality of openings 53 permitting communication between the box 51 and the vacuum space 9. The openings 53 are located in the lower part of the vacuum space 9.
Each individual reel L is taken from the chute 1 by the rotating feeder 3 and unloaded onto the supporting and conveying surface 5. The rotation of the feeder 3 about its axis A forces the reel between the supporting and conveying surface 5 and the lower half 21I of the flexible drive 21. Said flexible drive is driven in the direction shown by the arrow f21 by one of the rolls 17, 19, which for this purpose is powered in some way. Thus the reel L is rolled in a controlled manner along the first portion of the supporting and conveying surface 5. After rolling a certain distance over the surface 5, the reel L comes into contact with the upper portion of the unwinding roll 7, which projects from the surface 5. This is shown in FIG. 2. When the reel reaches this position, it begins to rotate about its axis, clockwise in the drawing, while remaining in the same position. This is obtained by moving the belts 21 at the same speed as the roll 7. Meanwhile the vacuum space 9 is in depression because of the suction exerted by the vacuum box 51. Consequently, when the tail end LF appears on the right hand side (in FIG. 2) of the reel L, it is detached from the external surface of the reel L, unwound from it and sucked into the vacuum space 9. FIG. 2 shows the tail end LF as it first comes away from the external surface of the reel L while FIG. 1 shows the position assumed by the tail end LF once sucked into the vacuum space 9. The roll 7 continues to rotate even when the tail end LF is inside the vacuum space 9 and therefore said end is gradually drawn out and rewound onto the reel L until the terminal edge of the tail end LF is in front of a sensor, which may be optical or the like. The position of the sensor can be adjusted to alter the length of tail end unwound. Alternatively (or in combination), the adjustment of the length of the tail end can be brought about by appropriately delaying the stopping of the rotating of the roll 7 relative to the signal from the sensor. This sensor, when it detects the position of the tail end, stops the roll 7 from rotating, thereby causing the reel to advance in a controlled manner and to rotate on the surface 5 over the aperture 155 of the dispenser 11. The controlled movement of the reel is obtained by means of belt 21 which continues to move at constant speed. In this way the glue is applied to the reel in the location uncovered by the partial unwinding of the tail end LF.
As the translation movement of the lower half 21I of the flexible drive 21 is continued, the reel is caused to roll in a controlled manner along the supporting and conveying surface 5 to a position underneath the pressure roll 29, which presses on the surface of the reel at the point where the tail end is to be stuck. The position of the pressure roll 29 is adjusted so as to act on the reel at the point where the glue has been applied, in order to guarantee a better closure without it being necessary to hold the reel in position, causing it to execute a complete revolution in this location.
The glued reel is subsequently discharged and a new reel is being processed in position L for its free end to be opened.
FIGS. 2 and 3 show the details of the glue dispenser 11. The dispenser 11 comprises a container 151 containing the glue C. The container is upwardly closed by a wall 153 with a dispensing slit or dispensing aperture 155 which opens in the surface 5 on which the reels are made to rotate. Inside the container 151 is a moving member 157 consisting of a transverse bar 159 hinged at 161 and 163 (FIG. 3) to a set of rockers, the first and the last of which are shown in FIG. 3, and designated 165, 167. The rockers are hinged at 169 and 170 to the wall of container 151. The bar 159 is connected, via a joint 173 to the shaft 175 of a cylinder-piston actuator 177. The actuator 177 generates a pivoting movement of rockers 165, 167 and thus a movement of bar 159 from the position shown in solid line in FIG. 3 to the position shown in broken lines and designated 159X in FIG. 3.
Upwardly the bar 159 is provided with a concave surface 157S which is in practice a longitudinal channel extending substantially along the whole length of the bar 159. When the bar is in its lower position, the surface 157S is immersed in the glue C, such that the subsequent lifting of the bar 159 caused by actuator 177 determines the lifting of a certain amount of glue which is collected in the channel formed by surface 157S. The dimension of the channel defines the amount of glue which is picked up by bar 159 at every stroke. The motion of bar 159 is synchronized with the feeding motion of the reels in such a way that the bar 159 is in its upper position when the reel L is made to roll along the supporting and rolling surface 5 over the dispensing aperture 155. When it rolls over the dispensing aperture 155 the reel collects the glue from the surface 157S and, continuing to roll its tail end is glued on the outer surface of the reel.
FIG. 4 shows a modified embodiment of the dispenser of FIGS. 2 and 3. In this embodiment the moving member 157 is supported by an oscillating arm 181 hinged at 183 to a transverse axis. The functioning of the dispenser of FIG. 4 is similar to that of the dispenser of FIGS. 2 and 3, the arm 181 being controlled e.g. by a brushless electric motor or other actuator, such as a fluid cylinder arranged outside the container 151. The arm could be shorter and made to continuously or intermittently rotate about a transverse axis arranged under the glue dispensing aperture.
The dispenser 11 has been described hereinabove in combination with a particular kind of reel feeding and tail end unwinding system. However, it should be understood that the same dispenser can be combined with different reel feeding and tail end unwinding means. In particular, it can be used in tail sealers of the kind described in EP-A-0.481.929 or U.S. Pat. No. 5,242,525. It is also possible to adopt other reel moving and tail unwinding means, such as those used in tail sealers models N. 65.30, 65.31 and 65.40 (U.S. Pat. No. 4,963,223) produced by the applicant, wherein the reels are moved from the tail unwinding station to the gluing station by oscillating a pair of reel supporting rolls.
A similar dispenser can be used for appling glue to the tubular cores on which the web is wound to form a reel, before the core is introduced in the rewinder.
It will be understood that the drawing shows only an illustrative embodiment provided purely by way of a practical demonstration of the invention, it being possible to vary said invention as regards shapes and arrangements, yet without departing from the scope of the concept underlying the invention. Any reference numerals in the accompanying claims are purely for facilitating the reading of the claims with reference to the description and to the drawing, and do not limit the scope of protection represented by the claims. | A device for gluing the tail end of a reel of wound web material, comprises: conveying means for moving the reel, unwinding means for unwinding the tail end of the web material, a dispenser of glue for applying the glue to the reel, and means for rewinding the tail end after the glue has been applied. Said dispenser includes an upwardly oriented aperture from which the glue is dispensed and includes a container for the glue with said upwardly oriented aperture and a moving member positioned inside said container which is immersed in the glue contained in the container and moved towards said upwardly oriented aperture in order to dispense the glue to the reel as it rolls over said aperture. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present patent document is a §371 nationalization of PCT Application Serial Number PCT/EP2014/050729, filed Jan. 15, 2014, designating the United States, which is hereby incorporated by reference, and this patent document also claims the benefit of DE 10 2013 205 044.5, filed on Mar. 21, 2013, which is also hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present embodiments relate to an actuator device.
BACKGROUND
[0003] Certain actuator devices have the task of realizing a required deflection in a defined range. To this end, the actuator device has to make a movement both to and fro possible. In order to provide a movement in both directions, the hydraulic liquid contained in the actuator device is prestressed. The prestress varies with the deflection in known actuator devices. This leads to pressure differences that limit the maximum possible deflection, and to inconsistent force development.
SUMMARY AND DESCRIPTION
[0004] The scope of the present invention is defined solely by the appended claims and is not affected to any degree by the statements within this summary. The present embodiments may obviate one or more of the drawbacks or limitations in the related art.
[0005] The present embodiments are based on the object of eliminating these disadvantages and providing an improved actuator device.
[0006] The actuator device has a drive unit and an output unit. The output unit includes a first translation unit with a first output and a second translation unit with a second output, wherein the second translation unit is fluidly connected to the first translation unit via a line system. The drive unit is fluidly connected to the line system. In order to deflect the outputs, a fluid may be exchanged by the drive unit between the first translation unit and the second translation unit. The first translation unit and the second translation unit have in each case one prestressing element. The prestressing elements are supported in opposite directions against the movably mounted clamp.
[0007] As a result of the movable mounting of the clamp, the component is moved by way of the two outputs. No differential force between the two prestressing elements is advantageously produced as a result. The pressures in the fluid chambers therefore remain constant independently of the stroke. As a result, firstly the force of the actuator device may be kept constant independently of the deflection, since the pressure difference of the fluid is not changed. Secondly, the maximum stroke may therefore also be increased considerably.
[0008] In one advantageous refinement of the actuator device, the first translation element and the second translation element have a hydraulic cross section of identical dimensions.
[0009] As a result, the deflections of the two outputs have the same travels. The clamp therefore moves uniformly with respect to the deflections of the two outputs.
[0010] In a further advantageous refinement of the actuator device, the first prestressing element and the second prestressing element have an identical prestressing force. In addition, the first prestressing element and the second prestressing element may have an identical spring rate.
[0011] As a result, a symmetrical system is achieved having the same properties in both directions. The use of the actuator device in a module is therefore simplified.
[0012] In a further advantageous refinement of the actuator device, the first translation element and/or the second translation element are/is a hydraulic cylinder.
[0013] Hydraulic cylinders advantageously have a very low longitudinal stiffness and therefore do not influence the spring rates of the prestressing elements. In addition, hydraulic cylinders may be designed for long deflections.
[0014] In an alternative advantageous refinement of the actuator device, the first translation element and/or the second translation element are/is a bellows. Here, the bellows is advantageously a metal bellows or a diaphragm bellows, the bellows having the same spring rate.
[0015] A high system tightness may be achieved relatively simply by way of a bellows, e.g., a metal bellows. In addition, bellows have a relatively low weight.
[0016] In a further advantageous refinement of the actuator device, the fluid chambers and the fluid lines are filled completely with a hydraulic liquid.
[0017] The fluid is therefore substantially incompressible and uniform operation of the actuator device is provided at different high pressures in the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Exemplary embodiments are explained in greater detail using the drawings and the following description.
[0019] FIG. 1 depicts an example of an actuator device.
[0020] FIGS. 2 to 4 depict translation units of the actuator device in various refinements.
DETAILED DESCRIPTION
[0021] FIG. 1 outlines by way of example an actuator device 1 in a coordinate system 13 . The actuator device 1 includes a drive unit 3 and an output unit 19 connected to the drive unit 3 in a fluid-conducting manner by a first fluid line 18 .
[0022] The drive unit 3 includes an actuator 2 and a drive element 20 . The drive element 20 has a drive fluid chamber 17 .
[0023] The actuator 2 may be, for example, a piezoelectric actuator 2 or a magnetoresistive actuator 2 . The drive unit 3 is configured in such a way that the magnitude of the volume of the drive fluid chamber 17 may be influenced by way of the deflection of the actuator 2 .
[0024] To this end, the actuator 2 is connected to the drive element 20 in a non-positive manner at least in the pressing direction. The actuator 2 may also be connected to the drive element 20 in a positively locking manner. The actuator may also be connected to the drive element 20 in a non-positive manner in the opposite direction to the pressing direction, which is to say in the pulling direction. Here, the pressing direction represents the direction of the deflection of the actuator 2 .
[0025] As depicted in FIG. 1 , a pressing force is exerted on the drive element 20 by way of an increase in the deflection of the actuator 2 . The volume of the drive fluid chamber 17 is decreased by way of an increase in the deflection of the actuator 2 . The volume of the drive fluid chamber 17 may at least be increased by way of a reduction in the deflection of the actuator 2 . In the case of a non-positive connection of the actuator 2 to the drive element 20 in the pulling direction, the volume of the drive fluid chamber 17 is increased by way of a reduction in the deflection of the actuator 2 . The relationship between the deflection of the actuator 2 and the volume of the drive fluid chamber 17 may also be reversed in principle by way of a direction change at the drive element 20 .
[0026] The drive element 20 may be, for example, a hydraulic cylinder with a piston, a bellows, in particular a metal bellows or else a diaphragm bellows. FIG. 1 depicts, by way of example, a hydraulic cylinder 20 as the drive element 20 , the actuator 2 being connected to the piston thereof in a non-positive manner.
[0027] The drive fluid chamber 17 is adjoined by the first fluid line 18 . In the case of a reduction in the volume of the drive fluid chamber 17 , a fluid situated in the drive fluid chamber 17 flows through the first fluid line 18 to the output unit 19 . In the case of an increase in the volume of the drive fluid chamber 17 , the fluid may flow into the drive fluid chamber 17 .
[0028] The output unit 19 has a first translation unit 15 and a second translation unit 16 . The first translation unit 15 is fluidly connected to the second translation unit 16 .
[0029] The first translation unit 15 has an output fluid chamber 11 , a first translation element 14 , a first output 7 and a first prestressing element 12 . In addition, the second translation unit 16 has a reserve fluid chamber 9 , a second translation element 24 , a second output 8 and a second prestressing element 25 .
[0030] As depicted in FIG. 1 , the first translation element 14 and the second translation element 24 are configured as hydraulic cylinders 14 , 24 , and the prestressing elements 12 , 25 are configured as helical springs 12 , 25 . As is customary, the hydraulic cylinders 14 , 24 have a displaceable piston. Here, the piston forms in each case the output 7 , 8 . The volume of the fluid chambers 11 , 9 is determined in each case according to the position of the outputs 7 , 8 , or the deflection of the outputs 7 , 8 is dependent in each case on the volume of the fluid chambers 11 , 9 . The prestressing elements 12 , 25 in each case exert a prestress on the outputs 7 , 8 , on the piston 7 , 8 here.
[0031] The first prestressing element 12 and the second prestressing element 25 are both supported on a clamp 4 . To this end, the prestressing elements 12 , 25 are arranged in a substantially opposed manner. The prestressing elements 12 , 25 work in one line. The clamp 4 is rigid and may be moved freely. The clamp 4 is mounted in a floating manner. The prestressing elements 12 , 25 act against one another in such a way that a force equilibrium is produced between the exerted force of the first prestressing element 12 and the exerted force of the second prestressing element 25 . The clamp 4 may be moved in the direction of the deflections of the outputs 7 , 8 . The clamp 4 moves with the outputs 7 , 8 .
[0032] The output fluid chamber 11 of the first translation unit 15 is fluidly connected to the reserve fluid chamber 9 of the second translation unit 16 by a line system 27 . The line system is configured in such a way that a second fluid line 21 and a third fluid line 22 are arranged parallel to one another and a fourth fluid line 26 is arranged in series with respect to the second and third fluid line 21 , 22 . A suction check valve 6 is arranged in the second fluid line 21 . A delivery check valve 5 is arranged in the third fluid line 22 . The suction check valve 6 closes in the suction direction and the delivery check valve 5 closes in the delivery direction in an opposed manner to the suction direction. The check valves 5 , 6 are arranged in an opposed manner with respect to one another. The check valves 5 , 6 open in each case only in one direction; the suction check valve 6 opens in the delivery direction and the delivery check valve 5 opens in the suction direction. The check valves 5 , 6 are prestressed, with the result that opening takes place only above a defined prevailing pressure. The first fluid line 18 is fluidly connected to the fourth fluid line 26 at a coupling point 23 .
[0033] In the exemplary embodiment according to FIG. 1 , the second fluid line 21 is arranged at the output fluid chamber 11 and the fourth fluid line 26 is arranged at the reserve fluid line 9 . The fourth fluid line 26 may be provided additionally with a throttle 10 that constricts the cross section of the fourth fluid line 26 .
[0034] The fluid chambers 9 , 11 , 17 and fluid lines 18 , 21 , 22 , 26 are filled with a fluid, (e.g., a hydraulic liquid such as silicone oil or glycerin).
[0035] The fluid may be exchanged between the first translation unit 15 and the second translation unit 16 by to and fro movements of the drive unit 3 . The outputs 7 , 8 are deflected in this way. Depending on a speed, at which the deflection of the actuator 2 is performed, the fluid may be conducted from the reserve fluid chamber 9 into the output fluid chamber 11 or in the reverse direction from the output fluid chamber 11 into the reserve fluid chamber 9 .
[0036] In order to conduct the fluid through the second or third fluid line 21 , 22 , a higher prevailing pressure is provided on account of the prestressed check valves 5 , 6 than for conducting the fluid through the fourth fluid line 26 . The prevailing pressure refers to a pressure difference between the inlet side and the outlet side of the valve. The prevailing pressure rises with the speed of the deflection of the actuator 2 .
[0037] FIGS. 2 to 4 depict design variants of the translation units 15 , 16 , in each case using the example of the first translation unit 15 . The output 7 is prestressed by the prestressing unit 12 . The prestressing unit 12 is supported on the clamp 4 . A corresponding volume change ΔV of the output fluid chamber 17 accompanies the movement of the output 7 by the distance Δs. A fluid mass flow takes place through the fluid line 21 .
[0038] Like FIG. 1 , FIG. 2 depicts a hydraulic cylinder as translation unit 15 . The piston of the hydraulic cylinder is the output 7 .
[0039] In FIG. 3 , the translation unit 15 is a metal bellows and, in FIG. 4 , the translation unit 15 is a diaphragm bellows. Here, the output 7 is formed in each case by a piston 7 that bears against the bellows.
[0040] It is to be understood that the elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present invention. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding or following claim, whether independent or dependent, and that such new combinations are to be understood as forming a part of the present specification.
[0041] While the present invention has been described above by reference to various embodiments, it may be understood that many changes and modifications may be made to the described embodiments. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description. | The embodiments relate to an actuator device including a drive unit and an output unit. The output unit includes a first translation unit having a first output and a second translation unit, connected in a fluid manner to the first translation unit via a pipeline system, having a second output. The drive unit is connected to the pipeline system in a fluid manner. To deflect the outputs, a fluid may be exchanged between the first translation unit and the second translation unit by the drive unit. The first translation unit and the second translation unit each have a pre-clamping element. The pre-clamping elements are supported in the opposite direction against a movably mounted clamping. | 5 |
This application claims the benefits of Indian Patent Application No. 868/Mas/99, filed Sep. 1, 1999, which status is pending.
FIELD OF INVENTION
This invention relates to a portable electric tool using AC motor or a brushless DC (BLDC) motor.
BACKGROUND OF INVENTION
It is well known that modern manufacturing techniques deploy a number of portable tools to tackle the repetitive jobs that are encountered in the shop floor of the industry. Tools like drills, grinders, shears, nibblers, screw drivers, nut runners and impact wrenches find extensive use in large fabrication shops, tool rooms, fettling shops and assembly lines. In addition such tools also find large usage as do-it-yourself (DIY) tools in the hands of the individuals in domestic applications. Also such portable tools are widely used in mines particularly in the form of drills. The main requirements of such tools are portability, ease of handling and usage, safety, high efficiency and maximum power output The manufacturer always aims to achieve the maximum power-to-weight ratio in such tools. Nowadays the energy consumed by such tools is also becoming an important criterion for selection.
Presently available range of portable tools can be broadly classified into three types. They are given as under:
AC/DC universal motor based electric tools;
pneumatic tools; and
conventional high frequency tools.
The first type mentioned above uses a universal electric motor. These motors are essentially series-wound DC commutator motors that have been specially designed to operate in AC as well. The stator core is invariably laminated to reduce losses. A well-designed universal motor is cheap, lightweight and operatable directly from the AC mains. The fact that it does not require a special power source is a major reason for its widespread use. This type of tool finds extensive use in DIY applications and small shops where one off usage is normal.
The universal electric tools suffer from certain disadvantages in that
The Commutator/Carbon Brush-gear is a perennial source of problem leading to reduced reliability and increased maintenance;
In these motors, the speed drop from no-load to full-load is very high, often of the order of 2:1. Excessive overloads can cause stalling of the motor, leading to armature burnout;
As the motor operates on mains supply, it has to be designed with double-insulation or reinforced insulation with proper earthing, to achieve the required safety levels; and
It is difficult to make these tools flameproof for use in mines and other hazardous areas.
Due to these reasons the universal electric tools are generally not preferred for heavy duty, continuous loads and in arduous working environment.
The second type, viz., the pneumatic tools was essentially developed to overcome some of the problems associated with the universal electric tools. The pneumatic tool operates from high-pressure compressed air by means of a simple drive called vane motor. A rotor with vanes supported on bearings runs inside a housing due to the passage of the compressed air and high speeds are achieved. A reduction gearbox is used to reduce the speed and increase the torque. While the pneumatic tool is versatile and absolutely safe, they also suffer from certain disadvantages, as detailed below:
Like universal tools, the pneumatic tools also exhibit steep fall in speed on increasing loads and a tendency for stalling;
They require a centralized compressed-air line, which is expensive and difficult to maintain;
As the pneumatic motor operates best on dry air, free from dust and moisture, each of the tools must be equipped with a FRL (Filter-Regulator-Lubricator) unit;
Over its life, due to continuous ware and tare the pneumatic tool requires regular maintenance, as also the air line;
Even with a well-designed compressor and air line, the pneumatic system is very inefficient. The overall efficiency of the system, as measured by the ratio of the power available at the output shaft of the tool to the input of the motor of the compressor, is very poor compared to the electric system; and
The overall systems costs are quite high.
It is mainly to obviate the drawbacks of the universal electric and pneumatic tools that the high frequency (BF) tools were developed. The HF tools employ a three-phase AC induction motor as the prime mover. This motor, with its virtually indestructible die-cast rotor, is very rugged and reliable. Also the motor exhibits a speed-torque characteristic that is totally different from the universal and pneumatic tools. The speed of the induction motor drops very little on the application of the fall load and this results in higher productivity and it is virtually impossible to stall this type of motor by hand.
It is also a known fact that the speed of the induction motor is proportional to the frequency and at the nominal power frequency of 50 or 60Hz that is generally available, the maximum speed that can be achieved from an induction motor is only about 3000/3600 rpm. As the size of an electric motor for a given output is inversely proportional to its operating speed, the size of the motor for a particular output will be higher than that of the universal motor with its high operating speeds. Thus an induction motor operating from the conventional line frequency will be heavy and portability can be achieved only by increasing the frequency of operation of the induction motor.
This type of HF tools made their appearance in the market a few decades ago. As the tools required higher frequency, there was a centralized frequency converter to convert the 50 or 60 Hz, three-phase supply to 200/300/400 Hz three-phase supply. There were separate running power lines to distribute the HF supply to various places in the shop floor. Non-standard electrical accessories in the form of plugs and sockets were used to differentiate them with the standard parts meant for 50/60 Hz usage.
While the HF tools were advantageous from the point of view of reliability, productivity and operational efficiency, they suffered in terms of high cost of installation of the centralized HF converter and distribution system. They were virtually excluded in the one-off usage or DIY applications due the high costs of the high frequency converter and the distribution network. They found their use only in cases where a battery of such tools is applied. Even here, there was the disadvantage that the HF converter had to be switched ON even when only one or a few tools were needed to be operated.
Also both the HF and the pneumatic tools suffer from the handicap that they are not truly portable in the sense that a separate air line or HF line is required for operation of them. And they certainly ruled themselves out in the case of DIY or typical one-off usage in smaller shops.
One of the objects of this invention is to obviate the above drawbacks by utilizing the electronic circuit of a frequency cum phase inverter, as described in my co-pending U.S. patent application filed concurrently for an AC motor or a brushless DC (BLDC) motor within the tool itself, which is incorporated herein by reference.
The second object of the invention is to provide heat sink for the power transistors of the PWM bridge inverter of a high frequency cum phase inverter in the tool.
The third object of the invention is to accelerate the motor in a soft-start mode limiting the in-rush current during starting.
SUMMARY OF THE INVENTION
To achieve these and other objectives, this invention provides a portable electric tool comprising:
a casing for a motor;
a non-drive end cover having a bearing at its center for the motor;
a heat sink provided either integrally or separately on the covers;
PWM bridge inverter consisting of power transistors with corresponding gates, the output of the PWM bridge inverter is connected to the said motor;
the power transistors terminals are connected to a printed circuit board (PB) and are mounted on the heat sink;
the controller unit having a software program of short code length and the driver IC for driving the gates are connected to another printed circuit board (CB);
the two boards (PB & CB) are inter-connected for determining the timing sequences for generating the signals for switching ON/OFF the gates of the power transistors of the PWM bridge inverter in order to produce variable voltage variable frequency (VVVF), sinusoidal wave forms for controlling the speed of the said motor using space vector pulse width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM) technique, and are mounted through mounting means to the heat sink; and
a cooling means mounted on the shaft of the motor to first cool the electronics of PB & CB mounted on the heat sink and thereafter cool the stator of the motor;
an input rectifier and the filter capacitors are connected to PWM bridge inverter, an auxiliary power supply, which provides the power supply to the controller unit and the driver IC are housed in the handle of the tool.
The motor is an AC motor or brushless DC motor. The AC motor is a single-phase motor or a three phase motor or a poly-phase motor. The AC motor is an induction, reluctance or synchronous motor. The brushless DC (BLDC) motor is in two or three phases with two or three pairs of winding.
The PWM bridge inverter (single phase inverter) includes at least 4 power transistors with corresponding gates in case a single-phase motor is connected at its output.
The software program provides no more than four switching configurations of the inverter bridge to produce variable voltage variable frequency (VVVF) sinusoidal voltage wave form for controlling the speed of the single-phase motor using space vector width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM) technique.
The PWM bridge inverter (three-phase inverter) includes at least six power transistors with corresponding gates and the AC motor connected to the output of the PWM bridge inverter is a three-phase motor or brushless DC (BLDC) motor with three pairs of windings (three-phases).
The software program provides no more than eight switching configurations of the inverter bridge to produce variable voltage variable frequency (VVVF) sinusoidal voltage wave form for controlling the speed of the three phase motor using space vector width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM) technique.
Two single phase PWM bridges totaling eight power transistors are provided for BLDC motor with two pairs of winding (two-phase motor), the output of each of these two bridges is connected to the two winding pairs such that the output of second winding is delayed by 90° from the first one.
The software program manipulates switching configurations of the inverter bridge to produce variable voltage variable frequency (VVVF) sinusoidal voltage wave form for controlling the speed of the motor using space vector width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM) technique.
The mounting means includes the mounting screws and the means for cooling is an induced draft fan.
A higher grade silicon steel of reduced thickness is used as core in the motor to reduce the core-losses of the said motor.
The ON/OFF switch of the tool is also incorporated in the handle.
The output shaft of the motor is connected to the gearbox, when required.
The controller is a micro-controller with the associated processor, ROM, RAM and the input/output (I/O ports) having the software program in ROM to produce timing signals through the output port to the gates through the driver IC.
The software program includes soft-start means.
The controller unit provides a multi-speed capability to the motor, if desired.
The power transistors in the PWM bridge inverter are of MOSFET (metal oxide semi-conductor field effect transistor) or IGBT (insulated gate bi-polar transistor) type to make the gate driver circuitry simple.
The heat sink for the power transistors and the non-drive side end cover of the motor have been integrated to achieve optimum utilization of space.
Thermal over-load protection means is provided for the motor windings.
The over-current protection means is provided for the PWM bridge inverter.
The short code length of the program is in the range of 100-1000 bytes, preferably in the range of 200-400 bytes depending upon the number of speed steps required.
The software program in the micro-controller is such that it obtains the maximum utilization of the input DC voltage to the inverter by the implementation of SVPWM technique.
The software program generates a symmetric pattern of timing signals thereby producing variable voltage variable frequency (VVVF) single phase or polyphase sinusoidal wave forms with the least harmonic content.
The software program also includes means to generate dead band in the switching signals to ensure that at no point of time any 2 transistors in the same leg of PWM bridge inverter are conducting simultaneously.
The software program further includes means to obtain the set speed of the motor from the operator console.
The auxiliary power supply means generates the 5V, 15V DC required for powering the micro-controller and the driver IC respectively.
The controller, driver IC and the auxiliary power supply are implemented in an ASIC.
The controller ASIC has means to interface with an external memory chip, if required.
A digital sign wave synthesizer is provided, which generates in real time, a set of single phase or polyphase wave forms as per the Space Vector Pulse Width Modulation (SVPWM) technique.
The controller unit and the passive components are implemented in a hybrid IC.
The invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIGS. 1-3 show the general assembly arrangement of three types and sizes of the tools, namely, HF Angle Grinder, HF Drill and HF Die Polisher respectively incorporating a frequency cum phase inverter inside the tool itself according to the invention. The layout of the electrical, electronic circuitry of micro-controller, PWM bridge inverter and mechanical systems are shown therein.
FIG. 4 shows the block diagram of the electronic circuitry of the frequency cum phase converter consisting of the rectifier-filter ( 1 ), the three phase PWM bridge Inverter ( 2 ), the gate driver IC ( 4 ), the motor ( 3 ), the microcontroller ( 5 ) and the auxiliary power supply ( 6 ) for the processor and the gate driver IC.
FIG. 5 a a shows PWM single phase bridge inverter consisting of 4 power transistors with corresponding gates for a single phase induction motor.
FIG. 5 b illustrates in greater detail the six power transistors, three-phase PWM bridge inverter. R, Y and B are the three phase outputs, QI-Q 6 are the power transistors and G 1 -G 6 are the six gates of the transistors.
FIG. 6 a illustrates the four possible switching combinations of the four power transistors of the single phase inverter bridge.
FIG. 6 b illustrates the eight possible switching combinations of the six power transistors, three-phase inverter bridge. The ON or OFF state of the bottom side power device of the bridge is considered to denote the state of the bridge. The eight possible combinations are V 0 -V 7 . V 0 and V 7 represent the bridge in OFF or non-conducting condition in that either all the three bottom or the top power devices are in ON State. In all the other six states V 1 -V 6 , the bridge is in ON State. One or two of the topside devices and two or one of the other bottom side devices are in ON State.
FIG. 7 illustrates the soft-start mechanism. The step by step incrementing of the frequency and speed and the shifting of the maximum torque position is explained therein.
FIG. 8 shows the variation of the current with speed as the motor is accelerated in the soft-start mode. The inrush current is limited to I max during the entire acceleration period.
FIG. 9 illustrates the flow-chart for implementation of the software for the micro-controller. The main program for the Start/Stop control and the subroutine for the implementation of the Space Vector PWM technique is shown therein.
FIG. 10 shows the variations of the weight of the motor and the gearbox with respect to speed. The variation of the complete weight of the tool as a function of the speed is also given.
FIG. 11 shows the exploded view of the portable high frequency (HF) tool and the positioning and packaging of the various sub-assemblies as indicated therein.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-3, the general layout of the assembly of tools viz. angle grinder, portable grill and Die Polisher is given. The assembly of the tool is made up of the electronic frequency-cum-phase converter, the stator, die-cast rotor, housing, the gearbox and the output shaft. In the die polisher, shown in FIG. 3, since the full high speed of the motor is required at the output shaft, there is no gearbox. There is also a cooling fan fitted to the motor shaft. The fan sucks the cool air from the ambient, first passing it over the heat sink of the power transistors and then passing it over the stator of the motor.
The packaging of the electronics, viz., the rectifier-filter ( 1 ), the printed circuit board (power board) (PB) and the another printed circuit board (controller board) (CB) is done in an innovative manner, as shown in FIG. 11 . The heat sink (HS) for the power transistors of the inverter bridge and the non-drive side end cover of the motor have been integrated in a novel fashion to achieve optimum utilization of space. The space inside the handle (H) is also utilized to house the filter capacitors and the auxiliary power supply ( 6 ).
The packaging of the electronic circuitry of the frequency cum phase inverter and layout of various sub-assemblies of the tool is displayed in FIG. 11, which is an exploded view of the assembly bringing out the novel features of the assembly. In this view, only the motor (M) and the handle side (H) of the assembly, where the electronic circuitry of the frequency cum phase inverter is packed, is shown. The gear-box side of the tool, where the output shaft of the motor is connected to the gear box and from there to the tool holder is not shown in this figure. The gear-box side of the tool is common for different types. In FIG. 11, (B) is the casing that houses the motor stator, (HS) is the non-drive end cover of the motor with heat sink, which houses the bearing (B 1 ) in the center and has slots at its periphery. This end cover also acts as a heat sink for the power transistors of the PWM bridge inverter ( 2 ) and thus has a dual function. (PB) is the power board in which the power transistors of the PWM bridge inverter (single or three phase inverter) are mounted and the power transistors are placed on the corresponding slots of the end cover cum heat sink (HS). (CB) is the control board on which the micro-controller and the driver IC are mounted. Item (C) in FIG. 11 shows the rectifier-filter and the auxiliary power supply ( 6 ) and these are housed inside the handle (H). The two boards (PB) and (CB) are interconnected and are mounted through the mounting screws (S) to the heat sink (HS). The ON/OFF switch of the tool is also incorporated in the handle (H). The heat sink for the power transistors and the non-drive end cover of the motor have been integrated to achieve optimum utilization of space. Further, the space inside the handle ( 11 ) is also utilized to house the rectifier-filter and the auxiliary power supply.
It is well known that the weight of an induction motor is inversely proportional to its speed of operation. Thus to achieve a high power/weight ratio, it is necessary to increase the frequency of the motor input voltage. However the tip or peripheral speeds of the tool like the drill-bit or the grinding wheel is limited and higher sized tools have to operate at correspondingly lower speeds. Thus there is a need for interposing a gearbox between the motor and the tool and this adds to the weight of the tool itself.
In FIG. 10 the effects of the speed on the weight of both the motor and the gearbox are given. The weight of the motor decreases hyperbolically with the increase in frequency (or speed) while that of the gearbox increases linearly with frequency. The resultant total weight of the tool thus exhibits a trough near 200-400 Hz. And this is generally the range in which the HF motors for power tools are designed and operated.
The core loss of the motor increases with frequency and to reduce the same it is necessary to use higher-grade silicon steel of reduced thickness. But the weight of the motor itself reduces, thereby resulting in cost reduction. Thus there is a trade off between the cost and efficiency of the motor.
In FIG. 4 the frequency-cum-phase converter includes of rectifier-filter (I), the six-power transistors Inverter Bridge ( 2 ) (three phase inverter), the micro-controller ( 5 ) for generation of the PWM signals through driver IC ( 4 ) and the auxiliary power supply ( 6 ). The power transistors are of MOSFFT (Metal Oxide Semiconductor Field Effect Transistor) or IGBT (insulated gate bi-polar transistor) type. Since the gate of the transistor is insulated from the other two terminals, source and drain, the design of the gate driver circuitry is made simple. The power transistors are mounted on power board (PB).
The three phase Inverter Bridge is displayed in FIG. 5 ( b ). Q 1 -Q 6 are the six MOSFETs and G 1 -G 6 are the corresponding gates. A high signal at the gate turns the transistor ON and a low signal turns it OFF. The switching signals to generate a sinusoidal, three-phase wave are given by the controller as per the logic of the algorithm. R, Y and B are three-phase outputs, which are connected to the stator windings of the motor.
A gate driver IC ( 4 ) is used to drive the gates of the six MOSFETs. The IC provides the right signals for the three lower side transistors Q 2 , Q 4 and Q 6 and the signals with the required offset voltages for the three high side transistors Q 1 , Q 3 and Q 5 . The micro-controller ( 5 ) gives the required input signals to this IC ( 4 ). The controller also ensures that at no time any or all of the three complementary pairs of transistors Q 1 /Q 2 , Q 3 /Q 4 or Q 5 /Q 6 are simultaneously switched ON, lest the DC bus gets short-circuited. The three tools shown in FIGS. 1-3, respectively, have ratings of the inverter varying between 300 W to 1800 W. The input a supply in all these cases is 240 V, 50 Hz, Single-phase.
The controller unit ( 5 ) is a microprocessor based one with the associated CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory) and I/O (Input/Output) ports. The main job of the controller unit ( 5 ) is to generate switching signals to the six gates G 1 -G 6 of the bridge in a cyclic manner determined by the SVPWM algorithm. This algorithm has been implemented in a novel way and occupies only about 200 bytes long code.
The principle of the SVPWM method of digital synthesis of the three-phase sinusoidal waveform is explained in T. G. Habetler, ‘A Space Vector Based Rectifier Regulator For AC/DC Converters’, IEEE trans. power electronics, vol VIII, no. 1, pp 30-36, 1993, the disclosure for which is incorporated herein by reference for background information only. The same is explained briefly in the following manner. There are basically eight basic safe switching combinations of the inverter bridge (three phase inverter, as shown in FIG. 6 b ). In two of them, either all the top or the bottom transistors are ON and their complementary bottom/top transistors are in OFF position. Under both these conditions the bridge is not conducting. There are six other possible combinations in which the bridge conducts, when one or two of the topside transistors is ON and their complementary bottom side transistors are in OFF position. It is to be remembered that at no time, any of the complementary pairs must be ON simultaneously.
Any two of the above switching combinations can represent the sum of the three phase voltages of the stator of the motor at a particular instant. The stator voltage vector is resolved into two of the six possible pairs and the algorithm computes the ON times for each of these two combinations. As this vector moves in time through one cycle, the switching combination and the dwelling times of the corresponding two switching combinations are computed by the algorithm. The switching signals are sent through the output port of the micro-controller to the driver IC and thereon to the gates of the transistors of the inverter bridge. This PWM signals repeat at the desired frequency and the program loops continuously. The program checks for the ON/OFF position of the switch by means of an interrupt routine on a regular basis and once an OFF position is sensed, the bridge is shut down.
There is also an over-current protection for the bridge and whenever this set value is exceeded the bridge is completely shut off by the controller. The controller also ensures that the default position of the bridge is the non-conducting state.
Another novelty of this invention is the soft-start feature that is provided for in the software. When the tool is switched ON, the controller does not set the voltage and the frequency corresponding to the rated values. Instead it sets the values of both V and f at a lower value and the same are increased in steps as per the rules of the soft-start routine to the rated values. The software takes care of this routine also. This feature can be explained in greater detail with the help of FIGS. 7 and 8.
In FIGS. 7 and 8 the soft-start feature with five steps are shown. FIG. 7 shows the Torque vs. Speed curves for the five steps while FIG. 8 illustrates the variation of Current with Speed for the same steps. The inverter and hence the motor is started in step 1 at a low frequency and its corresponding voltage. The starting torque is very high and the starting current is well within the allowed value of I max . As the motor accelerates, the speed reaches the value corresponding to step 2 . The current value also decreases. At this point both the voltage and frequency are increased. The maximum or pullout torque point is shifted to the right. The motor sees an increase in accelerating torque and the speed further picks up. The current also increases but is kept within I max . Similar exercise is carried out at points 3 , 4 and 5 . The curve relating to step 5 is the Torque Vs. Speed characteristics of the motor at the rated voltage and frequency and the motor follows this curve from the beginning of step 5 and reaches its rated speed.
The motor is started at a frequency f 1 and an output voltage V 1 corresponding to this, to keep V 1 /f 1 at the desired constant value. The value of f 1 is so chosen as to obtain the maximum torque of the motor at a low value of speed. At this point the current is also much less than the usual high value at starting. As the motor accelerates, the controller changes to another operating point V 2 and f 2 . The motor speed further increases, without any abnormal increase of current. This process is repeated through V 3 /f 3 , V 4 /f 4 , etc., to the rated voltage V and frequency f. At all these points the V/f is kept constant so that the torque developed by the motor is same at all points. At the same time the inrush current during the acceleration is kept within the desired limits. The repetitive peak current carrying capability of the MOSFETs determines this value. Thus the Inverter Bridge is safe even during direct-on-line starting of the power tool.
Another feature of the software is that whenever there is a change of ON/OFF State in the vertical legs of the bridge, it ensures that both the transistors are not turned ON simultaneously. For example the program will change the switching sequence from 100101 to 101001 during the course of the routine. 100101 means that the transistors Q 1 , Q 4 and Q 6 are ON and the transistors Q 2 , Q 3 and Q 5 are OFF. 101001 means that Q 1 , Q 3 and Q 6 are ON and Q 2 , Q 4 and Q 5 are OFF. During this transition it can be seen that Q 4 is switched from ON to OFF and Q 3 is switched from OFF to ON. It is to be noted that the transistor Q 4 has an inherent turn-off time, i.e., it takes a definite time for the transistor to completely switch off. It is then essential that the other transistor in the same leg, Q 3 be not switched ON before Q 4 is turned off completely. This means that there has to be a time delay between the switching OFF of Q 4 and the switching ON of Q 3 . This delay, known as the dead-band, is required whenever there is such a transition. During the dead-band both the transistors of a vertical leg of the bridge are OFF together. The software provides for such a dead-band and the designer can vary the same by giving a different value to a variable.
In FIG. 9 the flow chart for the program is illustrated. As explained earlier the entire code is optimized and occupies only 200 Bytes of the ROM. The processor executes the program residing in the ROM portion of the processor in real-time to generate the gating signals of the inverter bridge as per the SVPWM method. During starting the soft-start routine is executed. Once the frequency and voltage of the inverter have reached the rated maximum values, the program with suitable interrupt routines checks for the OFF position of the ON/OFF switch. Whenever it senses the OFF position the controller shuts down the bridge by keeping Q 1 , Q 3 and Q 5 or Q 2 , Q 4 and Q 6 in ON state. This is also the case when the over-current protection is activated. Otherwise when the program senses the ON position during the interrupt, the program computes the ON time for the two space vectors and the timer registers of the processor is loaded and another interrupt is enabled. The spatial position, θ of the stator voltage vector is incremented, starting from zero and the switching pattern is sent to the output port for onward transmission to the driver IC. When the timer interrupt overflows, θ is incremented by Δθ and the process repeated, till θ reaches 360. At this point the motor switch position is checked for ON/OFF. Unless an OFF is seen, the program repeats after initializing θ. The program thus can loop indefinitely.
The smoothness of the output sine wave is dependent on and can be varied by changing the value of Δθ. This value, decided by the designer, can be input as variable in the routine. As the memory and execution time requirements of the code is very low, the same can be implemented in a low-end microcontroller resulting in cost savings. Variable speed of the power tool can also be achieved by having a multi-speed switch and depending on the position of this switch, the program can read the corresponding voltage and frequency and generate the timer values for the space vectors. The control for such applications, even when multi-speed is required, is generally of open-loop type and hence the coding is quite simple.
Similar exercise is carried out with PWM bridge inverter (single phase inverter) having four power transistors with four switching configurations, as shown in FIGS. 5 a and 6 a to provide a multi-speed for a single phase motor. For a single phase motor there are two space vectors and four basic switching combinations. The software program in the microcontroller calculates the dwelling times for each of these configurations and the corresponding dead band program is also inserted in the appropriate place like in the case of three-phase circuit.
A brushless DC (BLDC) motor is similar to poly-phase induction motor in construction except that in the brushless DC motor, the rotor is a permanent magnet instead of die-cast aluminum. Generally, the BLDC motor come in 2 or 3 phases with 2 or 3 pairs of windings and the switching is done in a similar manner as two or three phase motor. While the three phase version is similar to the one, which has been described above, in the two phase motor there are two single phase bridges totaling eight power transistors. The output of each of these bridges is connected to the two winding pairs. The output of the winding is delayed by 90° from the first one. When the voltages are applied in a cyclical fashion to the windings as described above, a rotating magnetic field is setup and the permanent magnet rotor follows this field and revolves continuously.
The motor winding temperature can also be sensed by means of a thermal cutout, which opens, when excess temperatures are encountered in the windings. Thus the motor windings will also be protected. As explained earlier a suitable dead-band can be input to the program as a variable to protect against the short circuit of the DC bus.
One of the advantages in this portable tool is that apart from a single speed, one can have variable speed of the motor, if desired. | A new series of portable electric tools using high frequency three-phase induction motors with built-in power electronic converter. The tools operate from a single phase AC mains and a built-in power electronic circuitry converts the input supply to a three-phase, higher frequency (200-400 Hz) supply, which is used to drive a three-phase induction motor connected to the gearbox. A microprocessor-based controller, with a novel algorithm, generates three-phase, sinusoidal output waveforms and also provides the soft-start feature for the inverter and the motor. The entire electronics is packaged in a novel way within the housing of the tool itself. The output shaft of the motor, either directly or through a gearbox, can be connected to a wide range of tools like Drills, Grinders, Nut Runners, Screw Drivers, Impact Wrenches, Shears, Nibblers, Saws, Sanders, polishers, etc. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to telecommunication systems providing multiple services that may require possible adaptations depending on the capabilities of the terminal that an end-user is making use of at a certain time.
BACKGROUND
[0002] With the introduction of new network technologies, the spreading of services and applications grows in number and complexity. On the other hand, mobile devices supplied by different manufacturers are expected to be more and more divergent in performance, input and output capabilities, network connectivity, processing power, and many other capabilities.
[0003] As a result of this device heterogeneity, client devices may receive contents from different applications and services, that they cannot store, that they cannot display, or that it takes too long to deliver over the supported network technology.
[0004] Some applications and services need to know characteristics of the terminal used to access the network in order to be able to adapt contents and services to the capabilities of the user terminal, thus improving end-user satisfaction and optimizing network resources.
[0005] Therefore, it is a primary object of the present invention the provision of information about the terminal capabilities of the accessing device to those applications and services running on top of a telecommunication network for improving end-user satisfaction and for optimizing network resources.
RELATED ART
[0006] The standardization body for Wireless Application Protocol (WAP), which is generally known as the WAP Forum, specifies a mechanism incorporated in the WAP2.0 technical specification to enable an end-to-end flow of a User Agent Profile (hereinafter UAProf) between a WAP client, intermediate network points, and an originating server. This User Agent Profile includes a set of terminal capabilities information. Heretofore, this is a partial solution to the problem of letting the applications and services know about terminal capabilities, since it is only valid for WAP applications and WAP terminals. However, UAProf proposes an end-to-end negotiation of terminal capabilities between the application server and the mobile terminal, thus increasing traffic load and latency time whenever a new service is accessed.
[0007] In addition, the new Mobile Execution Environment (hereinafter MExE) specification within the 3 rd Generation Partnership Project (3GPP) describes an application environment for the latest generations of mobile devices. This MExE comprises a variety of current technologies and incorporates both WAP and Java, including also a framework which specifies, among others, capabilities and contents negotiation.
[0008] Different technologies follow different mechanisms in order to provide those applications running on top of such technologies with terminal capabilities information intended for adapting contents to particular terminals. That is the case of both WAP and MExE above. The use of UAProf, for instance, is widely spread around these technologies, and generally accepted as a convenient solution to the problem of representing and exchanging terminal capabilities information. Other suitable mechanism under WAP or MExE is the so-called Composite Capability Preference Profiles (CC/PP), which is an application of the extensible Mark-up Language (XML) used to describe capabilities and preferences associated with a user, and the agents used by a user to access the network. These user agents include the hardware platform, system software and applications used by the user. User agent capabilities and references can be thought as meta data or properties, and descriptions of the user agent hardware and software.
[0009] Despite the current trends of using solutions based on UAProf or CC/PP, these technologies above implement such solutions in a proprietary manner, making each solution incompatible with the others. Moreover, these solutions propose that a dialog for negotiating terminal capabilities is directly established between the terminal and each application server, making it necessary to the terminal the sending of such terminal capabilities to any new application server that the user wants to make use of. This leads to an unnecessary increment of traffic from terminal equipment to application servers and consequently to an increase on the latency time when accessing a service, what is more significant in a mobile environment.
[0010] In addition to this, the terminal equipment has to implement a new protocol for negotiation of terminal capabilities for every different technology. In other words, a terminal equipment implementing WAP and MExE has to implement UAProf and/or CC/PP for WAP and for MExE.
[0011] The international application WO 99/41931 describes a mechanism for an application server to deal with terminal capabilities. This application proposes a peer-to-peer mechanism between the terminal and the server to let the server know the terminal identifier by using an Unstructured Supplementary Service Data (USSD) message included in the Mobile Application Part (MAP) protocol. The server assumes the responsibility to look for terminal capabilities outside the mobile network and based on said terminal identifier. Thus, the establishment of a relation between the user identity and the terminal identifier is not solved. Terminal capabilities information is related in no way with the rest of the user profile, forcing the application server to use different mechanisms to access user profile and terminal capabilities.
[0012] Moreover, the European application EP 1 051 054 describes a mechanism for allowing the use of a service, or for adapting the service behaviour, depending on the terminal capabilities and the specific location, by accessing to certain databases tracking the mobile equipment and the geographic location. However, this mechanism only provides a reference of the equipment model to the application server, leaving to the application the responsibility of obtaining the specific terminal capabilities. Moreover, the invention does not solve the establishment of relations between the user identity and the terminal equipment identifier.
[0013] None of the patent applications or standardization bodies above provides for a telecommunication network based solution where the terminal capabilities of a terminal equipment, which is currently in use by a user, can be directly obtained by any application server from said telecommunication network by simply making use of the user identity.
[0014] It is therefore an object of the present invention the provision of a telecommunication network based solution where the terminal capabilities of a terminal equipment, which is currently in use by a user, can be directly obtained from the telecommunication network by any application server running on top of said telecommunication network by simply making use of the user identity.
[0015] It is a further object of the present invention to relate the terminal capabilities of said terminal equipment with the user profile data for the user currently making use of such terminal equipment.
SUMMARY OF THE INVENTION
[0016] The objects above are accomplished by the present invention with a method, a system and apparatus for providing capabilities of a terminal equipment operated by a user in a telecommunication system to an application server intended for offering services to said user through such terminal equipment.
[0017] The method comprising the steps of: storing in the telecommunication system capabilities of at least one of a plurality of terminal equipment; establishing a temporary relationship between the user operating a terminal equipment and the capabilities of said terminal equipment; and providing capabilities of the terminal equipment currently in use by the given user, from the telecommunication system to an application server.
[0018] In accordance with this method, the step of storing terminal capabilities in the telecommunication system includes a step of correlating capabilities of each terminal equipment with an identifier of said terminal equipment.
[0019] Also according to this method, the establishment of a temporary relationship between user and terminal equipment comprises the steps of: sending from the terminal equipment toward the telecommunication system an identifier of said terminal equipment along with the user identity; receiving the user identity and the current terminal equipment identifier at an entity holding user profile data in the telecommunication system; and linking user profile data, user identity and terminal equipment identifier.
[0020] An advantageous use of this method is the provision of capabilities of a terminal operated by a given user at request from an application server. Such mechanism comprises the steps of: requesting from an application server to a telecommunication network, by providing the user identity, the capabilities of the terminal operated by the given user; obtaining at an entity that holds user profile data in the telecommunication network the terminal equipment identifier linked to said user identity; fetching from storage the list of capabilities stored for such terminal equipment identifier; and responding to the application server from the telecommunication network with the list of capabilities requested.
[0021] There is also proposed a telecommunication system in accordance with the invention for providing capabilities of a terminal equipment operated by a user to an application server intended for offering services to said user through such terminal equipment.
[0022] This telecommunication system comprising: means for storing capabilities of at least one of a plurality of terminal equipment; means for establishing a temporary relationship between the user operating a terminal equipment and the capabilities of said terminal equipment; and means for providing capabilities of a terminal equipment currently in use by a given user to the application server.
[0023] Therefore, the telecommunication system further includes: means for receiving a user identity and a terminal equipment identifier of the terminal currently operated by said user; and means for linking user profile data, user identity and terminal equipment identifier; both means preferably located at an entity holding user profile data in the telecommunication system.
[0024] More specifically and directly addressed to objects of the invention, the telecommunication system also comprises: means for receiving a request from an application server for providing the capabilities of a terminal equipment, the request including the user identity of the user operating said terminal equipment; means for obtaining the terminal equipment identifier linked to said user identity; means for fetching from storage the list of capabilities stored for such terminal equipment identifier; and means for responding to the application server with the list of capabilities requested for the indicated user identity.
[0025] The telecommunication network in accordance with the invention may receive through an entry node the terminal equipment identifier and the user identity sent from the terminal equipment. This entry node likely interposed between the terminal and another entity holding user profile data in the telecommunication network. In this case, such telecommunication network entry node transfers the received terminal equipment identifier and user identity to said entity holding user profile data.
[0026] In particular, the network entity holding user profile data may be a Home Location Register (HLR), or a Home Subscriber Server (HSS) whereas the entry node may be a Mobile Switching Center (MSC), or a Serving GPRS Support Node (SGSN) . Under this scenario, the terminal equipment identifier and the user identity may be both included in an Update Location message. However, the entry node to the telecommunication network may be a Call Status Control Function (CSCF) as well, where the terminal equipment identifier and the user identity may be both included in an Cx-put message.
[0027] Also in particular, the network entity holding user profile data, and thus receiving the terminal equipment identifier and the user identity, may be an Authentication Authorization and Accounting (AAA) server. Such network entity may be accessed at the telecommunication network via a Network Access Server (NAS) or a WLAN Support Node (WSN) acting as network entry node. Under this scenario, the terminal equipment identifier and the user identity are both included in a message intended for Access Request from the entry node to the entity holding user profile data.
[0028] In accordance with the invention, user profile data, user identity and terminal equipment identifier are linked on a per user basis in a Home Location Register (HLR), or in a Home Subscriber Server (HSS), or in an Authentication Authorization and Accounting (AAA) server.
[0029] In addition, the invention proposes a Terminal Capabilities Database where user identities and terminal equipment identifiers are linked on a per user basis. Then, terminal capabilities are stored in a storage accessible to said Terminal Capabilities Database and correlated therein with a terminal equipment identifier.
[0030] Detailed preferred embodiments are further described wherein an application server requests to a Home Location Register (HLR), or a Home Subscriber Server (HSS), or an Authentication Authorization and Accounting (AAA) server the terminal capabilities of a terminal equipment by providing the user identity of the user operating said terminal equipment. Then, a list of terminal capabilities associated to said terminal equipment identifier is fetched from a storage accessible to the Terminal Capabilities Database.
BRIEF DESCRIPTION OF DRAWINGS
[0031] The features, objects and advantages of the invention will become apparent by reading this description in conjunction with the accompanying drawings, in which:
[0032] [0032]FIG. 1 basically represents how an application server can obtain from a telecommunication network information about the terminal capabilities of a terminal equipment currently in use by a user where the telecommunication network is a mobile network—Circuit, Packet, or IP Multimedia—or a wireless network.
[0033] [0033]FIG. 2 basically represents how an application server can obtain from a telecommunication network information about the terminal capabilities of a terminal equipment currently in use by a user accessing to services through an Internet Service Provider (ISP).
[0034] [0034]FIG. 3 shows a simplified view of the signalling flow for identifying the terminal capabilities of a terminal equipment currently in use by a user accessing the telecommunication network in FIG. 1 and the signalling flow for an application server to obtain said terminal capabilities, wherein the telecommunication network is a GSM, or GPRS network.
[0035] [0035]FIG. 4 shows a simplified view of the signalling flow for identifying the terminal capabilities of a terminal equipment currently in use by a user accessing via an Internet Service Provider as shown in FIG. 2, and the signalling flow for an application server to obtain said terminal capabilities.
[0036] [0036]FIG. 5 shows a simplified view of the signalling flow for identifying the terminal capabilities of a terminal equipment currently in use by a user accessing the telecommunication network in FIG. 1 and the signalling flow for an application server to obtain said terminal capabilities, wherein the telecommunication network is an IP Multimedia network following 3GPP standards.
[0037] [0037]FIG. 6 shows a simplified view of the signalling flow for identifying the terminal capabilities of a terminal equipment currently in use by a user accessing an Internet Service Provider through a Wireless Local Area Network (WLAN), and the signalling flow for an application server to obtain said terminal capabilities.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] The following describes currently preferred embodiments of means, methods and system for providing terminal capabilities of a terminal equipment, which is currently in use by a user, to any application server by simply making use of the user identity. In accordance with an aspect of the present invention, the terminal capabilities of said terminal equipment are related with the user profile data for said user currently making use of such terminal equipment.
[0039] Thus, this invention gives to any application server the possibility of getting the capabilities of the terminal being used by a certain user at any time. The application server thus performs this retrieval of capabilities in order to adapt the contents to be served to the terminal in the most suitable way. For example, if an streaming server is about sending an MPEG video to a terminal, it may be worthwhile to know if the terminal is able to display such kind of files.
[0040] Therefore, a proposed solution is depicted in FIGS. 1 and 2 for a user accessing an application server ( 20 ) through a telecommunication network ( 1 ) via a generic access network ( 2 ) or via an Internet Service Provider ( 3 ) respectively. There is provided in accordance with the invention a Terminal Capabilities Database ( 10 ) (hereinafter referred to as TC-DB) in a telecommunication network ( 1 ) in order to store a temporary relationship between the user and the terminal equipment ( 30 , 31 ) that he or she is making use of.
[0041] Also, this TC-DB is in charge of storing the terminal capabilities descriptions in a predefined and well known format, by using CC/PP for example, though this latter functionality can be achieved with an external storage in addition to the TC-DB. Such optional storage is shown in FIGS. 1 and 2 as a Capability Repository ( 11 ).
[0042] When a user provided with a terminal equipment ( 30 ) attaches (S-1×) to a telecommunication network ( 1 ), as depicted in FIG. 1, the terminal identifier is sent to the network entry point ( 12 ) which forwards (S-2×) the terminal identifier to a telecommunication network database ( 13 ) where subscriber profiles reside. In particular, in a traditional 2 nd generation mobile system, said telecommunication network database is a Home Location Register (HLR) whereas in 3 rd generation mobile systems with IP Multimedia the telecommunication network database is a Home Subscriber Server (HSS) . For the purpose of the present invention they are individually referred to as HLR/HSS irrespective of being given IP Multimedia or not.
[0043] This forwarding can be performed, for example, just by upgrading the existing Location Update message, which is addressed to both HLR and HSS, in order to contain such terminal identifier.
[0044] In accordance with another aspect of the present invention, the TC-DB ( 10 ) functionality may be collocated or included in a Home Location Register (HLR) or in Home Subscriber Server (HSS). An upgraded Location Update message comprising a user identity, as before, and a new data indicating the terminal identifier, is thus received at an HLR/HSS. The aforementioned temporary relationship between the user and the terminal equipment, the latter being identified by said terminal identifier, may be established at said HLR/HSS, wherein this relationship includes the whole user profile, or may be established as well at the TC-DB wherein just the indicated user identity and terminal identifier are stored.
[0045] In a first embodiment of the present invention, the HLR/HSS maintains the temporary relationship between the user identity and the terminal identifier whereas the TC-DB alone or in combination with the Capability Repository ( 11 ) merely comprises lists of capabilities on a per terminal identifier basis. In a second embodiment of the present invention, the TC-DB ( 10 ) is the one maintaining such relationship, whereas the Capability Repository ( 11 ) comprises the lists of capabilities on a per terminal identifier basis. Also under this second embodiment, the HLR/HSS is the only one maintaining the user profiles so that in case the TC-DB is directly queried from an application server about capabilities of the terminal a given user makes use of, such query done with a user identity other than the one linked to the terminal identifier under TC-DB premises, the TC-DB can always query the HLR/HSS about another user identity known to the TC-DB.
[0046] Notwithstanding this, the mechanism explained throughout this description, in terms of system, means and method, considers separate entities for the sake of clarity in respect of the different functions and means residing in said HLR/HSS and TC-DB.
[0047] The HLR/HSS then, and likely in cooperation with the TC-DB, links the terminal identifier to the relevant user identity of the user making use of such terminal equipment at that time. As referred above such link may as well be performed at the TC-DB without substantially modifying the scope of the invention. However, given that a user might make use of different user identities under different scenarios, the skilled person would find more advantageous that a relation between the terminal identifier and the user profile data resides at the HLR/HSS.
[0048] From now on and whilst the user makes use of such terminal equipment ( 30 ), the HLR/HSS ( 13 ), in co-operation with the TC-DB ( 10 ), is ready to provide any application server ( 20 ) with the terminal capabilities of a given user. Thus, the application server does not need to have any knowledge about terminal identities and their formats.
[0049] Consequently, when an application server ( 20 ) needs to perform a retrieval (S-3×) of terminal capabilities for a given user, a request message is sent (S-3×, S-4×) to the TC-DB, likely through the HLR/HSS ( 13 ) in charge of said user in the telecommunication network ( 1 ). The TC-DB searches in a list what is the terminal linked to said user at that time. Once the terminal identifier is found, it is used to get a list of the capabilities associated to that terminal. This list of capabilities can be found, for example, as a file in CC/PP format and stored either directly in the TC-DB, or alternatively in an external storage as the Capability Repository ( 11 ).
[0050] Generic signalling flows are shown in FIGS. 3 , and 5 where the telecommunication network is a mobile network. The generic flow in FIG. 3 is applicable to Circuit and Packet domains, whereas FIG. 5 is rather oriented to 3 rd generation (3G) mobile systems provided with IP Mobility (IP-M). Particular explanations are given following this on a per domain basis, when relevant for a skilled person to understand aspects of the invention.
[0051] As shown in FIGS. 3 , and 5 , the mobile terminal ( 30 ), namely a Mobile Station (MS), provides (S-1×) its terminal identifier to the mobile network entry point. Said network entry point is a Mobile Switching Center (MSC) in a Circuit domain, or a Serving GPRS Support Node (SGSN) in a Packet domain, or a Call Status Control Function (CSCF) in a 3G mobile system with IP-M.
[0052] In particular and as shown in FIG. 3, the “Identity Request” operation may be used by an MSC ( 12 ) or an SGSN ( 12 ) to ask the terminal ( 30 ) for applicable terminal identifiers like, for example, the International Mobile Equipment Identity (IMEI) . The MSC/SGSN ( 12 ) can initiate the identification procedure at any time by transferring an Identity Request message (S- 11 ) to the mobile station ( 30 ) indicating the requested identifier within the “identity type” field. The mobile station sends back (S- 12 ) to the network entry node ( 12 ) the terminal identity code, like the IMEI code for example, encapsulated in an “Identity Response” message. Such identity code is then stored in the MSC/SGSN ( 12 ) which forwards (S- 21 ) it to the HLR/HSS. In accordance with an aspect of the present invention, this terminal identifier can be encapsulated in the Location Update message amended to this end.
[0053] A similar behaviour is proposed for IP Multimedia access in 3GPP as shown in FIG. 5, wherein the mobile station ( 30 ) sends (S- 13 ) the terminal identity code at registration time, namely an IMEI or similar, by using a Register message towards a Serving CSCF (S-CSCF) where the received code is stored. The S-CSCF then forwards (S- 21 ) this terminal identity code to the HLR/HSS through the 3GPP-standardized Cx Interface. Therefore, either a new signalling message is provided for, or an upgraded Cx-Put message is used.
[0054] The complete process has been somewhat simplified in FIG. 5 for the sake of clarity as anyone skilled in the art may appreciate. In fact, a negotiation and selection of said S-CSCF has been carried out from an Interrogating CSCF (I-CSCF) that forwards then the Register message to the selected S-CSCF.
[0055] From now on and as illustrated in FIGS. 3 and 5, an application server ( 20 ) can request (S- 31 ), at any time, the terminal capabilities of the terminal currently in use by a given user by sending the user identity to the HLR/HSS. The HLR/HSS, after looking up the terminal identifier associated to said user, retrieves (S- 41 , S- 42 ) the terminal capabilities from the TD-DB ( 10 ) and returns (S- 32 ) the list of capabilities corresponding to the terminal back to the requester application server ( 20 ). The protocol used between HLR/HSS and the TC-DB could be Diameter, Lightweight Directory Access Protocol (LDAP), XML including Simple Object Access Protocol (SOAP), or whatever protocol allowing the transmission of terminal capabilities descriptions.
[0056] The solution can be applied as well to provide a centralised terminal capabilities database for those users accessing to services through an Internet Service Provider (ISP) as FIG. 2 illustrates. An ISP can check, bill and attend the user based on the username. A mechanism according to the invention, in terms of system, method and apparatus, thus allows the ISP to receive information about the capabilities of the terminal equipment used by a user by including additional information in existing messages used for Authentication, Authorisation and/or Accounting (hereinafter AAA) toward a corresponding server.
[0057] When a user provided with a terminal equipment ( 31 ) requests access (S-6×) to an ISP via a telecommunication network ( 1 ), as depicted in FIG. 2, the terminal identifier is sent to the network entry point ( 14 ) which forwards (S-7×) the terminal identifier to a telecommunication network database ( 15 ) where subscriber profiles reside. In particular, the network entry point ( 14 ) is a Network Access Server (NAS) for generic ISP users and the telecommunication network database is an Authentication, Authorization and Accounting (AAA) server, whereas for accessing via WLAN the network entry point ( 14 ) is a WLAN Support Node (WSN) and the telecommunication network database is a Home Subscriber Server (HSS).
[0058] Thus, as illustrated in FIG. 4, the terminal ( 31 ) makes use of existing access request operations to transmit (S- 61 , S- 62 ) the terminal identification and/or model to a Network Access Server (NAS) ( 14 ). Then, the NAS transmits (S- 71 , S- 72 ) the terminal identifier to the AAA-server ( 15 ), for instance by using extensions to the RADIUS and Diameter protocols. This new information may be included in whatever messages transmitted between the NAS ( 14 ) and the AAA-server ( 15 ). For example and as shown in FIG. 4, the terminal identifier has been included in the Access-Request message.
[0059] The AAA-server ( 15 ) under this embodiment behaves in a similar way as the HLR/HSS does in the preceding embodiments above. Such AAA-server ( 15 ) manages, in accordance with an aspect of the invention, the temporary relationship between the user profile and the terminal identifier of the terminal equipment currently in use by said user, whereas the TC-DB comprises the lists of terminal capabilities on per terminal identifier basis. Once more, in accordance with another embodiment of the invention, the TC-DB can be configured to comprise the relationship between particular user identity and terminal equipment identifier and thus receiving the related queries, whereas a co-operating Capability Repository ( 11 ) might be in charge of the lists of terminal capabilities on per terminal identifier basis.
[0060] In a currently preferred embodiment, an application server ( 20 ) may, at any time, request (S- 81 ) the terminal capabilities of the terminal currently in use by a given user by sending the user identity to the AAA-server ( 15 ). The AAA-server, after looking up the terminal identifier associated to said user, retrieves (S- 41 , S- 42 ) the terminal capabilities from the TD-DB ( 10 ) and returns (S 82 ) the list of capabilities corresponding to the terminal back to the requester application server ( 20 ). The protocol used between AAA-server ( 15 ) and the TC-DB ( 10 ) could be also Diameter, LDAP, XML/SOAP or whatever protocol allowing to transmit terminal capabilities descriptions.
[0061] The solution is directly applicable to provide a centralised terminal database for the users acceding ISP through WLAN as FIG. 6 illustrates. The signalling flow under this scenario is similar to the one in FIG. 5 wherein a WLAN Support Node (WSN) is the network entry point ( 14 ), and a Home Subscriber Server (HSS) is the network database in charge of the temporary relationship between user profiles and terminal identifier, both WSN and HSS respectively performing similar procedures as the NAS and AAA in FIG. 5.
[0062] In a further embodiment of the invention not depicted in any drawing it is noticeable its use for a direct access from the terminal equipment without intermediate actuation of a network entry point ( 12 , 14 ). In other words, an exemplary embodiment may be offered where a mobile terminal equipment takes the initiative of sending the terminal identifier to an HLR/HSS for example by means of an Unstructured Supplementary Service Data (USSD) message. Afterwards, and at any time, any application server may request the HLR/HSS about terminal capabilities associated to the given user identity, said terminal capabilities fetched from the TC-DB as in any of preceding preferred embodiments.
[0063] The invention is described above in respect of several embodiments in an illustrative and non-restrictive manner. The scope of the invention is determined by the claims, and any modification of the embodiments that fall within the scope of these claims is intended to be included therein. | The present invention relates to telecommunication systems providing multiple services which could require possible adaptations based on the capabilities of the terminal used to access those services.
Master databases in the telecommunication system take the responsibility to map between terminal and user identifiers. Applications and services are thus able to query terminal related capability information based on a user identity.
In accordance with the invention, a Terminal Capabilities database (TC-DB) is introduced in order to establish a temporary relationship between a user and a terminal operated by such user. When a user attaches to the network, a terminal identifier is sent to the network that forwards that identity to the TC-DB. For retrieval of terminal capabilities the application servers send a request message to the TC-DB by using the user identity as a correlating key. | 7 |
This application is a continuation, of application Ser. No. 826,964, filed Feb. 7, 1986, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to thermoplastic compositions based on grafted rubber and polyester, a process for their manufacture, and industrial articles obtained from the compositions.
Examples in published European Patent Application No. 0,056,123 describe the preparation of a thermoplastic mass comprising 90% by weight of polybutylene terephthalate (PBTP) and 10% by weight of a grafted rubber, by mixing in an extruder at 250° C. the PBTP and a grafted rubber produced in an aqueous dispersion and containing 35% by weight of water.
A slightly modified impact-polystyrene comprising:
from 20 to 80% by weight of a vinylaromatic polymer modified by the presence of 5 to 15% by weight of an unsaturated nitrile and, where applicable, a rubber, and
from 20 to 80% by weight of a crystalline polyester having a molecular weight of preferably 10,000 to 60,000
is known from British Patent No. 2,118,194.
More precisely, Example 6 of this document describes a mixture of 75% by weight of a modified polystyrene (consisting of 84% by weight of styrene, 8% by weight of acrylonitrile and 8% by weight of rubber) and of 25% by weight of polybutylene terephthalate. This mixture has an Izod impact resistance of 49 J/m, considerably lower than that of the initial modified polystyrene.
Furthermore, French Patent No. 2,154,800, and especially its Example 20, discloses a mixture of 20% by weight of high molecular weight polybutylene terephthalate, 60% by weight of a terpolymer of acrylonitrile, butadiene and styrene, and 20% by weight of glass fiber reinforcement. This mixture has an Izod impact resistance of 65 J/m, well below that of a similar binary mixture in which the polybutylene terephthalate is replaced by the terpolymer of acrylonitride, butadiene, and styrene.
Thus, according to the teaching of the prior art, the introduction of 20 to 25% by weight of a high molecular weight crystalline polyester into a polymer based on styrene, acrylonitrile, and rubber results in a decrease in the impact strength of the composition, whether the latter is filled or not.
SUMMARY OF THE INVENTION
The present invention is based on the surprising finding that, contrary to the teaching of the prior art, the introduction of a minor proportion of a high molecular weight crystalline polyester into a polymer based on a vinylaromatic monomer, an unsaturated nitrile, and rubber enables the Izod impact strength, and incidentally other properties, of the composition to be significantly improved, provided that:
the crystalline polyester is polybutylene terephthalate, and
the polymer based on a vinylaromatic monomer, nitrile, and rubber is a specific polymer according to the present invention, different from the polymers used in the prior art.
In addition, the present invention is based on the surprising finding that the Izod impact strength and other properties of such compositions can be further improved by the addition of a third elastomeric component in a well-specified quantity.
Another advantage of the present invention is an improved processability for the conversion of these compositions into industrial articles.
Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the thermoplastic composition of the invention based on a crystalline polyester and a modified vinylaromatic polymer comprises:
from 50 to 97% by weight of at least one polymer phase (A) consisting of at least one terpolymer produced by grafting (a) at least one vinylaromatic monomer and (b) at least one unsaturated nitrile onto (c) at least one rubber, the terpolymer being dispersed in a copolymer matrix comprising units derived from (d) at least one unsaturated nitrile and (e) at least one vinylaromati monomer, the overall composition of the polymer phase (A) being such that it contains from 17 to 35 parts of unsaturated nitrile, from 10 to 60 parts of rubber and from 10 to 60 parts of vinylaromatic monomer per 100 parts by weight of the polymer phase, and from 3 to 50% by weight of at least one high molecular weight polybutylene terephthalate (B).
Further to achieve the foregoing objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the process for the manufacture of a composition according to the invention comprises mixing the polymer phase (A), the polybutylene terephthalate (B), and, where applicable, other components at a temperature above the melting temperature of the polybutylene terephthalate (B) for a sufficient time to produce a homogeneous composition.
Still further to achieve the foregoing objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention comprises articles produced by injection molding, extrusion, or thermoforming of the composition of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention.
For proper understanding of the invention, it should be stated that:
The vinylaromatic monomer (a) and the vinylaromatic monomer (e), which are identical or different from each other, are preferably chosen from styrene and its derivatives such as alpha-methylstyrene, vinyltoluene and vinylnaphthalene,
the unsaturated nitrile (b) and the unsaturated nitrile (d), which are identical or different from each other, are preferably acrylonitrile,
the rubber (c) is preferably chosen from polybutadiene, polyisoprene, butadiene/isoprene copolymers, and ethylene-propylene and ethylene-propylene-diene elastomers,
the weight average molecular weight or the polybutylene terephthalate is preferably between 15,000 and 150,000.
According to an improved embodiment, the thermoplastic composition according to the invention can additionally comprise at least one elastomer (C) in a proportion of up to 25 parts by weight, preferably 3 to 20 parts by weight, per 100 parts of the (A)+(B) mixture. Advantageously, the elastomer (C) can be chosen from:
ethylene/vinyl acetate copolymers comprising from 30 to 80% by weight of acetate and from 20 to 70% by weight of ethylene, these copolymers being generally produced by emulsion polymerization,
butadiene/acrylonitrile copolymers comprising, for example, from 60 to 85% by weight of butadiene and from 15 to 40% by weight of acrylonitrile,
acrylic elastomers such as, in particular, styrene/butyl acrylate/methyl methacrylate copolymers and styrene/butadiene/methyl methacrylate copolymers,
copolymers of a saturated polyester and a polyester, such as, in particular, the block copolymers of poly(butylene terephthalate) and of poly(tetramethylene glycol).
The thermoplastic composition according to the invention can, moreover, comprise at least one lubricant, preferably in a proportion of up to 4 parts by weight per 100 parts by weight of the (A)+(B) mixture or, where applicable, (A)+(B)+(C) mixture. Such a lubricant can be chosen, in particular, from:
the carboxylic acid salts of a metal chosen from the elements of groups IA, IIA, and IIB of the Periodic Classification, especially calcium, zinc, lithium, and magnesium stearates,
oxidized polyethylene waxes,
fatty acid esters such as glycerine,
N,N'-ethylenebis(stearamide).
The thermoplastic composition according to the invention can, moreover, comprise at least one flame retardant. The flame retardant chosen will preferably be a system suitable for flame-retarding the major component of the composition, that is to say the phase (A). Such a system usually comprises at least one halogen compound and at least one metal oxide. The halogen compound, which can be chosen especially from brominated diphenyl ethers of tribromophenoxyethane, is preferably used in a proportion of up to 50 parts by weight per 100 parts by weight of phase (A). The metal oxide, which can be the antimony oxide Sb 2 O 3 in particular, is preferably used in a proportion of upto 30 parts by weight per 100 parts by weight of phase (A).
In accordance with the invention, the process for manufacturing the compositions of the invention described above comprises mixing the phase (A) and the polybutylene terephthalate (B) and, where applicable, the other components such as the elastomer (C), the lubricant, and the flame retardant, at a temperature above the melting temperature of the polybutylene terephthalate (B) for a sufficient time to produce a homogeneous composition. The mixing temperature is preferably between 223° C. and 260° C.; the mixing time is advantageously between 1 and 4 minutes. The process according to the invention can be carried out in any device suitable for mixing polymers such as (A) and (B), for example a kneader or an internal mixer.
The compositions described above have a set of properties that are remarkable relative to those of the prior art, in particular:
an improved Izod impact strength (measured according to the ISO Standard R-180, equivalent to ASTM D 256),
a higher Vicat temperature (measured according to the ISO Standard R-306, equivalent to ASTM D 1525),
an improved multiaxial impact strength (measured according to the DIN standard 53 443),
a higher hot flow index (measured according to the method described in the examples below).
This set of remarkable properties makes the compositions according to the invention especially advantageous from the standpoint of processability and for any applications requiring both good mechanical properties and good heat resistance.
Thus, in accordance with the present invention, the compositions described above are used to produce industrial articles by injection molding, extrusion, and thermoforming. Using the injection molding method, it is possible, in particular, to produce, by subjecting the composition to a temperature between 240° C. and 275° C., articles such as dashboards, consoles, and rear light casings for motor vehicles, meter or spotlight casings, air conditioning components, and the like. Using the extrusion method, it is possible, in particular, to produce sheets up to 3 meters in width and generally between 1 and 10 mm in thickness. These sheets are intended to be subjected to thermoforming, at a temperature increasing incrementally between 230° and 250° C., to produce articles such as casings and enclosures for electrical and electronic equipment, internal fittings for motor vehicles, and the like.
The present invention will also find applications in fields as diverse as furniture, luggage, boats and sailboards, building, caravans, motorcycles, domestic electrical appliances, office equipment, data processing, gardening equipment, refrigerators, radio, video, photographic and television equipment, skis, telephone and remote automation, pipework and connections, and motorcycle helmets.
The following examples are given by way of illustration of the present invention, without limiting it.
EXAMPLES 1 AND 2 (Comparative)
A composition comprising the following is prepared by mixing in an internal mixer rotating at a rate of 70 revolutions/min, at a temperature of 225° C. for 2 minutes:
a powdered polymer (A) marketed by the company CdF CHIMIE ABS under the trademark UGIKRAL TF, comprising 15% by weight of polybutadiene, 25% by weight of acrylonitrile, 15% by weight of styrene, and 45% by weight of alpha-methylstyrene,
a lubricant prepared under the trademark SYMTEWAX by the company COMIEL, and
where applicable (example 2), a flame retardant system consisting of octabromodiphenyl ether (OBDPE) and antimony oxide.
The quantities, expressed in parts by weight, of the various ingredients of the compositions are shown in Table 1 below.
The following properties are measured for the compositions prepared in this manner:
Izod impact strength expressed in J/m and determined at 23° C. on a notched bar specimen, 63.5×12.7×3.2 mm, in accordance with the ISO Standard R-180,
Vicat temperature, expressed in degrees Centigrade and determined at 10 daN in accordance with the ISO Standard R-306,
hot flow index (HFI), expressed in cm and determined as being the length travelled by the material injected at 270° C. into a spiral mold 2×12.5 mm in cross-section under the effect of a pressure of 100 MPa,
multiaxial impact strength (MIS), expressed in J and determined at 23° C. in accordance with the DIN Standard 53443,
limiting oxygen index (LOI), expressed in percent and determined according to ASTM Standard D 2863.
The results of these measurements are shown in Table I below.
EXAMPLES 3 TO 13
Compositions comprising the following, besides the polymer (A), the lubricant, and, where applicable, the flame retardant system, are prepared under the operating conditions (mixing temperature and time) of the preceding examples:
a polybutylene terephthalate (B) with a weight-average molecular weight of approximately 80,000, marketed by the company AKZO under the trademark ARNITE T08200, and
where applicable, an elastomer (C) whose nature varies from one example to another. In examples 6 to 9 the elastomer is a copolymer containing 72% by weight of butadiene and 28% by weight of acrylonitrile, marketed by the company POLYSAR under the trademark KRYNAC 1403 H 176. In Example 10 the elastomer is a copolymer containing 70% by weight of vinyl acetate and 30% by weight of ethylene, marketed by the WACKER company under the name VAE 711. In Example 11 the elastomer is a poly(methyl methacrylate-butadiene-styrene) marketed by the Rohm & Haas Company under the trademark PARALOID KM 522. In Example 12 the elastomer is an acrylic polymer marketed by the Rohm & Haas Company under the trademark PARALOID KM 330. In Example 13 the elastomer is a poly(ester-ether) marketed by the DuPont de Nemours Company under the trademark HYTREL 4056.
The quantities, expressed in parts by weight, of the various ingredients are shown in Table I below, together with the results of the measurements of properties carried out on these compositions.
TABLE I______________________________________EXAMPLE 1 2 3 4 5 6 7______________________________________(A) 100 100 100 100 100 100 100Lubricant 1 1 1 1 1 1 1OBDPE 0 20 25.5 0 0 0 0Sb.sub.2 O.sub.3 0 9 11.3 0 0 0 0(B) 0 0 25 11.1 25 5.3 25(C) 0 0 0 0 0 4.2 11.2Izod 230 100 135 330 335 490 720Vicat 113 104 106.5 113.8 115.8 113.5 114.8HFI 39 45 49 47 54 40 48MIS 30 -- -- 36 40 35 35LOI -- 25 25 -- -- -- --______________________________________EXAMPLE 8 9 10 11 12 13______________________________________(A) 100 100 100 100 100 100Lubricant 1 1 1 1 0 0(B) 42.8 73.3 25 25 25 25(C) 21.4 11.2 7.5 10.1 5.1 10.1Izod 840 350 430 445 325 375Vicat 117.7 130 114.7 116.2 116.2 116.6HFI 49 55 54 51 54 55MIS 36 45 44______________________________________
EXAMPLE 14 (Comparative)
A composition comprising the following is prepared under the operating conditions (mixing temperature and time) of the preceding examples:
100 parts by weight of a powdered polymer (A) marketed by the company CdF CHIMIE ABS under the trademark UGIKRAL SN, containing 57% by weight of styrene, 24% by weight of acrylonitrile, and 19% by weight of polybutadiene, and
3 parts by weight of N,N'-ethylenebis(stearamide).
The results of the measurements of properties of this composition are shown in Table II below.
EXAMPLE 15
A composition containing, besides the ingredients of Example 14:
11.1 parts by weight of the polybutylene terephthalate (B) employed in Examples 3 to 13,
4.5 parts by weight of the elastomer employed in Examples 6 to 9,
is prepared under the operating conditions of the preceding examples.
The results of the measurements of properties of this composition are shown in Table II below.
TABLE II______________________________________Example Izod Vicat HFI______________________________________14 290 98.7 6315 335 100.6 65.5______________________________________
It will be apparent to those skilled in the art that various modifications and variations could be made in the composition, process, and articles of the invention without departing from the scope or spirit of the invention. | Thermoplastic composition based on a crystalline polyester and a modified vinyl aromatic polymer. It comprises:
from 50 to 97% by weight of at least one polymer phase (A) consisting of at least one terpolymer produced by grafting (a) at least one vinyl aromatic monomer and (b) at least one unsaturated nitrile onto (c) at least one rubber, the terpolymer being dispersed in a matrix of a copolymer comprising units derived from (d) at least one unsatured nitrile and (e) at least one vinyl aromatic monomer, the overall composition of the polymer phase (A) being such that it contains from 17 to 35 parts of unsaturated nitrile, from 10 to 60 parts of rubber, and from 10 to 60 parts of vinyl aromatic monomer per 100 parts by weight of the polymer phase, and
from 3 to 50% by weight of at least one high molecular weight polybutylene terephthalate (B). | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/232,674, filed Sep. 15, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to 2-amino-2-alkyl-4 heptenoic and heptynoic acid derivatives and their use in therapy, in particular their use as nitric oxide synthase inhibitors.
RELATED ART
[0003] It has been known since the early 1980's that the vascular relaxation caused by acetylcholine is dependent on the vascular endothelium. The endothelium-derived relaxing factor (EDRF), now known to be nitric oxide (NO) is generated in the vascular endothelium by nitric oxide synthase (NOS). The activity of NO as a vasodilator has been known for well over 100 years. In addition, NO is the active species deriving from amylnitrite, glyceryltrinitrate and other nitrovasodilators. The identification of EDRF as NO has coincided with the discovery of a biochemical pathway by which NO is synthesized from the amino acid L-arginine by the enzyme NO synthase.
[0004] Nitric oxide is an endogenous stimulator of the soluble guanylate cyclase. In addition to endothelium-dependent relaxation, NO is involved in a number of biological actions including cytotoxicity of phagocytic cells and cell-to-cell communication in the central nervous system.
[0005] There are at least three types of NO synthase as follows:
[0006] (i) a constitutive, Ca ++ /calmodulin dependent enzyme, located in the endothelium, that releases NO in response to receptor or physical stimulation.
[0007] (ii) a constitutive, Ca ++ /calmodulin dependent enzyme, located in the brain, that releases NO in response to receptor or physical stimulation.
[0008] (iii) a Ca ++ independent enzyme which is induced after activation of vascular smooth muscle, macrophages, endothelial cells, and a number of other cells by endotoxin and cytokines. Once expressed, this inducible nitric oxide synthase (hereinafter “iNOS”) generates NO continuously for long periods.
[0009] The NO released by each of the two constitutive enzymes acts as a transduction mechanism underlying several physiological responses. The NO produced by the inducible enzyme is a cytotoxic molecule for tumor cells and invading microorganisms. It also appears that adverse effects of excess NO production, in particular pathological vasodilation and tissue damage, may result largely from the NO synthesized by iNOS.
[0010] There is a growing body of evidence that NO may be involved in the degeneration of cartilage which takes place as a result of certain conditions such as arthritis and it is also known that NO synthesis is increased in rheumatoid arthritis and in osteoarthritis.
[0011] Some of the NO synthase inhibitors proposed for therapeutic use are non-selective; they inhibit both the constitutive and the inducible NO synthases. Use of such a non-selective NO synthase inhibitor requires that great care be taken in order to avoid the potentially serious consequences of over-inhibition of the constitutive NO-synthase, such consequences including hypertension and possible thrombosis and tissue damage. In particular, in the case of the therapeutic use of L-NMMA (a non-selective NO synthase inhibitor) for the treatment of toxic shock it has been recommended that the patient must be subject to continuous blood pressure monitoring throughout the treatment. Thus, while non-selective NO synthase inhibitors have therapeutic utility provided that appropriate precautions are taken, NO synthase inhibitors which are selective in the sense that they inhibit the inducible NO synthase to a considerably greater extent than the constitutive isoforms of NO synthase would be of even greater therapeutic benefit and easier to use (S. Moncada and E. Higgs, FASEB J., 9, 1319-1330, 1995).
[0012] PCT International Publication No. WO 93/13055 and U.S. Pat. No. 5,132,453, the disclosure of which are hereby incorporated by reference in their entirety as if written herein, disclose compounds that inhibit nitric oxide synthesis and preferentially inhibit the inducible isoform of nitric oxide synthase.
[0013] PCT International Publication No. WO 95/25717 discloses certain amidino derivatives as being useful in inhibiting inducible nitric oxide synthase. Various attempts have been made to improve the potency and selectivity of NOS inhibitors by adding one or more rigidifying elements to the inhibitor's structure. Publications by Y. Lee et al ( Bioorg. Med. Chem. 7, 1097 (1999)) and R. J. Young et al ( Bioorg. Med. Chem. Lett. 10, 597 (2000)) teach that imposing conformational rigidity with one or more carbon-carbon double bonds is not a favorable approach to impart selectivity for NOS inhibitors.
SUMMARY OF THE INVENTION
[0014] Compounds have now been found which have the advantage of being very efficacious in the human cartilage explant assay, a model for osteoarthritis.
[0015] The present invention demonstrates that a carbon-carbon double bond can be used as a rigidifying element, and the resulting compounds have unexpected potency and selectivity for inhibition of inducible NOS.
[0016] Moreover, the publication by Y. Lee et al ( Bioorg. Med. Chem. 7, 1097 (1999)) teaches that when a carbon-carbon double bond is used to constrain the arginine backbone, the geometric isomer placing the carbon framework in a cis or Z orientation produces a less favorable interaction with NOS. In contrast, olefinic derivatives of arginine placing the carbon framework in the trans or E configuration are better substrates. The present invention demonstrates that a carbon-carbon double bond imparts a favorable interaction with inducible NOS, such that the resulting compounds have unexpected potency and selectivity for inhibition of inducible NOS over the constitutive isoforms.
[0017] Further, compounds of the present invention have the advantage of being very efficacious as iNOS inhibitors in the human cartilage explant assay, a model for osteoarthritis. At the same time the compounds of the present invention are surprisingly less able to penetrate certain non-target organs in test systems, especially in comparison to the compounds of WO 93/13055. This surprising differentiation in expected access between the target organ (cartilage) and other organs is an unexpected advantage for the compounds of the present invention.
[0018] In a broad aspect, compounds of the present invention are represented by:
[0019] or a pharmaceutically acceptable salt thereof, wherein:
[0020] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0021] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0022] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0023] In an embodiment represented by Formula I, the invention relates to:
[0024] or a pharmaceutically acceptable salt thereof, wherein:
[0025] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0026] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0027] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0028] In an embodiment represented by Formula II, the invention relates to:
[0029] or a pharmaceutically acceptable salt thereof, wherein:
[0030] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0031] In an embodiment represented by Formula III, the invention relates to:
[0032] or a pharmaceutically acceptable salt thereof, wherein:
[0033] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0034] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0035] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0036] In an embodiment represented by Formula IV, the invention relates to:
[0037] or a pharmaceutically acceptable salt thereof, wherein:
[0038] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0039] In an embodiment represented by Formula V, the invention relates to:
[0040] or a pharmaceutically acceptable salt thereof, wherein:
[0041] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0042] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0043] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0044] In an embodiment represented by Formula VI, the invention relates to:
[0045] or a pharmaceutically acceptable salt thereof, wherein:
[0046] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0047] In a broad aspect, the present invention is directed to novel compounds, pharmaceutical compositions, process for preparing novel compounds, process for preparing pharmaceutical compositions, and methods of using said compounds and compositions for inhibiting or modulating nitric oxide synthesis in a subject in need of such inhibition or modulation by administering a compound which preferentially inhibits or modulates the inducible isoform of nitric oxide synthase over the constitutive isoforms of nitric oxide synthase. It is also another object of the present invention to lower nitric oxide levels in a subject in need of such lowering. The present compounds possess useful nitric oxide synthase inhibiting activity, and are expected to be useful in the treatment or prophylaxis of a disease or condition in which the synthesis or over-synthesis of nitric oxide forms a contributory part.
[0048] Compounds of the present invention will be useful for treating, among other things, inflammation in a subject, or for treating other nitric oxide synthase-mediated disorders, such as, as an analgesic in the treatment of pain and headaches. The compounds of the present invention will be useful in the treatment of pain including somatogenic (either nociceptive or neuropathic), both acute and chronic, and could be used in a situation including neuropathic pain for which a common NSAID, opioid analgesic or certain anti-convulsants would traditionally be administered.
[0049] Included within the scope of the present invention are novel intermediates useful for synthesizing compounds of the present invention.
[0050] Conditions in which the compounds of the present invention will provide an advantage in inhibiting NO production from L-arginine include arthritic conditions. For example, compounds of the present invention will be useful to treat arthritis, including but not limited to rheumatoid arthritis, spondyloarthropathies, gouty arthritis, osteoarthritis, systemic lupus erythematosus, juvenile arthritis, acute rheumatic arthritis, enteropathic arthritis, neuropathic arthritis, psoriatic arthritis, and pyogenic arthritis.
[0051] Compounds of the invention will be further useful in the treatment of asthma, bronchitis, menstrual cramps (e.g., dysmenorrhea), premature labor, tendinitis, bursitis, skin-related conditions such as psoriasis, eczema, burns, sunburn, dermatitis, pancreatitis, hepatitis, and post-operative inflammation including inflammation from ophthalmic surgery such as cataract surgery and refractive surgery. Compounds of the invention also would be useful to treat gastrointestinal conditions such as inflammatory bowel disease, Crohn's disease, gastritis, irritable bowel syndrome and ulcerative colitis.
[0052] Compounds of the invention would be useful in treating inflammation and tissue damage in such diseases as vascular diseases, migraine headaches, periarteritis nodosa, thyroiditis, aplastic anemia, Hodgkin's disease, sclerodoma, rheumatic fever, type I diabetes, neuromuscular junction disease including myasthenia gravis, white matter disease including multiple sclerosis, sarcoidosis, nephrotic syndrome, Behcet's syndrome, polymyositis, gingivitis, nephritis, hypersensitivity, swelling occurring after injury, myocardial ischemia, and the like.
[0053] The compounds would also be useful in the treatment of ophthalmic diseases, such as glaucoma, retinitis, retinopathies, uveitis, ocular photophobia, and of inflammation and pain associated with acute injury to the eye tissue. Of particular interest among the uses of the present inventive compounds is the treatment of glaucoma, especially where symptoms of glaucoma are caused by the production of nitric oxide, such as in nitric oxide-mediated nerve damage. The compounds would also be useful in the treatment of pulmonary inflammation, such as that associated with viral infections and cystic fibrosis. The compounds would also be useful for the treatment of certain central nervous system disorders, such as cortical dementias including Alzheimer's disease, and central nervous system damage resulting from stroke, ischemia and trauma. These compounds would also be useful in the treatment of allergic rhinitis, respiratory distress syndrome, endotoxin shock syndrome, and atherosclerosis. The compounds would also be useful in the treatment of pain, including but not limited to postoperative pain, dental pain, muscular pain, pain caused by temperoramandibular joint syndrome, and pain resulting from cancer. The compounds would be useful for the prevention of dementias, such as Alzheimer's disease.
[0054] Besides being useful for human treatment, these compounds are also useful for veterinary treatment of companion animals, exotic animals and farm animals, including mammals and other vertebrates. More preferred animals include horses, dogs, and cats.
[0055] The present compounds may also be used in co-therapies, partially or completely, in place of other conventional antiinflammatory therapies, such as together with steroids, NSAIDs, COX-2 selective inhibitors, matrix metalloproteinase inhibitors, 5-lipoxygenase inhibitors, LTB 4 antagonists and LTA 4 hydrolase inhibitors.
[0056] Other conditions in which the compounds of the present invention will provide an advantage in inhibiting NO inhibition include cardiovascular ischemia, diabetes (type I or type II), congestive heart failure, myocarditis, atherosclerosis, migraine, glaucoma, aortic aneurysm, reflux esophagitis, diarrhea, irritable bowel syndrome, cystic fibrosis, emphysema, asthma, bronchiectasis, hyperalgesia (allodynia), cerebral ischemia (both focal ischemia, thrombotic stroke and global ischemia (for example, secondary to cardiac arrest), multiple sclerosis and other central nervous system disorders mediated by NO, for example Parkinson's disease. Further neurodegenerative disorders in which NO inhibition may be useful include nerve degeneration or nerve necrosis in disorders such as hypoxia, hypoglycemia, epilepsy, and in cases of central nervous system (CNS) trauma (such as spinal cord and head injury), hyperbaric oxygen convulsions and toxicity, dementia, such as, for example pre-senile dementia, and AIDS-related dementia, cachexia, Sydenham's chorea, Huntington's disease, Amyotrophic Lateral Sclerosis, Korsakoff's disease, imbecility relating to a cerebral vessel disorder, sleeping disorders, schizophrenia, depression, depression or other symptoms associated with Premenstrual Syndrome (PMS), anxiety and septic shock.
[0057] Still other disorders or conditions which will be advantageously treated by the compounds of the present invention include treatment of prevention of opiate tolerance in patients needing protracted opiate analgesics, and benzodiazepine tolerance in patients taking benzodiazepines, and other addictive behavior, for example, nicotine addiction, alcoholism, and eating disorders. The compounds and methods of the present invention will also be useful in the treatment or prevention of drug withdrawal symptoms, for example treatment or prevention of symptoms of withdrawal from opiate, alcohol, or tobacco addiction. The present inventive compounds may also be useful to prevent tissue damage when therapeutically combined with antibacterial or antiviral agents.
[0058] The compounds of the present invention will also be useful in inhibiting NO production from L-arginine including systemic hypotension associated with septic and/or toxic hemorrhagic shock induced by a wide variety of agents; therapy with cytokines such as TNF, IL-1 and IL-2; and as an adjuvant to short term immunosuppression in transplant therapy.
[0059] Compounds of the invention are useful for the prevention or treatment of cancer, such as colorectal cancer, and cancer of the breast, lung, prostate, bladder, cervix and skin. The present invention is further directed to the use of the compounds of the present invention for the treatment and prevention of neoplasias. The neoplasias that will be treatable or preventable by the compounds and methods of the present invention include brain cancer, bone cancer, a leukemia, such as, for example chronic lymphocytic leukemia, a lymphoma, epithelial cell-derived neoplasia (epithelial carcinoma) such as basal cell carcinoma, adenocarcinoma, gastrointestinal cancer such as lip cancer, mouth cancer, esophogeal cancer, small bowel cancer and stomach cancer, colon cancer, liver cancer, bladder cancer, pancreas cancer, urogenital cancers, such as ovary cancer, cervical cancer, vulvar cancer, and lung cancer, breast cancer and skin cancer, such as squamous cell, melanoma, and basal cell cancers, prostate cancer, renal cell carcinoma, and other known cancers that effect epithelial cells throughout the body. Compounds of the present invention will be effective as well for treatment of mesenchymal derived neoplasias. Preferably, the neoplasia to be treated is selected from gastrointestinal cancer, liver cancer, bladder cancer, pancreas cancer, ovary cancer, prostate cancer, cervical cancer, vulvar cancer, lung cancer, breast cancer and skin cancer, such as squamous cell and basal cell cancers. The present compounds and methods can also be used to treat the fibrosis which occurs with radiation therapy. The present compounds and methods can be used to treat subjects having adenomatous polyps, including those with familial adenomatous polyposis (FAP). Additionally, the present compounds and methods can be used to prevent polyps from forming in patients at risk of FAP.
[0060] Conjunctive treatment of a compound of the present invention with another antineoplastic agent will produce a synergistic effect or alternatively reduce the toxic side effects associated with chemotherapy by reducing the therapeutic dose of the side effect-causing agent needed for therapeutic efficacy or by directly reducing symptoms of toxic side effects caused by the side effect-causing agent. A compound of the present invention will further be useful as an adjunct to radiation therapy to reduce side effects or enhance efficacy. In the present invention, another agent which can be combined therapeutically with a compound of the present invention includes any therapeutic agent which is capable of inhibiting the enzyme cyclooxygenase-2 (“COX-2”). Preferably such COX-2 inhibiting agents inhibit COX-2 selectively relative to the enzyme cyclooxygenase-1 (“COX-1”). Such a COX-2 inhibitor is known as a “COX-2 selective inhibitor”. More preferably, a compound of the present invention can be therapeutically combined with a COX-2 selective inhibitor wherein the COX-2 selective inhibitor selectively inhibits COX-2 at a ratio of at least 10:1 relative to inhibition of COX-1, more preferably at least 30: 1, and still more preferably at least 50:1 in an in vitro test. COX-2 selective inhibitors useful in therapeutic combination with the compounds of the present invention include celecoxib, valdecoxib, deracoxib, etoricoxib, rofecoxib, ABT-963 (2-(3,4-difluorophenyl)-4-(3-hydroxy-3-methyl-1-butoxy)-5-[4-(methylsulfonyl)phenyl-3(2H)-pyridazinone; described in PCT Patent Application No. WO 00/24719), or meloxicam. A compound of the present invention can also be advantageously used in therapeutic combination with a prodrug of a COX-2 selective inhibitor, for example parecoxib.
[0061] Another chemotherapeutic agent which will be useful in combination with a compound of the present invention can be selected, for example, from the following non-comprehensive and non-limiting list:
[0062] Alpha-difluoromethylornithine (DFMO), 5-FU-fibrinogen, acanthifolic acid, aminothiadiazole, brequinar sodium, carmofur, Ciba-Geigy CGP-30694, cyclopentyl cytosine, cytarabine phosphate stearate, cytarabine conjugates, Lilly DATHF, Merrel Dow DDFC, dezaguanine, dideoxycytidine, dideoxyguanosine, didox, Yoshitomi DMDC, doxifluridine, Wellcome EHNA, Merck & Co. EX-015, fazarabine, floxuridine, fludarabine phosphate, 5-fluorouracil, N-(2′-furanidyl)-5-fluorouracil, Daiichi Seiyaku FO-152, isopropyl pyrrolizine, Lilly LY-188011, Lilly LY-264618, methobenzaprim, methotrexate, Wellcome MZPES, norspermidine, NCI NSC-127716, NCI NSC-264880, NCI NSC-39661, NCI NSC-612567, Warner-Lambert PALA, pentostatin, piritrexim, plicamycin, Asahi Chemical PL-AC, Takeda TAC-788, thioguanine, tiazofurin, Erbamont TIF, trimetrexate, tyrosine kinase inhibitors, tyrosine protein kinase inhibitors, Taiho UFT, uricytin, Shionogi 254-S, aldo-phosphamide analogues, altretamine, anaxirone, Boehringer Mannheim BBR-2207, bestrabucil, budotitane, Wakunaga CA-102, carboplatin, carmustine, Chinoin-139, Chinoin-153, chlorambucil, cisplatin, cyclophosphamide, American Cyanamid CL-286558, Sanofi CY-233, cyplatate, Degussa D-19-384, Sumimoto DACHP(Myr)2, diphenylspiromustine, diplatinum cytostatic, Erba distamycin derivatives, Chugai DWA-2114R, ITI E09, elmustine, Erbamont FCE-24517, estramustine phosphate sodium, fotemustine, Unimed G-6-M, Chinoin GYKI-17230, hepsul-fam, ifosfamide, iproplatin, lomustine, mafosfamide, mitolactol, Nippon Kayaku NK-121, NCI NSC-264395, NCI NSC-342215, oxaliplatin, Upjohn PCNU, prednimustine, Proter PTT-119, ranimustine, semustine, SmithKline SK&F-101772, Yakult Honsha SN-22, spiromus-tine, Tanabe Seiyaku TA-077, tauromustine, temozolomide, teroxirone, tetraplatin, trimelamol, Taiho 4181-A, aclarubicin, actinomycin D, actinoplanone, Erbamont ADR-456, aeroplysinin derivative, Ajinomoto AN-201-II, Ajinomoto AN-3, Nippon Soda anisomycins, anthracycline, azino-mycin-A, bisucaberin, Bristol-Myers BL-6859, Bristol-Myers BMY-25067, Bristol-Myers BMY-25551, Bristol-Myers BMY-26605, Bristol-Myers BMY-27557, Bristol-Myers BMY-28438, bleomycin sulfate, bryostatin-1, Taiho C-1027, calichemycin, chromoximycin, dactinomycin, daunorubicin, Kyowa Hakko DC-102, Kyowa Hakko DC-79, Kyowa Hakko DC-88A, Kyowa Hakko DC89-A1, Kyowa Hakko DC92-B, ditrisarubicin B, Shionogi DOB-41, doxorubicin, doxorubicin-fibrinogen, elsamicin-A, epirubicin, erbstatin, esorubicin, esperamicin-A1, esperamicin-Alb, Erbamont FCE-21954, Fujisawa FK-973, fostriecin, Fujisawa FR-900482, glidobactin, gregatin-A, grincamycin, herbimycin, idarubicin, illudins, kazusamycin, kesarirhodins, Kyowa Hakko KM-5539, Kirin Brewery KRN-8602, Kyowa Hakko KT-5432, Kyowa Hakko KT-5594, Kyowa Hakko KT-6149, American Cyanamid LL-D49194, Meiji Seika ME 2303, menogaril, mitomycin, mitoxantrone, SmithKline M-TAG, neoenactin, Nippon Kayaku NK-313, Nippon Kayaku NKT-01, SRI International NSC-357704, oxalysine, oxaunomycin, peplomycin, pilatin, pirarubicin, porothramycin, pyrindamycin A, Tobishi RA-I, rapamycin, rhizoxin, rodorubicin, sibanomicin, siwenmycin, Sumitomo SM-5887, Snow Brand SN-706, Snow Brand SN-07, sorangicin-A, sparsomycin, SS Pharmaceutical SS-21020, SS Pharmaceutical SS-7313B, SS Pharmaceutical SS-9816B, steffimycin B, Taiho 4181-2, talisomycin, Takeda TAN-868A, terpentecin, thrazine, tricrozarin A, Upjohn U-73975, Kyowa Hakko UCN-10028A, Fujisawa WF-3405, Yoshitomi Y-25024 zorubicin, alpha-carotene, alpha-difluoromethyl-arginine, acitretin, Biotec AD-5, Kyorin AHC-52, alstonine, amonafide, amphethinile, amsacrine, Angiostat, ankinomycin, anti-neoplaston A10, antineoplaston A2, antineoplaston A3, antineoplaston A5, antineoplaston AS2-1, Henkel APD, aphidicolin glycinate, asparaginase, Avarol, baccharin, batracylin, benfluron, benzotript, Ipsen-Beaufour BIM-23015, bisantrene, Bristo-Myers BMY-40481, Vestar boron-10, bromofosfamide, Wellcome BW-502, Wellcome BW-773, caracemide, carmethizole hydrochloride, Ajinomoto CDAF, chlorsulfaquinoxalone, Chemex CHX-2053, Chemex CHX-100, Warner-Lambert CI-921, Warner-Lambert CI-937, Warner-Lambert CI-941, Warner-Lambert CI-958, clanfenur, claviridenone, ICN compound 1259, ICN compound 4711, Contracan, Yakult Honsha CPT-11, crisnatol, curaderm, cytochalasin B, cytarabine, cytocytin, Merz D-609, DABIS maleate, dacarbazine, datelliptinium, didemnin-B, dihaematoporphyrin ether, dihydrolenperone, dinaline, distamycin, Toyo Pharmar DM-341, Toyo Pharmar DM-75, Daiichi Seiyaku DN-9693, elliprabin, elliptinium acetate, Tsumura EPMTC, ergotamine, etoposide, etretinate, fenretinide, Fujisawa FR-57704, gallium nitrate, genkwadaphnin, Chugai GLA-43, Glaxo GR-63178, grifolan NMF-5N, hexadecylphosphocholine, Green Cross HO-22 1, homoharringtonine, hydroxyurea, BTG ICRF-187, ilmofosine, isoglutamine, isotretinoin, Otsuka JI-36, Ramot K-477, Otsuak K-76COONa, Kureha Chemical K-AM, MECT Corp KI-8110, American Cyanamid L-623, leukoregulin, lonidamine, Lundbeck LU-23-112, Lilly LY-186641, NCI (US) MAP, marycin, Merrel Dow MDL-27048, Medco MEDR-340, merbarone, merocyanine derivatives, methylanilinoacridine, Molecular Genetics MGI-136, minactivin, mitonafide, mitoquidone, mopidamol, motretinide, Zenyaku Kogyo MST-16, N-(retinoyl)amino acids, Nisshin Flour Milling N-021, N-acylated-dehydroalanines, nafazatrom, Taisho NCU-190, nocodazole derivative, Normosang, NCI NSC-145813, NCI NSC-361456, NCI NSC-604782, NCI NSC-95580, octreotide, Ono ONO-112, oquizanocine, Akzo Org-10172, pancratistatin, pazelliptine, Warner-Lambert PD-111707, Warner-Lambert PD-115934, Warner-Lambert PD-131141, Pierre Fabre PE-1001, ICRT peptide D, piroxantrone, polyhaematoporphyrin, polypreic acid, Efamol porphyrin, probimane, procarbazine, proglumide, Invitron protease nexin I, Tobishi RA-700, razoxane, Sapporo Breweries RBS, restrictin-P, retelliptine, retinoic acid, Rhone-Poulenc RP-49532, Rhone-Poulenc RP-56976, SmithKline SK&F-104864, Sumitomo SM-108, Kuraray SMANCS, SeaPharm SP-10094, spatol, spirocyclopropane derivatives, spirogermanium, Unimed, SS Pharmaceutical SS-554, strypoldinone, Stypoldione, Suntory SUN 0237, Suntory SUN 2071, superoxide dismutase, Toyama T-506, Toyama T-680, taxol, Teijin TEI-0303, teniposide, thaliblastine, Eastman Kodak TJB-29, tocotrienol, Topostin, Teijin TT-82, Kyowa Hakko UCN-01, Kyowa Hakko UCN-1028, ukrain, Eastman Kodak USB-006, vinblastine sulfate, vincristine, vindesine, vinestramide, vinorelbine, vintriptol, vinzolidine, withanolides, Yamanouchi YM-534, uroguanylin, combretastatin, dolastatin, idarubicin, epirubicin, estramustine, cyclophosphamide, 9-amino-2-(S)-camptothecin, topotecan, irinotecan (Camptosar), exemestane, decapeptyl (tryptorelin), or an omega-3 fatty acid.
[0063] Examples of radioprotective agents which may be used in a combination therapy with the compounds of this invention include AD-5, adchnon, amifostine analogues, detox, dimesna, l-102, MM-159, N-acylated-dehydroalanines, TGF-Genentech, tiprotimod, amifostine, WR-151327, FUT-187, ketoprofen transdermal, nabumetone, superoxide dismutase (Chiron) and superoxide dismutase Enzon.
[0064] The compounds of the present invention will also be useful in treatment or prevention of angiogenesis-related disorders or conditions, for example, tumor growth, metastasis, macular degeneration, and atherosclerosis.
[0065] In a further embodiment, the present invention also provides therapeutic combinations for the treatment or prevention of ophthalmic disorders or conditions such as glaucoma. For example the present inventive compounds advantageously will be used in therapeutic combination with a drug which reduces the intraocular pressure of patients afflicted with glaucoma. Such intraocular pressure-reducing drugs include without limitation; latanoprost, travoprost, bimatoprost, or unoprostol. The therapeutic combination of a compound of the present invention plus an intraocular pressure-reducing drug will be useful because each is believed to achieve its effects by affecting a different mechanism.
[0066] In another combination of the present invention, the present inventive compounds can be used in therapeutic combination with an antihyperlipidemic or cholesterol-lowering drug such as a benzothiepine or a benzothiazepine antihyperlipidemic drug. Examples of benzothiepine antihyperlipidemic drugs useful in the present inventive therapeutic combination can be found in U.S. Pat. No. 5,994,391, herein incorporated by reference. Some benzothiazepine antihyperlipidemic drugs are described in WO 93/16055. Alternatively, the antihyperlipidemic or cholesterol-lowering drug useful in combination with a compound of the present invention can be an HMG Co-A reductase inhibitor. Examples of HMG Co-A reductase inhibitors useful in the present therapeutic combination include, individually, benfluorex, fluvastatin, lovastatin, provastatin, simvastatin, atorvastatin, cerivastatin, bervastatin, ZD-9720 (described in PCT Patent Application No. WO 97/06802), ZD-4522 (CAS No. 147098-20-2 for the calcium salt; CAS No. 147098-18-8 for the sodium salt; described in European Patent No. EP 521471), BMS 180431 (CAS No. 129829-03-4), or NK-104 (CAS No. 141750-63-2). The therapeutic combination of a compound of the present invention plus an antihyperlipidemic or cholesterol-lowering drug will be useful, for example, in reducing the risk of formation of atherosclerotic lesions in blood vessels. For example, atherosclerotic lesions often initiate at inflamed sites in blood vessels. It is established that antihyperlipidemic or cholesterol-lowering drug reduce risk of formation of atherosclerotic lesions by lowering lipid levels in blood. Without limiting the invention to a single mechanism of action, it is believed that one way the compounds of the present combination will work in concert to provide improved control of atherosclerotic lesions by, for example, reducing inflammation of the blood vessels in concert with lowering blood lipid levels.
[0067] In another embodiment of the invention, the present compounds can be used in combination with other compounds or therapies for the treatment of central nervous conditions or disorders such as migraine. For example, the present compounds can be used in therapeutic combination with caffeine, a 5-HT-1B/1D agonist (for example, a triptan such as sumatriptan, naratriptan, zolmitriptan, rizatriptan, almotriptan, or frovatriptan), a dopamine D4 antagonist (e.g., sonepiprazole), aspirin, acetaminophen, ibuprofen, indomethacin, naproxen sodium, isometheptene, dichloralphenazone, butalbital, an ergot alkaloid (e.g., ergotamine, dihydroergotamine, bromocriptine, ergonovine, or methyl ergonovine), a tricyclic antidepressant (e.g., amitriptyline or nortriptyline), a serotonergic antagonist (e.g., methysergide or cyproheptadine), a beta-andrenergic antagonist (e.g., propranolol, timolol, atenolol, nadolol, or metprolol), or a monoamine oxidase inhbitor (e.g., phenelzine or isocarboxazid).
[0068] A further embodiment provides a therapeutic combination of a compound of the present invention with an opioid compound. Opioid compounds useful in this combination include without limitation morphine, methadone, hydromorphone, oxymorphone, levorphanol, levallorphan, codeine, dihydrocodeine, dihydrohydroxycodeinone, pentazocine, hydrocodone, oxycodone, nalmefene, etorphine, levorphanol, fentanyl, sufentanil, DAMGO, butorphanol, buprenorphine, naloxone, naltrexone, CTOP, diprenorphine, beta-funaltrexamine, naloxonazine, nalorphine, pentazocine, nalbuphine, naloxone benzoylhydrazone, bremazocine, ethylketocyclazocine, U50,488, U69,593, spiradoline, nor-binaltorphimine, naltrindole, DPDPE, [D-la 2 , glu 4 ]deltorphin, DSLET, met-enkephalin, leu-enkaphalin, beta-endorphin, dynorphin A, dynorphin B, and alpha-neoendorphin. An advantage to the combination of the present invention with an opioid compound is that the present inventive compounds will allow a reduction in the dose of the opioid compound, thereby reducing the risk or severity of opioid side effects, such as opioid addiction.
DETAILED DESCRIPTION OF THE INVENTION
[0069] In an embodiment represented by Formula I, the invention relates to:
[0070] or a pharmaceutically acceptable salt thereof, wherein:
[0071] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0072] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0073] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0074] In one embodiment of the present invention represented by Formula I, the compound is the Z isomer.
[0075] In another embodiment of the present invention represented by Formula I, the compound is the E isomer.
[0076] In yet another embodiment of the present invention represented by Formula I, R 1 is hydrogen, halo, or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy.
[0077] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by fluorine or alkoxy.
[0078] In a further embodiment of the present invention represented by Formula I, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0079] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0080] In a still further embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen or halo; and R 3 is C 1 -C 3 alkyl.
[0081] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is C 1 -C 3 alkyl.
[0082] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is methyl.
[0083] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methyl.
[0084] In a further embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is fluorine; and R 3 is methyl.
[0085] In another embodiment of the present invention represented by Formula I, R 1 is halo; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0086] In a further embodiment of the present invention represented by Formula I, R 1 is halo; R 2 is halo; and R 3 is C 1 -C 3 alkyl.
[0087] In another embodiment of the present invention represented by Formula I, R 1 is fluorine; R 2 is fluorine; and R 3 is methyl.
[0088] In another embodiment of the present invention represented by Formula I, R 1 is fluorine; R 2 is hydrogen or C 1 -C 3 alkyl; and R 3 is methyl.
[0089] In a further embodiment of the present invention represented by Formula I, R 1 is fluorine; R 2 is hydrogen; and R 3 is methyl.
[0090] In another embodiment of the present invention represented by Formula I, R 1 is methyl; R 2 is hydrogen; and R 3 is methyl.
[0091] In a further embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is methyl; and R 3 is methyl.
[0092] In another embodiment of the present invention represented by Formula I, R 1 is methyl; R 2 is methyl; and R 3 is methyl.
[0093] In yet another embodiment of the present invention represented by Formula I,: R 1 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; and R 3 is methyl optionally substituted by one or more alkoxy or halo.
[0094] In a further embodiment of the present invention represented by Formula I, R 1 is hydrogen or fluorine; R 2 is C 1 -C 3 alkyl substituted by one or more halo; and R 3 is methyl.
[0095] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is CH 2 F; and R 3 is methyl.
[0096] In still another embodiment of the present invention represented by Formula I, R 1 is CH 2 F; R 2 is hydrogen; and R 3 is methyl.
[0097] In a further embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen; and R 3 is CH 2 F.
[0098] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is methoxymethyl; and R 3 is methyl.
[0099] In a further embodiment of the present invention represented by Formula I, R 1 is methoxymethyl; R 2 is hydrogen; and R 3 is methyl.
[0100] In another embodiment of the present invention represented by Formula I, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methoxymethyl.
[0101] In an embodiment represented by Formula II, the invention relates to:
[0102] or a pharmaceutically acceptable salt thereof, wherein:
[0103] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0104] In another embodiment of the present invention represented by Formula II, R 3 is C 1 -C 5 alkyl substituted by one or more halo.
[0105] In a further embodiment of the present invention represented by Formula II, R 3 is C 1 -C 5 alkyl substituted by one or more fluorine.
[0106] In still another embodiment of the present invention represented by Formula II, R 3 is methyl substituted by one or more halo.
[0107] In yet another embodiment of the present invention represented by Formula II, R 3 is methyl substituted by one or more fluorine. In another embodiment of the present invention represented by Formula II, R 3 is CH 2 F.
[0108] In still another embodiment of the present invention represented by Formula II, R 3 is C 1 -C 5 alkyl substituted by alkoxy.
[0109] In a further embodiment of the present invention represented by Formula II, R 3 is methoxy methyl.
[0110] In yet another embodiment of the present invention represented by Formula II, R 3 is C 1 -C 5 alkyl.
[0111] In another embodiment of the present invention represented by Formula II, R 3 is methyl.
[0112] In an embodiment represented by Formula III, the invention relates to:
[0113] or a pharmaceutically acceptable salt thereof, wherein:
[0114] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0115] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0116] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0117] In one embodiment of the present invention represented by Formula III, the compound is the Z isomer.
[0118] In another embodiment of the present invention represented by Formula III, the compound is the E isomer.
[0119] In yet another embodiment of the present invention represented by Formula III, R 1 is hydrogen, halo, or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy.
[0120] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by fluorine or alkoxy.
[0121] In a further embodiment of the present invention represented by Formula III, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0122] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0123] In a still further embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen or halo; and R 3 is C 1 -C 3 alkyl.
[0124] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is C 1 -C 3 alkyl.
[0125] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is methyl.
[0126] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methyl.
[0127] In a further embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is fluorine; and R 3 is methyl.
[0128] In another embodiment of the present invention represented by Formula III, R 1 is halo; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0129] In a further embodiment of the present invention represented by Formula III, R 1 is halo; R 2 is halo; and R 3 is C 1 -C 3 alkyl.
[0130] In another embodiment of the present invention represented by Formula III, R 1 is fluorine; R 2 is fluorine; and R 3 is methyl.
[0131] In another embodiment of the present invention represented by Formula III, R 1 is fluorine; R 2 is hydrogen or C 1 -C 3 alkyl; and R 3 is methyl.
[0132] In a further embodiment of the present invention represented by Formula III, R 1 is fluorine; R 2 is hydrogen; and R 3 is methyl.
[0133] In another embodiment of the present invention represented by Formula III, R 1 is methyl; R 2 is hydrogen; and R 3 is methyl.
[0134] In a further embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is methyl; and R 3 is methyl.
[0135] In another embodiment of the present invention represented by Formula III, R 1 is methyl; R 2 is methyl; and R 3 is methyl.
[0136] In yet another embodiment of the present invention represented by Formula III,: R 1 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; and R 3 is methyl optionally substituted by one or more alkoxy or halo.
[0137] In a further embodiment of the present invention represented by Formula III, R 1 is hydrogen or fluorine; R 2 is C 1 -C 3 alkyl substituted by one or more halo; and R 3 is methyl.
[0138] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is CH 2 F; and R 3 is methyl.
[0139] In still another embodiment of the present invention represented by Formula III, R 1 is CH 2 F; R 2 is hydrogen; and R 3 is methyl.
[0140] In a further embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen; and R 2 is CH 2 F.
[0141] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is methoxymethyl; and R 3 is methyl.
[0142] In a further embodiment of the present invention represented by Formula III, R 1 is methoxymethyl; R 2 is hydrogen; and R 3 is methyl.
[0143] In another embodiment of the present invention represented by Formula III, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methoxymethyl.
[0144] In an embodiment represented by Formula IV, the invention relates to:
[0145] or a pharmaceutically acceptable salt thereof, wherein:
[0146] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0147] In another embodiment of the present invention represented by Formula IV, R 3 is C 1 -C 5 alkyl substituted by one or more halo.
[0148] In a further embodiment of the present invention represented by Formula IV, R 3 is C 1 -C 5 alkyl substituted by one or more fluorine.
[0149] In still another embodiment of the present invention represented by Formula IV, R 3 is methyl substituted by one or more halo.
[0150] In yet another embodiment of the present invention represented by Formula IV, R 3 is methyl substituted by one or more fluorine. In another embodiment of the present invention represented by Formula IV, R 3 is CH 2 F.
[0151] In still another embodiment of the present invention represented by Formula IV, R 3 is C 1 -C 5 alkyl substituted by alkoxy.
[0152] In a further embodiment of the present invention represented by Formula IV, R 3 is methoxy methyl.
[0153] In yet another embodiment of the present invention represented by Formula IV, R 3 is C 1 -C 5 alkyl.
[0154] In another embodiment of the present invention represented by Formula IV, R 3 is methyl.
[0155] In an embodiment represented by Formula V, the invention relates to:
[0156] or a pharmaceutically acceptable salt thereof, wherein:
[0157] R 1 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0158] R 2 is selected from the group consisting of hydrogen, halo, C 1 -C 5 alkyl and C 1 -C 5 alkyl substituted by alkoxy or one or more halo;
[0159] R 3 is C 1 -C 5 alkyl or C 1 -C 5 alkyl be substituted by alkoxy or one or more halo.
[0160] In one embodiment of the present invention represented by Formula V, the compound is the Z isomer.
[0161] In another embodiment of the present invention represented by Formula V, the compound is the E isomer.
[0162] In yet another embodiment of the present invention represented by Formula V, R 1 is hydrogen, halo, or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy.
[0163] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by fluorine or alkoxy.
[0164] In a further embodiment of the present invention represented by Formula V, R 1 is hydrogen, halo, or C 1 -C 3 alkyl; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0165] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0166] In a still further embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen or halo; and R 3 is C 1 -C 3 alkyl.
[0167] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is C 1 -C 3 alkyl.
[0168] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen or fluorine; and R 3 is methyl.
[0169] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methyl.
[0170] In a further embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is fluorine; and R 3 is methyl.
[0171] In another embodiment of the present invention represented by Formula V, R 1 is halo; R 2 is hydrogen, halo or C 1 -C 3 alkyl; and R 3 is C 1 -C 3 alkyl.
[0172] In a further embodiment of the present invention represented by Formula V, R 1 is halo; R 2 is halo; and R 3 is C 1 -C 3 alkyl.
[0173] In another embodiment of the present invention represented by Formula V, R 1 is fluorine; R 2 is fluorine; and R 3 is methyl.
[0174] In another embodiment of the present invention represented by Formula V, R 1 is fluorine; R 2 is hydrogen or C 1 -C 3 alkyl; and R 3 is methyl.
[0175] In a further embodiment of the present invention represented by Formula V, R 1 is fluorine; R 2 is hydrogen; and R 3 is methyl.
[0176] In another embodiment of the present invention represented by Formula V, R 1 is methyl; R 2 is hydrogen; and R 3 is methyl.
[0177] In a further embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is methyl; and R 3 is methyl.
[0178] In another embodiment of the present invention represented by Formula V, R 1 is methyl; R 2 is methyl; and R 3 is methyl.
[0179] In yet another embodiment of the present invention represented by Formula V,: R 1 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; R 2 is hydrogen, halo or C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by alkoxy or one or more fluorine; and R 3 is methyl optionally substituted by one or more alkoxy or halo.
[0180] In a further embodiment of the present invention represented by Formula V, R 1 is hydrogen or fluorine; R 2 is C 1 -C 3 alkyl substituted by one or more halo; and R 3 is methyl.
[0181] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is CH 2 F; and R 3 is methyl.
[0182] In still another embodiment of the present invention represented by Formula V, R 1 is CH 2 F; R 2 is hydrogen; and R 3 is methyl.
[0183] In a further embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen; and R 3 is CH 2 F.
[0184] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is methoxymethyl; and R 3 is methyl.
[0185] In a further embodiment of the present invention represented by Formula V, R 1 is methoxymethyl; R 2 is hydrogen; and R 3 is methyl.
[0186] In another embodiment of the present invention represented by Formula V, R 1 is hydrogen; R 2 is hydrogen; and R 3 is methoxymethyl.
[0187] In an embodiment represented by Formula VI, the invention relates to:
[0188] or a pharmaceutically acceptable salt thereof, wherein:
[0189] R 3 is C 1 -C 5 alkyl, said C 1 -C 5 alkyl optionally substituted by halo or alkoxy, said alkoxy optionally substituted by one or more halo.
[0190] In another embodiment of the present invention represented by Formula VI, R 3 is C 1 -C 5 alkyl substituted by one or more halo.
[0191] In a further embodiment of the present invention represented by Formula VI, R 3 is C 1 -C 5 alkyl substituted by one or more fluorine.
[0192] In still another embodiment of the present invention represented by Formula VI, R 3 is methyl substituted by one or more halo.
[0193] In yet another embodiment of the present invention represented by Formula VI, R 3 is methyl substituted by one or more fluorine. In another embodiment of the present invention represented by Formula VI, R 3 is CH 2 F.
[0194] In still another embodiment of the present invention represented by Formula VI, R 3 is C 1 -C 5 alkyl substituted by alkoxy.
[0195] In a further embodiment of the present invention represented by Formula VI, R 3 is methoxy methyl.
[0196] In yet another embodiment of the present invention represented by Formula VI, R 3 is C 1 -C 5 alkyl.
[0197] In another embodiment of the present invention represented by Formula VI, R 3 is methyl.
[0198] The present invention also includes pharmaceutical compositions that comprise a compound of Formula I, II, III, IV, V, or VI.
[0199] Methods of using the compounds of Formula I, II, III, IV, V, or VI include the use of inhibiting nitric oxide synthesis in a subject in need of such inhibition by administering a therapeutically effective amount of the present compound, selectively inhibiting nitric oxide synthesis produced by inducible nitric oxide synthase over nitric oxide produced by the constitutive forms of nitric oxide synthase in a subject in need of such inhibition by administering a therapeutically effective amount of a compound of Formula I, II, III, V, or VI, lowering nitric oxide levels in a subject in need of such by administering a therapeutically effective amount of a compound of Formula I, II, III, IV, V, or VI, lowering nitric oxide levels in a subject in need of such by administering a therapeutically effective amount of a pharmaceutical composition comprising a compound of Formula I, II, III, IV, V, or VI.
[0200] The compounds of the present invention may also be used advantageously in combination with a second pharmaceutically active substance, particularly in combination with a selective inhibitor of the inducible isoform of cyclooxygenase (COX-2). Thus, in a further aspect of the invention there is provided the use of a present compound or a pharmaceutically acceptable salt thereof, in combination with a COX-2 inhibitor for the treatment of inflammation, inflammatory disease and inflammatory related disorders. And there is also provided a method of treating, or reducing the risk of, inflammation, inflammatory disease and inflammatory related disorders in a person suffering from or at risk of, said disease or condition, wherein the method comprises administering to the person a therapeutically effective amount of a present compound or a pharmaceutically acceptable salt, thereof in combination with a COX-2 inhibitor. COX-2 inhibitors are illustrated but not limited by Celecoxib Vioxx. The NOS inhibitor and the COX-2 inhibitor may either be formulated together within the same pharmaceutical composition for administration in a single dosage unit, or each component may be individually formulated such that separate dosages may be administered either simultaneously or sequentially.
[0201] The term “alkyl”, alone or in combination, means an acyclic alkyl radical, linear or branched, containing from 1 to 5, or from 1 to 3 carbon atoms. Said alkyl radicals may be optionally substituted with one or more halo.
[0202] The terms “alkoxy” embraces linear or branched oxy-containing radicals each having alkyl portions of one to five carbon atoms, such as methoxy radical. Examples of such radicals include methoxy, ethoxy, propoxy, butoxy and tert-butoxy alkyls.
[0203] The term “halo” means halogens such as fluorine, chlorine, bromine or iodine atoms.
[0204] Also included in the family of compounds of Formula I, II, III, IV, V, or VI are the pharmaceutically-acceptable salts thereof. The term “pharmaceutically-acceptable salts” embraces salts commonly used to form alkali metal salts and to form addition salts of free acids or free bases. The nature of the salt is not critical, provided that it is pharmaceutically acceptable. Suitable pharmaceutically-acceptable acid addition salts of compounds of Formula I, II, III, IV, V, or VI may be prepared from inorganic acid or from an organic acid. Examples of such inorganic acids are hydrochloric, hydrobromic, hydroiodic, nitric, carbonic, sulfuric and phosphoric acid. Appropriate organic acids may be selected from aliphatic, cycloaliphatic, aromatic, araliphatic, heterocyclic, carboxylic and sulfonic classes of organic acids, examples of which are formic, acetic, propionic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, ascorbic, glucoronic, maleic, fumaric, pyruvic, aspartic, glutamic, benzoic, anthranilic, mesylic, salicylic, p-hydroxybenzoic, phenylacetic, mandelic, embonic (pamoic), methanesulfonic, ethylsulfonic, benzenesulfonic, sulfanilic, stearic, cyclohexylaminosulfonic, algenic, galacturonic acid. Suitable pharmaceutically-acceptable base addition salts of compounds of Formula I, II, III, IV, V, or VI include metallic salts made from aluminum, calcium, lithium, magnesium, potassium, sodium and zinc or organic salts made from N,N′-dibenzylethylenediamine, choline, chloroprocaine, diethanolamine, ethylenediamine, meglumine (N-methylglucamine) and procain. All of these salts may be prepared by conventional means from the corresponding compound of Formula I, II, III, IV, V, or VI by reacting, for example, the appropriate acid or base with the compound of Formula I, II, III, IV, V, or VI.
[0205] Although nitrogen protecting groups are illustratively shown as, t-butoxycarbonyl, or t-BOC, any suitable nitrogen protecting group could be substituted in the synthesis of the compounds of the present invention. Numerous protected amino groups useful in the present invention for are described by Theodora W. Greene and Peter G. M. Wuts ( Protective Groups in Organic Synthesis, 3rd ed., John Wiley & Sons, New York, 1999, pp. 494-653). For example NZ can be a 4-chlorobenzylimino group. In one embodiment of the present invention, the protected amino group is any such group resulting from the reaction of an aldehyde with the corresponding amino group to form a Schiff base. A large variety of deprotecting reagents can be advantageously used in the present invention to effect the conversion of the intermediate to the desired compound. Many such deprotecting reagents are described by Greene and Wuts, supra. For example, when the protected amino group is a 4-chlorobenzylimino group or a t-butoxycarbonylamino group, preferably the deprotecting reagent is an acid. Some useful acid deprotecting agents include, without limitation, hydrochloric acid, hydrobromic acid, sulfuric acid, trifluoroacetic acid, phosphoric acid, phosphorus acid, and acetic acid.
[0206] When a compound is described by both a structure and a name, the name is intended to correspond to the indicated structure, and similarly the structure is intended to correspond with the indicated name.
[0207] While it may be possible for the compounds of Formula I, II, III, IV, V, or VI to be administered as the raw chemical, it is preferable to present them as a pharmaceutical composition. According to a further aspect, the present invention provides a pharmaceutical composition comprising a compound of Formula I, II, III, IV, V, or VI or a pharmaceutically acceptable salt or solvate thereof, together with one or more pharmaceutically acceptable carriers thereof and optionally one or more other therapeutic ingredients. The carrier(s) must be acceptable in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0208] The formulations include those suitable for oral, parenteral (including subcutaneous, intradermal, intramuscular, intravenous and intraarticular), rectal and topical (including dermal, buccal, sublingual and intraocular) administration although the most suitable route may depend upon for example the condition and disorder of the recipient. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing into association a compound of Formula I, II, III, IV, V, or VI or a pharmaceutically acceptable salt or solvate thereof with the carrier, which constitutes one or more accessory ingredients. In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0209] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste.
[0210] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, lubricating, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide slow or controlled release of the active ingredient therein.
[0211] Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example sealed ampoules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of the sterile liquid carrier, for example, saline, water-for-injection, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
[0212] Formulations for rectal administration may be presented as a suppository with the usual carriers such as cocoa butter or polyethylene glycol.
[0213] Formulations for topical administration in the mouth, for example buccally or sublingually, include lozenges comprising the active ingredient in a flavored basis such as sucrose and acacia or tragacanth, and pastilles comprising the active ingredient in a basis such as gelatin and glycerin or sucrose and acacia.
[0214] Preferred unit dosage formulations are those containing an effective dose, as herein below recited, or an appropriate fraction thereof, of the active ingredient.
[0215] It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention may include other agents conventional in the art having regard to the type of formulation in question, for example those suitable for oral administration may include flavoring agents.
[0216] The compounds of the invention may be administered orally or via injection at a dose of from 0.001 to 2500 mg/kg per day. The dose range for adult humans is generally from 0.005 mg to 10 g/day. Tablets or other forms of presentation provided in discrete units may conveniently contain an amount of compound of the invention which is effective at such dosage or as a multiple of the same, for instance, units containing 0.5 mg to 200 mg, usually around 0.5 mg to 100 mg.
[0217] The compounds of Formula I, II, III, IV, V, or VI are preferably administered orally or by injection (intravenous or subcutaneous). The precise amount of compound administered to a patient will be the responsibility of the attendant physician. However, the dose employed will depend on a number of factors, including the age and sex of the patient, the precise disorder being treated, and its severity. Also, the route of administration may vary depending on the condition and its severity.
[0218] Compounds of the present invention can exist in tautomeric, geometric or stereoisomeric forms. The present invention contemplates all such compounds, including cis- and trans-geometric isomers and mixtures thereof, E- and Z-geometric isomers and mixtures thereof, R- and S-enantiomers, diastereomers, d-isomers, 1-isomers, the racemic mixtures thereof and other mixtures thereof, as falling within the scope of the invention. Pharmaceutically acceptable salts of such tautomeric, geometric or stereoisomeric forms are also included within the invention.
[0219] The terms “cis” and “trans” denote a form of geometric isomerism in which two carbon atoms connected by a double bond will each have two highest ranking groups on the same side of the double bond (“cis” or “Z”) or on opposite sides of the double bond (“trans” or “E”). Some of the compounds described contain alkenyl groups, and are meant to include both cis and trans or “E” and “Z” geometric forms. Other compounds of the invention include mixtures of both the cis/Z and the trans/E isomers.
[0220] The compounds described contain a stereocenter and are meant to include R, S, and mixtures of R and S forms. Some of the compounds described contain geometric isomers and are meant to include E, Z and mixtures of E and Z forms for each stereocenter present.
[0221] The following general synthetic sequences are useful in making the present invention.
[0222] (a) KOH
[0223] (b) MeI
[0224] (c) TBSCl
[0225] (d) DIBAL
[0226] (e) MsCl/pyridine or imidazole
[0227] (f) (2S,4S)-3-benzoyl-2-t-butyl-4-methyl-1,3-oxazolidin-5-one, KHMDS
[0228] (g) AcOH
[0229] (h) Tf 2 O
[0230] (i) 3-methyl-1,2,4-oxadiazolin-5-one potassium salt
[0231] (j) HCl
[0232] i) ozone
[0233] ii) Wittig reaction
[0234] iii) LiBH 4
[0235] iv) mesyl chloride
[0236] v) base
[0237] vi) fluoride
[0238] vii) mesyl chloride
[0239] viii) DMF
[0240] ix) hydrolysis
[0241] x) Zn/HOAc/MeOH
[0242] i) Wittig
[0243] ii) LiBH4
[0244] iii) Mitsunobu
[0245] iv) LAH
[0246] v) Boc2O
[0247] vi) fluoride
[0248] vii) mesyl chloride
[0249] viii) base
[0250] ix) H+
[0251] x) ethyl acetimidate
[0252] xi) Acid hydrolysis
[0253] (a) KOH
[0254] (b) MeI
[0255] (c) TBSCl
[0256] (d) DIBAL
[0257] (e) MsCl/pyridine or imidazole
[0258] (f) (2S,4S)-3-benzoyl-2-t-butyl-4-methyl-1,3-oxazolidin-5-one, KHMDS
[0259] (g) AcOH
[0260] (h) Tf 2 O
[0261] (i) 3-methyl-1,2,4-oxadiazolin-5-one potassium salt
[0262] (j) HCl
[0263] (a) KOH
[0264] (b) MeI
[0265] (c) TBSCl
[0266] (d) DIBAL
[0267] (e) MsCl, Et 3 N:
[0268] (f) NaH
[0269] (g) 1N HCl
[0270] (h) Boc 2 O, KHCO 3
[0271] (i) PPh 3 Br 2 , pyridine
[0272] (j) 3-methyl-1,2,4-oxadiazolin-5-one potassium salt
[0273] (k) 1N HCl
[0274] (l) Pd/CaCO 3 , HCOOH
[0275] (m) 1N HCl, reflux
[0276] The following Examples are illustrative and not intended to limit the scope of the invention
EXAMPLE 1
[0277] [0277]
[0278] (2R/S,4Z)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
Example 1a
[0279] 5,6 dihydropyran-2-one (49.05 g, 0.5 mol) was dissolved in 200 mL of water. Potassium hydroxide (35 g, 0.625 mol) was added and the reaction mixture stirred at ambient temperature for 5 hours. The solvent was removed in vacuo to yield a colorless glassy solid (65 g, 84%) that was characterized by NMR to be predominantly the cis isomer of the title compound.
[0280] [0280] 1 H NMR (CDCl 3 ) δ: 2.7 (m, 2H), 3.6 (t, 2H), 5.8-5.85 (m, 1H), 5.9-5.97 (m, 1H).
Example 1b
[0281] The product of Example 1a was dissolved in 100 mL of dimethyl formamide. Methyl Iodide (52 mL, 0.84 mol) was then added resulting in an exotherm to 40° C. The reaction mixture was stirred at room temperature for 10 hours and partitioned between 150 mL of ethylacetate/diethylether in a 20/80 ratio and ice water. The aqueous layer was separated and re-extracted with 100 mL of diethyl ether. The organic layers were combined, dried (Na 2 SO 4 ), filtered and stripped of all solvent to yield the desired methyl ester product (40 g, 71%). This material was dissolved in 200 mL of methylene chloride and the solution cooled to 0° C. Tertiarybutyl dimethylsilylchloride, triethylamine and dimethylaminopyridine were added. The reaction mixture was slowly warmed to room temperature and stirred for 10 hours under nitrogen. The reaction was extracted with 100 mL of 1N aqueous potassium bisulfate solution. The organic layer was washed with 2×100 mL of brine and then with 3×150 mL of water. The organic layer was dried (Na 2 SO 4 ), filtered and stripped to yield 42 g (56%) of the title material.
[0282] [0282] 1 H NMR (CDCl 3 ) δ: 0.02 (s, 6H), 0.085 (s, 9H), 2.8-2.85 (m, 2H), 3.65 (s, 3H), 3.66-3.7 (m 2H), 5.8 (m, 1H), 6.3 (m, 1H)
Example 1c
[0283] The material from Example 1b was dissolved in 25 mL of toluene and cooled to 0° C. Diisobutylaluminum hydride (1.0 M in toluene, 32 mL, 48 mmol) was added dropwise maintaining the temperature between 5 and −10° C. The reaction mixture was stirred for 1.5 hours between 6 and −8° C. before it was cooled to −25° C. To this mixture was added 100 mL of 0.5N sodium potassium tartarate. The reaction mixture was allowed to warm up to room temperature and stirr for an hour. A gelatinous precipitate was formed which was filtered. The aqueous was extracted with 2×100 mL EtOAc. The combined organic layers were dried (sodium sulfate), filtered and concentrated in vacuo to yield title product (3.45 g, 66%) as a colorless oil.
[0284] [0284] 1 H NMR (CDCl 3 ) δ: 0.02 (s, 6H), 0.085 (s, 9H), 2.25-2.32 (m, 2H), 2.6 (bs, 1H), 3.6 (t, 2H), 4.08 (d, 2H), 5.45-5.55 (m, 1H), 5.7-5.75 (m, 1H)
Example 1d
[0285] The product (8 g, 37 mmol) from Example 1c was dissolved in 100 mL methylene chloride and this solution was cooled to 0° C. Methanesulfonyl chloride was then added and this mixture was stirred for 5 min. Triethylamine was then added. The temperature maintained between 0 and −10° C. during the addition of the aforementioned reagents. The reaction mixture was subsequently warmed up to room temperature and stirred for 24 hours. It was then extracted with 100 mL of 50% aqueous sodium bicarbonate solution. The organic layer was washed with 100 mL of saturated aqueous brine solution, dried (sodium sulfate), filtered and stripped in vacuo to yield the title material (8.2 g, 94%).
[0286] [0286] 1 H NMR (CDCl 3 ) δ: 0.02 (s, 6H), 0.085 (s, 9H), 2.25-2.32 (m, 2H), 3.6 (t, 2H), 4.08 (d, 2H), 5.6-5.7 (m, 2H)
Example 1e
[0287] A solution of N-p-chloro phenylimine alanine methyl ester (8.85 g, 34 mmol) dissolved in 59 mL of tetrahydrofuran was purged with Argon. NaH (1.64 g, 41 mmol) was added whereupon the solution turned bright orange and subsequently a deep red. A solution of the title material from Example 1d (8 g, 34 mmol) in 40 mL of tetrahydrofuran was added to the above anionic solution. An exotherm was observed raising the temperature to almost 40° C. The reaction mixture was maintained between 48 and −52° C. for 2 hours. It was then cooled to room temperature and filtered. Filtrate was stripped in vacuo to yield the title material (8.4 g, 50% crude yield) as a yellow oil.
[0288] [0288] 1 H NMR (CDCl 3 ) δ: 0.02 (s, 6H), 0.085 (s, 9H), 1.45 (s, 3H), 1.6 (s, 1H), 2.2-2.25 (m, 2H), 2.65 (d, 2H), 3.55 (m, 2H), 3.7 (s, 3H), 5.45-5.55 (m, 2H), 7.35-7.7 (m, 4H)
Example 1f
[0289] The title material from Example 1e (8.4 g, 18.2 mmol) was treated with 125 mL 1N hydrochloric acid and the reaction was stirred for an hour at room temperature. After the reaction mixture had been extracted 2×75 mL of ethylacetate the aqueous layer was stripped in vacuo at 56° C. to yield 4 g of the title material (100% crude yield).
[0290] [0290] 1 H NMR (CD 3 OD) δ: 1.6 (s, 3H), 2.3-2.4 (m, 2H), 2.65-2.8 (m, 2H), 3.6-3.65 (m, 2H), 3.87 (s, 3H), 5.4-5.5 (m, 1H), 5.75-5.85 (m, 1H)
Example 1g
[0291] The title product of Example 1f (1.9 g, 8.5 mmol) was dissolved in a mixture of 15 mL dioxane and 8 mL of water. Solid potassium bicarbonate was then carefully added to avoid foaming. The reaction mixture was stirred for 10 min before tertiarybutyloxycarbonyl anhydride was added portion-wise and reaction mixture was stirred at ambient temperature for 24 hours. The reaction mixture was diluted with 100 mL of ethylacetate and 50 mL of water before it was poured into a separatory funnel. The organic layer was separated, dried (Na 2 SO 4 ), filtered and stripped to yield the title material as a colorless oil (1.9 g, 78% crude yield).
[0292] [0292] 1 H NMR (CDCl 3 ) δ: 1.42 (s, 9H), 1.55 (s, 3H), 2.3-2.36 (m, 2H), 2.58-2.65 (m, 2H), 3.65-3.7 (t, 2H), 3.75 (s, 3H), 5.42-5.5 (m, 1H), 5.55-5.62 (m, 1H)
Example 1h
[0293] Another 1.9 g sample of the title material from Example 1f was converted by the methods of Example 1g to the crude Z/E mixture of the title product of Example 1g. This material further purified on silica with a solvent system of ethylacetate/hexane in a 20/80 ratio to obtain the minor E-isomer as well as the major Z-isomer.
Example 1i
[0294] The title Z-isomer from Example 1h (1.8 g, 6.25 mmol) was dissolved in 20 mL of acetonitrile and this solution was cooled to 0° C. Pyridine (0.76 g, 9.4 mmol) was then added followed by the portion-wise addition of solid dibromotriphenylphosphorane (3.46 g, 8.2 mmol) over 10 min. The reaction mixture was stirred under Argon for 24 hours at room temperature. The precipitate that formed was filtered off. The filtrate was concentrated in vacuo to give 2.8 g of an oil that was purified on silica gel using a solvent system of ethylacetate/hexane in a 60/40 ratio. The 1.1 g of title material (50%) was characterized by NMR.
[0295] [0295] 1 H NMR (CDCl 3 ) δ: 1.44 (s, 9H), 1.55 (s, 3H), 2.6-2.65 (m, 4H), 3.35-3.4 (m, 2H), 3.75 (s, 3H), 5.4-5.45 (m, 1H), 5.55-5.6 (m, 1H)
Example 1j
[0296] The title material from Example h (300 mg, 0.86 mmol) was dissolved in 25 mL of dimethylformamide (DMF). The potassium salt of 3-methyl-1,2,4-oxadiazolin-5-one (130 mg, 0.94 mmol) was added and the reaction mixture was heated to 52° C. and maintained there for 18 hours with stirring. It was then cooled to room temperature before the DMF was stripped in vacuo at 60° C. The residue was purified on silica gel with a gradient of 60/40 to 90/10 ethyl acetate/hexane to yield 300 mg (95%) of the title material.
[0297] [0297] 1 H NMR (CD 3 OD) δ: 1.35 (s, 3H), 1.43 (s, 9H), 2.32 (s, 3H), 2.45-2.55 (m, 4H), 3.65-3.7 (m, 2H), 3.72 (t, 3H), 5.5-5.6 (m, 2H)
Example 1k
[0298] The product of Example 1j (300 mg) was treated with 0.05 N of aqueous HCl and this solution was stirred for 30 min. The solvent was removed in vacuo to afford the desired material in nearly quantitative yield.
[0299] [0299] 1 H NMR (CD 3 OD) δ: 1.6 (s, 3H), 2.25 (s, 3H), 2.45-2.55 (m, 2H), 2.7-2.8 (m, 2H), 3.3-3.4 (m, 5H), 5.5-5.6 (m, 1H), 5.7-5.8 (m, 1H)
Example 1l
[0300] The title material from Example 1k (198 mg, 0.54 mmol) was dissolved in 50 mL of MeOH. Formic acid (40 mg) was then added followed by Palladium on Calcium carbonate (400 mg). The reaction mixture was heated to 65° C. with stirring in a sealed tube for 24 hours. It was then cooled to room temperature and filtered. The filtrate was concentrated in vacuo and the residue purified by reverse phase HPLC to yield 115 mg (75%) of the title material.
[0301] [0301] 1 H NMR (CD 3 OD) δ: 1.4 (s, 3H), 1.95 (s, 3H), 2.25 (s, 3H), 2.4-2.52 (m, 4H), 3.25-3.35 (m, 2H), 3.75 (t, 3H), 5.54-5.62 (m, 2H)
Example 1
[0302] The title material (75 mg) from Example 1l was dissolved in 15 mL of 2N hydrochloric acid. The reaction mixture was heated to a reflux and stirred for 6 hours before ot was cooled to room temperature. The solvent was removed in vacuo. The residue was dissolved in 25 mL of water and stripped on the rotary evaporator to remove excess hydrochloric acid. The residue was dissolved in water and lyophilized to give 76 mg (˜100%) of the title material.
[0303] Elemental analyses Calcd for C 10 H 19 N 3 O 2 +2.2HCl+2.2 H 2 O: C, 36.06; H, 7.75; N, 12.61. Found for C 10 H 19 N 3 O 2 +2.2HCl+2.2 H 2 O: C, 35.91; H, 7.61; N, 12.31 1 H NMR (CD 3 0D) δ: 1.47 (s, 3H), 2.32 (s, 3H), 2.45-2.64 (m, 4H), 2.58-2.65 (m, 2H), 3.65-3.7 (t, 2H), 5.55-5.65 (m, 2H)
EXAMPLE 2
[0304] [0304]
[0305] (2R/S,4E)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
Example 2a
[0306] The title trans-isomer of Example 1h dissolved in acetonitrile was cooled to 0° C. Pyridine was then added followed by the portion-wise addition of solid dibromotriphenylphosphorane over 10 min. The reaction mixture was stirred under Argon for 24 hours at room temperature. A precipitate that formed was filtered off. The filtrate was concentrated in vacuo to give an oil that was purified on silica gel using a solvent elution system of ethylacetate/hexane in a 60/40 ratio. The title product was characterized by NMR.
Example 2b
[0307] The title material from Example 2a is converted to the title material by the method of Example 1j.
Example 2c
[0308] The title material from Example 2b is converted to the title material by the method of Example 1k.
Example 2d
[0309] The title material from Example 2c is converted to the title material by the method of Example 1l.
Example 2
[0310] The title material from Example 2d is converted to the title material by the method of Example 1.
EXAMPLE 3
[0311] [0311]
[0312] (2S,4Z)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
[0313] The racemic title material from Example 1j is separated into its S and R isomers by chiral chromatography. The S isomer of Example 1j is converted to the title material by the methods of Examples 1j, 1k, and 1l.
EXAMPLE 4
[0314] [0314]
[0315] (2R,4Z)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
[0316] The racemic title material from Example 1j is separated into its S and R isomers by chiral chromatography. The R isomer of Example 1j is converted to the title material by the methods of Examples 1j, 1k, and 1l.
EXAMPLE 5
[0317] [0317]
[0318] (2S,4E)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
[0319] The racemic title material from Example 2b is separated into its S and R isomers by chiral chromatography. The R isomer of Example 2b is converted to the title material by the methods of Examples 1j, 1k, and 1l.
EXAMPLE 6
[0320] [0320]
[0321] (2R,4E)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
[0322] The racemic title material from Example 2b is separated into its S and R isomers by chiral chromatography. The S isomer of Example 2b is converted to the title material by the methods of Examples 1j, 1k, and 1l.
EXAMPLE 7
[0323] [0323]
[0324] (2S,4Z)-2-amino-2-ethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 8
[0325] [0325]
[0326] (2S,4Z)-2-amino-2-fluoromethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 9
[0327] [0327]
[0328] (2S,4Z)-2-amino-2-methoxymethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 10
[0329] [0329]
[0330] (2S)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptynoic Acid, Dihydrochloride
EXAMPLE 11
[0331] [0331]
[0332] (2S,4E)-2-amino-5-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 12
[0333] [0333]
[0334] (2S,4E)-2-amino-5-fluoro-2-ethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 13
[0335] [0335]
[0336] (2S,4E)-2-amino-5-fluoro-2-fluoromethyl-7-[(1-iminoethyl)amino]-4-heptenoic-Acid, Dihydrochloride
EXAMPLE 14
[0337] [0337]
[0338] (2S,4E)-2-amino-5-fluoro-2-methoxymethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 15
[0339] [0339]
[0340] (2S,4E)-2-amino-4-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 16
[0341] [0341]
[0342] (2R/S,4E)-2-amino-4-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 17
[0343] [0343]
[0344] (2R/S,4E)-2-amino-5-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 18
[0345] [0345]
[0346] (2R/S)-2-amino-2-methyl-7-[(1-iminoethyl)amino]-4-heptynoic Acid, Dihydrochloride
EXAMPLE 19
[0347] [0347]
[0348] (2S,4Z)-2-amino-2,5-dimethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 20
[0349] [0349]
[0350] (2S,4Z)-2-amino-2,4-dimethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 21
[0351] [0351]
[0352] (2S,4Z)-2-amino-4-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 22
[0353] [0353]
[0354] (2S,4Z)-2-amino-5-fluoro-2-methyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 23
[0355] [0355]
[0356] (2S,4E) -2-amino-2-methyl-5-fluoromethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
EXAMPLE 24
[0357] [0357]
[0358] (2S,4E)-2-amino-2-methyl-4-fluoromethyl-7-[(1-iminoethyl)amino]-4-heptenoic Acid, Dihydrochloride
[0359] (i) Biological Data
[0360] Some or all of the following assays are used to demonstrate the nitric oxide synthase inhibitory activity of the invention's compounds as well as demonstrate the useful pharmacological properties.
[0361] Citrulline Assay for Nitric Oxide Synthase
[0362] Nitric oxide synthase (NOS) activity can be measured by monitoring the conversion of L-[2,3- 3 H]-arginine to L-[2,3- 3 H]-citrulline (Bredt and Snyder, Proc. Natl. Acad. Sci. U.S.A., 87, 682-685, 1990 and Moore et al, J. Med. Chem. 39, 669-672, 1996). Human inducible NOS (hiNOS), human endothelial constitutive NOS (hecNOS) and human neuronal constitutive NOS (hncNOS) are each cloned from RNA extracted from human tissue. The cDNA for human inducible NOS (hiNOS) is isolated from a λcDNA library made from RNA extracted from a colon sample from a patient with ulcerative colitis. The cDNA for human endothelial constitutive NOS (hecNOS) is isolated from a λcDNA library made from RNA extracted from human umbilical vein endothelial cells (HUVEC) and the cDNA for human neuronal constitutive NOS (hncNOS) is isolated from a λcDNA library made from RNA extracted from human cerebellum obtained from a cadaver. The recombinant enzymes are expressed in Sf9 insect cells using a baculovirus vector (Rodi et al, in The Biology of Nitric Oxide, Pt. 4: Enzymology, Biochemistry and Immunology; Moncada, S., Feelisch, M., Busse, R., Higgs, E., Eds.; Portland Press Ltd.: London, 1995; pp 447-450). Enzyme activity is isolated from soluble cell extracts and partially purified by DEAE-Sepharose chromatography. To measure NOS activity, 10 μL of enzyme is added to 40 μL of 50 mM Tris (pH 7.6) in the presence or absence of test compounds and the reaction initiated by the addition of 50 μL of a reaction mixture containing 50 mM Tris (pH 7.6), 2.0 mg/mL bovine serum albumin, 2.0 mM DTT, 4.0 mM CaCl 2 , 20 μM FAD, 100 μM tetrahydrobiopterin, 0.4 mM NADPH and 60 μM L-arginine containing 0.9 μCi of L-[2,3- 3 H]-arginine. The final concentration of L-arginine in the assay is 30 μM. For hecNOS or hncNOS, calmodulin is included at a final concentration of 40-100 nM. Following incubation at 37° C. for 15 minutes, the reaction is terminated by addition of 400 μL of a suspension (1 part resin, 3 parts buffer) of Dowex 50W X-8 cation exchange resin (sodium form) in a stop buffer containing 10 mM EGTA, 100 mM HEPES, pH 5.5 and 1 mM L-citrulline. After mixing the resin is allowed to settle and L-[2,3- 3 H]-Citrulline formation is determined by counting aliquots of the supernatant with a liquid scintillation counter. IC 50 values can be determined by testing each compound at several concentrations. Results are reported in Table I as the IC 50 values of compounds for hiNOS, hecNOS and hncNOS.
TABLE I Example IC 50 [μM] Number hiNOS hecNOS hncNOS Example 1 34 386 122
[0363] In Vivo Assay
[0364] Rats can be treated with an intraperitoneal injection of 1-12.5 mg/kg of endotoxin (LPS) to induce systemic expression of inducible nitric oxide synthase, resulting in markedly elevated plasma nitrite/nitrate levels. Compounds are administered orally 0.5-1 hours prior to LPS administration and plasma nitrite/nitrate levels are determined 5 hours following LPS administration. The results can be used to show that the administration of the nitric oxide synthase inhibitors decreases the rise in plasma nitrite/nitrate levels, a reliable indicator of the production of nitric oxide induced by endotoxin. ED 50 values (mg/kg) for inhibition of the LPS-induced increase in plasma nitrite/nitrate levels can be determined.
[0365] Raw Cell Nitrite Assay
[0366] RAW 264.7 cells can be plated to confluency on a 96-well tissue culture plate grown overnight (17 h) in the presence of LPS to induce NOS. A row of 3-6 wells can be left untreated and serve as controls for subtraction of nonspecific background. The media can be removed from each well and the cells washed twice with Kreb-Ringers-Hepes (25 mM, pH 7.4) with 2 mg/ml glucose. The cells are then placed on ice and incubated with 50 μL of buffer containing L-arginine (30 μM) +/− inhibitors for 1 h. The assay can be initiated by warming the plate to 37° C. in a water bath for 1 h. Production of nitrite by intracellular iNOS will be linear with time. To terminate the cellular assay, the plate of cells can be placed on ice and the nitrite-containing buffer removed and analyzed for nitrite using a previously published fluorescent determination for nitrite (T. P. Misko et al, Analytical Biochemistry, 214, 11-16, 1993).
[0367] Human Cartilage Explant Assay
[0368] Bone pieces are rinsed twice with Dulbecco's Phosphate Buffered Saline (GibcoBRL) and once with Dulbecco's Modified Eagles Medium (GibcoBRL) and placed into a petri dish with phenol red free Minimum Essential Medium (MEM) (GibcoBRL). Cartilage is cut into small explants of approximately 15-45 mg in weight and one or two explants per well are placed into either 96 or 48 well culture plates with 200-500 μL of culture media per well. The culture media is either a custom modification of Minimum Essential Medium(Eagle) with Earle's salts (GibcoBRL) prepared without L-Arginine, without L-Glutamine and without phenol red or a custom modification of serumless Neuman and Tytell (GibcoBRL) medium prepared without L-arginine, without insulin, without ascorbic acid, without L-glutamine and without phenol red. Both are supplemented before use with 100 μM L-Arginine (Sigma), 2 mM L-glutamine, 1× HL-1 supplement (BioWhittaker), 50 mg/ml ascorbic acid (Sigma) and 150 pg/ml recombinant human IL-1β (RD Systems) to induce nitric oxide synthase. Compounds are then added in 10 μL aliquots and the explants incubated at 37° C. with 5% CO 2 for 18-24 hours.
[0369] The day old supernatant is then discarded and replaced with fresh culture media containing recombinant human IL-1β and compound and incubated for another 20-24 hours. This supernatant is analyzed for nitrite with a fluorometric assay (Misko et al, Anal. Biochem., 214, 11-16, 1993). All samples are done in quadruplicate. Unstimulated controls are cultured in media in the absence of recombinant human IL-1β. IC 50 values are determined from plotting the percent inhibition of nitrite production at six different concentrations of inhibitor.
[0370] Assay for Time Dependent Inhibition
[0371] Compounds are evaluated for time dependent inhibition of human NOS isoforms by preincubation of the compound with the enzyme at 37° C. in the presence of the citrulline enzyme assay components, minus L-arginine, for times ranging from 0-60 minutes. Aliquots (10 μL) are removed at 0, 10, 21 and 60 minutes and immediately added to a citrulline assay enzyme reaction mixture containing L-[2,3- 3 H]-arginine and a final L-arginine concentration of 30 μM in a final volume of 100 μL. The reaction is allowed to proceed for 15 minutes at 37° C. and terminated by addition of a suspension of Dowex 50W X-8 cation exchange ion resin as described above for the citrulline NOS assay. The % inhibition of NOS activity by an inhibitor is taken as the per cent inhibition in activity compared to control enzyme preincubated for the same time in the absence of inhibitor. Time-dependent inhibition can be demonstrated as an increase in inhibition with increasing preincubation time. | The present invention relates to 2-amino-2-alkyl-4 heptenoic and heptynoic ac derivatives and their use in therapy, in particular their use as nitric oxide synthase inhibitors. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention relates to a method and apparatus for extruding or spinning synthetic fibers and relates more particularly to the production of a homogeneous web of polymeric fibers wherein at least some of the fibers in the web have different characteristics from other fibers in the web, and to unique products that can be produced from such fibers. Of particular importance is the production of a homogeneously mixed fibrous web of the type described wherein at least certain of the fibers are multi-component polymeric fibers, such as sheath/core bicomponent fibers and wherein, if desired, more than one multiple-component fiber may be uniformly dispersed throughout a web of fibers, with at least the sheath of such multiple-component fibers being formed of different polymeric materials.
[0003] This invention is also concerned with unique fibrous products having diverse applications, and particularly to such products when made using the advanced homogeneous mixed fiber technology referred to above.
[0004] This invention also relates to a heat and moisture exchanger and more particularly to a gas-permeable element, preferably comprising a fibrous media which may be made by the improved mixed fiber technology discussed above and which is adapted to be warmed and to trap moisture from a patient's breath during exhalation and to be cooled and to release the trapped moisture for return to the patient during inspiration, to thereby conserve the humidity and body heat of the patient's respiratory tract during treatment of the patient requiring communication of the patient with an extracorporeal source of a gas through an artificial airway. The heat and moisture exchanger of this invention is also effective for the removal of particulate contaminants contained in the gas to protect the patient from inhaling such contaminants, and to protect the atmosphere from contaminants in the patient's exhalation.
[0005] Artificial airways are used in diverse medical procedures and take a variety of forms. The insertion of an endotracheal tube to permit a choking patient access to air provides a simple illustration. Short- and long-term connection to a mechanical ventilator when a patient requires breathing assistance is another example of a situation requiring the use of an artificial airway. Artificial airways are also necessary when infusing a patient with oxygen as is common in the intensive care unit, or an anesthetic in the surgical theater.
[0006] Regardless of the particular circumstances, the use of an artificial airway creates a common set of problems. When a person exhales normally, the mouth, nose and pharynx retain heat and moisture and tend to warm and humidify incoming air during the next breath, to thereby substantially saturate the air at body temperatures. The artificial airways in a breathing circuit of the type discussed above, bypass the natural humidification systems allowing relatively cool and dry gases, such as oxygen or an anesthetic, access to the trachea and lungs without modification impairing the ability of the respiratory tract to properly function. Dry anesthetic gases can damage cellular morphology, ciliary function and increase patient susceptibility to infection. The lack of humidity causes water to vaporize from the tracheal mucosa. Additionally, heat is lost when a cool gas is inspired, causing the mucosa to dry and secretions to thicken. The resultant difficulty in clearing the respiratory tract can produce an obstruction of the natural airway.
[0007] Thus, the inhalation of poorly humidified gases can not only cause a patient discomfort, but it can increase the risks of pulmonary damage. Moreover, the resultant heat loss through the respiratory tract may cause post-operative patient shivering and require unnecessary patient reheating during recovery.
[0008] Another complication resulting from the need to connect a patient to an extracorporeal source of gas through an artificial airway is the possibility of infecting the patient with bacterial, viral or other contaminants present in the inspired gas. Similarly, contaminants passing to the environment through the artificial airway can pollute the atmosphere. These problems are particularly important when treating infected or immuno-compromised patients, or in the intensive care unit where both the patient being treated and other patients in the area are likely to be especially sensitive to the airborne transmission of pathogenic organisms.
[0009] 2. Discussion of the Prior Art
[0010] Various prior art techniques are known for the production of polymeric fibers, including monocomponent fibers and multiple-component fibers of various configurations. Among such multiple-component fibers, bicomponent fibers comprising a core of one polymer and a coating or sheath of a different polymer are particularly desirable for many applications.
[0011] For example, in my prior U.S. Pat. No. 5,509,430 issued Apr. 23, 1996, the subject matter of which is incorporated herein in its entirety by reference, unique polymeric bicomponent fibers comprising a core of a low cost, high strength, thermoplastic polymer, preferably polypropylene, and a bondable sheath of a material which may be cellulose acetate, ethylene-vinyl acetate copolymer, polyvinyl alcohol, or ethylene-vinyl alcohol copolymer are disclosed for use particularly in the production of tobacco smoke filters. The bicomponent fibers produced according to the techniques of the '430 patent may be melt blown to produce very fine fibers, on the order of about 10 microns or less in diameter, in order to obtain enhanced filtration. Such products are shown to have improved tobacco smoke filtration efficiency, acceptable taste, and can be produced at a substantially lower cost than conventional tobacco smoke filters formed from fibers consisting entirely of cellulose acetate.
[0012] In my subsequent U.S. Pat. No. 5,607,766 issued Mar. 4, 1997, U.S. Pat. No. 5,620,641 issued Apr. 15, 1997, and U.S. Pat. No. 5,633,082 issued May 27, 1997, the subject matters of which are also incorporated herein in their entireties by reference, unique melt blown bicomponent fibers comprising a core of a thermoplastic material covered by a sheath of polyethylene terephthalate and methods of making same are disclosed as particularly useful in the production of elongated, highly porous elements having numerous applications. For example, such products are useful as wick reservoir elements for marking and writing instruments, that is, materials designed to take up a Liquid and later controllably release the same as in an ink reservoir. Additionally, because of their high capillarity, such materials function effectively in the production of simple wicks for transferring liquid from one place to another, such as in the production of the fibrous nibs found in certain marking and writing instruments. Wicks of this sort are also useful in diverse medical applications, for example, the transport of bodily fluid by capillary action to a test site in a diagnostic device.
[0013] Products made from the bicomponent fibers of the '766, '641 and '082 patents are also shown to be useful as absorption reservoirs, i.e., as a membrane to take up and simply hold the Liquid as in a diaper or an incontinence pad. Absorption reservoirs are also useful in medical applications. For example, a layer or pad of such material may be used in an enzyme immunoassay test device where they will draw a bodily fluid through the fine pores of a thin membrane coated, for example, with monoclonal antibodies that interact with antigens in the bodily fluid which is pulled through the membrane and then held in the absorption reservoir. Such materials are also suggested, with the possible addition of a smoke-modifying or taste-modifying material, for use in tobacco smoke filters.
[0014] Polymeric fibers, in general, may be produced by a number of common techniques, oftentimes dictated by the polymer itself or the desired properties and applications for the resultant fibers. Among such techniques, are conventional melt spinning processes wherein molten polymer is pumped under pressure to a spinning head and extruded from spinneret orifices into a multiplicity of continuous fibers. Melt spinning is only available for polymers having a melting point temperature less than its decomposition point temperature, such as nylon, polypropylene and the like whereby the polymer material can be melted and extruded to fiber form without decomposing. Other polymers, such as the acrylics, cannot be melted without blackening and decomposing. Such polymers can be dissolved in a suitable solvent (e.g., acetate in acetone) of typically 20% polymer and 80% solvent. In a wet solution spinning process, the solution is pumped, at room temperature, through the spinneret which is submerged in a bath of liquid (e.g. water) in which the solvent is soluble to solidify the polymeric fibers. It is also possible to dry spin the fibers into hot air, rather than a liquid bath, to evaporate the solvent and form a skin that coagulates. Other common spinning techniques are well known and do not form a critical part of the instant inventive concepts.
[0015] After spinning, the fibers are commonly attenuated by withdrawing them from the spinning device at a speed faster than the extrusion speed, thereby producing fibers which are finer and, depending upon the polymer, possibly, more crystalline in nature and, thereby, stronger. The fibers may be attenuated by taking them up on rotating nip rolls or by melt blowing the fibers, that is, contacting the fibers as they emanate from the spinneret orifices with a fluid, such as air, under pressure to draw the same into fine fibers, commonly collected as an entangled web of fibers on a continuously moving surface, such as a conveyor belt or a drum surface, for subsequent processing.
[0016] As described in my aforementioned patents, the extruded fibrous web may be gathered into a sheet form which may be pleated to increase the surface area for certain filtering applications. Alternatively, the web of fibers may be gathered together and passed through forming stations, such as steam treating and cooling stations, which may bond the fibers at their points of contact to form a continuous rod-like porous element defining a tortuous path for passage of a fluid material therethrough.
[0017] While earlier techniques and equipment for spinning fibers have commonly extruded one or more polymer materials directly through an array of spinneret orifices to produce a web of monocomponent fibers or a web of multiple-component fibers, recent development incorporate a pack of disposable distribution or spin plates juxtaposed to each other, with distribution paths being etched into upstream and/or downstream surfaces of the plates to direct streams of one or more polymer materials to and through spinneret orifices at the distal end of the spinning system. These techniques are embodied, for example, in Hills U.S. Pat. No. 5,162,074 issued Nov. 10, 1992, the subject matter of which is incorporated herein in its entirely by reference, and provide a reasonably inexpensive way to manufacture highly sophisticated spinning equipment and to produce a high density of continuous fibers formed of more than one polymeric material. Hills recognizes the production of multiple-component fibers, such as bicomponent fibers, wherein the components adhere to each other in a durable fashion, or, alternatively, are poorly adhering so that the components may be split apart to increase the effective fiber yield from each spinneret opening and to produce finer fibers from the individual components.
[0018] Although Hills and others provide relatively inexpensive, even disposable, distribution plates capable of spinning a high density of identical fibers, which may include separable segments of different polymeric materials, and the production of a web of mixed fibers, i.e., fibers having different physical and/or chemical characteristics, is broadly referred to in the literature, to my knowledge the prior art fails to recognize the advantages of directly spinning a homogeneous or uniform mixture of fibers from a spinning device, wherein the fibers extruded from certain of the spinneret orifices in the same element have different characteristics from the fibers extruded from other spinneret orifices in that element. Moreover, the techniques and equipment currently commercially available are not adapted to produce such a homogeneous web of mixed fibers, most especially, a uniformly distributed mixture of monocomponent and multiple-component fibers, or even a uniform mixture of different multiple-component fibers, e.g., where adjacent fibers in the web have different polymeric coatings such as alternating bicomponent fibers having a common core-forming polymer and different sheath-forming polymers.
[0019] Although fibrous products, including the unique melt-blown bicomponent fibers of my '430, '766, '641 and '082 patents discussed above, have significant commercial applications, the functional properties of the available products are limited by the inability of prior art technology to produce uniform and consistent webs of mixed fibers of differing chemical and/or physical characteristics. To the extent that the prior art is capable of producing mixed fibrous webs, the apparatus and techniques for doing so are generally inadequate for commercial application and/or are unable to provide reproducible, highly homogeneous, mixtures of diverse fibers from the same set of spinneret orifices.
[0020] With an improved ability to produce mixed fiber webs of substantially complete uniformity, improved functional properties can be afforded in a variety of fibrous products, whether they are intended to for use as high efficiency filters such as are required in electric dust collection devices and power plants, coalescent-type filters such as those used to separate water from aviation fuel, wicking products such as may be used for ink transfer in marking and writing instruments or as medical wicks, or in similar liquid holding and transferring applications, or in diverse other fields.
[0021] With respect to a particular application of the improved technology of this invention, that is, in the production of heat and moisture exchangers and high efficiency particulate air filters for use in a breathing circuit requiring an artificial airway, various prior art devices are commercially available. Oftentimes, however, separate devices are necessary to conserve the humidity and body heat of the patient's respiratory tract and to filter undesirable constituents from a gas being inhaled by the patient, or from the patient's breath exhaled during such treatments. Although some devices are available which incorporate media capable of performing all of these functions, it is not uncommon in such devices for particular properties to be compromised in order that other properties can be enhanced. The availability of a device capable of maximizing both heat and moisture exchange and filtration in an economic manner would be most desirable.
[0022] Early attempts to humidify a patient's respiratory tract and thereby reduce heat loss during short or long-term mechanical ventilation or the like, utilized electrically heated, water-filled humidifiers to add water vapor to the airway. This approach produced almost as many problems as it solved. The water level and temperature of the water vapor required constant monitoring. Further, particular difficulty was experienced in controlling the delivery of the small volumes of moisture needed for children or infants. Condensation of the water vapor could plug the small airways and, in extreme situations, even cause drowning. Additionally, the development of deposits in the humidifier reservoir often contaminated the moisture, thereby damaging the equipment and possibly harming the patient. The presence of such contaminants simply increased the need for effective filtration.
[0023] More recently, regenerative humidifiers or “artificial noses” have been developed as safe and effective alternatives to overcome many of the foregoing problems with heated water bath humidifiers. Such units are commonly referred to as heat and moisture exchangers (HMEs) because they function much in the same way as the patient's natural resources, that is, they capture the moisture and heat as the patient exhales and return them to the patient during the next breath.
[0024] HMEs are passive, requiring no outside source of moisture or power. They are placed in line with the artificial airway and are provided with a media producing a large surface area for the exchange of heat and moisture The HME media is warmed as humidity in the patient's breath condenses during exhalation, is cooled during inhalation as it gives up heat and moisture vapor to the inspired gases, and the process is repeated as the patient breathes in and out.
[0025] Attempts have been made to increase the hygroscopicity of the HME media to thereby directly absorb moisture from exhaled gases, whereby the media retains more moisture than would have been collected from condensation alone to thereby improve the HME output. Further, since the moisture held by the hygroscopic media is absorbed and not condensed, vaporative cooling of the HME is limited when this moisture is released during inhalation.
[0026] While the concept is technically sound, the particular hygroscopic materials commercially available are either inadequate or undesirable for use as HME media. Additives such as salts, e.g., lithium chloride, or glycerin provide advantageous hygroscopicity to HME media, but can contaminate and even interact with gases passing through such media during inspiration by the patient. Provision of an HME media capable of attracting and holding additional moisture from a patient's breath during exhalation without the need for extraneous chemicals is important to the safe and effective operation of an HME in auxiliary breathing equipment.
[0027] A number of criteria are particularly important in the design of an HME for medical applications. Low thermal conductivity of the heat and moisture exchange media increases the temperature differential across the HME, improving its efficiency. A low pressure drop across the HME is essential to minimize effort during normal breathing or mechanical ventilation. An HME must also be relatively lightweight since it is to be supported at a tracheotomy, endotracheal or nasotracheal site in most applications. The HME media should be disposable or easily sterilized to minimize costs in maintaining the breathing circuit. Finally, the HME media should be effective without the need for chemical additives that could affect the treated gases, and the media should not release any particulate matter, thereby protecting the patient and the environment as well as the equipment with which the HME is associated against contamination.
[0028] In summary, the HME must efficiently, inexpensively and safely provide adequate heat and moisture, preferably, to enable a single unit to effectively conserve the humidity and body heat of the patient's respiratory tract and, if possible, concomitantly filter gases passing therethrough to remove particulate contaminants, thereby avoiding the need for redundant units.
OBJECTS AND SUMMARY OF THE INVENTION
[0029] It is, therefore, a primary object of this invention to provide a unique fiber spinning process and apparatus for use therewith which feeds polymer materials from independent sources through mutually separated distribution paths to an array of spinneret orifices, wherein the fibers extruded from selected ones of the spinneret orifices have different characteristics from fibers extruded from other spinneret orifices.
[0030] Consistent with the foregoing object, adjacent fibers may be formed of the same or different polymers, may have different color, shape or texture and/or may have different denier. Moreover, according to a preferred feature of this invention, some fibers in the web may be monocomponent and others multiple-component. Thus, this invention enables the simultaneous extrusion of monocomponent fibers side-by-side with bicomponent fibers having a core of the monocomponent polymer material and a sheath of a different polymer material. Alternatively, bicomponent fibers with a common core-forming polymer and different sheath-forming polymer materials may be formed side-by-side and uniformly distributed throughout the same web of fibers as it is extruded.
[0031] Another object of this invention is the provision of a spinning device comprising a pack of distribution or spin plates defining separated distribution paths for receiving polymeric materials from multiple independent sources and delivering each of such materials to selected spinneret orifices of an array of spinneret orifices to produce a uniform blend of fibers of differing characteristics from the individual spinneret orifices.
[0032] A further object of this invention is the provision of a pack of distribution plates wherein independent distribution paths may be relatively inexpensively formed in one or both surfaces by any of a variety of techniques, including etching, milling or electrical discharge machining and the like, such that the plates can be reused or replaced from time to time.
[0033] A still further object of this invention is the provision of a pack of spin plates of the type described, wherein a line of spinneret orifices is defined in a single plate as through-holes parallel to the plane of the plate, such that the fibers are totally surrounded by a seamless forming surface as they are extruded, thereby precluding polymer leakage and non-uniformity in the resultant fibers.
[0034] Further objects of this invention reside in the uniquely homogeneous nature of the mixture of polymeric components and/or fibers of different characteristics in a web of fibers, enabling products made therefrom to have unusual chemical and/or physical properties. Consistent with this object, for example, the web of fibers can incorporate selected fibers having surface characteristics capable of bonding different fibers into a self-sustaining porous matrix defining a tortuous path for passage of a fluid material therethrough. Certain fibers in the mixture may provide the resultant product with increased strength, while other components may provide special characteristics, such as wicking, absorption, coalescing, filtration, heat and/or moisture exchange, and the like.
[0035] A still further object of the instant inventive concepts is the provision of products incorporating the unique web of mixed fibers such as wick reservoirs, including ink reservoirs and marking and writing instruments incorporating the same, filtering materials, including tobacco smoke filters and filtered cigarettes formed therefrom, wicks for transporting liquid from one place to another by capillary action, including fibrous nibs for marking and writing instruments and capillary wicks in medical applications designed to transport a bodily fluid to a test site in a diagnostic device and absorption reservoirs, membranes for taking up and holding liquid as in a diaper or an incontinence pad, or in medical applications such as enzyme immunoassay diagnostic test devices wherein a pad of such material will draw a bodily fluid through a thin membrane and hold the fluid pulled therethrough.
[0036] Yet another important object of this invention to provide a unique heat and moisture exchanger which overcomes the aforementioned and other disadvantages of prior art HMEs designed for use in artificial airways. Most importantly, the instant invention provides an HME media which is highly efficient, without the need for chemical additives that might otherwise contaminate either the gas inspired by the patient, the patient's breath exhaled through the HME to the atmosphere, or the airway tubing or valves or other equipment forming part of the breathing circuit.
[0037] A still further object of this invention is the provision of an HME which is relatively lightweight, has a low thermal conductivity and a low pressure drop to increase the efficiency of the HME and decrease the difficulty in use of same in an artificial airway.
[0038] Consistent with these objects, the instant invention provides an HME, adapted to be interposed in both inspiratory and expiratory airways for oxygen infusion, anesthesia, ventilation and other such medical applications, which includes a gas-permeable element, preferably a fibrous media, comprised of a hydrophilic nylon polymer which has been surprisingly found to be more effective than other HME media, including hygroscopic media currently available, in capturing moisture and heat from a patient's breath during exhalation, and cooling and releasing the trapped moisture for return to the patient during inspiration, without the need for chemical additives.
[0039] Another object of this invention is the provision of an HME comprising hydrophilic nylon polymeric fibers, especially fine fibers, bonded at their points of contact into a three-dimensional porous element defining a tortuous path for passage of a gas therethrough to increase its heat and moisture transfer effectiveness and, additionally, to remove undesirable particulate contaminants from the gases passing therethrough, thereby protecting the patient and the medical workers from cross-contamination, isolating the breathing circuit from the patient, and extending the useful life of mechanical ventilation equipment. The filtration effectiveness of an HME according to this invention finds particular use in an expiratory line to prevent undesirable contaminants from being expelled into the environment and on a main line to filter incoming gas.
[0040] Yet another object of this invention is the provision of an HME wherein the filter media includes bicomponent fibers comprising a sheath of the hydrophilic nylon polymer and a core of a different and less expensive polymer, such as polypropylene, enabling the media to be readily replaced between uses in a cost-effective manner.
[0041] Most preferably, it is an important object of this invention to provide an HME wherein the media is formed using the improved mixed fiber technology of this invention from a substantially uniform mixture of bicomponent fibers, some of which comprise a hydrophilic nylon polymer sheath, and others of which comprise a sheath of a thermoplastic polymer having a melting point lower than the hydrophilic nylon polymer, such as a polyester, to thereby provide an effective bonding agent for the hydrophilic nylon polymer fibers, with all of the bicomponent fibers having a common, and relatively inexpensive, core-forming polymer.
[0042] Upon further study of the specification and the appended claims, additional objects and advantages of this invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] A better understanding of the present invention, as well as other objects, features and advantages thereof, will become apparent upon consideration of the detailed description herein in connection with the accompanying drawings, wherein like reference characters refer to like parts.
[0044] Reference in the description of the drawings and the subsequent detailed description of the preferred embodiments to “upstream” and “downstream” relates to the direction of initial flow of the fiber-forming polymers into the die assembly.
[0045] [0045]FIG. 1 is an exploded perspective view of the principal elements of a spinning device according to the instant inventive concepts designed to produce a homogeneous web of sheath/core bicomponent fibers wherein all of the fibers share the same core-forming polymer and alternate fibers having different sheath-forming polymers.
[0046] [0046]FIG. 2 is a view similar to FIG. 1 looking in the opposite direction.
[0047] [0047]FIG. 3 is an assembled perspective view of portions of the elements shown in FIG. 1, with parts being broken away for illustrative clarity.
[0048] [0048]FIG. 4 is an exploded view of the elements shown in FIG. 3.
[0049] [0049]FIG. 5 is an enlarged detailed view of the portion of FIG. 3 within the circle A.
[0050] [0050]FIG. 6 is a view similar to FIG. 3, but taken from a different angle.
[0051] [0051]FIG. 7 is an enlarged detailed view of the portion of FIG. 6 within the circle B.
[0052] [0052]FIG. 8 is a perspective view similar to FIG. 3, but looking from the opposite side of the assembly.
[0053] [0053]FIG. 9 is an exploded view of the elements shown in FIG. 8.
[0054] [0054]FIG. 10 is an enlarged detailed view of the portion of FIG. 8 within the circle C.
[0055] [0055]FIG. 11 is an upstream plan view of a portion of the secondary right distribution plate.
[0056] [0056]FIG. 12 is a downstream plan view thereof FIG. 13 is a side elevational view thereof, with hidden parts shown in dotted lines.
[0057] [0057]FIG. 14 is an upstream perspective view of a portion of the secondary right distribution plate.
[0058] [0058]FIG. 15 is a downstream perspective view thereof FIG. 16 is an upstream plan view of a portion of the right distribution plate.
[0059] [0059]FIG. 17 is a downstream plan view thereof.
[0060] [0060]FIG. 18 is a side elevational view thereof with hidden parts shown in dotted lines.
[0061] [0061]FIG. 19 is an upstream perspective view of a portion of the right distribution plate.
[0062] [0062]FIG. 20 is a downstream perspective view thereof.
[0063] [0063]FIG. 21 is an upstream plan view of a portion of the left distribution plate.
[0064] [0064]FIG. 22 is a downstream plan view thereof.
[0065] [0065]FIG. 23 is a side elevational view thereof, with hidden parts shown in dotted lines.
[0066] [0066]FIG. 24 is an upstream perspective view of a portion of the left distribution plate.
[0067] [0067]FIG. 25 is a downstream perspective view thereof.
[0068] [0068]FIG. 26 is an upstream plan view of a portion of the secondary left distribution plate.
[0069] [0069]FIG. 27 is a downstream plan view thereof.
[0070] [0070]FIG. 28 is a side elevational view thereof, with hidden parts shown in dotted lines.
[0071] [0071]FIG. 29 is an upstream perspective view of a portion of the secondary left distribution plate.
[0072] [0072]FIG. 30 is a downstream perspective view thereof.
[0073] [0073]FIG. 31 is a fragmentary upstream plan view of the distribution plate assembly of the spinning device of this embodiment of the instant invention, with hidden parts shown in dotted lines for illustrative clarity.
[0074] [0074]FIG. 32 is an enlarged cross-sectional view taken along lines 32 - 32 of FIG. 31, illustrating the path of the core-forming polymer and the first sheath-forming polymer in the production of alternating sheath/core bicomponent fibers with the same core-forming polymer and different sheath-forming polymers according to this embodiment.
[0075] [0075]FIG. 33 is a view similar to view 32 , but taken along lines 33 - 33 of FIG. 31, illustrating the path of the core-forming polymer and the second sheath-forming polymer.
[0076] [0076]FIG. 34 is an exploded perspective view of the distribution plates only of another embodiment of a spinning device according to the instant inventive concepts adapted to produce a homogeneous web of different monocomponent fibers from two independent sources of polymer, as seen from the upstream side.
[0077] [0077]FIG. 35 is a view of the elements illustrated in FIG. 34, taken from the downstream side.
[0078] [0078]FIG. 36 is an assembled upstream plan view of the distribution plates illustrated in FIG. 34, with hidden parts shown in dotted lines for illustrative clarity.
[0079] [0079]FIG. 37 is a cross-sectional view taken along lines 37 - 37 of FIG. 36 showing the path of one of the polymers through the distribution plates.
[0080] [0080]FIG. 38 a cross-sectional view taken along lines 38 - 38 of FIG. 36 showing the path of the other polymer through the distribution plates.
[0081] [0081]FIG. 39 is an exploded perspective view of the distribution plates only of yet another embodiment of a spinning device according to the instant invention adapted to produce a homogeneous web of fibers comprising bicomponent sheath/core fibers and monocomponent fibers formed from the core-forming polymer of the bicomponent fibers, as seen from the upstream side.
[0082] [0082]FIG. 40 is a view of the elements illustrated in FIG. 39, taken from the downstream side.
[0083] [0083]FIG. 41 is an assembled upstream plan view of the distribution plates illustrated in FIG. 39, with hidden parts shown in dotted lines for illustrative clarity.
[0084] [0084]FIG. 42 is a cross-sectional view taken along lines 4242 of FIG. 41 showing the path of the core-forming polymer and the sheath-forming material through the distribution plates to form the sheath/core bicomponent fibers.
[0085] [0085]FIG. 43 a cross-sectional view taken along lines 43 - 43 of FIG. 41 showing the path of the core-forming polymer through the distribution plates to form the monocomponent fibers.
[0086] [0086]FIG. 44 is a schematic view of a web of fibers extruded from a spinning device according to this invention fed into the nip of a pair of rotating take-up rollers.
[0087] [0087]FIG. 45 is a schematic view of one form of a process line for producing porous rods from a web of mixed fibers according to the present invention.
[0088] [0088]FIG. 46 is an enlarged schematic view of a melt blown die portion which may be used in the processing line of FIG. 45.
[0089] [0089]FIG. 47 is a schematic view illustrating a breathing circuit wherein an HME according to the instant inventive concepts is interposed in an artificial airway, the use of a “Y” connection being shown in dotted lines for connection of the artificial airway to incoming and/or outgoing lines; and
[0090] [0090]FIGS. 48 a - 48 c schematically illustrate the passage of a gas through the media of an HME according to the instant inventive concepts during a normal breathing cycle.
[0091] Like reference characters refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0092] For simplicity, in illustrating the improved mixed fiber-forming apparatus of this invention, individual openings or distribution paths are not necessarily repeated in every view of each element in the drawings. It is to be understood, in any event, that the relative size of the elements, the numbers and shapes of the openings and/or cutouts forming the distribution paths for the various fiber-forming polymers as well as the number of spinneret openings shown in the drawings are illustrative and not limiting on the instant inventive concepts.
[0093] Also, although the techniques and apparatus disclosed herein are equally applicable to melt spinning, solution spinning and other conventional spinning techniques, for ease of understanding, the following description of the preferred embodiments will be primarily directed to the use of melt spun polymers.
[0094] Referring now to the drawings, and more particularly to FIGS. 1 - 33 , the principal elements of a preferred die assembly for a spinning device according to the instant inventive concepts adapted to produce a homogeneous mixture of bicomponent fibers sharing a common core-forming polymer and comprising different sheath-forming polymers includes, starting from the upstream end (the right in FIG. 1), a mounting block 100 , a right-hand nozzle 200 , a distribution plate system comprising a secondary right distribution plate 300 , a right distribution plate 400 , a left distribution plate 500 , and a secondary left distribution 600 , with a left-hand nozzle 700 and a clamp block 800 on the downstream end. Note particularly FIGS. 1 and 2. Obviously, in use, the illustrated elements will be secured together by bolts or the like (not shown) to preclude polymer leakage in any conventional manner.
[0095] The core-forming polymer and the two sheath-forming polymers are fed from independent sources through melt pumps (not shown) to enter the die assembly through inlet openings in the mounting block 100 . In FIG. 1, the core-forming polymer enters the mounting block 100 through openings 102 in the direction of arrows 104 ; the first sheath-forming polymer enters the mounting block 100 through openings 106 in the direction of arrows 108 ; and the second sheath-forming polymer enters the mounting block 100 through openings 110 in the direction of arrows 112 .
[0096] The passage of the core-forming polymer through the die assembly will now be considered in detail. From the mounting block 100 , the core-forming polymer passes straight through aligned openings in all of the die plates in one interrupted stream until it enters hole 802 of clamp block 800 . The core-forming polymer then reverses direction within the clamp block 800 (not shown), returns through openings 804 to collect in cutouts 806 in the upstream side of the clamp block 800 . See FIG. 1.
[0097] The core-forming polymer then proceeds through four screen packs (not shown) into mating cutouts 702 in the downstream surface of left-hand nozzle 700 , see FIG. 2, from which the core-forming polymer passes completely through the left-hand nozzle 700 riding up into a number of small grooves or distribution paths 704 on the upstream surface of the left-hand nozzle 700 which feed the core-forming polymer into larger cutouts 706 as seen in FIG. 1. From here, the core-forming polymer is fed into the distribution plate system.
[0098] As the core-forming polymer exits the cutouts 706 of the left-hand nozzle 700 , it passes through distribution holes 602 in the secondary left distribution plate 600 and mating distribution holes 502 in the left distribution plate 500 filling up triangular cutouts 504 on the upstream surface of the left distribution plate.
[0099] At this point, the core-forming polymer literally travels around bosses 506 and 508 which surround first and second sheath-forming polymer distribution openings 510 and 512 to be discussed below and passes immediately into the inlet ends of each of the spinneret orifices 514 , 516 as seen best in FIG. 24. The spinneret orifices 514 , 516 are alternating spaced holes parallel to the plane of the left distribution plate 500 , defined through the thickened lip portion 517 along the exit edge of the left distribution plate 500 .
[0100] As discussed in more detail hereinafter, as the core-forming polymer passes into and through the spinneret openings 514 , 516 , it is enveloped by the first and second sheath-forming polymers, respectively, to extrude a uniform or homogeneous mixture of alternating bicomponent fibers which share the same core-forming polymer, and comprise different sheath-forming polymers.
[0101] Referring now the distribution path of the first sheath-forming polymer, after passing through the openings 106 in the mounting block 100 , the first sheath-forming polymer collects in cutouts 114 on the downstream side of the mounting block 100 . See FIG. 2. The first sheath-forming polymer then proceeds through four screen packs (not shown) into mating cutouts 202 on the upstream side of right-hand nozzle 200 , passing through the right-hand nozzle 200 into distribution paths 204 which communicate with larger cutouts 206 on the downstream side of the right-hand nozzle 200 . From here the first-sheath forming polymer is fed into the distribution plate system.
[0102] The first sheath-forming polymer exits the cutouts 206 in the right-hand nozzle 200 , entering slots 302 of the secondary right distribution plate 300 , filling up triangular cutouts 402 on the upstream side of the right distribution plate 400 . From this point, the first sheath-forming polymer is divided into two separate distribution paths to allow the first sheath-forming polymer to envelop the core-forming polymer from both sides as these fiber-forming polymers pass through alternate spinneret openings 514 to provide a complete sheath covering over the core-forming polymer in the first sheath/core bicomponent fibers.
[0103] Half of the first sheath-forming polymer in the cutouts 402 enters distribution holes 404 , passing through the right distribution plate 400 . The other half of the first sheath-forming polymer passes around bosses 406 surrounding distribution openings 408 for the second sheath-forming polymer as discussed below. Half moon shaped spacers 409 are provided on either side of the distribution openings 404 to assist in withstanding pressure between the distribution plates, particularly in the areas of substantial cutouts such as the cutout 402 , in the die assembly. This portion of the first sheath-forming polymer passes through alternating slots 410 formed on a scalloped thickened lip 412 on the edge of the right distribution plate 400 (see FIGS. 16 and 17) entering mating slots 518 in the left distribution plate 500 to envelop one side of the core-forming material passing into alternate spinneret openings 514 .
[0104] The portion of the first sheath-forming material passing through distribution openings 404 mates with distribution openings 510 , referred to above, on the upstream surface of the left distribution plate 500 . This portion of the first sheath-forming polymer passes through the distribution openings 510 into short triangular cutouts 520 on the downstream side of the left distribution plate 500 . At this point this portion of the first sheath-forming polymer enters alternating slots 522 on the scalloped side of the lip 517 , enveloping the opposite side of the core-forming polymer.
[0105] With the core-forming polymer enveloped from both sides by the first sheath-forming polymer, the first sheath/core bicomponent fibers are extruded from the alternate spinneret opening 514 in the left distribution plate 500 .
[0106] Dealing now with the distribution path for the second sheath-forming polymer, having exited a melt pump it is passed through external screen packs (not shown) and fed into the openings 110 in the mounting block 100 , being directed therein to exit openings 116 on the downstream surface thereof. See FIG. 2. The openings 116 mate with openings 208 which pass through the right-hand nozzle 200 into expanded cutouts 210 on the downstream side thereof. See FIG. 2.
[0107] From cutouts 210 of the right-hand nozzle 200 , the second sheath-forming polymer enters triangular cutout 304 on the upstream surface of the secondary right distribution plate 300 . At this point, the second sheath-forming polymer is divided into two separate distribution paths to allow the second sheath-forming polymer to envelop the core-forming polymer from two sides in alternate spinneret openings to provide a complete sheath covering the core-forming polymer and to thereby extrude the second sheath/core bicomponent fibers through those spinneret openings.
[0108] Half of the second sheath-forming polymer passes through distribution openings 306 in the secondary right distribution plate 300 , while the other half passes from the cutouts 304 directly into slots 308 juxtaposed to one edge of the secondary right distribution plate 300 . Spacers 310 are again provided to maintain the proper spacing between the elements of the die assembly.
[0109] The half of the second sheath-forming polymer that goes through the slots 308 of the secondary right distribution plate 300 pass through mating slots 414 formed in the scalloped edge portion 412 on the upstream side of the right distribution plate 400 (see FIGS. 16 and 19) into mating slots 518 in the raised lip 517 of the left distribution plate 500 from which the second sheath-forming polymer envelops that side of the core-forming polymer.
[0110] The half of the second sheath-forming polymer that enters distribution hole 306 of the secondary right distribution plate 300 proceeds through mating hole 408 in the right distribution plate 400 , mating hole 512 of the left distribution plate 500 , and mating holes 604 of the secondary left distribution plate 600 to fill up the small triangular pocket 606 on the downstream side thereof. That portion of the second sheath-forming material then passes back through slots 608 in the secondary left distribution plate 600 which mate with slots 524 in the scalloped side of the lip 517 of the left distribution plate from which it envelops the opposite side of the core-forming polymer passing through alternate spinneret openings 516 . In this manner, the second sheath-forming polymer envelops both side of the core-forming polymer in alternate spinneret openings 516 to extrude second sheath/core bicomponent fibers from every other spinneret opening.
[0111] With the foregoing explanation in mind, it will now be seen that the spinning device of FIGS. 1 - 33 is adapted to provide a homogeneous or uniform distribution of mixed fibers, every fiber having the same core-forming material, with every other fiber having a different sheath-forming material. The ability to form alternate sheath/core bicomponent fiber in this manner would not be possible without the presence of the right and left secondary distribution plates which enable the different sheath-forming polymers to be maintained in separate distribution paths and divided so that a portion of each sheath-forming polymer is delivered to one side of the core-forming material passing through alternate spinneret openings, and the remainder of each sheath-forming polymer is passed through the pack of distribution plates and returned to the opposite side of the core-forming polymer to completely envelop alternate core-forming polymer streams with the different sheath-forming polymers.
[0112] The secondary distribution plates, 300 and 500 allow the second-sheath-forming polymer to pass through the system free of any contact with first sheath-forming polymer, the distribution paths needed for the second sheath-forming polymer to travel in this manner residing in the secondary distribution plates. When the first sheath-forming polymer enters the triangular cutouts 402 of the right distribution plate 400 , the circular bosses 406 block the first sheath-forming polymer from mixing with the second sheath-forming polymer passing through the openings 408 . The scalloped boss 412 serves the same purpose. As the first sheath-forming polymer proceeds down the triangular cutouts 402 to slot 410 , the scalloped boss 412 prevents the first sheath-forming polymer from entering the slots 414 intended to receive the second sheath-forming polymer.
[0113] Likewise, the circular bosses 506 and 508 on the left distribution plate 500 prevent the core-forming polymer from mixing with either of the sheath-forming polymers, and vice-versa and the scalloped formations on the lip 517 of the left distribution plate 500 separates the sheath-forming polymers from each other.
[0114] The uniform distribution of these two dissimilar fibers in the web of fibers is enhanced by the use of a single line of spinneret orifices in the edge portion of one of the distribution plates, in this instance, the left distribution plate 500 . If an array of spinneret openings in multiple planes is utilized, the ability to provide uniform distribution of fibers with different characteristics is complicated. This is particularly true in a melt blowing operation, as discussed below, wherein a fluid such as air under pressure is directed across the spinneret openings as the fibers emanate therefrom to attenuate the fibers while the polymer is still molten. With more than one stream of fibers, the melt blowing fluid tends to cause some of the fibers to flip over thereby reducing the homogeneity of the mixture of fibers in the resultant web.
[0115] The uniformity of the individual fibers produced by the spinning device of this embodiment of the instant invention is further enhanced by the formation of spinneret openings laterally through the raised lip 517 in the left distribution plate 500 , rather than forming half of each spinneret opening by mating surfaces of juxtaposed distribution plates as in the prior art. With the construction of the spinneret openings disclosed herein, the fiber-forming surface is continuous and seamless, precluding any loss of fiber-forming polymer that may result from imperfect mating of the sealing surfaces forming the spinneret openings.
[0116] Of course, the shape of the spinneret openings can be chosen to accommodate the cross-section desired for the extruded fibers. While circular spinneret openings are commonly utilized, other non-round cross-sections may be provided for special applications. Multi-lobal fibers, i.e., X-shaped, Y-shaped, or other such cross-sections (not shown) are possible. With the instant inventive concepts, alternate spinneret openings can have different configurations to provide a uniform mixture of fibers of different cross-sections.
[0117] Referring now to FIGS. 34 - 38 , the distribution plates of a simplified form of the spinning apparatus described hereinabove is illustrated. In this embodiment, only two independent sources of polymer materials are provided, the alternate fibers in the homogeneous web of fibers being formed of the polymer from only one of the sources. It is to be understood that, as described with respect to the embodiment of FIGS. 1 - 33 , the embodiment of FIGS. 34 - 38 would include a mounting block such as the mounting block 100 , a right-hand nozzle, such as the right-hand nozzle 200 , a left-hand nozzle, such as the left-handle nozzle 700 , and a clamp block, such as the clamp block 800 shown in the earlier Figures, although these elements have not been included in FIGS. 34 - 38 for illustrative convenience. In this instance, however, only two distribution plates are necessary, identified in FIGS. 34 - 38 as right distribution plate 60 and left distribution plate 70 , the secondary right and left distribution plates being unnecessary since only two polymers are being processed in this system.
[0118] The first polymer enters the distribution plate system on the upstream side of the right distribution plate 60 filling up the triangular cutouts 61 defined therein. Half moon spacers 62 and circular spacers 63 are provided in the triangular cutouts 61 to maintain the proper distance between the right distribution plate 60 and the right-hand nozzle (not shown in these Figures). At this point, the first polymer is divided into two portions, one portion passing through the distribution holes 64 , the remaining portion passing into the slots 65 .
[0119] The portion of the first polymer that goes into the distribution holes 64 passes through mating distribution holes 71 in the left distribution plate 70 . The distribution holes 71 are surrounded by bosses 72 in triangular cutouts 75 formed in the upstream surface of the left distribution plate 70 . The bosses 72 in concert with spacers 74 protect the left distribution plate 70 from distortion.
[0120] This portion of the first polymer enters triangular cutouts 75 , also provided with spacers 74 on the downstream surface of the left distribution plate 70 . This portion of the first polymer then passes directly into slots 77 which communicate with one side 78 of enlarged portions at the base of alternating spinneret openings 79 in the left distribution 70 .
[0121] The portion of the first polymer passing through the slots 65 in the right distribution plate 60 is received directly on the opposite sides 66 of the enlarged portions of the spinneret openings 67 , the two portions of the first polymer being thereby joined to extrude through the alternating spinneret openings formed by the grooves 67 , 79 to form spaced monocomponent fibers of the first polymer.
[0122] The second polymer is received from the right-hand nozzle as in the earlier embodiment, passing uninterrupted through right and left distribution plates 60 , 70 to the clamp block which returns the second polymer through the left-hand nozzle into distribution openings 78 in the downstream surface of the left distribution plate 70 . As the second polymer passes through the distribution openings 78 it is received in the triangular cutouts 73 on the upstream face of the left distribution plate 70 . A portion of the second polymer in the cutouts 73 flows down about bosses 72 and spacers 74 to grooves 76 forming portions of the spinneret openings in the left distribution plate 70 . The remainder of the second polymer in the cutouts 73 on the upstream surface of the left distribution plate 70 flows into the triangular cutouts 68 on the downstream side of the right distribution plate 60 to flow therefrom through the opposite portions 69 of the alternate spinneret openings for the second polymer material.
[0123] Thus, in this embodiment, molten polymer from two independent sources are fed through the die assembly, the two distribution plates extruding polymer from each source through alternate spinneret openings, thereby forming a homogeneous mixture of monocomponent fibers, fibers of one polymer being side-by-side with fibers of the other polymer in the web.
[0124] Referring now to FIGS. 39 - 43 , the distribution plates of yet another embodiment of spinning device according to the instant inventive concepts are illustrated, this embodiment spinning a web of fibers, wherein selected fibers comprise sheath/core bicomponent fibers, which alternate with monocomponent fibers formed of the core-forming polymer. Again, since only two fiber-forming polymers are processed in this system, only two distribution plates are necessary, the secondary right and left distribution plates of the embodiment of FIGS. 1 - 33 being eliminated.
[0125] It will be understood that the sheath-forming polymer and the core-forming polymer of the bicomponent fibers to be extruded from the distribution plates of this embodiment are received from independent polymer sources, passing through a mounting block such as the mounting block 100 , a right-hand nozzle, such as the right-hand nozzle 200 , the distribution plate system, which in this instance comprises the right distribution plate 80 and the left distribution plate 90 , with a left-hand nozzle such as the left-hand nozzle 700 and a clamp block such as the clamp block 800 completing the die assembly, but not being shown in FIGS. 39 - 43 .
[0126] The polymer forming both the monocomponent fibers in this system and the core of the bicomponent fibers passes straight through all the die plates in one interrupted stream and enters the clamp block where it is reversed and passed back through the left-hand nozzle to be received in openings 91 on the downstream face of the left distribution plate 90 , passing therethrough into the triangular cutouts 92 on the upstream face thereof. A portion of the core-forming polymer passes directly from the cutouts 92 into each of the alternating grooves 93 , 94 forming half of the spinneret openings for the monocomponent and bicomponent fibers, respectively.
[0127] The remainder of the core-forming polymer from the cutouts 93 enters the mating triangular cutouts 81 on the downstream surface of the right distribution plate 80 to pass into the inlet portions of the grooves 82 , 83 , forming the opposite portions of the spinneret openings.
[0128] The material received in the mating grooves 82 , 93 is extruded from alternate spinneret openings as monocomponent fibers formed of the core-forming polymer. The material received in the mating grooves 83 , 94 form the central core of the sheath/core bicomponent fibers to be extruded from alternate spinneret openings as discussed below.
[0129] The sheath-forming polymer is received from the right-hand nozzle and fills up the triangular cutouts 84 in the upstream face of the right distribution plate 80 where it is divided into two portions. One portion passes directly through the distribution openings 85 in the right distribution plate 80 and the aligned opening 95 in the left distribution plate 90 to the triangular cutouts 96 in the downstream surface thereof. That portion of the sheath-forming polymer passes through slots 97 into enlarged openings 98 to encompass one side of the core-forming polymer as it is extruded from the spinneret openings partially defined by the grooves 94 .
[0130] The other portion of the sheath-forming polymer passes from the triangular cutouts 84 through the slots 87 to be received in the enlarged portions 88 of the grooves 83 in the right distribution plate 80 to encompass the other side of the core-forming material, thereby extruding sheath/core bicomponent fibers from the alternating spinneret openings.
[0131] Appropriate bosses and spacers are provided in each of the larger cutout areas to insure that the individual distribution plates are not distorted by the pressure of the molten polymer in these thinned out portions of the distribution plates.
[0132] As will now be evident, the embodiment of FIGS. 39 - 43 enables the production of a homogeneous mixture of bicomponent and monocomponent fibers wherein the monocomponent fibers are formed of the core-forming polymer of the bicomponent fibers.
[0133] The web of homogeneously or uniformly distributed fibers extruded from any of the embodiments of the spinning device of the instant invention may be subsequently treated by conventional techniques to produce products of unique characteristics. For example, with an embodiment as simple as the mixed monocomponent system of FIGS. 34 - 38 , the same or different polymers can be fed into a die assembly 900 under different pressures or at different speeds so that the speed of extrusion of the polymer material through alternate spinneret openings is different. If a web of fibers 902 formed in this fashion is taken up by a single pair of nip rolls 904 as shown in FIG. 44, alternating fibers will be attenuated differently. If the speed of rotation of the nip rolls is the same as the speed of extrusion of one of the polymers, but faster than the speed of extrusion of the other polymer, the fibers formed from the one polymer will not be attenuated at all, and the fibers formed from the other polymer will be attenuated, resulting in a mixed web of fibers of the same or different polymer, but of different denier. This uniformly distributed type of mixed fibers can then be subsequently processed in any conventional way, providing products which have relatively thicker fibers, perhaps contributing strength to the product, admixed with relatively finer fibers, perhaps for increased filtration efficiency.
[0134] Another application of a web of mixed fibers produced according to the various embodiments of the instant inventive concepts discussed above, is the alternate extrusion of fibers containing a bondable surface with fibers which are not readily bondable by commercial processing equipment. In this situation, materials that are otherwise difficult to bond, but have chemical or physical characteristics that are important to an end product, can be effectively bonded in an economical manner.
[0135] For example, with reference to FIGS. 45 and 46 one form of a process line for producing continuous, elongated, porous rods is schematically illustrated at 910 wherein a web of such mixed fibers 912 may be bonded to each other at spaced points of contact to produce a tortuous path for the passage of a fluid, perhaps to filter undesirable constituents therefrom as in the production of tobacco smoke filters. Depending upon the particular polymers exposed at the surface of the adjacent fibers in the web, the bonded porous elements resulting therefrom may be effective as coalescing filters, medical filters, heat and moisture exchangers, wick members, absorptive elements, and the like, any of the general applications having been mentioned hereinabove and many others.
[0136] While the processing line 910 illustrated in FIGS. 45 and 46 is only exemplary, a web of mixed fibers produced by the spinning device of this invention may be passed through a high velocity air stream such as provided through an air plate shown schematically at 914 , to attenuate and solidify the fibers, enabling the production of ultra-fine fibers, on the order of ten microns or less. Such treatment produces a randomly dispersed and tangled web 916 of the fibers, which is in a form suitable for immediate processing without subsequent attenuation or crimp-inducing processing.
[0137] If desired, a layer of particulate additive, such as granulated activated charcoal, may be deposited on the web or roving 916 as shown schematically at 918 . Alternatively, a liquid additive such as a flavorent or the like may be sprayed onto the tow 916 at 918 . A screen-covered vacuum collection drum (not shown), or a similar device, may be used to separate the fibrous web or roving 906 from entrained air to facilitate further processing.
[0138] The remainder of the processing line 910 as seen in FIG. 45 is conventional and is shown and described in my aforementioned '430 patent, and other of my prior art patents, although modifications may be required to individual elements thereof in order to facilitate heat-bonding of particular mixtures of fibers.
[0139] The illustrated heat-bonding techniques show the web or roving of the mixed fibers 916 produced from the melt blowing techniques to be passed through a conventional air jet at 920 , bloomed at seen at 922 and gathered into a rod shape in a heated air or steam die 924 where a bondable material in at least some of the fibers of the web is activated to render the same adhesive. The resultant material may be cooled by air or the like in the die 926 to produce a relatively stable and self-sustaining rod-like fiber structure 928 .
[0140] Depending upon the ultimate use of the rod 928 , it may be wrapped with paper or the like 930 in a conventional manner to produce a continuously wrapped fiber rod 932 . The continuously produced fiber rod 932 , whether wrapped or not, may be passed through a standard cutter head 934 , at which point it may be cut into preselected lengths and deposited on a conveyor belt 936 for subsequent processing, or for incorporation into other equipment.
[0141] Obviously, depending upon the particular fibers in the web and their individual chemical and physical characteristics, the post-extrusion processing of the web of fibers can be modified as necessary to produce the desired product.
[0142] Regardless of the selection of polymer components, the advantages of producing a homogeneous and uniformly distributed mixture of fibers of differing characteristics, even including bicomponent fibers having different sheath-forming polymeric coatings, is readily recognized. Significant cost reductions can result from the use of relatively inexpensive core materials, with limited amounts of a more expensive sheath-forming polymer, or even two different sheath-forming polymers, to provide particular attributes to the final products.
[0143] In each of the embodiment disclosed herein, a web of fibers is shown as having alternately extruded fibers of differing characteristics. While such an arrangement is desirable for most applications, with relatively minor modifications, one type of fiber can be extruded through every third spinning orifice, every fourth spinning orifice, etc., thereby providing a web of homogeneously mixed fibers, wherein the different fibers are not necessarily present in a 50/50 ratio.
[0144] Reference will now be made to various applications of the improved mixed fiber technology described herein above. One particular such use is in the provision of high filtration products for electrical dust collection devices and other such demanding environments, including baghouse filters used in power plants to filter flue gases. It has been found that filters comprising a uniquely homogeneous mixture of homopolymers or copolymers of fluorocarbon polymers or chlorinated fluorocarbon polymers with nylon fibers produces significantly improved filtration efficiently as compared with filters formed from either polymer alone.
[0145] The fluorocarbon and chlorinated fluorocarbon polymers and their copolymers naturally carry a negative charge and nylon naturally carriers a positive charge. Hydrophilic nylon, discussed below in detail with respect to the HME concepts of this invention, is particularly desirable because of its high hydrophilic properties. However, other forms of nylon polymer are also effective in this application.
[0146] The nature of the fluorocarbon or chlorinated fluorocarbon polymers and copolymers used is generally dictated by their spinning properties. HALAR® ECTFE fluoropolymer, commercially available from Ausimont USA, Inc., a subsidiary of Montedison, is the preferred material for this use. Although other fluorocarbon polymers or chlorinated fluorocarbon polymers or copolymers of such polymers may be used for several applications of the instant inventive concepts, for simplification the following discussion will refer to HALAR® as exemplary of any such materials.
[0147] A homogeneous mixture of fibers having surfaces of these polymers provides unexpectedly improved filtration properties, even with reduced weight of materials. Since HALAR® is quite expensive, bicomponent fibers comprising on the order of 10-20% by weight of a HALAR® sheath over a nylon core in a homogeneous mix with monocomponent fibers formed of nylon, significantly reduces the cost. The apparatus illustrated in FIGS. 39 - 43 may be advantageously used to produce such a mixture of fibers. Although a 50/50 mixture of these fibers is particularly adapted for many applications, the nylon fibers, which act as a bonding agent, may be present at levels of 40% or even less.
[0148] Alternatively, using the apparatus of FIGS. 1 - 33 , a homogeneous mix of bicomponent fibers having alternating sheaths of HALAR® and nylon over a relatively inexpensive common core material such as polypropylene, can be produced to even further reduce the cost of the ultimate product.
[0149] Preferably, in the formation of filtering materials from a homogenous mixture of HALAR® and nylon containing fibers, the web of fibers would be melt-blown and processed as shown in FIGS. 45 and 46 to produce very fine fibers, on the order of 10 microns or less.
[0150] The filter itself could take various forms depending upon its particular application. A simple calendered non-woven sheet is appropriate for some applications such as in assays from medical tests. Alternatively, the sheet material can be pleated to increase the surface area, using standard techniques, some of which are shown in my prior patents.
[0151] For other applications, the mixed fibers can be formed into a continuous porous element according to the techniques shown in FIGS. 45 and 46 to produce plugs of filter material. Another form that the filter may take, would be a hollow tube, formed from the homogeneous web of mixed fibers according to any conventional manufacturing technique usually incorporating a central mandrel in the forming zone to produce an annulus.
[0152] In Table 1, below, a comparison of 27 millimeter plugs formed of a 50/50 HALAR®/nylon mix of fibers, with plugs formed of 100% nylon fibers and plugs formed of 100% HALAR® fibers is seen.
TABLE 1 27 mm Plug SAMPLE WT. TIP PD RETENTION % 100% Nylon 11.2 g/m 4.4 72.64 100% Halar ® 8.4 g/m 4.7 69.38 Halar ®/Nylon (50/50) 5.3 g/m 4.6 80.02
[0153] From the above Table, it will be recognized that, with similar pressure drops, the retention of a plug formed according to the instant inventive concepts from a homogeneous mixture of fibers of HALAR® and nylon, has a significantly higher filtration efficiency (retention percent) than corresponding plugs formed of 100% nylon and 100% HALAR®, notwithstanding the lower weight of materials in the plugs of this invention.
[0154] Table 2 compares flat surface elements formed from a mixed fiber HALAR®/nylon web according to this invention, cut as Cambridge filtration pads, with elements formed of 100% nylon and 100% HALAR®.
TABLE 2 Flat Surface Cut as Cambridge Filtrona Pad SAMPLE WT. PAD PD RETENTION (%) 100% Nylon 0.6403 0.1 47 100% Halar ® 0.621 0.1 48.94 Halar ®/Nylon (50/50) 0.6329 0.1 52.05
[0155] Again, improved filtration efficiency is seen.
[0156] Another application for the improved mixed fiber technology of this invention is the production of a coalescent-type filters such as those used to separate water from aviation fuel. Hydrophobic fibers are needed for this type of filter to allow the water to be held and not spread along the fiber. Currently, such products are made of silicon-coated fiberglass.
[0157] Utilizing the low surface tension of HALAR®, and the ability to create small fibers using melt-blown techniques, which help to collect small droplets of water, it has been found that the HALAR® fibers can be bonded into a highly efficient coalescent filter by spinning a mixed fibrous web comprising the HALAR® fibers and a bonding fiber. Although other bonding fibers can be used, such as polypropylene or polyethylene, it is preferred to use polyester fibers, such as polyethylene terephthalate, because such material is very inert, and in its amorphous state provides excellent bonding for the HALAR® fibers in the presence of steam. Moreover, polyethylene terephthalate does not stick to the equipment, a problem common with polypropylene and/or polyethylene.
[0158] As discussed above with respect to the high filtration products, the HALAR® fibers can be formed as bicomponent fibers, either with a core of polyethylene terephthalate extruded side-by-side with polyethylene terephthalate monocomponent fibers according to the techniques of FIGS. 39 - 43 , or the HALAR® and polyethylene terephthalate polymers may each be extruded as bicomponent fibers with a core of polypropylene or the like using the apparatus of FIGS. 1 - 33 to reduce the cost and improve the strength of the ultimate product.
[0159] As noted, for coalescent applications, the fibers are preferably very fine, certainly less than about 10 microns. The high surface area of these hydrophobic fibers causes the water to bead up and thereby facilitates separation of water from a mixture of water with a petroleum product such as aviation fuel.
[0160] Coalescent-type filters according to this invention can be formed in any of a variety of configurations, e.g., laid down webs, preferably pleated pads, plugs, and, for many applications, tubes, using conventional technology.
[0161] A third application of the instant inventive concepts is the production of a homogeneous mixture of nylon and polyethylene terephthalate fibers to create a wicking product for use as a reservoir in the transfer of ink in marking and writing instruments, or for medical wicks or other products designed to hold and transfer liquids, many of which are discussed in detail my prior '082 patent. Polyethylene terephthalate is preferred over other bonding fibers for the same reasons discussed above with respect to its selection in the production of coalescent filters. Moreover, polyethylene terephthalate has a higher surface energy than the polyolefins, which allows it to wick more liquids.
[0162] The use of very fine fibers, on the order of 3-7 microns enhances the absorption effectiveness as would be expected.
[0163] By reference to Table 3, an ink reservoir product currently in use in marking and writing instruments and commercially available from the assignee of the instant application under the trademark TRANSORB®, is compared with melt-blown mixed fiber products according to this invention comprising polyethylene terephthalate and nylon.
TABLE 3 ABS (H 2 O) ABS 48 DYNE SAMPLE WT. LENGTH DIAMETER % ABSORPTION % ABSORPTION XPE-PET 0.7776 88 6.71 74.58 74.58 w/surfactant PET 4449/Nylon 0.7067 88 6.82 86.84 82.89 SCFX6 PET 4449/Nylon 0.8072 88 7.91 86.78 86.30 SCFX6
[0164] The above Table shows the surprising increase in absorption produced from plugs of the mixed polyethylene terephthalate/nylon products, as compared to the commercially available TRANSORB® product.
[0165] The polyethylene terephthalate/nylon mixed fiber products of this invention are particularly useful in writing instruments due to the hydroscopic nature of the nylon. Such products show an improvement in absorption over standard olefin and polyethylene terephthalate samples, even those including a surfactant. See Table 4.
TABLE 4 ABS (H 2 O) ABS (ALCOHOL) SAMPLE WT. LENGTH DIAMETER % ABSORPTION % ABSORPTION Olefin 2.0110 100 12.30 69.19 73.74 w/surfactant PET 1.3020 100 11.86 59.63 65.61 w/surfactant Nylon/PET 60/40 1.2446 100 12.41 84.05 77.24 w/o surfactant Nylon/PET 60/40 0.6690 100 7.63 92.56 87.75 w/o surfactant
[0166] A variation on the foregoing application is the production of an insoluble resin that is hydrophilic, particularly for writing and medical products where nylon may interfere with the assay or chemistry. In such instances, the products formed from a uniformly mixed web of polyvinyl alcohol and polyethylene terephthalate fibers can be produced, the polyethylene terephthalate being desirable for its unique bonding capabilities as well as its inertness and high temperature resistance. Polyvinyl alcohol is advantageous because it is one of the few hydroscopic fibers which may be soluble at different temperatures. Polyvinyl alcohol fibers mixed with polyethylene fibers could be used for the production of less expensive filters wherein the required properties are not as demanding.
[0167] From the foregoing, it will be recognized that the mixed fiber technology of the instant invention enables the production of diverse products with unexpectedly improved functional properties, resulting at least in significant part from the exceptional uniformity and homogeneity of the distribution of the different fibers in the web. Moreover, the use of the technology of this invention enables the production of such products in a highly efficient, commercially desirable, manner, overcoming many of the disadvantages both in the prior art products, as well as in the methods and apparatus for making such products.
[0168] Finally, a unique application of the instant inventive concepts is in the production of a novel heat and moisture exchanger (HME) which may be made using the mixed fiber technology of this invention to even further improve the functional aspects of the product and enable its production in a less expensive, more effective manner. In this respect, reference is made initially to FIGS. 47 and 48. In FIG. 47 an intubated patient 950 is schematically illustrated, with an HME 960 according to the instant inventive concepts being interposed in an artificial airway 970 which communicates the patient's respiratory tract with the atmosphere as schematically shown by arrows 980 and/or with a source of an incoming gas, such as oxygen or an anesthetic, as schematically shown by arrows 990 .
[0169] The artificial airway 970 can communicate through the HME directly between the patient's respiratory tract and the atmosphere, as in a tracheotomy. Alternatively, the artificial airway 970 may communicate through the HME with a standard commercially available short- or long-term mechanical ventilator (not shown), or a source of a dry gas such as an anesthetic in a medical theater, or, possibly, oxygen as may be found in an intensive care unit or a patient's hospital room. If necessary or desirable, a “Y” connector 972 as shown in dotted lines may connect the HME with the artificial airway 970 via a valve of any conventional nature, shown schematically at 974 , to permit the breathing circuit to cycle between inspiration and exhalation in a well known manner.
[0170] The HME 960 can take any conventional form, but regardless of design, will include a heat and moisture exchanger element shown in dotted lines in FIG. 47 at 962 within a housing 964 . The element 962 according to the instant inventive concepts is a gas-permeable media adapted to be warmed and to trap moisture from a patient's breath during exhalation, and to be cooled and to release the trapped moisture for return to the patient during inspiration, formed, at least in part, of a hydrophilic nylon polymer in sufficient quantity to effectively conserve the humidity and body heat of the patient's respiratory tract.
[0171] Hydrophilic nylon polymers are known and it is believed that any of these materials may be used in the production of an HME according to the instant invention concepts. Such materials have been used heretofore for various applications, primarily in the production of apparel. Other uses include face masks, prosthesis liners to protect sensitive skin from abrasion discomfort due to the presence of body moisture, incontinence garments, and other personal protection devices.
[0172] A particularly desirable hydrophilic nylon is available commercially under the trademark Hydrofil® from Allied Fibers, and is a block copolymer of nylon 6 and polyethylene oxide diamine (PEOD). The ratio by molecular weight is approximately 85% nylon 6 and 15% PEOD. Hydrofil® nylon resin is designed for fiber extrusion but it has been successfully melt-blown and spun-bonded for use in the production of non-wovens for the aforementioned and other such fields. Fibers produced of this polymer are said to have a higher elongation and a lower tenacity than traditional nylon, with a melting point only about 1-2 degrees lower than nylon 6 and a softening point about 40° lower. This hydrophilic polymer is said to yields fibers that are more amorphous, much softer and much more absorbent than nylon.
[0173] The gas-permeable element 962 may be formed in a variety of ways. It could simply be a hydrophilic nylon polymeric shaped member provided with passageways communicating the upstream and downstream ends so that a gas, whether it be the patient's inhaled or exhaled breath, or an extraneous gas such as oxygen or an anesthetic, can readily pass through the element, as necessary.
[0174] Preferably, however, the gas-permeable element 962 of the instant invention is a fibrous media comprising a multiplicity of fibers having at least a surface of the hydrophilic nylon polymer. Of course, the fibers can be entirely formed of a hydrophilic nylon polymer and bonded at their points of contact to form interconnecting passages from one end to the other. For example, a multiplicity of hydrophilic nylon polymeric fibers can be extruded in any conventional manner from a spinneret onto a continuously moving surface to form an entangled fibrous mass which may be calendered to bond the fibers to each other and thereby form a porous sheet or pad removably retained in the housing 964 of the HE 960 for replacement as needed.
[0175] Alternatively, and preferably, a bonding agent can be incorporated in any conventional manner into a mass of fibers comprising a hydrophilic nylon polymer to bond the hydrophilic nylon fibers to each other at their points of contact into a three-dimensional porous element defining a tortuous path for passage of a gas therethrough. The bonding agent is also preferably provided as a multiplicity of fibers comprising at least a surface of a polymer having a lower melting point than the hydrophilic nylon, such as a polyester, for example, polyethylene terephthalate.
[0176] Such mixed fibers can be processed in any conventional manner to form the gas-permeable element 962 . For example, the fibers can be gathered into a rod-like shape and passed through sequential steam-treating and cooling zones to form a continuous three-dimensional porous element, portions 962 of which can be incorporated as a plug in the HME housing 964 to provide a tortuous path for passage of a gas therethrough.
[0177] In order to minimize the cost of the relatively expensive hydrophilic nylon polymer, bicomponent fibers can be formed in any conventional manner, comprising a sheath of the hydrophilic nylon polymer and a core of a less expensive thermoplastic polymer such as, for example, polypropylene. Such bicomponent fibers can then be bonded as discussed previously to produce the gas-permeable element for use as an HME according to the instant inventive concepts. Such a core-forming polymer is not only less expensive, but provides the fibrous media with increased strength to lengthen the effective life of the HME.
[0178] Finally, and most preferably, both the hydrophilic nylon polymer fibers and the bonding agent fibers can be formed as bicomponent fibers, preferably provided with a common core-forming thermoplastic polymer, such as polypropylene. In this fashion, reduced costs and increased strength will be provided to the HME by both the hydrophilic nylon fibers and the bonding agent fibers.
[0179] The preferred production of a web of fibers comprising a homogeneous mixture of fibers formed from different polymeric materials for the production of an HME according to this invention is described above with particular reference to FIGS. 1 - 46 . Utilizing the techniques disclosed in FIGS. 34 to 38 , a uniformly distributed mixture of monocomponent fibers, some of which are formed entirely of hydrophilic nylon and others of which are formed entirely of a bonding agent polymer, can be readily extruded, melt-blown and subsequently processed into a continuous rod-like porous element as shown in FIGS. 45 and 46. Alternately, as disclosed in FIGS. 39 to 43 , monocomponent bonding agent fibers can be extruded side-by-side with bicomponent fibers having a core of the polymer from which the monocomponent fibers are made, e.g., a polyester, and a sheath of the hydrophilic nylon polymer. Finally, utilizing the techniques of FIGS. 1 to 33 , a uniform web of mixed bicomponent fibers, some of which have a sheath of a hydrophilic nylon polymer, and others of which have a sheath of a bonding agent polymer, such as a polyethylene terephthalate, with all of the bicomponent fibers having a core of a thermoplastic material such as polypropylene, may be extruded and formed int a porous rod-like element in a simple and inexpensive manner.
[0180] Thus, while the HME media of this invention may be formed in a variety of ways, the preferred construction comprises a gas-permeable element formed of a homogeneous mixture of bicomponent fibers having respective sheaths of hydrophilic nylon and polyester produced according to the improved mixed fiber technology disclosed herein and bonded at their points of contact to define a tortuous path of a passage of a gas therethrough.
[0181] The fibers utilized in the preparation of the HME according to the instant invention are preferably very fine in nature, having a diameter, on average, of ten microns or less. Such fibers, whether monocomponent or bicomponent fibers, or mixtures of monocomponent and bicomponent fibers, or mixtures of different bicomponent fibers, can be readily produced utilizing conventional melt-blowing techniques. The advantages of HMEs formed from such fine fibers is two-fold. First, the increased surface area afforded by the fibers provides more effective heat and moisture exchange properties. Moreover, the use of fine fibers of this nature also provides increased surface area and reduced interstitial spaces for filtering undesirable contaminants such as bacteria or viruses or other particulates from a gas passing therethrough.
[0182] With respect to the concomitant use of the HMEs of this invention as high efficiency particulate air (HEPA) filters, there are at least three known physical mechanisms by which particles of a gas may be captured by a filter media. First, and particularly for the larger particles, direct interception of the particles wherein they are physically removed on the upstream surface of the filter medium because they are too large to pass through the interstitial pores, is most significant. However, for smaller particles, inertial impaction, wherein the particles collide with the filter medium because of their inertia to changes in the direction of gas flow within the filter media, may be more significant. Finally, very small particles may be captured by diffusional interception wherein they undergo considerable Brownian motion, increasing the probability of efficient capture of such particles by the filter medium. For all practical purposes, it is believed that each of these mechanisms may be at work in the use of a hydrophilic nylon HME in an artificial airway according to the instant inventive concepts.
[0183] Although certain of the advantageous properties of hydrophilic nylon have been recognized for unrelated applications, the effectiveness of such materials in increasing the effectiveness of an HME, without the need for extraneous chemicals to enhance its hygroscopicity, is surprising. Moreover, the improved functional effectiveness of an HME formed from the unique homogeneous mixture of simultaneously extruded hydrophilic nylon and bonding agent fibers according to the mixed fiber technology of this application is even more unexpected. Additionally, as has been noted above, the ability to minimize the quantity of both the hydrophilic nylon polymer and the bonding agent polymer in the mixed fibrous web, significantly reduces the costs of the HME media while strengthening the same to withstand extended use, enabling an HME according to this invention to be manufactured inexpensively, and yet be readily disposed of and replaced between uses in a cost-efficient system. Finally, the ability of a melt-blown hydrophilic nylon HME to effectively function as a HEPA filter in an artificial airway of a medical device, enhances the advantages afforded by the instant inventive concepts.
[0184] With reference now to FIGS. 48 a - 48 c , the use of an HME according to this invention is schematically illustrated. A plug of hydrophilic nylon-containing HME media is designated generally by the reference numeral 962 in each of these Figures. As the patient breathes out, illustrated by the arrows 980 in FIG. 48 a , the media 962 captures the warmth and moisture from the patient's exhaled breath. When the patient breaths in as shown by the arrows 990 in FIG. 48 b , condensate on the media 962 is evaporated and moisture is released so that the incoming gas is warmed and humidified as it is returned to the patient. FIG. 48 c illustrates a repetition of the process of FIG. 48 a the next time the patient exhales, the heat and moisture exchange sequentially and continuously taking place thereafter as gas passes to and through the media 962 in one direction and then the other.
[0185] It is to be understood that the various preferred embodiments of the instant inventive concepts discussed above are not independent of each other. For example, mixed fibers of different denier can be formed of the same polymer according to this invention, or of different polymers. Additionally, mixed fibers of different denier can be formed of both monocomponent and bicomponent fibers, or of different bicomponent fibers. Any of the products described above as formed of a homogeneous mixture of fibers of two polymers, made, for example, by the apparatus of FIGS. 34 - 38 , can be modified to utilize a mixture of monocomponent fibers of one polymer with bicomponent fibers comprising a sheath of the second polymer and a core of the monocomponent fiber by utilizing equipment as shown in FIGS. 39 - 43 . Finally, such products can be formed of sheaths of the two primary polymers with a core of a common third polymer with apparatus such as shown in FIGS. 1 - 33 . Other obvious combinations of the various features of the instant inventive concepts will be readily apparent to those skilled in the art.
[0186] Having described the invention, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the appended claims. | A device and method for spinning polymer fibers utilizes one or more independent sources of polymer materials, pumps for feeding polymer material from each of the sources, and a series of distribution plates with surface grooves, through holes and/or slots together defining separated distribution paths, each of which receives polymer material from one of said independent sources. The surface grooves are defined to a depth less than the thickness of the distribution plate. At least one distribution plate contains spinneret orifices defined by outlet surface grooves extending from the distribution path to the edge of that plate, whereby fibers are extruded from the spinneret orifices edgewise from the plate. The spinneret orifices may be defined by overlayed outlet surface grooves or slots defined in abutting plates. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to articulated crane-type machines, such as hydraulic excavators, and is more particularly directed to machines of the type having a boom, a stick, and a tool attachment articulated with respect to one another, in which one or more sticks are interchangeably connectable to the boom.
A typical excavator or similar heavy equipment apparatus has an attachment arm formed of an articulate boom and a stick rockably mounted on the boom, with a bucket, blade, shear, grapple, fork, or other tool attached to the end of the stick. Hydraulic cylinders are mounted on the attachment arm to raise or lower the stick in the same plane. A tool cylinder connected between the tool and the stick operates the tool, i.e., raises or lowers the bucket, opens or closes the shear, etc.
Different tools are often required for an operation. If these are to be joined to the same excavator or other similar apparatus, it is required to remove the tool from the stick, or to remove the stick from the boom to substitute a different tool or stick. The stick is taken off the boom to substitute a different stick, for example, a stick of a different length or width, or a stick having a different tool formed unitarily on it. A pivot pin is driven from the articulated joint between the distal end of the boom and the stick, and an eye pin is driven from the connection of the stick with the stick cylinder rod. Then the substitute stick has to be manipulated, the pivot pin driven back into place, and the eye pin driven into place. After that, hydraulic lines have to be run from the excavator body to the tool cylinder. Aligning the stick with the boom is difficult. This operation can require the work of a crew of several skilled workmen and can consume an hour or more.
Quick-disconnect mechanisms have been well known for the tool end of the stick, for example, to facilitate the interchange of buckets of different sizes or configurations. This has been especially proposed with respect to backhoe attachments in the field. However, no such satisfactory quick-disconnect mechanism has been known for use between the stick and the boom.
It is often required to use attachments with integral stick and tool configurations, for example, a large shears employed for the recycling of steel scrap. It is well accepted now that one-piece shear-stick arrangements are far superior to a combination of a stick and an interchangeable or pin-on shear. This is so, at least in part, because of the structural soundness of the shear-stick and the relatively low installation and removal time requirements of an integral shear-stick. In a steel scrapping operation, it is often necessary to change from a shear to a grapple, clamshell, or other attachment quickly and without a crew in attendance. However, this cannot be done unless there are some means provided for the quick connecting and disconnecting of the stick to the boom of the excavator machine employed for that purpose.
If quick disconnect mechanism presently used on wheel loaders between the loader arms and buckets were used between the boom and the stick, the stick may tend to wobble somewhat because of play in the mechanism amplified over the length of the stick.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide an articulated crane-like machine which avoids the drawbacks of the prior art, and which permits the quick interchangeability of various stick configurations onto a boom of the machine.
It is another object of this invention to provide a machine with a suitable quick-disconnect mechanism wherein the sticks can be interchanged with a minimum crew size, without need to manipulate the sticks to effect the connecting or disconnecting, and which gives a secure stable mounting.
In accordance with an aspect of this invention, an articulated crane-type machine, such as a hydraulic excavator, has a base, an overcarriage swingably mounted on the base and including a drive for swinging the overcarriage in a generally horizontal plane, a boom having its proximal end pivotally mounted on the overcarriage for motion in a generally vertical arc, a boom cylinder or equivalent means for raising and lowering the boom in its arc, a stick having its proximal end rockably mounted at the distal end of the boom, with a tool being mounted at the distal end of the stick, and with a stick cylinder or other equivalent means for rocking the stick relative to the boom. At the distal end of the boom there is an articulated quick-disconnect shoe, and mating structure is affixed on the proximal end of the stick for permitting the stick to be removably joined to the quick-disconnect shoe.
In a favorable embodiment, the mating structure has a transverse grab pin and male aligner member, while the quick-disconnect shoe includes a grab hook disposed at one side of the shoe and opening towards that one side of the shoe for engaging the grab pin, with the hook being rotatable on the grab pin. The quick-disconnect shoe also has a pair of female aligner members disposed laterally opposite each other for receiving the male aligner member to align them into mating engagement. When the quick-disconnect plate and the mating mechanisms have been aligned by the male and female aligners, a pair of transverse pairs on the shoe engage mating recesses in the mating structure, and draw the mating structure into engagement with the shoe. The grab pin slides on the grab hook. An arrangement of gear-tooth rocks on the shoe and on the mating structure to engage one another and prevent lateral play or wobble.
The improvement of this invention is especially useful when the stick takes the form of a unitary stick-shear arrangement, with its tool being a hydraulic shear having a jaw unitarily formed at the distal end of the stick.
The foregoing and many other objects, features and advantages of this invention will be more fully understood from the ensuing detailed description of a preferred embodiment, when considered in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view of an articulated crane-type machine according to one embodiment of this invention.
FIG. 2 is a perspective, partly exploded view of the quick-disconnect mechanism of the embodiment of FIG. 1.
FIG. 3 is an elevational sectional view of the quick-disconnect mechanism of FIG. 1.
FIG. 4 is a sectional view taken at line 4--4 of FIG. 3.
FIG. 5 is a sectional view taken at line 5--5 of FIG. 3.
FIG. 6 is a sectional view taken along lines 6--6 of FIGS. 4 and 7.
FIG. 7 is a sectional view of a portion of the quick-disconnect mechanism, taken along line 7--7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawing, and initially to FIG. 1 thereof, a crane-type excavator machine 10 is shown to have an undercarriage 12, an overcarriage 14, and a front attachment 16. The undercarriage 12 consists basically of track and roller assemblies 18 and a carbody and swing bearing assembly 20. The overcarriage 14 of the excavator machine 10 has an engine compartment 22 which contains the prime mover engine for the machine and also contains the hydraulic system, an operator's cab 24, a platform 26, which is mounted for swingable action on the carbody and swing bearing 20, and a counterpoise 28 at the side remote from the cab 24.
The front attachment 16 of the machine 10 is formed of a dogleg boom 30 whose proximal end is mounted by means of a pivot pin 32 to the overcarriage 14. A boom cylinder 34 has a cylinder end mounted to the platform 26 and has its rod end connected to the arch of the boom 30. A quick-disconnect shoe 36, discussed in greater detail later, is rockably mounted at the distal end of the boom 30, and a stick cylinder 38 has a cylinder end mounted on the boom 30 and a cylinder rod coupled to a point on the quick-disconnect shoe 36 spaced from the mounting on the distal end of the boom 30.
A stick 40, here in the form of a stick shear, has its proximal end removably mounted on the quick-disconnect shoe 36, and has a shear 42 unitarily formed on its distal end. The shear 42 has a fixed jaw 44 unitarily formed with the stick 40, and has a movable jaw 46 pivotally mounted on the stick 40 to open and close to the fixed jaw 44, and which is rocked by a shear cylinder 48.
Hydraulic lines, not shown in great detail here, extend from the overcarriage 14 to the cylinders 34, 38, and 48 to effect the extension and retraction of the cylinders. These lines are fitted with quick-disconnect fittings of any conventional type.
A fitting 50 on the proximal end of the stick 40 permits the stick 40 to be quickly installed on or removed from the boom. As shown in FIGS. 2 and 3, the quick-disconnect shoe 36 is mounted by a pivot pin 51 to the distal end of the boom 30. The pivot pin 51 mates with a bore at the end of the boom 30, and is rotatably journalled in the shoe 36. An eye pin 52 extends through an eye on the rod of the stick cylinder 38, and is also journalled in the shoe 36. The quick-disconnect shoe 36 is formed of a pair of side wall plates 54 penetrated by the pins 51 and 52, and a main plate 56 affixed transversely thereto. A pair of grab hooks 58 are attached on the distal face of the plate 56 and towards the edge nearest which the stick cylinder 38 is connected. These grab hooks extend distally, and each has a curved hook surface 60 and a slanting slide surface 62 that extends proximally from the surface 60. The grab hooks 58 slope towards each other, as shown in FIG. 5 for more clearance at their distal ends to grip the fitting 50. A set of gear-tooth racks 64 are affixed onto the distal side of the main plate 56 and extend longitudinally across it, while a set of gear tooth racks 66 extend transversely thereacross. Each rack includes a plurality of teeth extending generally vertically from the base or main plate 56 such that they extend toward each other as the coupling members 36 and 50 come together. The teeth are provided with slanting flat surfaces wherein slanting surfaces of the teeth on one member mate with slanting surfaces of teeth on the other member. Some of the slanting surfaces slant in one direction while other of said surfaces slant in another direction relative to the vertical. Moreover, since racks 66 are at right angles to racks 64, some of the slanting surfaces of some teeth are angularly turned relative to each other of the slanting surfaces of other teeth. The slanting surfaces of teeth on racks 64 are turned at right angles to the slanting surfaces of teeth on racks 66. Thus, the teeth on coupling member 36 are of like shape to the teeth on coupling member 50. In this embodiment, the rack 64 and 66 form a quadrilateral, although other arrangements are possible within the scope of this invention.
There are clearance holes 68 in the plate 56 for accommodating a lock assembly to be described later.
A pair of female aligners 70 extend distally from opposite sides of the shoe 36, and are situated about halfway from the end thereof where the grab hooks 58 are located. A cylinder mount 74 is affixed onto the plate 56 between the two clearance holes 68.
A lock assembly 76 fits onto the shoe 36 and includes a front frame half 78 and a rear frame half 80. A pair of draw bolts 82 and 84 are respectively situated through the frames 78, 80, and are formed of top and bottom halves that are oppositely threaded. Respective elongated threaded nuts 86 are rotatably mounted in each of the frame halves 78, 80, and each has a rotatable worm gear 88 affixed onto its outer surface. Worm gear motors 90 are mounted on each of the frame halves 78, 80 and each drives a worm gear pinion 92 on its output shaft, the pinion 92 rotating the associated gear 88.
A lock mechanism cylinder 94 has one end attached to the front frame half 78, and another end attached to the cylinder mount 74, while a link 96 is articulated onto the two frame halves 78, 80. The front frame half bolt 82 has an eye that is journalled onto a pin 98 that extends through the shoe wall plates 54, while the other bolt 84 has a corresponding eye journalled onto the eye pin 51. The bolts 82 and 84 extend through the respective clearance holes 68. A pair of transverse pins 100 and 102 are affixed through upper eyes of the two bolt assemblies 82 and 84, and serve to engage mating structure in the stick fitting 50. Hydraulic connections to the motors 90 and the cylinder 94 have been omitted for the sake of avoiding drawing clutter, but their connections would be apparent to those of skill in the art.
The stick fitting 50 has a pair of elongated side plates 104 with a main plate 106 extending between them. A transverse web 108 extends between the side plates 104 above the main plate 106, and attaches to the main portion of the stick 40.
A pair of T-shaped clearance holes 110 are provided to permit insertion of the pins 100, 102 of the lock assembly 76. There are a pair of parallel flanges 112 affixed to the plate 106 and web 108. As shown in FIG. 4, one of these flanges 112 can be at or near the stick center line and the other offset to one side of the stick 40. This means that the bolt assemblies 82, 84 have center lines offset from the stick center line.
There are a pair of longitudinal cutouts 114 in the flanges 112 to receive the pins 100, 102. Details of this are also shown in FIG. 6.
As shown in FIGS. 2 and 3, one end of each of the side plates 104 extends beyond a forward edge of the main plate 106, and a grab pin 116 is mounted between ends of the side plates 104. A clearance 118 is defined behind the grab pin 116. The grab hooks 58 of the shoe 36 fit into this clearance 118, and the grab pin 116 is received onto the hook surface 60 as indicated in ghost lines in FIG. 5.
Longitudinal gear tooth racks 120 and transverse gear tooth racks 122 are situated on the proximal surface of the main plate 106 and these mesh with the gear tooth racks 64 and 66 of the shoe 36, as indicated in solid lines on FIG. 3. As also indicated on FIGS. 2 and 3, the longitudinal racks 120 are split into front and rear halves, and a male aligner guide member 124 is affixed on each side of the plate 106 between the two halves of the associated rack 120. The aligner members 124 have beveled proximal faces 126. This means that the male members 124 are situated opposite one another on the fitting 50 between the positions of the associated female aligners 70. This is shown in FIG. 4.
The quick-connect/disconnect mechanism of this invention can be explained as follows, and with reference, e.g., to FIGS. 3, 5, and 6.
When the operator desires to connect a stick onto the boom 30, the operator manipulates the boom and quick-disconnect shoe 36, by means of the cylinders 34 and 38, to position the grab hook 58 between the fitting side plates 104 and under the grab pin 116. The grab hooks 58 are closer together at their free ends, as shown in FIG. 5, to permit insertion when there is not good alignment. The operator can then rock the boom 30 upwards, and the grab pin comes in contact with the rounded hook surface 60. Then, as the boom is lifted, the stick 40 and the associated fitting 50 swing into contact with the shoe 36. Here, the beveled surfaces 126 of the male aligner guide blocks 124 meet the beveled surfaces 72 of the female aligners 70. As the stick 40 and fitting 50 continue to swing downward, these aligning members 70 and 124 will straighten out the stick 40 and fitting 50 so that the teeth of the racks 64, 66 and 120, 122 can enter into intermeshing engagement. Thus, this structure permits unassisted operator hookup, even when the attachment and stick are not facing each other squarely, or are not located on level ground.
Once the grab hooks 58 and grab pin 116 and the male and female aligners 124, 70 have brought the stick fitting 50 into general alignment with the shoe 36, the lock assembly 76 engages the fitting 50 in the cutouts 114 and pulls the fitting 50 into secure engagement as shown in FIG. 3, with the teeth of the racks 64, 66 intermeshed with the teeth of the fitting racks 120, 122.
When the fitting 50 and the shoe 36 are more or less aligned, the grab pin 116 slides proximally from the curved hook surfaces 60 of the grab hooks 58 along the slanting side surfaces 62, thereby permitting the gear teeth to snap into engagement. At that point, the pins 100, 102 are in the position shown in chain in FIG. 6, i.e., with the distal eye of the bolts 82, 84 extending through the T-shaped clearance holes 110. The operator in the cab 24 can then actuate a lever to move the cylinder 94, and thereby swing the lock assembly mechanism 76 to the solid-line position of FIG. 6, with the pins 100, 102 engaging the transverse cutouts 114. The operator then actuates another lever and supplies hydraulic or electric power to the motors 90. This rotates the worm gears 88 and elongated threaded nuts 86, thereby drawing the bolt assemblies 82, 84 in the proximal direction, to lock the stick fitting 50 securely to the quick-disconnect shoe 36.
The above procedure is done in reverse order to remove the stick 40 from the boom 30.
It should be appreciated that the gear-type teeth of the racks 64, 66 on the shoe 36 and of the racks 120, 122 of the stick fitting 50 prevent either vertical or horizontal movement as between the shoe 36 and the mating fitting 50. This eliminates all slop or play, thus eliminating any undesired wobble in the positioning of the stick 40. The gear-lock arrangement increases the reliability and positioning of the tool that is connected to the stick, usually at some distance from the shoe 36 and fitting 50, thereby promoting reliability and precision in most industrial equipment functions, such as digging, excavating, shearing, lifting, etc.
A worm gear modulating valve (not shown) can be located in the cab 24. This valve prevents overtightening and thus eliminates the possibility of stripping the threads on the bolts 82, 84 or nuts 86. The modulating valve also allows the worm gear motors 90, pinions 92, and worm gears 88 to maintain constant tension on the bolts 82, 84, so that the fitting 50 is held snug against the shoe 36.
The present invention has application not only to the excavator type machine illustrated in FIG. 1, but also to other machines, which can be either track or rubber tire, such as wheel loaders, rack loaders, motor graders, loader back hoes, skid-steer loaders, and agricultural or industrial equipment of the type that has a boom and stick, or has linkage or arms that can be adapted to operate like a boom and stick. Of course, the stick 40 can have any desired tool attached to it, such as a bucket, clam shell, stinger, dozer, impact hammer, tamper, or other tool.
While the invention has been described in detail with respect to a single embodiment, it should be understood that the invention is not limited to that embodiment. Rather, many modifications and variations would be apparent to those of skill in the art without departing from the scope and spirit of this invention, as defined in the appended claims. | An articulated arm type machine, such as an excavator, has a boom articulated for motion in a generally vertical arc, a stick articulated onto the distal end of the boom, and a tool mounted at the distal end of the stick. The stick is connected to the boom by a quick-disconnect shoe that is rockably mounted at the distal end of the boom and a mating fitting mounted at the proximal end of the stick. A pair of grab hooks on the shoe are used to pick up the stick fitting by hooking onto a grab pin mounted thereon. A set of gear tooth racks on the quick-disconnect shoe intermesh with a corresponding set of gear tooth racks on the stick fitting, and these eliminate play between the stick and boom. | 4 |
REFERENCE TO RELATED APPLICATION
[0001] This application is a division of commonly owned co-pending U.S. application Ser. No. 09/657,333 filed on Sep. 7, 2000.
TECHNICAL FIELD
[0002] This invention relates to methods of treating neuronal inflammatory disorders.
THE INVENTION
[0003] Certain hydroxyalkylquinoline acids and ether acids, as well as their corresponding salts, are known to be leukotriene antagonists. See, e.g., U.S. Pat. Nos. 5,266,568, 5,270,324, 5,428,033, 5,565,473 and 5,856,322. As noted in the foregoing patents, these compounds are known to be useful in the treatment of pulmonary disorders including diseases such as asthma, chronic bronchitis, and related obstructive airway diseases, allergies and allergic reactions such as allergic rhinitis, contact dermatitis, allergic conjunctivitis, and the like, inflammation such as arthritis or inflammatory bowel disease, pain, skin disorders such as psoriasis, atopic eczema, and the like, cardiovascular disorders such as angina, myocardial ischemia, hypertension, platelet aggregation and the like, renal insufficiency arising from ischemia induced by immunological or chemical (cyclosporin) etiology, migraine or cluster headache, ocular conditions such as uveitis, hepatitis resulting from chemical, immunological or infectious stimuli, trauma or shock states such as burn injuries, endotoxemia and the like, allograft rejection, prevention of side effects associated with therapeutic administration of cytokines such as Interleukin II and tumor necrosis factor, chronic lung diseases such as cystic fibrosis, bronchitis and other small and large-airway diseases, cholecystitis; erosive gastritis; erosive esophagitis; diarrhea; cerebral spasm; premature labor; spontaneous abortion; dysmenorrhea; ischemia; noxious agent-induced damage or necrosis of hepatic, pancreatic, renal, or myocardial tissue; liver parenchymal damage caused by hepatoxic agents such as CCl 4 and D-galactosamine; ischemic renal failure; disease-induced hepatic damage; bile salt induced pancreatic or gastric damage; trauma- or stress-induced cell damage; glycerol-induced renal failure; and cytoprotective activity in gastrointestinal mucosa and prevention of gastric lesions.
[0004] However, it has now been found that select hydroxyalkylquinoline acids (and the pharmaceutically acceptable salts thereof) are useful in the treatment of conditions which are believed to be caused by neuronal inflammation. Neuronal inflammatory disorders share a particular pathophysiology in relation to the select hydroxyalkylquinoline compounds. In particular, compounds which have the biological property in mammals of acting as “leukotriene antagonists” are particularly effective in the treatment of neuronal inflammatory disorders.
[0005] Furthermore, it has been discovered that certain hydroxyalkylquinoline acids and their salts can be utilized to treat some disorders which have not been conclusively shown to originate with inflamed neurons. One particularly painful and debilitating group of disorders, members of which have responded remarkably well to treatment with hydroxyalkylquinolines, are those commonly referred to as repetitive motion disorders. In the case of such disorders, hydroxyalkylquinolines not only effectively relieve the symptoms, but often effect a complete cure, allowing return to the same repetitive motion-type activity which caused the disorder without incidence of relapse. Regardless of any previous association with repetitive motion, the disorders referred to hereinafter are considered to be neuronal inflammatory disorders for the purposes of this description, even if it has not been conclusively established that the symptoms of the particular disorder are caused or mediated by inflamed neuronal elements.
[0006] Disorders which are known to be neural inflammatory in nature include viral infections, such as Herpes simplexes I and II. The present invention has demonstrated success in the treatment of symptoms of viral infections. Thus a method is provided for the treatment and/or the long term suppression of symptoms of viral infection such as skin lesions and postherpetic neuralgia, as well as other symptoms of viral infection which are neuronal inflammatory in origin.
[0007] The present invention has also been successful in halting the course of a condition which has long been suspected by the present inventor to be neuronal inflammatory in origin: the progressive graying of the scalp hair. Thus the present invention provides a method for the treatment and/or long-term suppression of symptoms of scalp hair conditions which are neuronal inflammatory in nature, such as progressive graying.
[0008] In addition, the present invention provides a method for treating and/or suppression of symptoms of neuronal inflammatory conditions whose etiology is often partially or fully unknown, some of which are Multiple sclerosis, Guillian-Barre syndrome and Bell's palsy.
[0009] Furthermore, the present invention provides a method for the treatment of neuronal inflammatory conditions which originate with external factors, such conditions including traumatic spinal injury.
[0010] Moreover, the present invention provides a method for treatment and long term suppression of symptoms associated with disorders previously considered repetitive motion disorders.
[0011] The above-described methods comprise administering, to a mammal in need of such treatment, a therapeutically effective amount of a compound having a chemical structural formula as follows:
[0012] [0012]
[0013] wherein:
[0014] R 1 is H, halogen, —CF 3 , —CN, —NO 2 , or N 3 ;
[0015] R 2 is lower alkyl, lower alkenyl, lower alkynyl, —CF 3 , —CH 2 F, —CHF 2 , CH 2 CF 3 , substituted or unsubstituted phenyl, substituted or unsubstituted benzyl, substituted or unsubstituted 2-phenethyl, or two R 2 groups joined to the same carbon to form a carbocyclic ring of up to 8 members;
[0016] R 3 is H or R 2 ;
[0017] R 4 is halogen, —NO 2 , —CN, —OR 3 , —SR 3 , NR 3 R 3 , NR 3 C(O)R 7 or R 3 ;
[0018] R 5 is H, halogen, —NO 2 , —N 3 , —CN, —SR 2 , —NR 3 R 3 , —OR 3 , lower alkyl, or —C(O)R 3 ;
[0019] R 6 is —(CH 2 ) s —C(R 7 R 7 )—(CH 2 ) s —R 8 or —CH 2 C(O)NR 12 R 12 ;
[0020] R 7 is H or C 1 -C 4 alkyl;
[0021] R 8 is the radical W—R 9 ;
[0022] R 9 contains up to 20 carbon atoms and is (1) an alkyl group or (2) an alkylcarbonyl group of an organic acyclic or monocyclic carboxylic acid;
[0023] R 11 is lower alkyl, —C(O)R 14 , unsubstituted phenyl, or unsubstituted benzyl;
[0024] R 12 is H, or R 11 ;
[0025] R 13 is lower alkyl, lower alkenyl, lower alkynyl, —CF 3 or substituted or unsubstituted phenyl, benzyl, or 2-phenethyl;
[0026] R 14 is H or R 13 ;
[0027] R 16 is H, C 1 -C 4 alkyl, or OH;
[0028] R 17 is lower alkyl, lower alkenyl, lower alkynyl, or substituted or unsubstituted phenyl, benzyl, or 2-phenethyl;
[0029] R 18 is lower alkyl, lower alkenyl, lower alkynyl, —CF 3 or substituted or unsubstituted phenyl, benzyl, or 2-phenethyl;
[0030] R 19 is lower alkyl, lower alkenyl, lower alkynyl, —CF 3 or substituted or unsubstituted phenyl, benzyl, or 2-phenethyl;
[0031] R 21 is H or R 17 ;
[0032] R 22 is R 4 , CHR 7 OR 3 , or CHR 7 SR 2 ;
[0033] m is 0-8;
[0034] m′ is 2 or 3;
[0035] n and n′ are independently 0 or 1,
[0036] p and p′ are independently 0-8;
[0037] m+n+p is 1-10 when r is 1 and X 2 is O, S, S(O), or S(O) 2 ;
[0038] m+n+p is 0-10 when r is 1 and X 2 is CR 3 R 16 ;
[0039] m+n+p is 0-10 when r is 0;
[0040] m′+n′+p′ is 2-10;
[0041] r and r′ are independently 0 or 1;
[0042] s is 0-3;
[0043] Q 1 is —C(O)OR 3 , 1H (or 2H)-tetrazol-5-yl, —C(O)OR 6 , —C(O)NHS(O) 2 R 13 , —CN, —C(O)NR 12 R 12 , NR 21 S(O) 2 R 13 , —NR 12 C(O)NR 12 R 12 , —NR 21 C(O)R 18 , —OC(O)NR 12 R 12 , —C(O)R 19 , —S(O)R 18 , —S(O) 2 R 18 , —S(O) 2 NR 12 R 12 , —NO 2 , —NR 21 C(O)OR 17 , —C(NR 12 R 12 )═NR 12 , —C(R 13 )═NOH;
[0044] Q 2 is OH;
[0045] W is O, S, or NR 3 ;
[0046] X 2 and X 3 are independently O, S, S(O), S(O) 2 , or CR 3 R 16 ; with the proviso that at least one is S or SO 2 :
[0047] Y is —CR 3 ═CR 3 —
[0048] Z 1 and Z 2 are independently —HET(—R 3 —R 5 )—;
[0049] HET is the diradical of a benzene, a pyridine, a furan, or a thiophene; or a pharmaceutically acceptable salt thereof. The term “pharmaceutically acceptable salt” refers to a salt that retains the desired biological activity of the parent compound and does not impart any undesired toxicological effects, e.g., an acid or base addition salt.
[0050] Preferred is a compound having a chemical structural formula as follows:
[0051] wherein the substituents are as follows:
* R 1 Y A B RS 7-Cl CH═CH SCH 2 CHMeCO 2 H (1,3-phe)CMe 2 OH RS 7-Cl CH═CH SCH 2 CHMeCO 2 H (1,4-phe)CMe 2 OH RS 7-Cl CH═CH SCH 2 CHEtCO 2 H (1,3-phe)CMe 2 OH RS 7-Cl CH═CH SCH 2 CHEtCO 2 H (1,2-phe)CMe 2 OH RS 7-Cl C≡C SCH 2 CHMeCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH S 7-Cl C≡C SCH 2 (S)CHMeCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH RS 7-Cl C≡C SCH 2 CHEtCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH RS 7-Cl C≡C S(CH 2 ) 2 CO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH RS 7-Cl CH═CH SCH 2 CHMeCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 NH 2 RS 7-Cl CH═CH SCH 2 CHEtCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 NHMe RS 7-Cl CH═CH SCH 2 CHEtCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 NMe 2 RS 7-Br C≡C SCH 2 CHEtCO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH S 7-Cl CH═CH SCH 2 CH(CH 2 CH═CH 2 )CO 2 H (CH 2 ) 2 (1,2-phe)CMe 2 OH S 7-Cl CH═CH SCH 2 CHEtCO 2 H (CH 2 ) 2 (1,2-phe)C(CH 2 OCH 2 )OH
[0052] Particularly preferred as the compound is 1-(((1(R)-(3-(2-(7-chloro-2-quinolinyl)ethenyl)phenyl)-3-(2-(2-hydroxy-2-propyl)phenyl)propyl)thio)methyl) cyclopropaneace-tic acid or a pharmaceutically acceptable salt thereof, and in particular the monosodium salt thereof (i.e., montelukast sodium), which is the active ingredient in the pharmaceutical marketed by Merck & Co., Inc. under the trademark, Singulair®. This and related compounds, including methods of producing such compounds, are described in greater detail in U.S. Pat. No. 5,565,473, the disclosure of which is incorporated herein by reference.
[0053] This invention also provides an an article of manufacture for human pharmaceutical use, comprising packaging material and a container comprising 1-(((1(R)-(3-(2-(7-chloro-2-quinolinyl)ethenyl)phenyl)-3-(2-(2-hydroxy-2-propyl)phenyl)propyl)thio)methyl) cyclopropaneace-tic acid or a pharmaceutically acceptable salt thereof, wherein said packaging material comprises a label which indicates that said cyclopropaneacetic acid, or said pharmaceutically acceptable salt thereof, is suitable for treatment, or alleviation of symptoms, of one or more disorders selected from the group consisting of carpal tunnel, cubital tunnel, tarsal tunnel, traumatic spinal cord injury, graying of scalp hair, thoracic outlet, herpes simplex, herpes zoster, Bell's palsy, multiple sclerosis, and Gillian-Barre.
[0054] These and other embodiments and features of the invention will become still further apparent from the ensuing description, examples and appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0055] When utilizing hydroxyalkyl quinolines to treat the aforementioned conditions, the compound can be introduced into the body by oral administration, (i.e., by ingestion of a tablet, pill, liquid suspension or the like), by sub-dermal injection, or other means. If taken orally, it is preferable to use a dose of about 4 to about 10 milligrams per day. If administered by injection, it is preferable to utilize a dose of about 1 to about 10 milligrams per injection, about 2-4 times per monthly. The entire daily dosage can be taken as a single dose, or it can be administered as two or more smaller doses taken at appropriate intervals. However, preferred dosages, preferred modes of administration, and subdivision of dosages vary somewhat with the condition or disease for which treatment is sought. Suggestions pertaining to particular conditions are given below.
[0056] Hydroxyalkylquinoline compounds can be used for the relief of symptoms due to active viral infections. In particular, the active ingredient of Singulair® can relieve blisters and skin lesions such as 1) skin lesions on the face, lip and oral mucosa overlying soft tissue due to an active Herpes Simplex I infection (HSV-I); 2) skin lesions on the genitals and anus due to an active Herpes Simplex I (HSV-I) infection or Herpes Simplex II infection (HSV-II); and 3) variously located skin lesions due to an active infection of Herpes zoster (chicken pox virus). The standard oral dose of about 4 to about 10 milligrams is appropriate for the treatment of existing blisters in a patient.
[0057] Hydroxyalkylquinolines can be administered at any time during the presence of the blisters. However, best results are obtained when treatment is initiated as soon as the initial symptoms of blistering are detected.
[0058] It is preferable that the patient continue to take an effective amount of a composition of this invention until blisters and pain have subsided. Treatment time can be expected to be in the range of from about 5 to about 10 days. In most cases, patient experiences complete relief in a time in the range of from about 2 to about 4 days.
[0059] Hydroxyalkylquinolines can also be used to treat or prevent or reduce the severity of the localized pain caused by viral infection, typically following the resolution of skin blisters. In particular, such compounds are effective in treating post-herpetic neuralgia such as is often associated with chicken pox virus infection. The dosages and means of administration are as noted in the first paragraph of the “Detailed Description.” It is preferred that the dosages be administered orally for a period of two to four weeks. Treatment can be initiated at any time after the appearance of blisters, from the first appearance to crusting and resolution. However, the likelihood of complete prevention of neuralgia, as opposed to merely reducing its severity, is increased with promptness of treatment. It is preferred that the patient continue treatment for the duration of the pain. In severe cases, it may be advisable to administer continuous treatment. Most patients can be expected to begin experiencing relief within from about 10 to about 21 days.
[0060] Other symptoms of the aforementioned viral infections which respond to the administration of hydroxyalkylquinoline compounds are the localized itching, burning or tingling, often for prolonged periods, which accompany the infection and generally closely precede the development of blisters. The dosages and means of administration are as given in the first paragraph of the “Detailed Description.”
[0061] Furthermore, if hydroxyalkylquinoline compounds are administered after the onset of localized irritation (i.e., itching, burning or tingling), but before the onset of blistering, it can be used to prevent blisters or reduce their severity. In order to prevent blistering, it is preferable to begin treatment within about forty eight hours of the onset of the localized irritation, however, in some cases, even at later times, the administration of hydroxyalkylquinoline compounds can prevent the formation of blisters. The dosages and means of administration are as given in the first paragraph of the “Detailed Description.” It is advisable to treat patient with hydroxy alkyl quinoline compounds until the localized irritation subsides, or, if sores develop, until the sores resolve.
[0062] Moreover, the administration of appropriate dosages of hydroxyalkylquinoline compounds can be utilized for the long term management of dormant viral infections. For example, hydroxyalkylquinoline compounds can effectively suppress the periodic appearance of stress-induced sores (often induced by overwork, too little sleep, etc.) in a patient with a latent HSV-I or HSV-II infection. A patient can be treated on a continual basis. The dosages and means of administration are as given in the first paragraph of the “Detailed Description.”
[0063] However, long term suppression of virally-induced pain and blistering can be accomplished by treating the patient on a schedule of intervals which anticipate 1) a sore forming cycle manifested by a particular patient, or 2) stresses to which a patient is, will be, or is likely to be exposed. Examples of such stresses are trauma to self, a friend or a family member; occupational stresses; and the like.
[0064] In the inhibition of scalp hair graying, it is advisable to begin treatment before all the scalp hair has grayed. Preferably, only small patches of gray are present. Treatment is on a continuous basis, and interruptions in treatment can result in the resumption of graying. The dosages and means of administration are as given in the first paragraph of the “Detailed Description.”
[0065] Disorders such as Bell's Palsy, Gillian-Barre Syndrome and Multiple Sclerosis, the etiology of which is unknown and which are thought be the result of virus-initiated neural inflammation, are likely candidates for treatment with hydroxyalkyl quinoline compounds. The dosages and means of administration are as given in the first paragraph of the “Detailed Description.” It is preferable to treat Bell's Palsy and Gillian-Barre Syndrome with oral dosages immediately after the onset of symptoms. In the case of Bell's Palsy, such symptoms include facial numbness, weakness or lack of motor control in the facial muscles and lack of taste in the anterior portion of the tongue. A symptom of Guillian-Barre Syndrome which can be expected to improve with the administration of hydroxyalkylquinoline compounds is the accompanying extensive muscular weakness.
[0066] In the case of Multiple Sclerosis, treatment with hydroxyalkylquinolines can be expected to reduce the severity of symptoms and number of relapses, the symptoms including, e.g., numbness, weakness and neurogenic pain. A preferred manner of treatment is intrathecal injection of hydroxyalkyl quinoline compounds at the time of diagnosis, with additional injections as long as patient manifests symptoms. Those hydroxyalkylquinoline compounds which have the capacity to penetrate the blood-brain barrier can be administered orally. With such compounds, it is most preferable that oral administration accompany periodic intrathecal injection. Such oral administration can be performed daily, with injections as frequent as two to four times per month.
[0067] Traumatic spinal cord injury can be expected to respond to treatment with hydroxyalkyl quinoline compounds. The dosages and means of administration are as described above in the first paragraph of the “Detailed Description.” However, it is preferred to begin treatment immediately following the occurrence of spinal cord injury. Such treatment preferably consists of daily oral administration given in conjunction with high doses of intravenous and/or oral steroids. Such treatment preferably continues until such a time as the inflammatory neuronal response to the injury, is maximally diminished or eliminated.
[0068] Hydroxyalkyl quinoline compounds can also be expected to be useful in treating disorders, heretofore thought to have been caused by swelling of soft tissue and known as repetitive motion disorders, but which may be due instead to neuronal inflammation. In the treatment of carpal tunnel, cubital tunnel, tarsal tunnel and thoracic outlet syndromes, the dosages and means of administration are as given above in the first paragraph of the “Detailed Description.” A preferred treatment is the oral administration of hydroxyalkylquinoline compounds for four to eight weeks and/or intermittently as symptoms occur. Another preferred treatment is the injection of the standard injectable dose of the presently described leukotriene antagonists at or near the site of neuronal compression. Such injections may be performed intermittently, or only once. The intended dose can be delivered as a single injection, or as a series of injections, each containing an amount of the hydroxyalkylquinoline which is less than the intended dose.
[0069] The pharmaceutical compositions of this invention may be packaged in a variety of ways depending upon the method used for administering the drug. Generally, an article for distribution includes packaging material and a container which contains the pharmaceutical formulation in an appropriate form. Suitable containers are well-known to those skilled in the art and include materials such as bottles (plastic and glass), sachets, ampoules, plastic bags, metal cylinders, blister packs, silica gel desiccant canisters and the like. The container may also include a tamper-proof assemblage to prevent indiscreet access to the contents of the package. In addition to the container, the article further comprises packaging material comprised of a label deposited upon or packaged with the container, the label describing the contents of the container and indicating that contents of the container is suitable for treatment, or alleviation of symptoms, of one or more disorders selected from the group consisting of carpal tunnel, cubital tunnel, tarsal tunnel, traumatic spinal cord injury, graying of scalp hair, thoracic outlet, herpes simplex, herpes zoster, Bell's palsy, multiple sclerosis, and Gillian-Barre. The label may also include appropriate warnings.
[0070] Examples 1-7 demonstrate the effectiveness of a preferred hydroxyalkylquinoline acid (or the pharmaceutically acceptable salt thereof) in treating and/or suppressing the symptoms of repetitive trauma disorders such as carpal tunnel, cubital tunnel, and thoracic outlet syndromes.
EXAMPLE 1
[0071] A carpenter who was experiencing the symptoms of carpal tunnel syndrome was treated with 10 mg of Singulair® per day, taken orally, for four weeks. He continued to perform his daily occupational activities throughout the period of treatment. He obtained complete remission of symptoms. Following cessation of treatment, the symptoms recurred. Patient was then treated for short courses of 10 mg of Singulair® per day, whenever symptoms were present, until symptoms subsided.
EXAMPLE 2
[0072] A patient who worked as a billing clerk had carpal tunnel symptoms which had not responded to non-surgical methods of treatment. Patient was treated with Singulair® at 10 mg daily, taken orally. After six weeks, she experienced complete resolution of her carpal tunnel symptoms. Though she continued her occupational activities as a billing clerk, after forty weeks, she remained symptom-free.
EXAMPLE 3
[0073] A patient who works as a data entry clerk, experienced severe carpal tunnel symptoms. She ceased her occupational activities and began treatment with Singulair® at 10 mg per day, taken orally. After four weeks of therapy, her symptoms had completely resolved, and she returned to work, continuing the Singulair® treatment. Upon recheck in two weeks, she remained symptom-free. At this time, treatment with Singulair® was discontinued, and patient remained symptom-free thereafter.
EXAMPLE 4
[0074] Patient was an insurance clerk who experienced severe carpal tunnel symptoms which had not abated, even after carpal tunnel decompression surgery. For years following surgery, she had experienced severe carpal tunnel symptoms. After six weeks of therapy with Singulair® at 10 mg per day taken orally, she experienced complete resolution of her symptoms, despite the fact that she continued routine occupational activities. When treatment was stopped, her symptoms rapidly returned. Symptoms abated with resumption of treatment, and with continuing treatment, she remains symptom-free.
EXAMPLE 5
[0075] Patient was an assembly line worker at an automobile production facility who was experiencing symptoms of carpal tunnel syndrome was treated with 10 mg of Singulair® per day taken orally. He continued to perform his daily occupational activities and noted that his symptoms abated after six weeks of treatment. He required continuous treatment with 10 mg of Singulair® per day taken orally to maintain remission of his symptoms.
EXAMPLE 6
[0076] Patient was a golfer who experienced symptoms of cubital tunnel syndrome. Lengthy treatments with multiple non-steroidal anti-inflammatory drugs, cessation of the causative activity (golf), and use of elbow splints failed to relieve patient's symptoms. Patient was treated with Singulair® at 10 mg daily, taken orally. Symptoms were entirely abated after four weeks. No further treatment was required despite his return to his regular golfing activity.
EXAMPLE 7
[0077] Patient exhibited symptoms of thoracic outlet syndrome including a pain radiating down the left arm, a burning sensation beneath the left scapula, weakness of the left hand, and intermittent numbness of the left hand. Patient was treated with Singulair® at 10 mg per day taken orally. After four weeks, symptoms had completely resolved. No further treatment was required.
[0078] Examples 8-12 demonstrate the effectiveness of a preferred hydroxyalkylquinoline acid (or the salt thereof) in the treatment of Herpes simplex I and II (HSV I and II), a latent latent viral disease.
EXAMPLE 8
[0079] Patient had recently discontinued use of Singulair® as a treatment for asthma. Five days later, patient developed a cold sore, possibly caused by excessive exposure to ultraviolet light. The cold sore resolved in three days after treatment with Singulair® was resumed. The rate of resolution was faster than the resolution of previous sores which were treated with antiviral treatments such as those marketed under the trademarks Zovirax® or Famvir® (approximately seven to ten days). During the subsequent two years, patient took Singulair® on a daily basis (10 mg, twice a day). In that time period, patient was exposed to levels of ultraviolet light which were as high as those which had possibly induced the sore, yet no new sore developed.
EXAMPLE 9
[0080] A patient who had a history of developing an average of two cold sores per month was treated with Singulair® at 10 mg per day, taken orally. No cold sore was present at the time therapy was started. Patient remained free of cold sores with continuous daily treatment for ten months. Within five days of termination of treatment, a cold sore developed. The patient restarted treatment, and remained free of cold sores as of thirteen months after resumption of treatment.
EXAMPLE 10
[0081] Patient had post-herpetic neuralgia due to a latent Herpes infection. Neuralgia developed despite initial treatment with anti-viral agents as per standard treatment recommendations. Patient began treatment with Singulair® (10 mg per day, taken orally). The post-herpetic neuralgia resolved in ten days. No further treatment was required.
EXAMPLE 11
[0082] Patient had postherpetic neuralgia due to a latent Herpes infection. Neuralgia developed despite initial treatment with anti-viral agents as per standard treatment recommendations. Patient began treatment with Singulair® (10 mg per day, taken orally). The post-herpetic neuralgia resolved in 14 days. No further treatment was required.
[0083] Example 12 demonstrates the effectiveness of a preferred hydroxyalkylquinoline acid (or the salt thereof) in inhibiting the natural graying process of scalp hair.
EXAMPLE 12
[0084] Patient had noted the onset of graying of the temple regions of his hair. No progression of the graying process in the temple region or development of graying in any other scalp areas noted after two years and four months of continuous treatment with Singulair® (10 mg per day, taken orally).
[0085] The disclosure of each patent and patent application referenced above is incorporated herein by reference to the fullest extent and for all purposes as may be permitted by law.
[0086] This invention is susceptible to considerable variation in its practice. Therefore, the foregoing description is not intended to limit, and should not be construed as limiting, the invention to the particular exemplifications presented hereinabove. Rather, what is intended to be covered is as set forth in the ensuing claims and the equivalents thereof permitted as a matter of law. | Methods of treating select mammalian disorders using a leukotriene antagonist are described. The methods involve administering to the mammal a therapeutically effective amount of a compound having the formula:
The methods may be employed to treat disorders such as traumatic spinal cord injury, graying of the scalp hair, herpes simplex, herpes zoster, Bell's palsy, multiple sclerosis, and Gillian-Barre. | 0 |
FIELD OF THE INVENTION
[0001] In inkjet printing, anionic dye and cationic polymer fixer are often used. Together they form a complex that sometimes must be dissolved and removed from places where it has formed, such as the printhead.
BACKGROUND OF THE INVENTION
[0002] Dye-based inkjet inks have become a dominant technology in the inkjet ink arena. However, as many dyes are water-soluble, images printed using many of such dye-based inkjet inks are not as waterfast as may be desirable. The waterfastness and durability of anionic dye-based inkjet ink printed on media has been shown to be enhanced by overprinting or underprinting the printed image with a fixer, preferably from a separate pen. Fixers work to crash the colorants, e.g. anionic dyes, anionic pigments or carboxylated dyes, by changing the pH of the printed inkjet image or by adding salts such as Ca 2+ and Mg 2+ to the printed inkjet image. These fixers had the disadvantages of lacking durability, of causing pen wear and tear and corrosion due to the high salt content and the low pH.
[0003] More recently, cationic polymers have been used in the fixer. Thus, when the cationic polymer and the anionic dye contact one another on a substrate, a reaction between the dye and the polymer creates an image with improved durability and waterfastness. Inkjet images with improved waterfastness and durability can therefore be obtained by underprinting or overprinting a printed inkjet image with a cationic polymeric fixer.
[0004] Thus, anionic inks can be rendered more durable by printing with a fluid containing a cationic polymer. Sometimes during printing, the ink and the polymer fluids come into contact on the surface of one of the printheads, creating a durable complex which is difficult to remove with such servicing fluids as 1,2 hexanediol, glycerol and water.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a method of dissolving an anionic dye/cationic polymer complex comprising the step of applying to the complex a water-soluble solvent having a dielectric constant from 20 to 43 at standard temperature and pressure.
[0006] The present invention additionally relates to an inkjet printhead cleaning system, wherein an anionic dye/cationic polymer complex on the printhead is removed by applying to the complex on the printhead a water-soluble solvent having a dielectric constant from 20 to 43 at standard temperature and pressure.
[0007] Also, the present invention relates to a method of removing an anionic dye/cationic polymer complex from an inkjet printhead, comprising the step of applying to the complex on the printhead a water-soluble solvent having a dielectric constant from 20 to 43 at standard temperature and pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a detailed description of embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0009] [0009]FIGS. 1A and 1B plot the Fixer/Dye ratio against the % Colorant Soluble for complexes of anionic dyes with cationic fixers in deionized (DI) water.
[0010] [0010]FIGS. 2A and 2B plot the Fixer/Dye ratio against the % Colorant Soluble for complexes of anionic dyes with cationic fixers in 8% 2P.
[0011] [0011]FIGS. 3A and 3B plot the Fixer/Dye ratio against the % Colorant Soluble for complexes of anionic dyes with cationic fixers in 40% 2P.
[0012] [0012]FIGS. 4A and 4B plot the % 2P against the % Colorant Soluble with the Fixer/Dye Weight Ratio equal to 1/1.
DETAILED DESCRIPTION
[0013] In order to obtain images that are durable to highlighter smear or water drip and smudge, inks containing anionic dyes are underprinted and/or overprinted with fluids containing cationic polymers. The dye/polymer complex forms a durable mixture. When the ink and the polymer fluid end up on a printhead surface, the mixture is not easily removed by typical water-soluble servicing solvents such as 1,2-hexane diol, glycerol and water.
Effective and Ineffective Water Soluble Solvents
[0014] To study which water-soluble servicing solvents are best for removing the ink/polymer complex, the solubility of the precipitate formed between dye and fixers was evaluated in a variety of solvents. Specifically inks and fixers were pipetted onto cellulose TLC plates, dried and developed in a variety of solvents as described in Examples 1 and 2.
[0015] As shown in the Examples below, it was found that the dye/fixer complex precipitate is immobile in water, dipropylene glycol, 1,2 hexanediol, and 1,6-hexanediol indicating a lack of solubility in these solvents. In 2-amino-2-methyl propanol and 1,2 propanediol, it was found that some, but not all, of the complex precipitates are mobile, indicating that at least some of the complex precipitates are soluble in these solvents.
[0016] Also in the Examples, it is seen that all of the complex precipitates are mobile and therefore solubilized in 2-pyrrolidone, diethylene glycol, 1,2-propanediol, tetraethylene glycol, 1-methyl-2-pyrrolidone and n,n-dimethyl propionamide.
[0017] It has been found that 2-pyrrolidone is very effective at dissolving the dye-polymer complex. Furthermore, mixtures of 2-pyrrolidone and water are capable of dissolving the complex and are compatible with the printhead materials. The weight percentage ratio of 2-pyrrolidone to water can be from 100:0 to 20:80. In a preferred embodiment, the weight percentage ratio is 40:60.
[0018] It has also been found that 2-pyrrolidone inhibits precipitation of the anionic dye/cationic polymeric fixer complex as manifested by a greater equilibrium solubility and a slower precipitation rate. No precipitation was observed in systems containing less than 45 weight % 2-pyrrolidone.
[0019] Dielectric constants at standard temperature and pressure for most of the water-soluble servicing solvents tested have been obtained at standard temperature and pressure. Generally, it has been found that solvents that are “effective” at solubilizing anionic dye/cationic fixer complexes have dielectric constants that fall within the range of from approximately 20 to approximately 43 at standard temperature and pressure. In contrast, it has been found that solvents that are “ineffective” at solubilizing anionic dye/cationic fixer complexes have dielectric constants that fall outside the above range of 20-43 at standard temperature and pressure. Comparative tables are shown below:
Dielectric Constants at STP “Effective” Solvents 2-pyrrolidone 28.18 Diethylene glycol 31.82 1,2-propanediol 32 Tetraethylene glycol 20.44 1-methyl-2-pyrrolidone 32.2 N,n-dimethylpropionamide 34.6 Triethylene glycol 23.7 1,5-pentanediol 26.2 1,4-pentanediol 31.9 “Ineffective” Solvents Water 78 Cyclohexanone 16.1 Butoxyethanol 9.43 Diacetone alcohol 18.2 1-pentanol 16.9 1,2-pentanediol 17.3 Glycerol 46.5
Anionic Dyes Forming a Complex with Fixer
[0020] Non-limiting examples of anionic dyes that are effective with this invention are: direct black dyes, such as Direct Black 168 (DB168), Direct Black 19 (DB19) or variants of Fast Black 2; phthalocyanine cyan dyes, such as ProJet Cyan 485; acid cyan dyes, such as Acid Blue 9 (AB9); mixtures of acid cyan and phthalocyanine cyan, such as AB9 and ProJet Cyan 485 (PJ485); gamma acid magenta dyes, such as Magenta 377 (M377); H-acid magenta dyes, such as ProJet Magenta 364 (M364); Xanthene magenta dyes, such as Acid Red 289 (AR289); mixtures of H-acid magenta and Xanthene magenta dyes, such as mixtures of ProJet Magenta 364 and AR289; direct yellow dyes, such as Direct Yellow 132 (DY132); acid yellow dyes such as Acid Yellow 23 (AY23); and mixtures of direct yellow dyes and acid yellow dyes, such as mixtures of DY132 and AY23.
Cationic Polymeric Fixers Forming a Complex with Anionic Dyes
[0021] In a preferred embodiment of the fixer, polyguanidines and polyethyleneimines, have been found to be effective cationic polymers for this purpose.
[0022] In a more preferred embodiment, the cationic polymers are polymonoguanidines, preferably poly (C 3-18 -hydrocarbyl monoguanidines).
[0023] In a most preferred embodiment, the poly(C 3-18 -hydrocarbyl monoguanidines) comprise groups selected from the group consisting of Formula (1) and Formula (2) or salts thereof:
[0024] wherein:
[0025] each m is independently 0 or 1;
[0026] each Y is independently a C 2-18 -hydrocarbyl group;
[0027] A and B are hydrocarbyl groups which together comprise a total of 3 to 18 carbon atoms; and
[0028] each R is independently hydrogen, alkyl, alkoxy, substituted alkyl or substituted alkoxy.
[0029] In another most preferred embodiment, the poly(C 3-18 -hydrocarbyl monoguanidines) comprise at least one group of Formula (3) or salts thereof:
[0030] wherein:
[0031] n is from 2 to 50.
EXAMPLES
Example 1
[0032] For each of Runs 1, 2 and 3, 1 microliter anionic dye-based ink and cationic polymeric fixer is pipetted in the order Fixer/Color/Fixer for each of colors black, cyan, magenta and yellow onto cellulose thin layer chromatography (TLC) plates. The three TLC plates were dried for 30 minutes at ambient temperature. The TLC plates were developed in solvent at 55° C.
[0033] The table below summarizes the mobility of Run 1, Run 2, and Run 3 dye/fixer complex/precipitates in various water-based servicing solvents.
TABLE 1 Run/ Dipropylene 1,2 Tetraethylene Diethylene Ink Dye Fixer glycol Hexanediol Water glycol glycol 2-pyrrolidone Run Direct Black Poly-alkyl Immobile Immobile Immobile Slight Slight Moderate 1/K amine Run Phthalo- Poly-alkyl Immobile Immobile Immobile Immobile Immobile Slight 1/C cyanine cyan amine Run Gamma acid Poly-alkyl Immobile Immobile Immobile Immobile Immobile Completely 1/M magenta amine Run Direct yellow Poly-alkyl Immobile Immobile Immobile Slight Moderate Completely 1/Y amine Run Direct Black Poly-guanidine Immobile Immobile Immobile Slight Slight Moderate 2/K (different from 1/K) Run Phthalo- Poly-guanidine Immobile Immobile Immobile Immobile Immobile Slight 2/C cyanine cyan Run H-acid Poly-guanidine Immobile Immobile Very Slight Moderate Moderate 2/M magenta slight Run Direct yellow Poly-guanidine Immobile Immobile Immobile Slight Moderate Completely 2/Y Run Direct Black Poly-guanidine Immobile Immobile Immobile Slight Slight Moderate 3/K (different from 1/K) Run Mixture of acid Poly-guanidine Immobile Immobile Immobile Slight Slight Moderate 3/C cyan and phthalo- cyanine cyan Run Mixture of H- Poly-guanidine Very slight Very slight Very Slight Moderate Moderate 3/M acid magenta slight and xanthene magenta Run Mixture of Poly-guanidine Immobile Immobile Very Slight Moderate Completely 3/Y direct yellow slight and acid yellow
Example 2
[0034] For each of Runs 4, 5 and 6, 1 microliter anionic dye-based ink and cationic polymeric fixer, is pipetted in the order Fixer/Color/Fixer for each of colors black, cyan, magenta and yellow onto cellulose TLC plates. The three TLC plates were dried for 30 minutes at ambient temperature. The TLC plates were developed in various water-based servicing solvent at 55° C.
[0035] The table below summarizes the mobility of Run 3, Run 4, and Run 5 dye/fixer complex/precipitates in the various solvents.
TABLE 2 2-amino-2- methyl Fixer/ Cyclohexa- Butoxy- Diacetone propanol 1,2- Ink Dye Fixer none ethanol alcohol (AMP) propanediol Run Direct Polyalkyl Immobile Immobile Immobile Moderate Slight 4/K Black amine Run Phthalo- Polyalkyl Immobile Immobile Immobile Completely Immobile 4/C cyanine amine cyan Run Gamma Polyalkyl Immobile Immobile Immobile Moderate Very 4/M acid amine slight magenta Run Direct Polyalkyl Immobile Immobile Immobile Completely Slight 4/Y yellow amine Run Direct Poly- Immobile Immobile Immobile Immobile Slight 5/K Black guanidine (different from 1/K) Run Phthalo- Poly- Immobile Immobile Immobile Immobile Very 5/C cyanine guanidine slight cyan Run H-acid Poly- Immobile Immobile Immobile Immobile Moderate 5/M magenta guanidine Run Direct Poly- Immobile Immobile Immobile Slight Moderate 5/Y yellow guanidine Run Direct Poly- Immobile Immobile Immobile Slight Slight 6/K Black guanidine (different from 1/K) Run Mixture Poly- Immobile Immobile Immobile Slight Moderate 6/C of acid guanidine cyan and phthalo- cyanine cyan Run Mixture Poly- Very Very Very slight Slight Moderate 6/M of H-acid guanidine slight slight magenta and xanthene magenta Run Mixture Poly- Immobile Immobile Immobile Slight Moderate 6/Y of direct guanidine yellow and acid yellow
Example 3
[0036] A stock solution of ink containing anionic dye, Acid Blue 9(AB9), and fixer containing cationic polymer, Polyguanidine, are diluted with ratios of water and 2-P. For steady state solubility, equal volumes of the ink solutions and the fixer solutions are mixed. Solubility is determined by examining the mixture for precipitate after 1-day at ambient conditions
[0037] Stock solutions are listed in Table 3A below:
TABLE 3A Ink A FIXER B % % Components active Components active Dye AB-9 6 Polyguanidine 4 Bis(2- 0.90 1,2-Hexanediol 7.5 ethylhexyl)sulfosuccinate Fluorocarbon surfactant 0.30 2,3,4,5- 7.5 Tetrahydrothiophene-1,1- dioxide 4-Octylphenol 0.4 Fluorocarbon surfactant 0.3 Polyethoxylate Na 2 EDTA 0.2 POE (4) lauryl ether 0.4 MOPS 0.4 B-Alanine 0.2 Na 2 EDTA 0.05
[0038] Table 3B below summarizes the solubility of Ink A and the Polyguanidine Fixer at various water/2P ratios. The concentration of 2-pyrrolidone has a strong effect on the interaction of the dye and fixer. Increasing the concentration of 2-P increases the solubility of the dye/fixer complex.
Weight % Weight % ppt with ppt with Sample (Dye) water Weight % 2P Sample X Sample Y 1 0.60 90 0 Yes Yes 2 0.60 80 20 Yes Yes 3 0.60 60 40 Yes None 4 0.60 40 60 Yes None 5 0.60 20 80 Yes None 6 0.60 0 90 None None Weight % Weight % Sample (Fixer) water Weight % 2P X 2 98 0 Y 2 48 50
Example 4
[0039] The solubility of the DB168 Dye/Polyguanidine Fixer complex was tested in various solvents. Dye and fixer were added to aqueous cosolvent solutions to attain a concentration of 9.4 g/L DB168 Dye and 9.4 g/L Polyguanidine Fixer—the resulting mixture partitions into a liquid supernatant phase and a solid precipitate phase. Entries in Table 4 below represent the % of the total colorant that goes into the supernatant phase (100% would represent complete dye/fixer solubility in a solvent). The data shows that DB 168 Dye/Polyguanidine Fixer is the most soluble in 88% 2P—and that the reproducibility of this measurement is good (comparing ‘2P’ and replicate ‘2P-2’). It also shows that the relative ability of solvents to dissolve the dye/fixer complex changes as water is taken out of the system. For example, at 44% aq TMS is a better solvent for DB 168 Dye/Polyguanidine Fixer than 44% aqueous TEG, but 88% aqueous TEG is a better solvent than 88% aqueous TMS.
44% solvent 88% solvent 2-pyrrolidone 0.28 34.27 2-pyrrolidone (rep 2) 0.27 34.87 1,2-hexanediol 0.11 0.18 Tetramethylene sulfone 0.38 7.63 1-methyl-2-pyrrolidone 0.45 30.54 1,2-propanediol 0.00 0.67 Diethylene glycol 0.00 3.47 Tetraethylene glycol 0.00 8.86 Glycerol 0.00 0.00 Ethylene glycol 0.00 0.40 Tetrahydrofuran 1.32 15.45 n,n-dimethylpropionamide 0.76 20.30
Example 5
[0040] Fixer-dye mixtures containing 0, 8, and 40% 2P were made by mixing 3% of dye in water or in 40% 2P with 3% of FA11/5 (polymonoguanidine) or FA2 (polybiguanadine) in water, pH adjusted to 4. Higher 2P-containing solutions (40% 2P in mixture) were prepared by mixing 3% dye in water with 6% FA11/5 or FA2 (in water, pH adjusted to 4) As dyes, PJ485, AB9, M364, AR289, DY132, AY23-TMA, DB19 and DB168 were used in this study. The samples were centrifuged.
[0041] The “Colorant Soluble” was plotted in FIGS. 1, 2, 3 in DI water, 8% 2P and 40% 2P, respectively, where “% Colorant Soluble” is defined as absorbance at λ max (w/o fixer). For DB168 and DB19, the minimum of “% Colorant Soluble” was reached at ˜0.5 fixer/dye ratio. There was virtually no difference observed in “% Colorant Soluble” of the fixer-black dye complexes using FA2 or FA11/5.
[0042] Regardless of fixer type or % 2P present in the solution, fixer-DB168 complex is the least soluble. Fixer-DB19 complex was more soluble than fixer-DB168 complex but still less soluble than most of the fixer-color dye complexes.
[0043] As shown in FIG. 4, “% Colorant Soluble” increased with increasing % 2P. The amount of colorant soluble increased by roughly one order of magnitude from 0 to 40% 2P for most dyes including DB19. “% Colorant Soluble” of fixer-DB168 appeared to be insensitive to 2P content in this region.
Example 6
[0044] As in Example 1, 1 microliter anionic dye-based ink and cationic polymeric fixer is pipetted in the order Fixer/Color/Fixer for each of colors black, cyan, magenta and yellow onto cellulose thin layer chromatography (TLC) plates. The TLC plates were dried for 30 minutes at ambient temperature. The TLC plate was developed in solvent at 55° C.
[0045] The table below summarizes the mobility of Run 2 dye/fixer complex/precipitates in various additional water-based servicing solvents. The dielectric constants at standard temperature and pressure are given for each of the solvents. Both “ineffective” and “effective” solvents are included on the list. The more “effective” solvents tend to occur within the range of 20-41 dielectric constant at standard temperature and pressure.
TABLE 6 Run/ 1,2- Triethylene 1,5- 1,4- Ethylene Ink Dye Fixer 1-pentanol pentanediol glycol pentanediol butanediol glycol Run Direct Poly- Immobile Slight Slight Immobile Very slight Slight 2/K Black guanidine Run Phthalo- Poly- Immobile Very slight Slight Slight Slight Moderate 2/C cyanine guanidine cyan Run H-acid Poly- Immobile Very slight Slight Slight Slight Moderate 2/M magenta guanidine Run Direct Poly- Immobile Immobile Slight Very slight Slight Moderate 2/Y yellow guanidine Dielectric Constants at STP 16.9 17.3 23.7 26.2 31.9 41.4
[0046] Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. | The invention relates to dissolving an anionic dye/cationic polymer complex comprising the step of applying to the complex a water-soluble solvent having a dielectric constant from 20 to 43 at standard temperature and pressure. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to the field of washing machines, particularly to a clean-water-washing function control method of a washing machine.
BACKGROUND OF THE INVENTION
[0002] On the one hand, with the improvement of people's quality of life, people have more and better choices in their food, clothing, houses and vehicles. Among them, the people's more choices in the “clothing” not only lie in the presence of a variety of styles of choice, but also in the variety of clothing materials. As the molding and color of the clothing are designed to follow a certain standard, the material design in today's fashion design is more and more rich and occupies an increasingly important position. In the clothing world, there are a wide variety of clothing materials, which are changed rapidly. For example, in the production of clothing in formal social occasions, pure cotton, pure wool, pure silk, and pure linen products should be chose. With the clothing materials are more and more rich and more and more expensive, the protection of the clothing is also more and more important. Damage to the clothing often occurs during cleaning of the clothing.
[0003] In the prior art, during cleaning of the clothing, the washing program can be selected according to the material of the clothing to reduce the damage to the clothing caused by the physical operation during cleaning of the clothing. However, for the same type of clothing, the degrees of stain may be different, choosing the same washing program will cause the less dirty clothing also to be washed for a long time, affecting the life of the clothing.
[0004] On the other hand, the laundry process of the existing conventional washing machines usually comprises water intake, washing—spin-drying—drainage, repeated rinsing—spin-drying—drainage, etc., wherein the washing and each rinsing need to consume a lot of water. The washed or rinsed water is drained to the outside of the washing machine through a drainage pipe. The water consumption of the entire laundry process is relatively large, and the water resource is greatly wasted, especially for the less dirty clothing.
SUMMARY OF THE INVENTION
[0005] in view of the presence of at least one defect in the prior art, the inventors of the present application have found that during rinsing of the clothing in a washing machine which uses a recycled water filtration system comprising, for example, a front filter and a filter membrane assembly (such as an ultrafiltration-membrane assembly), the rinsing water in a washing tub may be filtered to recycle the rinsing water.
[0006] An object of the present invention is to overcome at least one defect of the prior art washing machine having a rinsing water filtration and recycling function and to provide a clean-water-washing function control method of a washing machine having a recycled water filtration system, which helps guide the user in choosing to wash clothing in a water saving manner, and can wash the clothing effectively and protect the clothing and the recycled water filtration system.
[0007] A further object of the present invention is to provide a control method. capable of selecting different laundry processes depending on the type of clothing to further protect the clothing and the recycled water filtration system.
[0008] In order to achieve at least one of the above objects, the present invention provides a clean-water-washing function control method of a washing machine, the method comprising:
[0009] step: receiving a selection instruction of a laundry process; and
[0010] step B: enabling or disabling selection of a clean-water-washing function of the washing machine according to the selection instruction.
[0011] Optionally, the selection instruction corresponds to information about the type of clothing.
[0012] Optionally, the control method further comprises:
[0013] step C: determining a laundry sub-program according to whether the clean-water-washing function of the washing machine is selected; and
[0014] step D: receiving an execution operating instruction to execute the laundry operation in accordance with the determined laundry sub-process,
[0015] Optionally, the step C comprises:
[0016] judging whether or not the selection of the clean-water-washing function is enabled, and if the selection of the clean-water-washing function is disabled, or if the selection of the clean-water-washing function is enabled and an instruction for selecting the clean-water-washing function is not received, determining that the laundry sub-process is a first laundry sub-process executed by default; and
[0017] if the selection of the clean-water-washing function is enabled and an instruction for selecting the clean-water-washing function is received, determining that the laundry sub-process is a second laundry sub-process having the clean-water-washing function.
[0018] Optionally, the second laundry sub-process comprises a recycled water rinsing stage for rinsing the clothing in a washing tub of the washing machine with rinsing water, and in the recycled water rinsing step of the recycled water rinsing stage, the rinsing water in the washing tub flows into a recycled water filtration system of the washing machine and flows hack into the washing tub after filtration in the recycled water filtration system.
[0019] Optionally, the second laundry sub-process further comprises a washing stage executed prior to the recycled water rinsing stage and a dewatering stage executed after the recycled water rinsing stage; wherein
[0020] the washing stage comprises:
[0021] a washing water injection step of supplying water from a water intake pipe of the washing machine to provide washing water for the washing stage;
[0022] a washing step of washing the clothing in the washing tub with a detergent and the washing water; and
[0023] a washing dewatering step of dewatering the clothing in the washing tub,
[0024] the recycled water rinsing stage comprises:
[0025] a rinsing water injection step of supplying water from the water intake pipe to provide rinsing water for the recycled water rinsing stage;
[0026] a recycled water rinsing step; and
[0027] a rinsing dewatering step of dewatering the clothing in the washing tub, and
[0028] the dewatering stage is used to spin-dry the clothing in the washing tub.
[0029] Optionally, the first laundry sub-process comprises at least one normal rinsing stage executed consecutively, each of which is used to rinse the clothing in the washing tub of the washing machine with the rinsing water, and in a normal rinsing step of each of the normal rinsing stages, the recycled water filtration system of the washing machine is in a stop state.
[0030] Optionally, when the type of the clothing is cotton, a chemical fiber, a compound or undergarment, the selection of the clean-water-washing function is enabled, where it is determined that the type of the clothing is a compound when a plurality of types of clothing are simultaneously placed in the washing tub, or it is determined that the type of the clothing made of multiple materials is a compound.
[0031] Optionally, when the type of the clothing is a curtain, the selection of the clean-water-washing function is disabled.
[0032] Optionally, the step B further comprises: enabling or disabling selection of a special stain function of the washing machine according to the selection instruction; and
[0033] the step C further comprises: determining a laundry sub-process according to whether the special stain function of the washing machine is selected.
[0034] Optionally, the clean-water-washing function comprises filtering the laundry water discharged from the washing tub of the washing machine and returning the filtered laundry water back to the washing tub for reuse.
[0035] In the control method of the present invention, the user can self-select the laundry process and decide whether to use the clean-water-washing function, so that the control method not only helps guide the user in choosing to wash Is clothing in a water saving manner, but can also wash the clothing effectively, and protect the clothing and a recycled water filtration system. Moreover, an autonomous and intelligent washing environment is created for the user.
[0036] Further, the washing machine can select the corresponding laundry process according to the type of the clothing; and the user can select whether or not to use the clean-water-washing function according to the degrees of stain of the clothing to improve the convenience of the user's operation.
[0037] The foregoing and other objects, advantages and features of the present invention will become more apparent to those skilled in the art from the following detailed description of specific embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Some specific embodiments of the present invention will be described in detail by way of example only rather than by way of limitation with reference to the accompanying drawings. The same reference numerals in the accompanying drawings denote the same or similar components or parts. It should be understood by those skilled in the art that these drawings are not necessarily to scale. In the accompanying drawings:
[0039] FIG. 1 is a schematic diagram of a washing machine according to an embodiment of the present invention;
[0040] FIG. 2 is a schematic flow chart of a clean-water-washing function control method of a washing machine according to an embodiment of the present invention;
[0041] FIG. 3 is a schematic flow chart of the clean-water-washing function control method of a washing machine according to an embodiment of the present: invention; and
[0042] FIG. 4 is a schematic flow chart of a step C of the clean-water-washing function of the washing machine according to an embodiment of the present invention,
DETAILED DESCRIPTION OF THE INVENTION
[0043] FIG. 1 is a schematic diagram of a washing machine according to an embodiment of the present invention. The washing machine may comprise a washing tub 12 , a drainage pump 22 , and a filter assembly. The filter assembly comprises a front filter 24 and an ultrafiltration-membrane assembly 26 . The washing tub 12 is usually composed of an outer tub and an inner tub which is rotatable within the outer tub. An upper part of the washing tub 12 is provided with a fresh water inlet which is connected to a water supply port through a pipeline 11 , and when a valve 13 on the pipeline 11 is opened, fresh washing water or fresh rinsing water may enter the washing tub 12 . A lower part of the washing tub 12 is provided with a drainage port, and the drainage port is in communication with the filter assembly via a drainage pump 22 through a pipeline. A water output port of the ultrafiltration-membrane assembly 26 is in communication with the washing tub 12 through a water intake pipeline 14 .
[0044] The washing machine of the embodiment of the present invention may further comprise an air pump 32 , and an air outlet of the air pump 32 is in communication with an air inlet of the filter assembly through an airflow pipeline. A check valve 34 is provided on the airflow pipeline. When air cleaning is required for the filter assembly, the air pump 32 and the check valve 34 are opened, and the air pump 32 provides an airflow to the filter assembly for air cleaning, so as to loose and remove impurities remained or adhered in the filter assembly with the airflow. A dense drainage port of the rough filter 24 and a sewage draining port of the ultrafiltration-membrane assembly 26 may be respectively in communication with two inlets of a three-way valve 36 , and an outlet of the three-way valve 36 is in communication with an efflux pipeline 18 of the washing machine, such that the fluid having performed the air cleaning or water washing on the rough filter 24 and/or the ultrafiltration-membrane assembly 26 is directly discharged from the washing machine. The washing water of the washing machine may pass through the drainage pump 22 and the rough filter 24 , and the washing water which is not filtered by the rough filter flows out of the washing machine through the outlet of the three-way valve 36 and the efflux pipeline 18 of the washing machine.
[0045] The recycled water filtration system of the washing machine of the embodiment of the present invention may comprise a drainage pump 22 , a filter assembly and a water intake pipeline 14 . The clean-water-washing function may comprise filtering the laundry water discharged from the washing tub 12 of the washing machine and returning the filtered laundry water back to the washing tub 12 for reuse. In the case of using the clean-water-washing function of the washing machine of the embodiment of the present invention, the water in the washing tub 12 is pumped out and conveyed into the filter assembly for filtration, and the filtered water passes through the water output port of the ultrafiltration-membrane assembly 26 and the water intake pipeline 14 , and is returned to the washing tub 12 for reuse. That is to say, the recycled water filtration system is configured to allow water in the washing tub of the washing machine to flow into the recycled water filtration system during at least one operation stage of the clean-water-washing function of the washing machine and to allow the water to be filtered in the recycled water filtration system and then flow back into the washing tub for reuse. For example, in the recycled water rinsing stage where the rinsing is carried out in the washing machine, the water in the washing tub may flow into the recycled water filtration system and is filtered therein and then flows back into the washing tub; and in other stages, such as the washing stage or the dewatering stage, the water in the washing tub cannot flow into the recycled water filtration system for filtration, and is discharged directly from the washing machine.
[0046] FIG. 2 is a schematic flow chart of the clean-water-washing function control method of a washing machine according to an embodiment of the present invention. The clean-water-washing function control method of a washing machine in the embodiment of the present invention comprises:
[0047] step A: receiving a selection instruction of a laundry process. The user can choose the laundry process according to his/her own preference, the degrees of stain of the clothing, etc., and the washing machine can receive the selection instruction of the laundry process, so that the corresponding laundry process can be selected from the system.
[0048] step B: enabling or disabling selection of a clean-water-washing function of the washing machine according to the selection instruction. In order to better wash the clothing and protect the clothing and the recycled water filtration system, some of the laundry processes within the system do not have the clean-water-washing function, and therefore the selection of the clean-water-washing function of the washing machine is disabled; and some other laundry processes enable the selection of the clean-water-washing function of the washing machine, so that the washing machine allows or forbids the user to select the clean-water-washing function of the washing machine according to the selection instruction of the selected laundry process.
[0049] In some preferred embodiments of the present invention, the appropriate laundry process can be determined according to the type of the clothing to better protect the clothing and to effectively wash the clothing, while allowing the user to operate the washing machine conveniently. Specifically, the selection instruction may correspond to information about the type of clothing. That is to say, when the selection instruction includes the information about the type of clothing or when the user operates a button of an operation interface of the washing machine, the washing machine may retrieve the corresponding information about the type of clothing which corresponds to the button and stored in advance. For example, when the type of the clothing is cotton, a chemical fiber, a compound or undergarment, the laundry process to be executed is selected to enable the selection of the clean-water-washing function. When the type of the clothing is a curtain, the laundry process to be executed is selected to disable the selection of the clean-water-washing function.
[0050] In some embodiments of the present invention, as shown in FIG. 3 , the clean-water-washing function control method of a washing machine in the embodiment of the present invention further comprises:
[0051] step C: determining a laundry sub-process according to whether the clean-water-washing function of the washing machine is selected.
[0052] step D: receiving an execution operating instruction to execute the laundry operation in accordance with the determined laundry sub-process.
[0053] Specifically, the step C (determining a laundry sub-process according to whether the clean-water-washing function of the washing machine is selected) may comprise:
[0054] judging whether or not the selection of the clean-water-washing function is enabled, and if the selection of the clean-water-washing function is disabled, or if the selection of the clean-water-washing function is enabled and an instruction for selecting the clean-water-washing function is not received, determining that the laundry sub-process is a first laundry sub-process executed by default; and
[0055] if the selection of the clean-water-washing function is enabled and an instruction for selecting the clean-water-washing function is received, determining that the laundry sub-process is a second laundry sub-process having the clean-water-washing function.
[0056] As shown in FIG. 4 , the specific working procedure of the step C may be: judging whether or not the selection of the clean-water-washing function is enabled, and if the selection of the clean-water-washing function is disabled, determining that the laundry sub-process is a first laundry sub-process executed by default. If the selection of the clean-water-washing function is enabled, it is judged whether or not an instruction for selecting the clean-water-washing function is received, and if the instruction for selecting the clean-water-washing function is not received, determining that the laundry sub-process is a first laundry sub-process executed by default, otherwise determining that the laundry sub-process is a second laundry sub-process.
[0057] In some embodiments of the present invention, the second laundry sub-process comprises a recycled water rinsing stage in which the rinsing water in the washing tub flows into a recycled water filtration system of the washing machine and flows back into the washing tub after filtration in the recycled water filtration system, so as to make full use of the rinsing water and save water resources.
[0058] The second laundry sub-process further comprises a washing stage executed prior to the recycled water rinsing stage and a dewatering stage executed after the recycled water rinsing stage. The washing stage may comprise: a washing water injection step of supplying water from the water intake pipe of the washing machine to provide the washing water for the washing stage; a washing step of washing the clothing in the washing tub with a detergent and the washing water; and a washing dewatering step of dewatering the clothing in the washing tub. The recycled water rinsing stage may comprise: a rinsing water injection step of supplying water from the water intake pipe to provide the rinsing water for the recycled water rinsing stage; a recycled water rinsing step; and a rinsing dewatering step for dewatering the clothing in the washing tub, the dewatering stage is used to spin-dry the clothing in the washing tub. The rotation speed of the washing tub during the dewatering of the clothing in the washing dewatering step and in the rinsing dewatering step is lower than the rotation speed of the washing tub during the dewatering in the dewatering stage, and the time of the dewatering of the clothing in the washing dewatering step and in the rinsing dewatering step is shorter than the time of dewatering in the dewatering stage, because the dewatering of the clothing in the washing dewatering step and in the rinsing dewatering step is only as much as possible to remove the water in the laundry, whereas the dewatering of the clothing in the dewatering stage is to be as much as possible to remove the water in the laundry to facilitate drying. In some alternative embodiments of the present invention, the recycled water rinsing stage has no rinsing dewatering step.
[0059] Optionally, the first laundry sub-process comprises at least one normal rinsing stage executed consecutively, each of which is used to rinse the clothing in the washing tub of the washing machine with the rinsing water, and in a normal rinsing step of each of the normal rinsing stages, the recycled water filtration system of the washing machine is in a stop state, so that the rinsing water in the washing tub is held in the washing tub (the stop state here may refer to a deactivated state or a closed state in which the filter in the recycled water filtration system does not operate).
[0060] The first laundry subprocess may further comprise a washing stage executed prior to the at least one normal rinsing stage and a dewatering stage executed after the at least one normal rinsing stage. The washing stage comprises: a washing water injection step of supplying water from the water intake pipe of the washing machine to provide the washing water for the washing stage; a washing step of washing the clothing in the washing tub with a detergent and the washing water; and a washing dewatering step of dewatering the clothing in the washing tub. Each of the normal rinsing stages comprises: a rinsing water injection step of supplying water from the water intake pipe to provide the rinsing water for the recycled water rinsing stage; a normal rinsing step; and a rinsing dewatering step for dewatering the clothing in the washing tub, the dewatering stage is used to spin-dry the clothing in the washing tub. In some alternative embodiments of the present invention, the last normal rinsing stage has no rinsing dewatering step.
[0061] When the type of the clothing is cotton, a chemical fiber, a compound or undergarment, the laundry process to be executed is selected to enable the selection of the clean-water-washing function, where it is determined that the type of the clothing is a compound when a plurality of types of clothing are simultaneously placed in the washing tub, or it is determined that the type of the clothing made of multiple materials is a compound. For example, in one embodiment of the present invention, the machine is started, entering a laundry process selection interface where the user clicks on the type of clothing that needs to be washed, i.e., the washing machine receives a selection instruction of the laundry process, which includes the information about the type of clothing, when the user selects the type of clothing to be washed as being cotton/linen, the selection instruction, which is received by the washing machine and comprises the information about the type of clothing, is cotton/linen, and the laundry process to be executed is determined to be cotton/linen laundry process which enables the selection of the clean-water-washing function, entering a function selection interface.
[0062] The user can decide whether to select the clean-water-washing function according to the degrees of stain of the clothing; if the clothing is dirty, the user can click the start button, the washing machine receives the execution operating instruction and executes the laundry operation according to the first cotton/linen laundry sub-process. If the clothing is less dirty, the user can select the clean-water-washing function to enter the clean-water-washing function interface, the user can click a start button of the clean-water-washing function interface, and the washing machine receives the execution operating instruction and executes the laundry operation according to the second cotton/linen laundry sub-process to wash the clothing. Washing parameters respectively set in the first cotton/linen laundry sub-process and the second cotton/linen laundry sub-process are also different, for example, the first cotton/linen laundry sub-process comprises three consecutive rinsing stages, and the second cotton/linen laundry sub-process only comprises one recycled water rinsing stage.
[0063] When the type of the clothing is a curtain, the laundry process to be executed is selected to disable the selection of the clean-water-washing function. For example, when the type of the clothing selected by the user is a curtain, the selection instruction, which is received by the washing machine and comprises the information about the type of clothing, is a curtain, and the laundry process to be executed is selected to be a curtain laundry process which disables the selection of the clean-water-washing function. As the curtain may be washed once or twice a year, there must be a lot of stains thereon; if the clean-water-washing is selected, the curtain will often not be washed cleanly and a lot of stains may be stains that should not be cleaned, which would affect the recycled water filtration system, and therefore, the selection of the clean-water-washing function is disabled for such clothing. The clean-water-washing function button on the function selection interface of the washing machine is in an unselectable state. The user directly clicks the start button, and the washing machine receives the execution operating instruction, and executes the laundry operation in accordance with the first curtain laundry sub-process executed by default. For the different types of clothing, the washing parameters respectively set in the first cotton/linen laundry process and the first curtain laundry sub-process are also different, for example, the washing of the cotton/linen clothing in the first cotton/linen laundry sub-process lasts for 15 minutes, and the washing of the curtain in the first curtain laundry sub-process lasts for 20 minutes.
[0064] In some alternative embodiments of the present invention, the clean-water-washing function control method of a washing machine, between the step C and the step D, further comprises a step E of receiving change information of some or all of the parameters of the determined laundry sub-process. For example, the user may make changes on some or all of the washing parameters of the first laundry sub-process in the function selection interface such that the laundry procedure of the first laundry sub-process satisfies his/her own laundry habits, and such changes may be changes in the washing time and the rinsing time. The number of times the recycled water rinsing stages are carried out in the second laundry sub-process cannot be changed, whereas the number of times the normal rinsing stages are carried out in the first laundry sub-process can be changed.
[0065] In some other embodiments of the present invention, the step B further comprises: enabling or disabling selection of a special stain function of the washing machine according to the selection instruction. The step C further comprises: determining a laundry sub-process according to whether the special stain function of the washing machine is selected, so as to effectively wash special stains (blood stains, grease, etc.) on the clothing.
[0066] At this point, those skilled in the art will recognize that, while numerous exemplary embodiments of the present invention have been shown and described in detail herein, many other variations or modifications that conform to the principles of the present invention may be determined or derived directly from the disclosure of the present invention without departing from the spirit and scope of the present invention. It therefore should be understood and determined that the scope of the present invention covers all such other modifications or modifications. | A clean-water-washing function control method of a washing machine, the method comprising: step A: receiving a selection instruction of a laundry process; step B: enabling or disabling selection of a clean-water-washing function of the washing machine according to the selection instruction. A user at self-select the laundry process and decide whether to use the water-washing function, so that the control method not only helps guide the user in choosing to wash clothing in a water saving manner, but can also wash the clothing effectively, and protect the clothing and a recycled water filtration system. Moreover, an autonomous and intelligent washing environment is created for the user. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a process for producing aliphatic tricarbonitriles, in particular 1,3,6-hexanetricarbonitrile, in a two-stage synthesis by reacting in a first stage an aliphatic α-ω-dinitrile in the presence of a strong base to form an intermediate, which is reacted in a second stage with acrylonitrile under weakly basic conditions.
[0003] 2. Description of the Prior Art
[0004] 1,3,6-hexanetricarbonitrile is an important intermediate for a number of industrially used products. For example tricarboxylic acids, which can be used as detergents, can be obtained by hydrolysis (DE-A-196 37 428). The corresponding hydrogenation of trinitrile leads to 1,3,6-triaminohexane, which can then be reacted in a further stage by phosgenation to form 1,3,6-triisocyanatohexane. This compound is used as an important basic building block in polyurethane (PU) chemistry, for example, for producing polyurethane adhesives or polyurethane coatings.
[0005] 1,3,6-hexanetricarbonitrile is formed as a by-product during electrochemical production of adiponitrile (JP-A-62270550). The undesirable by-product has to be isolated from the distillation residue in a complex process. Currently, this is the only industrial method of obtaining 1,3,6-hexanetricarbonitrile.
[0006] SU-A-194 088 describes the adjustment of the electrochemical synthesis of adiponitrile with an unsaturated intermediate of adiponitrile being used as starting product for producing 1,3,6-hexanetricarbonitrile. However, this intermediate cannot be obtained industrially.
[0007] The cyclization of adiponitrile to 2-amino-1-cyclopentene-1-carbonitrile is known (Journal of the Chemical Society 1909, 700). The reaction is carried out under strongly basic reaction conditions, i.e. bases such as alkali hydrides, alkali amides or alkali-t-butylates are used.
[0008] The production of 1,3,6-hexanetricarbonitrile from 2-amino-1-cyclopentene-1-carbonitrile and acrylonitrile in the presence of elemental sodium is also known (Journal of Applied Chemistry of the USSR, 1972, 2683-2684). The use of elemental sodium and the increased safety risk associated therewith rules out transfer to a large scale industrial process.
[0009] It has been found that a direct reaction of adiponitrile with acrylonitrile leads to a poorly selective reaction as the deprotonized intermediate can lead to dimerizations and polymerization (Tsuruda, T.; O'Driscoll, K. F.; Eds. Structure and Mechanism in Vinyl Polymerisation; Marcel Dekker: New York, 1969; Chapter 11, p. 345 ff).
[0010] An object of the present invention is to provide a process for the selective synthesis of tricarbonitriles, in particular 1,3,6-hexanetricarbonitrile, starting from conventional and readily available starting products and controllable reaction conditions.
[0011] This object may be achieved in accordance with the present invention by conducting the reaction in two stages. In a first reaction stage an intermediate is obtained via an aliphatic α-ω-dinitrile under strongly basic conditions; the intermediate is then cyanoethylized selectively while opening the ring with acrylonitrile. Undesirable secondary reactions of the acrylonitile are not observed.
SUMMARY OF THE INVENTION
[0012] The present invention relates to a process for producing tricarbonitriles corresponding to formula I
[0013] wherein n is an integer from 2 to 11 by forming an intermediate in the presence of a strong base in a first stage from an aliphatic α-ω-dinitrile corresponding to formula II
[0014] wherein n is an integer from 3 to 12, and reacting the intermediate in a second stage to form a trinitrile corresponding to formula I by the addition of acrylonitrile.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In a preferred embodiment of the process according to the invention an intermediate is obtained in the first stage from adiponitrile under strongly basic reaction conditions, and is then reacted with acrylonitrile in a second stage to form 1,3,6-hexanetricarbonitrile. The synthesis is preferably carried out as a one pot reaction.
[0016] The intermediate can optionally be isolated in the process according to the invention and then reacted with acrylonitrile to form a trinitrile corresponding to formula l.
[0017] The intermediate can be identified, for example, as shown by the evaluation of the analytical data, as 2-amino-1-cyclopentene-1-carbonitrile corresponding to formula III
[0018] in which n is an integer from 1 to 10.
[0019] The first stage of the process according to the invention is carried out at a temperature of 70 to 120° C., preferably 80 to 100° C.
[0020] Suitable strong bases include alkali metals, hydrides, amides or alkoxides such as alkali-tert-butylates; potassium-tert-butylate is preferred. Metal oxides and hydroxides of the first and second main group of the periodic table have adequate basicity in complexing solvents such as polyethylene glycols, preferably diglymes, ethyleneglycol dimethylether or polyethyleneglycol dimethylether M 500 (Aldrich), or phase-transfer catalyzed systems, preferably heat-stable phase-transfer catalysts, more preferably Aliquat 175 or Aliquat 336 (Cognis) or Aliplex 186BD (Cognis).
[0021] The strong base used in the process according to the invention is added in an amount of 0.5 to 2, preferably from 1 to 1.5 equivalents, based on the α-ω-dinitrile.
[0022] After reaction of the α-ω-dinitrile to form the intermediate, acrylonitrile is added with lower basicity of the reaction medium than in the first stage. Preferably, before the addition of acrylonitrile, an equimolar amount of water is added.
[0023] The second stage of the synthesis is carried out at a temperature range of 0 to 120° C., preferably 10 to 70° C.
[0024] If the intermediate of formula III is optionally isolated, it can be cyanoethylized to form 1,3,6-hexanetricarbonitrile (corresponding to formula I) in a separate second stage with acrylonitrile and with addition of a weak base. 1 to 1.5 equivalents of acrylonitrile based on the molar amount of isolated intermediate corresponding to formula III is added to the reaction.
[0025] Suitable weak bases include potassium carbonate, sodium carbonate, sodium phosphate, sodium hydroxide or potassium hydroxide or systems controlled by phase-transfer catalysts such as quaternary ammonium, phosphonium and other onium compounds or crown ether and cryptands. A quaternary ammonium salt (Aliquat 336) in aqueous sodium hydroxide solution is preferably used as a phase-transfer catalyst.
[0026] Suitable reaction media for the process according to the invention include inert organic solvents such as benzene, toluene or petroleum ether, preferably toluene.
[0027] The process according to the invention can be carried out under an inert atmosphere or in the presence of oxygen and at a pressure of 1 to 50 bar, preferably at atmospheric pressure. The treatment of the dinitrile with bases is advantageously carried out under inert conditions.
[0028] Further working up of the tricarbonitrile produced according to the invention is carried out by standard methods known to the person skilled in the art.
EXAMPLES
[0029] The stated selectivities describe the ratio of product to conversion. In examples 1 to 4 unreacted intermediates can be worked up in a further stage and re-added to the reaction.
Example 1
[0030] One pot synthesis for producing 1,3,6-hexanetricarbonitrile A mixture of 2.16 g (20 mmol) of adiponitrile, 1.8 g (32 mmol) of KOH powder and 200 mg (0.59 mmol) of tetrabutyl ammonium hydrogen sulphate in 50 ml of toluene were heated to 100° C. under argon for a reaction period of 2 hours. After cooling to room temperature (RT) 1.17 g (22 mmol) of acrylonitrile were added to 10 ml of toluene and the mixture stirred at RT for 2 hours. After adding water the organic phase was separated off and dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0031] Trimer yield: 17%
[0032] Selectivity with respect to trimers: 40%
Example 2
[0033] One pot synthesis for producing 1,3,6-hexanetricarbonitrile 5.41 g (50 mmol) of adiponitrile were added to a suspension of 5.6 g (50 mmol) of potassium-tert.-butylate in 50 ml of toluene under argon and the mixture was heated for 1 hour with reflux. After the mixture was cooled to room temperature 4 ml (60 mmol) of acrylonitrile were slowly added. The mixture was subsequently stirred for 1 hour at RT and diluted with water. The phases were separated, the aqueous phase was extracted with ethyl actetate, the combined organic phases were dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0034] Trimer yield: 9.3%
[0035] Selectivity with respect to trimers: 18%
Example 3
[0036] One pot synthesis for producing 1,3,6-hexanetricarbonitrile 5.41 g (50 mmol) of adiponitrile were added at 65° C. to a suspension of 5.6 g (50 mmol) of potassium-tert.-butylate in 50 ml of toluene under argon and the mixture was heated for 1 hour with reflux. After the mixture was cooled to room temperature 0.9 ml (50 mmol) of water were added and then 4 ml (60 mmol) of acrylonitrile were added slowly. The mixture was subsequently stirred for 1 hour at RT and diluted with water. The phases were separated, the aqueous phase was extracted with ethyl acetate, the combined organic phases were dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0037] Trimer yield: 35%
[0038] Selectivity with respect to trimers: 47%
Example 4
[0039] One pot synthesis for producing 1,3,6-hexanetricarbonitrile 5.41 g (50 mmol) of adiponitrile were added at 65° C. to a suspension of 5.6 g (50 mmol) of potassium-tert.-butylate in 50 ml of toluene under argon and the mixture was heated for 1 hour with reflux. After the mixture was cooled to room temperature 0.9 ml (50 mmol) of water were added and then 4 ml (60 mmol) of acrylonitrile dissolved in 20 ml of toluene were slowly added. The mixture was subsequently stirred for 1 hour at RT and diluted with water. The phases were separated, the aqueous phase was extracted with ethyl acetate, the combined organic phases were dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0040] Trimer yield: 43%
[0041] Selectivity with respect to trimers: 69%
Example 5
[0042] Production of 1,3,6-hexanetricarbonitrile by isolating 2-amino-1 -cyclopentene-1 -carbonitrile 216 mg (2 mmol) of adiponitrile and 128 mg (3.2 mmol) of sodium hydroxide micropills were heated for 22 hours to 95° C. in 5 ml of polyethylene glycol dimethyl ether (M 500, Aldrich) as solubilizer. 3 ml of water were added and extracted with toluene. 2-amino-1-cyclopentene-1-carbonitrile yield: 84%
[0043] Analysis by NMR Spectroscopy:
[0044] [0044] 1 H-NMR (400 MHz, d 6 -DMSO):
[0045] δ (ppm): 1.7-1.8 (m, 2H); 2.3-2.4 (m, 4H); 6.4 (s, br, 2H).
[0046] [0046] 13 C-NMR (100 MHz, d 6 -DMSO):
[0047] δ (ppm): 22.0; 31.2; 34.2; 68.3; 120.3; 164.4.
[0048] 583 mg (11 mmol) of acrylonitrile were added at room temperature to a mixture of 1.08 g (10 mmol) of 2-amino-1-cyclopentene-1-carbonitrile, 2 ml of 45% sodium hydroxide solution, 100 mg of Aliquat 336 (Cognis) and 6 ml of toluene and stirred at room temperature for 22 hours. The mixture was diluted with water, the phases were separated, the organic phase was dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0049] Trimer yield: 63.2%
[0050] Selectivity with respect to trimers: 75%
Example 6
[0051] Production of 1,3,6-hexanetricarbonitrile by isolating 2-amino-1 -cyclopentene-1 -carbonitrile 583 mg (11 mmol) of acrylonitrile were added at room temperature to a mixture of 1.08 g (10 mmol) of 2-amino-1-cyclopentene-1-carbonitrile (from Example 5), 2 ml (33.7 mmol) of 45% sodium hydroxide solution, 100 mg of Aliquat 336 and 6 ml of toluene and stirred at 50° C. for 22 hours. The mixture was diluted with water, the phases were separated, the organic phase was dried, the solvent was distilled off and the residue was examined by gas chromatography.
[0052] Trimer yield: 66.9%
[0053] Selectivity with respect to trimers: 79%
Example 7
[0054] Production of 1,3,6-hexanetricarbonitrile by isolating 2-amino-1 -cyclopentene-1 -carbonitrile A mixture of 32 mg (0.3 mmol) of 2-amino-1-cyclopentene-1-carbonitrile (from Example 5), 3 ml (48 mmol) of 45% sodium hydroxide solution, 0.5 mg (0.0015 mmol) of tetrabutylammonium hydrogen sulphate and 16 mg (0.3 mmol) of acrylonitrile in 7 ml of toluene was heated to 50° C. for 2 hours. After cooling, the toluene phase was examined by gas chromatography.
[0055] Trimer yield: 8%
[0056] Selectivity with respect to trimers: 90%
[0057] 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. | The present invention relates to a process for producing tricarbonitriles corresponding to formula I
wherein n is an integer from 2 to 11 by forming an intermediate in the presence of a strong base in a first stage from an aliphatic α-ω-dinitrile corresponding to formula II
wherein n is an integer from 3 to 12, and reacting the intermediate in a second stage to form a trinitrile corresponding to formula I by the addition of acrylonitrile. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Divisional application of U.S. Ser. No. 14/681,375, filed Apr. 8, 2015, which claims priority under 35 U.S.C. §119 of Great Britain Patent Application No. 1406296.2, filed Apr. 8, 2014, the disclosures of which are hereby expressly incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates to a method of estimating imaging device parameters in relation to a captured image, including position and orientation or the imaging device, particularly for use in 3D modelling and Augmented Reality applications.
BACKGROUND OF THE INVENTION
[0003] The first stage in creating 3D models from photographs or other images is to estimate the 3D positions and orientations of the camera or other imaging device used to take the input photographs or other images. Similarly in Augmented Reality (AR) applications, a virtual camera position and orientation is required to overlay 3D graphical elements onto live video. In previous methods such as that used in 3D Software Object Modeller (3DSOM) Pro produced by Creative Dimension Software Ltd a single quite complex and known planar calibration pattern (“mat”) is placed under the object. However for large objects it is not always practical to produce a suitably large calibration mat to place under the object.
[0004] Conventional photogrammetry (e.g., Microsoft® PhotoSynth® software) uses image scene structure to automatically estimate all camera parameters (orientation, position, focal length) from a large set of photographs of a scene—typically outdoors. However there are several drawbacks to this approach—it is computationally complex, requires large number of overlapping photos with suitable “natural” features that can be automatically matched. In practice users may wish to model a large object in a less cluttered environment where there are fewer reliable features and using fewer images.
[0005] In AR and mobile sensing, techniques exist called Simultaneous Localization and Mapping (SLAM) which is a technique used by robots and autonomous vehicles to build up a map within an unknown environment (without a priori knowledge), or to update a map within a known environment (with a priori knowledge from a given map), while at the same time keeping track of their current location. Visual SLAM (VSLAM) uses the same techniques for video images. These techniques do not require a prior target or map but require considerable processing power and may not be reliable enough for real world applications. In particular video tracking approaches can suffer from accumulation of tracking error as the camera is moved around the scene.
[0006] Gilles Simon, Andrew W. Fitzgibbon and Andrew Zisserman published a paper entitled Markerless Tracking using Planar Structures in the Scene (http://www.robots.ox.ac.uk/˜vgg/publications/papers/simon00.pdf), which describes the use of one or more planes for camera tracking. However the approach essentially tracks a single plane at a time with a “hand-off” between tracking one plane and the next. The paper does not address the problem of reliably estimating the relationship between a plurality of planar targets and the targets which are not known a priori (i.e., the positions of features on the target planes is not known in advance) making the process less robust.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention there is provided a method for estimating parameters of an imaging device with respect to an image of a scene said method comprising the steps of:
[0008] a. locating a target coordinate system in a scene;
[0009] b. using an imaging device to capture an image of the scene; and
[0010] c. processing the image using the target coordination system as a reference to estimate the parameters of the imaging device with respect to the image.
[0011] wherein the target coordinate system comprises at least one planer target and wherein the at least one planar target contains a set of identifiable features with known relative positions.
[0012] Preferably the method further comprises augmenting the image of the scene by displaying a rendered 3D model over the image of the scene.
[0013] Preferably the target coordination system comprise at least two planer targets and wherein each of the at least two planar targets individually contain a set of identifiable features with known relative positions within each respective planar target.
[0014] Whilst the at least two planar targets individually contain a set of identifiable features with known relative positions within each respective planar target, the precise relationship between the at least two planar targets in not known.
[0015] Preferably each planer target comprises a pattern of known size and position. The pattern may be for example a series of dots with known relative positions. Preferably the pattern is a series of dots in a 2×3 array, in the alternative the series of dots may be in a 3×4, 4×5, 3×5, or 4×4 array. Preferably at least one of the dots is a contrasting colour to the other dots, preferably the pattern of dots is arranged such that the pattern is not identical after a 180 degree rotation. The pattern or array is preferably one which comprises a series of easily detectable dots or blob features. In the alternative the planer target(s) may comprise for example paintings in an art gallery wherein front-on shots are taken of the paintings from which 2D positions of features in the flat paintings can be determined.
[0016] Preferably the imaging device comprises a camera.
[0017] Preferably the image is a photograph or video still.
[0018] Preferably the parameters of the imaging device to be estimated comprise the position and orientation of the imaging device.
[0019] Preferably a plurality of images are captured.
[0020] Preferably processing the image using the target coordination system as a reference to estimate the parameters of the imaging device in relation to the image comprises the steps of:
[0021] a. identifying the identifiable features of the at least two planer targets belonging to target planes;
[0022] b. determining the relationships between the at least two planar targets to calculate the positions of the identifiable features in a 3D space;
[0023] c. estimating the imaging device parameters using the calculated position of each of the identifiable features in the 3D space and associated 2D co-ordinates of each of the identifiable features determined from the image.
[0024] Preferably step b. includes determining the relationships between a plurality of pairs of planar targets to calculate the positions of the identifiable features in a 3D space and combining the results.
[0025] Preferably the combined results are averaged. Preferably more reliable results are combined and less reliable results are omitted. Preferably the reliability of the results are based on the percentage of images in which each of the planar targets of a pair are visible.
[0026] Preferably processing may be offline, real-time or a combination of the two. For example the processing may be divided between an offline processing of selected images for determining the relative planar target positions and subsequently performing real-time visual tracking using this pre-recorded information to estimate camera parameters for use in AR applications.
[0027] Preferably the estimated parameters of the imaging device in relation to the image are used in the reconstruction of 3D information.
[0028] Preferably the reconstruction of 3D information utilises standard techniques including shape-from-silhouettes.
[0029] Preferably the 3D information may comprise surface geometry, 3D point data or 3D mesh models.
[0030] Preferably 3D graphical elements are superimposed onto the images using the estimated parameters of the imaging device.
[0031] Preferably the method is for use in augmented reality applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
[0033] FIG. 1 illustrates a computer generated image illustrating the method of locating a plurality of planar targets to act as a target coordinate system in a scene to be imaged;
[0034] FIG. 2 illustrates a photograph with a plurality of planar targets in situ to act as a target coordinate system;
[0035] FIG. 3 illustrates the system of capturing data from the plurality of planar targets acting as a target coordinate system;
[0036] FIG. 4 illustrates a 3DSOM Pro visualisation showing recovered cameras from a sequence taken around a chair on an office table; and
[0037] FIGS. 5 to 8 illustrate the steps in the method of inserting a 3D model into an image of a scene.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] FIGS. 1 and 2 illustrate an embodiment of the method of the present invention. A set of planar targets which comprise known calibration targets are placed around the object or scene to be imaged (photographed) to act as the target coordination system. The position of the targets should be fairly random and unknown. In the embodiment illustrated the targets are known patterns (appearance and relative size is known), however in the alternative the targets may comprise for example paintings in an art gallery wherein front-on shots are taken of the paintings from which 2D positions of features in the flat painting can be determined. Specifically in the embodiment illustrated a set of A4 2×3 dot patterns with 2 colours (black and grey) have been used. It is important that the pattern used should allow for the orientation of the pattern to be identified, for example it would not be suitable to use only dots of a single colour in the embodiment illustrated, as there would be two indistinguishable orientations of the pattern for each given view. Thus, only patterns should be used that would not appear to be identical after a 180 degree rotation. The targets are either all placed around the object on the floor or in the alternative attached to walls for example so that the 2D surface of all the targets are in the same plane and so that for all the input images around the object at least 2 targets can be observed by the imaging device, which in the embodiment illustrated is a camera.
[0039] Once the targets have been located, images are the captured of the object or scene using the imaging device. Ideally, a number of images should be captured from different orientations.
[0040] Once the images have been captured the images are then processed and the targets detected. In one alternative existing planer target recognition such as the Vuforia® AR target tracker can be used to identify the positions of the targets in each image. In the alternative if the dot pattern is used as in the embodiment described the target position can be identified using the image processing technique outlined below:
detect dots using image processing “dot detection” algorithms, which are capable of detecting dark compact regions on a light background; identify nearby dots and link them together; detect arrays of dots, i.e., where there are more than 2 dots linked together; keep 2×3 arrays of dots; identify which dots are black and which are grey (can also use other colour combinations such as blue/green, etc.); and create an ID from black/grey dot coding to determine which target each 2×3 array of dots corresponds to (taking account of symmetries).
[0047] Suitable dot detection algorithms use the standard approach have been described by Tony Lindeberg in Feature detection with automatic scale selection, International Journal of Computer Vision, 1998, Volume 30, Pages 79-116.
[0048] Once each target has been identified and its position in the image located it is then possible to determine the image position and 3D position in a 3D space for each dot on the target. In the embodiment illustrates the target dot coordinates are defined such that the dots lie on the X-Y plane and the centre of the target is (0,0,0). The position and orientation of the imaging device (camera) in the 3D space are then estimated using standard “3D to 2D” camera solving such as the OpenCV command “solvePnPRansac”. (Open CV is the Open Source Computer Vision project available at opencv.org).
Estimating the 3D Position and Orientations of the Targets
[0049] For each image we now have:
a set of identified targets an estimate of the camera position and orientation for each target in 3D space.
[0052] The position and orientation of all the targets in a “global” 3D space are now estimated. This is achieved by considering the relative position and orientation of pairs of targets. For any pair of targets A,B visible in a single image it is possible to estimate the relative translation and orientation of A relative to B using the camera estimates from targets A and B as illustrated in FIG. 3 .
[0053] The target “connections” (relative position and orientation estimates) between pairs of targets are then averaged where we have more than one estimate (from multiple images in which both targets visible). The number of averaged estimates (ignoring outliers) are stored as a connection weight.
[0054] Starting from an initial “seed” target (the target visible in the most images), it is then possible to position and orientate “connected” targets to propagate the position of new targets with respect to the “seed” target in the global 3D space. To do this the most reliable (largest weight) connection between a new target and one that has been already processed (known orientation, position) is determined. The new target orientation and position is obtained by combining the known relative position and orientation for the connection with the known target position and orientation. This process is repeated until no more targets can be added.
Solving Camera Parameters
[0055] We now have an estimate of all the target positions and orientations which means each dot on each target has an estimated 3D position in the global 3D space. In addition for each image we have a set of 2D image coordinates for the known target dot (or other pattern) locations. Using standard “RANSAC” or other camera solving techniques the camera parameters (orientation and position) for each image are then estimated.
Global Optimisation
[0056] Once we have an initial estimate for camera and target positions and orientations, these parameters are optimised using standard “bundle adjustment” techniques so as to minimise the sum of square image projection errors. Given a set of images depicting a number of 3D points from different viewpoints, bundle adjustment can be defined as the problem of simultaneously refining the 3D coordinates describing the scene geometry as well as the parameters of the relative motion and the optical characteristics of the camera(s) employed to acquire the images, according to an optimality criterion involving the corresponding image projections of all points. Bundle adjustment is almost always used as the last step of every feature-based 3D reconstruction algorithm. It amounts to an optimization problem on the 3D structure and viewing parameters (i.e., camera pose and possibly intrinsic calibration and radial distortion), to obtain a reconstruction which is optimal under certain assumptions regarding the noise pertaining to the observed image features.
[0057] FIG. 4 illustrates a prototype visualisation showing recovered cameras from a sequence taken around a chair on an office table. One set of camera parameters failed to be recovered in the visualisation illustrated as there was no target completely visible in that image.
Applications and Scope of Invention
[0058] Camera estimation can be used as a first step in 3D model construction, e.g., by separating the shape of an object in each solved photo, we can use “shape from silhouettes” techniques to estimate a 3D mesh. The construction of a three-dimensional object model from a set of images taken from different viewpoints is an important problem in computer vision. One of the simplest ways to do this is to use the silhouettes of the object (the binary classification of is to use the silhouettes of the object (the binary classification of for the object. To efficiently represent this volume, an octree is used, which represents the object as a tree of recursively subdivided cubes. A suitable technique has been described in RICHARD SZELISKI, Rapid Octree Construction from Image Sequences, CVGIP; IMAGE UNDERSTANDING, Vol. 58, No, I, July, pp. 23-32, 1993 which describes an algorithm for computing the octree bounding volume from multiple silhouettes and applying it to an object rotating on a turntable in front of a stationary camera.
[0059] Due to the potential simplicity of the target detection and solving it is also possible to use this approach in a real-time augmented reality application. The targets could be placed around a room (home, office, showroom etc.) and used to calibrate the space by processing a sequence of images (video or stills) taken around the room. Once calibrated, virtual reality 3D models can be overlaid over live video as long as at least one of the targets is visible in the video—this vastly extends the potential for conventional target-based AR where a single target needs to be visible at all times.
Extensions for AR
[0060] Potentially the targets do not need to be known in advance. The user could take 2D images of any interesting planar objects in the scene, such as paintings in an art gallery, and these could be used as targets. The scale of the targets would have to be obtained in another way, e.g., by using a single distance estimate obtained by a range sensor or manually entered or estimated in another manner such as the user specifying the length of one side of the target.
Example Use of Simple Dot Pattern for Image Augmentation
Problem
[0061] How to insert a furniture or similar 3D model into a photo (or video) of a room wherein the 3D model needs to appear to scale and be positioned automatically.
Solution:
[0062] The user places a planar target in the scene to be imaged as illustrated in FIG. 5 . The target is A4 size in the embodiment illustrated and needs to be able to be reliably detected even when it is quite small in the image. Hence a simple target consisting of an array of 2 rows of 3 large dots in a pattern is used. The dots may all be of the same colour, for example black, or may be of different colours, for example a mixture of black and grey dots. The advantage of using simple grid over more complex patterns is that more complex patterns are not as reliable when the pattern takes up a small image area. When augmenting images it is important that the pattern only takes up a small area which is usually the case when augmenting a large object in a room.
[0063] The target is placed on the floor—the 3D model will be positioned in the same plane as the target and with the back of the object aligned to the back edge of the target which has been placed up against the room wall in the example scene. The 3D model will also be centred along the length of the target.
[0064] The size of the target is known and may be much smaller than the size of the 3D model which may be for example an item of furniture.
[0065] The input image illustrated in FIG. 5 has been taken using the camera on an iPad®—note that the quality of the image is low as it was taken hand-held.
[0066] The input image was then processed by completing the following steps as exemplified in FIGS. 6 and 7 :
analysing the image with a “dot detector” which is capable of detecting dark compact regions on light background; for each detected dot detect up to 4 closest neighbours of similar size within search window based on dot size detected; locate closest neighbour dot to define vertical or horizontal direction; select up to 3 additional neighbour dots in horizontal-vertical directions; chain together linked dots into arrays; and identify the 2×3 array.
[0073] The 3D object is then overlaid onto the image with appropriate shadows using the estimated target position. In the example the target has 6 known points (dot centres) allowing the world to image 3D camera transformation to be determined (obtain the focal length data from JPEG tags if available). The 3D object can be placed in the same world coordinate frame positioned relative to the target and accurately scaled as seen in FIG. 8 .
[0074] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicant's invention. | A method is provided for estimating parameters of an imaging device with respect to an image of a scene said method comprising the steps of locating a target coordinate system in a scene, using an imaging device to capture an image of the scene, and processing the image using the target coordination system as a reference to estimate the parameters of the imaging device with respect to the image, wherein the target coordinate system comprises at least one planer target and wherein the at least one planar target contains a set of identifiable features with known relative positions. | 6 |
This application is a continuation-in-part of co-pending application Ser. No. 08/241,288, filed May 11, 1994.
FIELD OF THE INVENTION
The present invention relates to sectional, hinged doors and, more particularly, to overhead doors comprised of a plurality of hinged door panel sections which fold with respect to each other during opening and closing operations of the door.
BACKGROUND OF THE INVENTION
Typical overhead doors are constructed from a plurality of door panels which are hinged together and supported from a track system with rollers attached to opposite ends of the door panels. The rollers generally allow the door to be moved from a vertically oriented closed position to a substantially horizontal open position. Particularly with regard to residential applications, these doors are generally either eight or sixteen feet wide and are typically comprised of horizontally oriented integrally formed panels which are likewise about eight or sixteen feet long. For example, a single car residential garage may have an eight foot wide door while a two car residential garage may have a single sixteen foot wide door or two eight foot wide doors.
One of the main problems with conventional overhead doors concerns their bulk and inability to be easily and cost efficiently transported to the end user. This is especially true when considering the potential retail market for overhead doors which would include, for example, the market serving small builders, remodelers and homeowners or "do-it-yourselfers". At present, the retail market cannot easily serve the needs of such customers due to the problems inherent in the delivery of the eight or sixteen foot wide overhead door. Similarly, "do-it-yourselfers" often avoid the task of installing or replacing overhead doors themselves because of the bulk of the lengthy door panels as well as the unavailability of overhead doors in retail outlets.
Attempts have been made to construct overhead door panels with a plurality of component parts, including smaller door panel sections which may be assembled into a single, longer door panel. U.S Pat. No. 1,983,098 to Pixley; U.S. Pat. No. 2,951,533 to Lucas et al.; and, U.S. Pat. No. 5,060,711 to Fimbell disclose various overhead doors having a panel or panels comprising multiple subsections.
The panels disclosed in the above patents, however, have disadvantages associated with their complexity, bulkiness and/or lack of strength. For example, the single sectioned panel disclosed in the Pixley patent uses complicated vertically oriented clamp members which connect two adjacent panel sections. Such clamp members are not aesthetically pleasing to the typical homeowner and would not provide the door with adequate strength or wind resistance, especially if used to construct an entire door.
The doors disclosed in the Lucas et al. and Fimbell patents each comprise panels formed with multiple constituent pieces, however, each of these doors require upper and lower horizontal frame or support members and a plurality of vertical support mullions or struts for connecting panel subsections together. In addition to being complicated structures as a result of all of the supporting frame members, the upper and lower horizontal frame members disclosed in each of these patents are required to be approximately as long as the door is wide. Therefore, for example, in a residential application the horizontal frame members would have to be either eight or sixteen feet long. As a result, just as with doors comprised of one-piece integral door panels, these doors would be difficult to stock and difficult for the average retail consumer to both transport and assemble.
There is a need, therefore, for an overhead door which may be more easily transported and stocked, yet which is aesthetically pleasing and sufficiently strong and wind resistant for a large variety of applications.
SUMMARY OF THE INVENTION
To solve problems which have become apparent in the art, including those problems mentioned above, the present invention provides an multiple-piece, door panel which may be used in a hinged, sectional door. The door panel is rigid and wind resistant but may also be easily stored and transported in broken down form. More specifically, each multiple-piece door panel provides one hinged section of a sectional door and comprises a plurality of rigidly connected subpanels disposed in end to end relationship. Each subpanel thus forms a portion of the overall length of the door panel. When the sectional door is an overhead door, the length of the door panel essentially defines the overall width of the door. Also in accordance with the basic principles of this invention, a plurality of connecting bars are provided to rigidly secure adjacent subpanels together to form the longer door panel. Importantly, all of the connecting bars extend lengthwise between the subpanels but have a length substantially less than the overall length of the door panel. Preferably, the length of each connecting bar is approximately as long as each subpanel such that full length support of each subpanel is achieved while still maintaining the above-mentioned advantage of ready storage, transportation and assembly of the component parts.
In disassembled form, all component parts of either one door panel or multiple door panels may be stored and transported in relatively small cartons or packages which are sufficiently manageable by retail consumers. Such packages may be between two and six feet long and each package may, for example, comprise a kit for assembling one door panel. Multiple subpanels may then be rigidly secured to one another to form a fully unitary door panel and, more particularly, a strong sectional or overhead door comprised of a plurality of such unitary door panels.
In the preferred embodiment, each subpanel includes a base subpanel member having a plurality of connecting bar channels. The channels of adjacent, subpanels disposed end- to-end allow a single connecting bar to be secured to each subpanel and extend therebetween to provide a rigid connection at the junction between the two subpanels. At least one and preferably two channels are provided for each subpanel and two connecting bars are used to connect two subpanels. The channels are preferably tubular inner portions of the subpanels which line up with one another when two subpanels are placed together in end-to-end fashion. One connecting bar extends within each tubular inner portion of each of the adjacent subpanels with a sliding frictional fit a distance equal to at least about half the length of the subpanel. It will therefore be appreciated that the subpanels and connecting bars each include connector portions which allow attachment therebetween. In addition, alignment members are provided for aligning two subpanels end-to-end. These preferably comprise junction caps each being formed with multiple protrusions for fitting within mating recesses of adjacent subpanels.
Preferably, each connecting bar in a particular door panel is secured to at least one adjacent connecting bar. Most preferably, the connecting bars are formed with a length slightly longer than the subpanels and are also sized with respect to one another such that two connecting bars telescopically connect with one another proximate a midpoint along the length of a subpanel. This results in not only a strong connection point at the junction of two connected subpanels, but significant bending strength along the entire length of each subpanel, Because of this latter property of the preferred embodiment of the invention, the base subpanels themselves need not be designed with significant strength properties. Instead, the telescopically attached connecting bars provide the necessary strength and wind resistance properties to each door panel, especially when used in an overhead garage door.
In addition to the subpanel base members and connecting bars, each subpanel may also include various non-load bearing components for aesthetic refinement of the basic structure. In this regard, decorative front panels or "facades" and/or moldings may be provided so that each subpanel includes a surface design which combines with the other subpanels to form an overall door surface which has pleasing aesthetic qualities and which does not substantially reveal that each door panel is constructed of a plurality of individual, connected subpanels. This is especially true in residential garage door applications in which it would not be desirable to have visible seams between adjacent subpanels. As one alternative to the front panel and various moldings specifically disclosed herein for the purpose of providing a decorative or aesthetically pleasing front surface of each panel, it will be appreciated that snap-on front facades of the type disclosed in co-pending and commonly assigned patent application Ser. No. 08/241,288 may be used. The disclosure contained in application Ser. No. 08/241,288 is hereby fully and expressly incorporated by reference herein.
Finally, the present invention further contemplates methods of making a sectional door panel, such as an overhead door panel and a sectional door, such as an overhead door, utilizing the advantageous structure described above. Generally, a method of making a sectional door panel according to the principles of the invention includes the steps of provided subpanels each having a length substantially less than the overall length of the door panel; providing a plurality of connecting bars each also having a length substantially less than the overall length of the door panel; and, rigidly securing multiple subpanels together using at least one connector bar affixed between each adjacent subpanel placed in end-to-end relationship with another subpanel such that multiple connecting bars extend generally lengthwise with the subpanels.
A method of making a sectional door in accordance with the principles of the present invention involves repeating the steps described immediately above to thereby provide a plurality of sectional door panels, each being constructed of multiple subpanels, and then hingedly connecting adjacent door panels together to form a sectional door, such as an overhead door.
From the foregoing, it will be appreciated that the invention provides a strong, wind resistant sectional or overhead door which may be assembly from components which are easily stored or stocked and then transported to the job site in relatively small, manageable cartons or packages. Further advantages and features of the invention will become more apparent upon review of the following detailed description of one preferred embodiment, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective of an overhead garage door incorporating subpanels of the present invention in fully assembled and aesthetically refined form;
FIG. 2 is a schematic perspective of the basic components, used to construct the subpanels of the present invention as well as to connect the subpanels to form the door of FIG. 1;
FIG. 3 is fragmented perspective view showing the connection of one subpanel to another;
FIG. 4 is a cross section of a hinge joint for adjacent subpanels of different door panels for an assembled overhead sectional door; and,
FIG. 5 is a perspective view of a kit including a plurality of door components of the invention contained in a carton or package.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an overhead sectional door 10, such as residential garage door, which is generally constructed from four door panels 12a, 12b, 12c, 12d which are hingedly secured together in a manner to be discussed below. In the illustrated embodiment, door 10 comprises a "double length" garage door which is typically used in a residential application for a two car garage. Thus, each door panel 12a, 12b, 12c, 12d is approximately 16 feet long and extends the entire width of door 10. Each door panel 12a, 12b, 12c, 12d is comprised of four respective subpanels 14a, 14b, 14c, 14d. As shown in FIG. 1, with door 10 in a closed position, the four door panels 12a, 12b, 12c, and 12d will be disposed vertically to close door opening 16 of a building structure or garage 18. Although only one set of rollers 21 and one track 22 appear in FIG. 1, each of the door panels 12a, 12b, 12c, 12d have rollers on both ends thereof which mount door 10 to a track allowing door 10 to be moved between the closed, vertical position shown in FIG. 1 and an open, horizontal position (not shown) as is conventional. Each door panel 12a, 12b, 12c, 12d is attached to an adjacent door panel along a hinge line 24 to allow movement of door 10 between these open and closed positions.
The hinges which are used to connect adjacent door panels may be of any conventional type, however, preferred flexible hinges are described fully in Leist, U.S. Pat. Nos. 4,995,441; 5,054,536; and 5,129,441, which are assigned to the assignee of the present invention and the disclosures are which incorporated herein by reference. A preferred flexible hinge 26 is shown in FIG. 4 and is configured to be securely mounted within respective notches or recesses 27 of relative upper and lower adjacent door panels 12a, 12b, of which only one subpanel 14a, 14b of each is shown in FIG. 4. It is to be understood that identical joints and hinges 27 are contained between adjacent door panels 12b, 12c and 12c, 12d at hinge lines 24 shown in FIG. 1.
It will be appreciated that each of the subpanels 14a, 14b, 14c, 14d are approximately four feet in length such that the aggregate of four subpanels equals the length of, for example, a standard 16 foot sectional door panel. Using the same principles to be described herein, a single eight foot wide door may be constructed from a plurality of eight foot long door panels each comprising two subpanels which are each four feet long or, for example, four subpanels which are each two feet long. Other numbers and lengths of subpanels may be used as is suitable for the application needs. It is contemplated that a convenient range of lengths for the subpanels will be between about two and six feet. This range retains both the practicality and manageability of the subpanels.
Turning now to FIG. 2, the basic components used in the construction of subpanels 12a, 12b, 12c, 12d is shown in connection with subpanel 14a. It will be appreciated that the remaining subpanels 14b, 14c, 14d are constructed in essentially the same manner and therefore, the description of subpanel 14a should be understood as also describing the construction of each of the remaining subpanels 14b, 14c, 14d. Subpanel 14a includes a base subpanel member 30 which may be rigidly connected to another base subpanel member 30 by two connecting bars 32, only one of which is shown in FIG. 2, which are securely received in respective spaces or tubular inner portions 34, 36 of base subpanel member 30 preferably with a frictional fit as will be described. Each connecting bar 32 is comprised of a portion 38 having a reduced cross sectional area and a portion 40 having a relatively larger cross sectional area. As best shown in FIG. 3, connecting bars 32 are preferably of tubular shape and rectangular cross sectional configuration such that the reduced portion 38 of one connecting bar 32 may be slidably and telescopically inserted into the larger tubular portion 40 of another connecting bar 32 to make the connection between two subpanels 14a placed end-to-end.
Referring again to FIG. 2, other general components which are used to either secure two subpanels 14a together or to secure and mount one end or another of a subpanel 14a to track 22 (FIG. 1) include respective right and left end caps 42, 44, and junction cap 46. Right and left end caps 42, 44 each include respective rollers 20, 21. It will be appreciated that when subpanel 14a is used as an end subpanel of door panel 12a on the left side of door 10 as viewed in FIG. 1, end cap 44 will be connected to the left end of subpanel 14a to supply rollers 21 for mounting the left side of door 10 to track 22. Likewise, when subpanel 14a is used as an end subpanel of door panel 12a on the righthand side of door 10, end cap 42 will be used to similarly supply rollers 20 for mounting the righthand side of door 10 to a track (not shown). In this regard, end caps 42, 44 connect and function in the same manner as the caps disclosed in related application Ser. No. 08/241,288. In a manner to be detailed below, junction caps 46 are used between adjacent subpanels 14a to provide a connecting and alignment function at the junction of two subpanels 14a placed end-to-end. To align end caps 42, 44 and junction cap 46 with base subpanel member 30 as well as to make connections therebetween, rectangular protrusions 56 extend from one side of each of the end caps 42, 44 as well as from both sides of junction cap 46. Protrusions 56 of each cap 42, 44 and each junction cap 46 slidably but securely fit within rectangular recesses or channels 58 at the ends of base subpanel member 30.
Components are also preferably provided for creating an aesthetically pleasing look for each of the subpanels. In this regard, the snap-on facades which are detailed and claimed in co-pending application Ser. No. 08/241,288 may be used for creating this pleasing aesthetic appearance. Alternatively, as shown in FIGS. 1 and 2, simpler structure such as front decorative panel 60, molding strips 62 and molding 64 may be used to create an aesthetically pleasing front surface for door 10. Decorative panel 60 and moldings 62 and 64 may each be adhesively secured to base subpanel member 30 in the respective locations shown in FIG. 1 to create a uniform front decorative surface for door 10. Base subpanel member 30, caps 42, 44, 46 and decorative components 60, 62, 64 may all be formed from plastic such as ABS, polycarbonate or polyvinyl chloride, and appropriate, conventional adhesives may be used for securing these components together.
Each base subpanel member is also provided with an upper male joint member 66 and a lower female joint member 68. Junction cap 46 is provided with a corresponding male end 70 and female end 72. End caps 42, 44 also each include respective male and female ends 74, 76, and 78, 80. It will be appreciated that when end caps 42, 44 and junction cap 46 are secured at the appropriate ends of each subpanel 14a, 14b, 14c, 14d, the male and female ends thereof form part of the corresponding male joint members 66 or female joint member 68. Junction cap 46 further includes upper and lower rectangular apertures 82, 84 for receiving connecting bar 32 therethrough when two subpanels 14a are connected in end-to-end relationship. End caps 42 and 44 each include respective upper and lower notches 86, 88 and 90, 92 for receiving flexible hinge member 26. Junction cap 46 likewise includes upper and lower notches on 94, 96 for the same purpose. As the construction and operation of the joint structure and hinge structure does not form any part of the present invention, the above incorporated Leist patents are relied upon to provide such details. It will be appreciated that other conventional joint designs may be used in place of this joint structure as well.
The rigid connection between two subpanels 14a placed in end-to-end relationship will be understood from a review of FIG. 3. In this regard, FIG. 3 illustrates two subpanels 14a placed end-to-end with a junction cap 46 disposed therebetween. Rectangular protrusions 56 of junction cap 46 are inserted into mating rectangular channels for recesses 58 at opposed ends of each base subpanel member 30. One connecting bar extends through upper rectangular aperture 82 and junction cap 46 as well as into respective upper receiving spaces or rectangular tubular portions 34 of each base subpanel member 30 and a second connecting bar extends through lower rectangular aperture 84 in junction cap 46 and into the respective lower receiving spaces or rectangular tubular portions 36 of each base subpanel member 30. Connecting bars 32 are preferably sized such that the larger dimensioned portion 40 is received by tubular portion 34 or 36 with a sliding, but snug frictional fit. If desired or necessary, further connecting plates or their similar structure may be fastened across the joint between two subpanels 14a to ensure that the subpanels 14a do not pull apart at the joint. Such additional connecting structure would not supply significant structural or bending strength, as this is supplied by connecting bars 32.
Each connecting bar 32 is preferably somewhat longer than the length of each subpanel 14a such that the reduced portion 38 thereof may be received within the larger tubular portion 40 of the next connecting bar proximate a mid portion of each subpanel 14a. For example, the larger tubular portion 40 of each connecting bar may be approximately 4 feet long, thus corresponding to the length of each subpanel 14a, 14b, 14c, 14d while reduced portion 38 may be approximately 8 inches long. When two base subpanel members 30, two connecting bars 32 and a junction cap 46 are generally connected and oriented as shown in FIG. 3, rigid connection between adjacent subpanel members 30 is made simply by pushing the two base subpanel members 30 together such that oppositely extending rectangular protrusions 56 of junction cap 46 register within the associated rectangular channels or recesses 58 of each base subpanel member 30.
A review of FIG. 1 will reveal that a 16 foot wide door 10 having four 16 foot long door panels 12a, 12b, 12c, 12d each comprised of four 4 foot long subpanels 14a, 14b, 14c, 14d will require a minimum of 24 connecting bars 32. That is, upper and lower connecting bars 32 extend across each joint between adjacent, end-to-end subpanels 14a, 14b, 14c, 14d. These joints are defined at moldings 64 in the door 10 illustrated in FIG. 1. If necessary or desired, further support bars may be inserted into channels 34 and 36 at opposite ends of each door panel 12a, 12b, 12c, 12d and may telescopically or otherwise connect with connecting bars 32. Although this would not be necessary for connecting subpanels together, it may be desirable in order to provide sufficient bending strength along the fully length of the subpanels 14a, 14b, 14c, 14d located along opposite ends of door 10.
FIG. 5 illustrates the present invention in "kit" form. That is, the components of a sectional door including, but not limited to, subpanels 30, connecting bars 32, end caps 42, 44, junction caps 46, facades 60 and moldings 64 may be conveniently stored and transported in a package, such as carton 100. Such cartons 100 may be conveniently sized to fit within an average sized automobile such that a retail consumer may transport multiple kits 100 home to construct a door 10 (FIG. 1). Each carton might, for example, hold the component parts to one door panel 12a (FIG. 1).
By virtue of the foregoing, the present invention therefore provides a sectional door comprised of a plurality of interconnected sections which are rigidly secured together by a minimal number of parts, each being dimensioned to allow easy storage and transportation of the door in its unassembled state but which may be readily assembled into a larger, rigid and aesthetically pleasing sectional door structure.
While the present invention has been illustrated by a detailed description of one preferred embodiment, changes may be made to these details without departing from the concepts of the invention. For example, while the means for attaching the connecting bars to one another has been described as a telescopic connection, it will be understood that other conventional types of connections made with fasteners may be employed instead. Moreover, such connections may not be necessary in many applications, but rather a connection between only the connecting bars and the subpanels may be employed. It is generally preferable that there be some overlap between the ends of adjacent connecting bars such that weak points along the length of the door panel are not present.
As will be appreciated it is not Applicants' intention to be bound by the details of the above detailed description. Rather, the invention in its broadest respects is not limited to these specific details, representative apparatus or illustrative examples shown and described. Accordingly, departures from these details may be made without departing from the spirit or scope of Applicant's general inventive concept. | A sectional door, which may be an overhead door such as a residential garage door, including hingedly connected door panels each being formed from a plurality of subpanels. The subpanels forming each door panel are disposed end-to-end to form the entire length of the door panel. Rigid connection between adjacent subpanels of the same door panel is made by at least one and preferably two connecting bars extending within channels of adjacent subpanels in a lengthwise direction. The connecting bars are each formed of a length substantially less than the overall length of the door panel but slightly longer than the length of an individual subpanel. All components of the door may be stored and transported in relatively small packages or cartons, yet may be assembled into a structurally rigid, wind resistant sectional door. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a fuel cell for a fuel cell stack and, more particularly, to a fuel cell for a fuel cell stack, where the fuel cell includes nested flow channels in an active region of the fuel cell and non-nested flow channels in inactive feed regions of the fuel cell, and where the diffusion media layers in the cells are removed in the inactive feed regions to provide more space for the non-nested channels.
[0003] 2. Discussion of the Related Art
[0004] Hydrogen is an attractive fuel because it is clean and can be used to efficiently produce electricity in a fuel cell. The automotive industry expends significant resources in the development of hydrogen fuel cells as a source of power for vehicles. Such vehicles would be more efficient and generate fewer emissions than today's vehicles employing internal combustion engines.
[0005] A hydrogen fuel cell is an electrochemical device that includes an anode and a cathode with an electrolyte therebetween. The anode receives hydrogen gas and the cathode receives oxygen or air. The hydrogen gas is dissociated in the anode to generate free protons and electrons. The protons pass through the electrolyte to the cathode. The protons react with the oxygen and the electrons in the cathode to generate water. The electrons from the anode cannot pass through the electrolyte, and thus are directed through a load to perform work before being sent to the cathode. The work acts to operate the vehicle.
[0006] Proton exchange membrane fuel cells (PEMFC) are a popular fuel cell for vehicles. The PEMFC generally includes a solid-polymer-electrolyte proton-conducting membrane, such as a perfluorosulfonic acid membrane. The anode and cathode typically include finely divided catalytic particles, usually platinum (Pt), supported on carbon particles and mixed with an ionomer. The catalytic mixture is deposited on opposing sides of the membrane. The combination of the anode catalytic mixture, the cathode catalytic mixture and the membrane define a membrane electrode assembly (MEA). MEAs are relatively expensive to manufacture and require certain conditions for effective operation. These conditions include proper water management and humidification, and control of catalyst poisoning constituents, such as carbon monoxide (CO).
[0007] Several fuel cells are typically combined in a fuel cell stack to generate the desired power. The fuel cell stack receives a cathode input gas, typically a flow of air forced through the stack by a compressor. Not all of the oxygen is consumed by the stack and some of the air is output as a cathode exhaust gas that may include water as a stack by-product. The fuel cell stack also receives an anode hydrogen input gas that flows into the anode side of the stack.
[0008] The fuel cell stack includes a series of flow field plates or bipolar plates positioned between the several MEAs in the stack. The bipolar plates include an anode side and a cathode side for adjacent fuel cells in the stack. Anode gas flow channels are provided in the anode side of the bipolar plates that allow the anode gas to flow to the anode side of each MEA. Cathode gas flow channels are provided in the cathode side of the bipolar plates that allow the cathode gas to flow to the cathode side of each MEA. The bipolar plates are made of a conductive material, such as stainless steel, so that they conduct the electricity generated by the fuel cells from one cell to the next cell as well as out of the stack.
[0009] It has previously been proposed by the inventors in U.S. patent application Ser. No. 10/661,195, titled Nested Stamped Plates for a Compact Fuel Cell, filed Sep. 12, 2003, that the thickness or repeat distance of a fuel cell stack can be reduced by nesting the flow channels in the active region of the fuel cells. FIG. 1 is a cross-sectional view of a portion of a fuel cell stack 10 showing this proposed design. The fuel cell stack 10 includes two MEAs 12 and 14 for adjacent fuel cells in the stack 10 . Each MEA 12 and 14 includes a membrane of the type referred to above and an anode side catalyst layer and a cathode side catalyst later. An anode side gas diffusion media layer 16 is positioned adjacent to the MEA 12 and a cathode side gas diffusion media layer 18 is positioned adjacent to the MEA 14 . The diffusion media layers 16 and 18 are porous layers that provide for input gas transport to and water transport from the MEAs 12 and 14 . Various techniques are known in the art for depositing the catalyst layers on the membranes in the MEAs 12 and 14 or on the diffusion media layers 16 and 18 .
[0010] A bipolar plate assembly 20 is positioned between the diffusion media layers 16 and 18 . The bipolar plate assembly 20 includes two stamped metal bipolar plates 22 and 24 that are assembled together in the nested configuration as shown. The nested plates 22 and 24 define parallel anode gas flow channels 28 and parallel cathode gas flow channels 30 , where the anode flow channels 28 provide a hydrogen flow to the anode side of the MEA 12 and the cathode flow channels 30 provide airflow to the cathode side of the MEA 14 . Additionally, the plates 22 and 24 define coolant flow channels 32 through which a cooling fluid flows to cool the fuel cell stack 10 , as is well understood in the art. In this design, the size of the coolant flow channels 32 is reduced from the size of the cooling channels provided in the non-nested stamped plates of the prior art, which provides the reduction in the repeat distance of the fuel cell stack 10 . Reducing the size of the coolant flow channels 32 over the known cooling channels does not significantly affect the cooling capability of the cooling channels because the larger channels were more than adequate to provide the necessary cooling. The reduction in coolant volume also reduces the thermal mass that must be heated during system start-up.
[0011] The anode flow channels 28 are in fluid communication with an anode flow channel header at each end of the fuel cell stack 10 , where one header receives the anode gas flow to distribute it to the anode gas flow channels 28 and the other anode header receives the anode exhaust gas from the anode flow channels. Likewise, the cathode gas flow channels 30 are in fluid communication with a cathode flow channel header at each end of the stack 10 , and the cooling flow channels 32 are in fluid communication with a coolant flow channel header at each end of the stack 10 . However, in order to couple the anode flow channels 28 to the anode channel headers, the cathode flow channels 30 to the cathode channel headers and the coolant flow channels 32 to the coolant channel headers, it is necessary to separate and un-nest the plates 22 and 24 in the non-active feed regions of the stack.
[0012] Because the non-nested configuration of the flow channels 28 , 30 and 32 requires more space than the nested configuration of the channels 28 , 30 and 32 , the reduction in thickness of the stack 10 provided by the nested configuration would be eliminated by using the known non-nested configuration in the inactive regions. It is possible to reduce the size of the flow channels 28 , 30 and 32 in the non-nested inactive regions so that the flow channels 28 , 30 and 32 do not use more space than they use in the nested configuration. However, such a reduction in the size of the channels 28 , 30 and 32 would cause a pressure drop across the channels that would adversely affect the flow rate and performance of the stack 10 .
[0013] The present invention proposes a solution to a transition from the nested configuration to the non-nested configuration of the bipolar plates without reducing the size of the channels or increasing the thickness of the stack.
SUMMARY OF THE INVENTION
[0014] In accordance with the teachings of the present invention, a fuel cell in a fuel cell stack is disclosed that provides a transition from nested bipolar plates in the active region of the stack to non-nested bipolar plates in the inactive feed regions of the stack without giving up the reduced stack thickness provided by the nested plates or changing the size of the flow channels. Particularly, the diffusion media layers in the fuel cells of the stack are removed in the inactive feed regions where the bipolar plates are non-nested so that the volume necessary to maintain the size of the flow channels is provided without the need to increase the distance between adjacent MEAs. Additionally, the membrane of the MEAs would not be catalyzed in the inactive regions. A thin shim can be provided between the membranes and the plates in the inactive regions to support the membrane where the diffusion media layer has been removed to prevent the membrane from intruding into the flow channels and blocking the reactive flow.
[0015] Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a partial cross-sectional view of an active region of a fuel cell stack employing nested stamped bipolar plates;
[0017] FIG. 2 is a partial cross-sectional view of an inactive feed region of a fuel cell stack employing non-nested stamped bipolar plates where the gas diffusion media layers have been removed, according to an embodiment of the present invention;
[0018] FIG. 3 is a partial cross-sectional view of an inactive feed region of a fuel cell stack employing non-nested stamped bipolar plates where the gas diffusion media layers have been removed and shims have been added, according to another embodiment of the present invention;
[0019] FIG. 4 is a partial cross-sectional view of the transition between an inactive feed region and an active region of a fuel cell stack, according to the invention;
[0020] FIG. 5 is a top view of a plate in a fuel cell stack, according to an embodiment of the present invention; and
[0021] FIG. 6 is a solid model of a fuel cell stack including an active region having nested stamped bipolar plates and an inactive feed region having non-nested stamped bipolar plates.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0022] The following discussion of the embodiments of the invention directed to a fuel cell design is merely exemplary in nature, and is in no way intended to limit the invention or its applications or uses.
[0023] According to the present invention, a fuel cell design is described that includes nested stamped bipolar plates in an active region of the fuel cell and non-nested stamped bipolar plates in an inactive feed region of the fuel cell. FIG. 2 is a partial cross-sectional view through an inactive feed region of a fuel cell stack 40 . The stack 40 includes adjacent membranes 42 and 44 that are part of two adjacent MEAs in the stack 40 . The fuel cell stack 40 also includes a bipolar plate assembly 46 having two stamped non-nested bipolar plates 48 and 50 . The plates 48 and 50 are stamped so that they define anode flow channels 52 , cathode flow channels 54 and coolant flow channels 56 .
[0024] It is necessary that the plates 48 and 50 be non-nested in the feed regions of the stack 40 so that the input gasses and the cooling fluid can be separated and coupled to appropriate manifold headers. The fuel cell stack 40 would include a transition region, discussed below, between the active region and the inactive regions of the fuel cell stack 40 where the anode flow channels 52 are in fluid communication with the anode flow channels 28 , the cathode flow channels 54 are in fluid communication with the cathode channels 30 and the coolant flow channels 56 are in fluid communication with the coolant flow channels 32 .
[0025] According to the invention, the size of the non-nested channels 52 and 54 are the same, or nearly the same, as the size of the nested channels 28 and 30 , respectively, by eliminating the diffusion media layers 16 and 18 in the inactive feed regions of the fuel cell stack 40 . In the inactive feed regions, the catalyst layers of the MEAs 12 and 14 would also be eliminated leaving sub-gasketed membranes 42 and 44 . Note that the MEAs 12 and 14 would typically include a sub-gasket (not shown) outside of the active region. The sub-gasket prevents direct contact of the ionomer membrane to the plates 48 and 50 or the seals. The sub-gasket would typically a 0.25 um film of Kapton or other suitable plastic. Therefore, the volume that was used by the diffusion media layers 16 and 18 in the active region of the fuel cell stack 40 can be used to accommodate the non-nested bipolar plates 48 and 50 in the inactive regions so that the size of the flow channels can be maintained without increasing the repeat distance of the stack 40 . The diffusion media layers 16 and 18 are generally about 0.2 mm thick, which is enough to provide the necessary space.
[0026] The size of the coolant flow channels 56 does increase to about twice the size from the nested configuration to the non-nested configuration, but the pressure drop provided by the coolant channel transition does not adversely affect the performance of the stack 40 . Further, the inactive feed regions with non-nested plates may increase the plate footprint for the active region, but the overall volume of the stack is reduced because of the decrease in stack height provided by the nested plates.
[0027] Because the membranes 42 and 44 are not supported by the diffusion media layers 16 and 18 in the feed regions of the stack 40 , they may have a tendency to intrude into the flow channels 52 and 54 . As the MEA typically includes sub-gaskets beyond the active region, with sufficient thickness, the sub-gaskets could provide adequate membrane support in the feed regions. FIG. 3 is a cross-sectional view of a fuel cell stack 60 that is similar to the fuel cell stack 40 , where like elements are identified by the same reference numeral. The fuel cell stack 60 includes a thin shim 62 positioned between the membrane 42 and the plate 48 and a thin shim 64 positioned between the membrane 44 and the plate 50 . The shims 62 and 64 prevent the membranes 42 and 44 , respectively, from intruding into the flow channels 52 and 54 , respectively. The shims 62 and 64 can be located in place or can be either bonded to the membranes 42 and 44 , respectively, or to the plates 48 and 50 , respectively. The shims 62 and 64 may also function as a gasket carrier. The shims 62 and 64 can be made of any suitable material, such as metal or plastic, and can have a suitable thickness, such as 0.025 um, to provide the desired support.
[0028] FIG. 4 is a cross-sectional view of a portion of a fuel cell stack 70 showing an example of a transition region 72 between nested bipolar plates 74 and 76 in an active region 78 of the fuel cell stack 70 and non-nested bipolar plates 80 and 82 in an inactive feed region 84 of the fuel cell stack 70 . The fuel cell stack 70 includes membranes 86 and 88 extending across the active region 78 and the inactive region 84 . Gas diffusion media layers 90 and 92 are provided adjacent to the membranes 86 and 88 , respectively, in the active region 78 . Shims 94 and 96 are positioned between the non-nested plates 80 and 82 and the membranes 86 and 88 , respectively, in the inactive region 84 . The relative size of anode and cathode flow channels 98 and 100 in the inactive region 84 and the active region 78 are substantially the same. Flow channel 102 in the active region 78 can represent any of the anode flow channel, the cathode flow channel or the coolant flow channel.
[0029] FIG. 5 is top view of a bipolar plate assembly 110 in a fuel cell stack 112 . The fuel cell stack 112 includes an active region 114 having stamped bipolar plates that are nested, and inactive feed regions 116 and 118 , at opposite ends of the active region 114 , having stamped bipolar plates that are non-nested, consistent with the discussion above. The stamped bipolar plates include the various flow channels discussed above. A cathode inlet header 120 at one end of the fuel cell stack 112 directs the cathode air into the cathode flow channels in the inactive region 116 . The cathode air flows through the cathode flow channels in the inactive feed region 116 , through the cathode flow channels in the active region 114 and through the cathode flow channels in the inactive region 118 . The cathode exhaust gas is collected by a cathode outlet header 122 .
[0030] An anode inlet header 126 at one end of the fuel cell stack 112 directs the hydrogen gas into the anode flow channels in the inactive region 118 . The hydrogen gas flows through the anode flow channels in the inactive feed region 118 , through the anode flow channels in the active region 114 and through the anode flow channels in the inactive region 116 . The anode exhaust gas is collected by an anode outlet header 128 . In this non-limiting embodiment, the anode gas and the cathode gas are counter-flow.
[0031] A coolant inlet header 132 at one end of the fuel cell stack 112 directs the cooling fluid into the coolant flow channels in the inactive region 116 . The cooling fluid flows through the coolant flow channels in the inactive feed region 116 , through the coolant flow channels in the active region 114 and through the coolant flow channels in the inactive region 118 . The cooling fluid is collected by a coolant outlet header 134 .
[0032] FIG. 6 is a solid model perspective view of a fuel cell stack 140 including an active region 142 having the nested bipolar plates and an inactive feed region 144 having the non-nested bipolar plates. A transition region 146 between the region 142 and the region 144 provides the transition of the channels from the nested configuration to the non-nested configuration. The cooling fluid from the coolant header (not shown in FIG. 6 ) is directed into flow channels 148 in the inactive region 144 , the hydrogen gas flow from the anode header (not shown in FIG. 6 ) is directed into flow channels 150 in the inactive region 144 and the cathode gas from the cathode header (not shown in FIG. 6 ) is directed into flow channels 152 in the inactive region 144 . In this embodiment, the anode gas and the cathode gas are co-flow.
[0033] Table 1 below provides a comparison of various parameters discussed above for a nested plate design, a non-nested plate design and a nested plate design including half height channels. This data is from a fuel cell stack including a 360 cm 2 active area, 200 cells, 66 kW output power, 1.5 Acm 2 current density and a low pressure. The nested designs are smaller (higher kW/l) and have an even greater reduction in thermal mass from 27 to 19-20 kJ/K due to the reduced coolant volume. The half height feed region provides a smaller stack than the nested present invention because the feed regions can be active regions. However, the pressure drop due to these very shallow feed channels leads to an unacceptably high pressure drop (85 kPa vs 30 kPa on the cathode side).
TABLE 1 Nested Nested (present Non- (half height feed invention) nested channels) Channel depth (mm) 0.34 0.35 0.34 An ch depth (mm) — 0.31 — Channel depth (mm) 0.37 — 0.37 (no region GDM) repeat distance (mm) 0.97 1.29 0.97 An dP (kPa) 13 13 30 Ca dP (kPa) 30 30 85 Coolant dp (kPa) 57 22 106 Power density (kW/l) 6.0 4.8 6.3 Thermal mass (kJ/K) 20 27 19 (with coolant)
[0034] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A fuel cell in a fuel cell stack that provides a transition from nested bipolar plates in the active region of the stack to non-nested bipolar plates in the inactive regions of the stack without giving up the reduced stack thickness provided by the nested plates or changing the size of the flow channels. Particularly, the diffusion media layers in the fuel cells are removed in the inactive regions where the bipolar plates are non-nested so that the volume necessary to maintain the size of the flow channels is provided without the need to increase the distance between adjacent MEAs. A thin shim can be provided between the membranes and the plates in the inactive regions to support the membrane where the diffusion media layer has been removed to prevent the membrane from intruding into the flow channels and blocking the reactive flow. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to device for controlling a coupling mechanism, and in particular to a motorised device which enables the conventional friction clutch of a motor vehicle which does not incorporate a conventional clutch pedal, to be controlled. A control device in accordance with the invention may also be suitable for operating a variable speed drive, a brake or similar mechanism.
2. Description of the Related Art
A motorised clutch control device of the above-mentioned kind is described, for example, in French Patent Application No. 84.08323 filed on 28th May 1984. A device of this kind mainly comprises an electric motor associated with a reduction gear, a member for activating the coupling mechanism (comprising, for example, a lever in the form of a fork, which is known per se) and a connection mechanism disposed in a housing between the motor and the activating member and comprising, inter alia, a toothed sector connected to the activating member, at least one pinion disposed between the motor shaft and the toothed sector, and a force moderator arrangement comprising a spring connected to a pinion which is in engagement with the toothed sector. The arrangement is such that the spring can assist the electric motor, which is of relatively small power, by moderating the force which the latter must provide along an engaging or disengaging stroke.
In these previous constructions the force moderator spring is a helical spring operating under tension and disposed in the housing.
A problem arises when fitting out a powerful vehicle in which substantial power has to be applied to the clutch, as in this case the force applied to the compensating spring increases to the point at which it eventually results in fatigue in the spring attachment end, which can cause it to break. A stronger spring has to be used, although the space required for mounting a stronger spring of this kind is often limited.
The object of the invention is to minimise this drawback.
SUMMARY OF THE INVENTION
A control device as described above is characterised in that the spring comprises a spring operating under compression.
A spring of this kind is always mounted between a fixed bearing and a mobile stop, which are parallel and perpendicular to the axis of the spring, by always being guided such that it remains rectilinear during operation.
For the purpose of using a compression spring which, while having identical characteristics, has a much smaller volume than a tension spring, the invention proposes a device for controlling a coupling mechanism, such as a clutch, of the kind comprising a motor, a member for activating the coupling mechanism, and a connection mechanism arranged in a housing between the motor and the activating member, and a force moderator arrangement comprising a spring connected to the connection mechanism, in which the spring is mounted under compression between a fixed bearing and a stop which can rotate and describe a translatory movement such as a collar connected to an arm which is articulated at its other end to a pinion of the connection mechanism.
The mobile stop, which is connected to an arm articulated at its other end to a pinion, does not always remain parallel to the fixed bearing during use, and the spring is caused to act in an unusual manner, as it has a substantially toric shape. However tests have shown that, unexpectedly, it operates in an entirely satisfactory manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the control device; and
FIG. 2 is a section along the line II--II in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrated device 11 is designed to control a coupling mechanism (not shown) such as a friction clutch which is activated by a conventional clutch release bearing moved by an activating member 12 which is formed by a fork-shaped lever 20 integral with a shaft 19. This control device, which is able to pivot the lever 20, is motorised. It is formed by a main housing 22, which is relatively flat, and an electric motor 23 fixed to the outside of the said housing. The shaft 24 of the motor 23 penetrates the housing 22 and ends in a threaded portion 25 having two sections 26, 27 with inverse threads. The housing 22 also accommodates a connection mechanism 31 arranged between the motor 23 and the above-mentioned activating member. This connection mechanism comprises a toothed sector 33, which is connected to the shaft 19 and pivots with respect to its axis, and two pinions 34, 35, each of which comprises two toothed wheels disposed coaxially next to one another. In this case the toothed sector 33 is formed in two parts, a main part 33a extending from the shaft 19 to the toothed part, and a secondary reinforcing part 33b which is essential in the form of a strip having the same teeth. The juxtaposition of these parts enables a punched sheet sector with relatively wide teeth to be formed.
Each of the pinions 34, 35 is formed such that one of its toothed wheels engages with the toothed sector 33 and the other toothed wheel engages with one of the threaded sections 26 or 27. The two pinions pivot about parallel axes disposed on either side of the threaded portion 25. This mounting arrangement, which is known per se, has the advantage of absorbing the axial reactions on the threaded portion of the motor shaft. Furthermore, the connection mechanism comprises a wear take-up mechanism 65 combined with the toothed sector 33. This mechanism comprises a flat lever 66, which is mounted in a pivotable manner parallel with the toothed sector, and a ratchet 68. The lever 66 consists of two components 66a and 66b. The component 66a comprises a toothed edge co-operating with teeth of the ratchet 68. The component 66b is fixed to the shaft 19 so as to cause the latter to rotate; it comprises a lug 72 engaged in an elongated hole in the component 66a. This mounting arrangement gives the component 66a a wider range of movement than that of the component 66b. This guarantees a high degree of operating precision. The component 66a is caused to rotate by a spring 77 which is wound around a lug 78 integral with the toothed sector 33. The ratchet 68 can pivot on a trunnion 80 mounted on the toothed sector 33 and is acted upon by a spring 82 such that its toothed portion engages with that of the component 66a.
The ratched is disengaged from the component 66a at the end of the travel of the toothed sector 33 by the said ratched bearing against a stop 84 integral with the housing 22.
This wear take-up mechanism is similar to the one described in French Patent Application No. 84.08324 filed on 28th May 1984.
In order to close the housing 22 by a cover 22a made of a punched single sheet of a low cost price, the pinions 34 and 35 and the toothed sector 33 are held in position, by means of the trunnion 80 of the ratchet 68, by a plate 22b shown by dot-dash lines in FIG. 1. This plate is fixed by screws 22a to the bottom of the housing 22.
The housing 22 also comprises an angle measuring means formed by a potentiometer 90 whose shaft 91 is connected to the pinion 40 by an arm 94. This measuring means enables the exact position of the control device to be known at any moment. This is necessary in order to operate the motor 23.
The device according to the invention also comprises an operating force moderator arrangement 38 which assists the electric motor 23 during the engaging operations, as described in the above-mentioned patent applications.
An operating force moderator arrangement 38 of this kind comprises a helical spring 39 connected to a pinion 40 which is mounted in a rotatable manner about a shaft 41 fixed to the housing.
This pinion is formed with a circular toothed portion on one side engaging with the toothed sector 33 and a radial extension 48 on the other bearing a spindle 47 to which a bent arm 43 is connected in such a way that it can pivot. This arm, which is connected to the spring 39 by its other end, is partly formed by two parallel components which are articulated, as can be seen in the drawings, in the vicinity of the pinion 40 and of the toothed sector 33, without hampering the movements of these.
According to the invention the spring 39 is mounted under compression between a fixed bearing and a collar 50 which is connected to the end of the arm 43 which is not connected to the pinion 40. For this purpose the end of the arm is enlarged to form a joining piece 45. The collar 50 comprises a central opening 51 and, in its face opposite the spring 39, a bore 52 for positioning the joining piece 45.
The external diameter of the face against which the spring 39 is mounted is the same as the internal diameter of the spring, while the external diameter of the collar 50 is the same as the external diameter of the spring. This enables a shoulder 53 to be formed which has the function of positioning and centering the spring against the collar 50.
In this case the fixed bearing is formed by a projection 55 cast with the housing 22. A collar 56 is disposed between the projection 55 and the spring and positions the latter against a shoulder 57 with which it is provided for this purpose.
The arm 43 passes through the collar 56 via an opening 58 of a sufficient size not to hamper the lateral movement which is imparted to the collar when the pinion 40 rotates.
In order to mount the spring, the arm 43 is passed through the collar 50, the spring 39 is disposed on the collar 50 and then the collar 56 on the spring. The arm, which is thus provided with the spring and the collars, is then mounted in the housing 22 by positioning the collar 56 against the projection 55, after which the spring is compressed until the end of the arm 43 is attached to the extension of the pinion 40 by the spindle 47.
During operation of the device the rotating pinion 40 moves the arm 43 into the extreme position shown by dot-dash lines in FIG. 1. As the spring is positioned against the shoulders 53, 57 of the collars, it is correctly held in place during its lateral movements, and the use of this spring, which is mounted under compression, for non-rectilinear movements gives satisfactory results. | Motorized control device, suitable for a motor vehicle clutch, comprises a motor which activates a shaft and a lever by means of a connection mechanism associated with a force moderator arrangement incorporating a spring; according to the invention, this spring is mounted under compression. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to networked computer systems, and more particularly, to a self-contained portable networked computer system having integral storage, power and communications for all components of the networked computer system.
2. Description of the Related Technology
Use of computers, especially personal computers, is becoming more and more pervasive because the computer has become an integral tool of most information workers who work in the fields of accounting, law, engineering, insurance, services, sales and the like. Rapid technological improvements in the field of computers have opened up many new applications heretofore unavailable or too expensive for the use of older technology mainframe computers. These personal computers may be used as stand-alone workstations (high end individual personal computers) or linked together in a network by a “network server” which is also a personal computer which may have additional features specific to its purpose in the network. The network server may be used to store massive amounts of data, and may facilitate interaction of the individual workstations connected to the network for electronic mail (“e-mail”), document databases, video teleconferencing, whiteboarding, integrated enterprise calendar, virtual engineering design, Internet access and the like.
A significant part of the ever increasing popularity of the personal computer, besides its low cost relative to just a few years ago, is its ability to run sophisticated programs and perform many useful and new tasks. The personal computer thus has become an indispensable part of business, government and the economy. The network server ties together the personal computer workstations into a local area network (LAN), and may be used for storing, sharing and/or forwarding critical information for use by a group of people in a collaborative project, during group meetings, making presentations to customers or clients, during depositions or trial, and the like. This information may comprise for example: databases, word processing, spreadsheets, drawings, graphics, e-mail, pictures, transcripts, exhibits, demonstrative evidence, and the like.
A typical computer system, comprising a server and a plurality of workstations interconnected together by a LAN, requires installation of network cables between the computer workstations and server, or through radio frequency or carrier current means. Setup of this type of computer system involves placing individual hardware components where needed, supplying power to each component, and establishing communications between the components of the networked computer system. These components may require special configuration or have differing physical operating requirements in order to function together. Ad hoc installation of various components of the networked computer system requires skilled technicians, special tools, and good preplanning or a ready source for needed items to get the networked computer system operational. Thus, rapid setup for temporary, portable, or emergency networked computer system applications may be difficult or even impossible.
What is needed is a system, method and apparatus for easily and quickly setting up an operational networked computer system without having to custom wire circuits for power and/or communications, and without the problem of not having critical components necessary to make the computer system fully functional.
SUMMARY OF THE INVENTION
The present invention overcomes the above-identified problems as well as other shortcomings and deficiencies of existing technologies by providing a portable networked computer system that is easily transportable, is completely self-contained and may be set-up anywhere without special tools, custom facilities or technical personal. An embodiment of the invention comprises a network server fabricated within the walls of a carrying case also having a compartment(s) for storing portable (clamshell style) workstations and necessary cabling for power and communications to these workstations. The carrying case may be a brief case, a sample case or a suitcase made of metal, fiberglass, plastic, nylon, graphite composites, or any other type of case and material that may be used for storage and transporting of papers, and/or equipment. Handles, wheels, collapsible rods, etc., may be used as an aid in carrying and/or moving the carrying case. The case may be small enough to slide under an airplane seat or be as large as a steamer trunk. The case may be waterproof, bullet proof, airtight, lockable and the like. Compartments for storage may be included on the inside and the outside of the case.
An analog or digital telephone connection, either hardwired telephone lines or wireless cellular, satellite or the like, may be used in conjunction with a built-in modem, router, or switch for connection to the Internet or private line wide area networks (WAN). The workstations may be simple to complex, e.g., from a personal digital assistant (PDA), thin client or network computer (NC) to a fully implemented personal computer (PC), or any combination thereof. It is contemplated and within the scope of the invention that the workstations may also comprise voice recognition and speech output. The network server may be built into the top, bottom and/or side walls of the carrying case. Batteries may also be incorporated into the case as well as a battery charger. The battery charger inside of a wall of the case may also be used to charge the batteries of the clamshell style portable workstations. Insertion of the closed clamshell workstation into the case may also engage power connections for charging a battery in each of the clamshell workstations.
The embodiment of the invention may be easily and quickly transported to any location as needed, set up and be ready to use in a matter of minutes. Another embodiment of the invention utilizes a battery powered server, battery powered workstations, and infrared or radio frequency communications for wireless operation of the networked computer system. This is especially beneficial in emergency and guest environments. Emergency environments may be for example but not limitation: disaster management such as Red Cross, Civil Defense, FEMA and the like; military battlefield command post, police or fire command post, riot control, immigration control; customs inspections of goods entering a country, and road blocks and/or manhunts for escaped prisoners. Guest environments may be for example but not limitation: depositions, court trials, sales presentations, seminars and lectures, conventions, expositions, trade shows, board meetings, temporary office, group meetings in conference rooms at an office or a hotel, financial audits by visiting auditors, store or warehouse inventory audits; group networking on an airplane, bus, train or automobile, and the like.
Another embodiment of the invention may be integrated into public or private transportation such as, for example but not limitation: an airplane, train, subway, boat, bus, automobile, truck, spaceship, balloon, space station, submarine, and the like (hereinafter “transportation vehicle”). More and more information workers use and require a networked computer system to perform their jobs. Companies are utilizing Intranets in the office and Extranets to enable workers to telecommute from home or a remote office, however, the worker may be cutoff from the company's Extranet when commuting between the home and office, or between cities or countries. Valuable time may be wasted, or contact with key decision makers lost when the worker is not connected to the company's Intranet or Extranet. Workers may take portable computers with them to do off line work and to then later connect to the company's network, or through a cellular or satellite telephone link which can be used while the worker is being transported. Problems exist however, when private communications is attempted in public transportation. FAA regulations prohibit the use of uncertified radio frequency generating equipment which may interfere with an airplane's navigational and landing systems, or private communications may not function reliably in a boat or a train.
An embodiment of the invention may be installed in the public or private transportation vehicle, with communications access to the Internet optimized for the route thereof Portable workstations may be provided on a rental or lease basis, and the traveling workers can access their company websites (portal to the company network) through the Internet. Advantages of this embodiment of the invention are: 1) the worker does not have to supply and carry a privately owned portable workstation, and 2) Internet communications is more reliable since the communications connection has been optimally engineered for the route of the transportation vehicle.
The carrying case of the network server may be designed to fit into a storage compartment of the transportation vehicle, or the network server may be built into a compartment of the transportation vehicle specifically designed therefor. The portable workstations are stored and charged in the server case or compartment of the transportation vehicle. It is also contemplated and within the scope of the invention that an embodiment of the invention may be integrated into office or home furniture such as, for example but not limitation: a desk, conference room table, cabinet, credenza and the like. The network server may be built into a pedestal and the like of the furniture and the workstations may be integrated into the work surface of the furniture. Intranet and Internet communications may be provided to the server of the invention for use by the workstations, as more fully described herein.
The embodiments of the invention may also be integrated with other existing networked computer systems such as a fixed installation LAN, a wide area network (WAN), and/or a storage area network (SAN). The embodiments of the invention may be used to supplement an existing networked computer system for additional or temporary employees, as an emergency backup system, or as a temporary networked computer system during a main networked computer system upgrade, repair or replacement.
A feature of the invention is storage of the workstations and cables within the server/case.
Another feature is easy transportation of an entire networked computer system.
Still another feature is rapid deployment of a networked computer system anywhere.
Another feature is independence of the need for external power or special communications wiring.
Another feature is charging workstations while they are stored and protected in the case.
Still another feature is access to the Internet for all workstations operating therewith.
An advantage of the invention is being able to use the networked computer system anywhere without needing power or special communications wiring.
Another advantage is security and control of unauthorized access.
Another advantage is low cost of the networked computer system and ease of setup and use thereof.
Another advantage is computer and Internet access for public commuters.
Other and further embodiments, features and advantages will be apparent from the following description of presently preferred embodiments of the invention, given for the purpose of disclosure and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a wired networked computer system according to an embodiment of the present invention;
FIG. 2 is a schematic block diagram of a wireless networked computer system according to another embodiment of the present invention;
FIG. 3 is a schematic block diagram plan view of the briefcase server illustrated in FIGS. 1 and 2;
FIG. 3A is a schematic block diagram elevational view of the briefcase server illustrated in FIGS. 1 and 2;
FIG. 4 is a schematic block diagram of a computer system according to the embodiments of the invention; and
FIG. 5 is a schematic elevational view of another embodiment of the invention integrated into a piece of furniture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a system, method and apparatus which provides a portable networked computer system that is easily transportable, is completely self-contained and may be set-up anywhere without special tools, custom facilities or technical personal.
For illustrative purposes, preferred embodiments of the present invention are described hereinafter for computer systems utilizing the Intel x86 microprocessor architecture and certain terms and references will be specific to that processor platform. It will be appreciated by those skilled in the art of computer systems that the present invention may be adapted and applied to any computer platform.
Referring now to the drawings, the details of preferred embodiments of the present invention are schematically illustrated. Like elements in the drawings will be represented by like numbers, and similar elements will be represented by like numbers with a different lower case letter suffix.
Referring now to FIG. 1, a schematic block diagram of a wired networked computer system according to an embodiment of the invention is illustrated. The networked computer system is generally indicated by the numeral 100 and comprises a briefcase computer server 102 , a plurality of networked workstations 104 , and interconnection cables 106 . The interconnection cables 106 may be used for communications such as Ethernet, USB, and the like, between the server 102 and the plurality of workstations 104 . The cables 106 may be for example, twisted copper wire pairs, fiber optic cables, coaxial cables, and the like. The cables 106 may also include power cables for supplying power from the server 102 to the workstations 104 . A printer and/or telephone line (not illustrated) may also be connected to the server 102 for use by any of the workstations 104 . The networked computer system 100 represents a completely functional and operation computer system which may be easily and quickly setup anywhere by unskilled personnel. Referring to FIG. 2, a schematic block diagram of a wireless networked computer system according to another embodiment of the invention is illustrated. The wireless networked computer system is generally indicated by the numeral 200 and comprises a briefcase computer server 202 and a plurality of wireless networked workstations 204 . Each of the workstations 204 may be a clamshell style laptop computer having built-in batter power and a wireless modem for communicating with the server 202 . The wireless modem may operate, for example but not limitation, at infrared wavelengths, radio frequencies such as very high frequency (VHF), ultra high frequency (UHF) and microwaves; and the like. Frequency modulation (FM), pulse code modulation (PCM), and the like on fixed frequency channels, or spread spectrum may be used for communications in this embodiment. The wireless medium of communications is represented generally by the numeral 206 . Wireless communication between the server 202 and the workstations 204 allows easier, quicker and more flexible setup that the hardwired embodiment of FIG. 1, however, security and interference issues are more pronounced with the embodiment illustrated in FIG. 2 . Encryption, and error checking and correction of the data between the server 202 and the workstations 204 makes this wireless embodiment quite feasible and cost effective. A printer (not illustrated) may also be connected to the server 202 for use by any of the workstations 204 .
Referring now to FIG. 3, a schematic block diagram plan view of the briefcase servers 102 and 202 of FIGS. 1 and 2, respectively, is illustrated. The briefcase servers 102 and 202 comprise a case 302 having exterior walls 330 and interior walls 332 . Sandwiched between the interior walls 332 and the exterior walls 330 are the components necessary for a full function network server. Within the interior walls 332 are compartments comprising workstation slots 304 , a cable space 306 , and workstation slots 304 . The briefcase servers 102 and 202 may be made of any material(s) typically used for high quality brief cases, luggage, reusable shipping containers and the like. It is contemplated and within the scope of the invention that the size, shape and materials used for construction of the case 302 only be dictated by the intended use of the embodiments of the networked computer systems described herein. Handles, wheels, collapsible rods, etc. (not illustrated) may be used as an aid in carrying and/or moving the carrying case.
The electronic components for the briefcase servers 102 and 202 may comprise a central processing unit and system board 326 , expansion random access memory (RAM) 308 , RAID hard disks 310 a , 310 b and 310 c ; a power supply 312 , batteries 314 (optional depending upon configuration and use), a modem 316 , a printer port 318 , tape back-up 320 , a network interface 322 , and a CD and/or DVD 324 . The aforementioned electronic components make up a state of the art server in a compact and portable package. The modem 316 may comprise a radio frequency modem used in conjunction with a cellular, microwave, VHF, UHF, spread spectrum, satellite, and the like as a wireless telephone which may be used to connect to other WAN or Internet systems.
The workstation slots 304 are adapted for storing the workstations 104 and 204 , and the cable space 306 is adapted for storing the cables 106 . A network hub or switch (not illustrated) may also be stored in the briefcase servers 102 and 202 . Workstation slots 304 may have adapters 354 (FIG. 3A) for connecting to the workstations 204 (and 104 if battery powered) when the workstations 204 are inserted into the workstation slots 304 . This enables the power supply 312 (or a separate battery charger supply) to charge the workstation 204 batteries. Power for charging the workstation 204 batteries may also come from the batteries 314 . The briefcase server 102 may connect to an external power source and the briefcase server 202 may either be powered from the external power source or run from its internal batteries 314 . The workstations 104 may be powered from the server 102 . The workstations 204 have internal battery power or may be powered by a self-contained power supply (not illustrated) connected to a power receptacle. Every component which is required to complete the networked computer systems 100 and 200 may be stored or contained within the server case 302 , and be readily transported where needed.
Referring to FIG. 3A, a schematic block diagram elevational view of the briefcase servers 102 and 202 of FIGS. 1 and 2, respectively, is illustrated. A telescoping carrying handle 350 and wheels 352 may be attached to the server case 302 for ease in transportation. A radio frequency antenna (not illustrated) for cellular, satellite, or spread spectrum radio frequency communications may be integral with, attached to, or separate from the handle 350 . Batteries 314 may be located in the bottom portion of the server case 302 . Adapters 354 may be used to connect the workstations 204 to the power supply 312 for charging the workstation 204 batteries. A top cover comprising top flaps 356 a and 356 b may be used to close off and lock in the contents of the server case 302 for transportation purposes.
Referring to FIG. 5, a schematic cross section elevational view of an embodiment of the invention built into a conference room table is illustrated. The networked computer system is generally indicated by the numeral 500 and comprises a pedestal computer server 502 , a plurality of networked workstations 504 built into a table top 506 , and interconnection cables (not illustrated). The pedestal computer server 502 may comprise the aforementioned components and also be connected to a larger LAN, WAN, Intranet and Internet as disclosed hereinabove. The workstations 504 may be folded closed into the desktop 506 when not in use. Thus, the desktop 506 may be used as a regular desk top surface when the workstations 504 are not being utilized.
The briefcase server 202 illustrated in FIG. 3 may be built into a storage compartment of an airplane, train (including subway), boat, bus, automobile, truck, spaceship, balloon, space station, submarine, or other mode of public or private transportation, and the workstations 204 may be distributed throughout the airplane, train, bus, ship, etc., for use by travelers doing office work during their journey. The travelers may use the Internet through the workstations 204 , and the Internet connection can be provided through the server by using a wireless telephone connection such as, for example but not limitation, cellular, satellite, spread spectrum, microwave and the like.
Referring to FIG. 4, a schematic block diagram, generally, of the workstations 104 and 204 and the servers 102 and 202 is illustrated. A typical computer system is generally indicated by the numeral 400 and comprises a central processing unit(s) (CPU) 402 , core logic 404 , system random access memory (“RAM”) 406 , a video graphics controller 410 , a local frame buffer 408 , a video display 412 , a PCI/SCSI bus adapter 414 , a PCI/EISA/ISA bridge 416 , and a PCI/IDE controller 418 . Single or multilevel cache memory (not illustrated) may also be included in the computer system 400 according to the current art of microprocessor computer systems. The CPU 402 may be a plurality of CPUs 402 in a symmetric or asymmetric multi-processor configuration. The video graphics controller 410 may be an AGP device (illustrated) connected to an AGP bus 407 or a PCI device (not illustrated) connected to the PCI bus 409 .
The CPU(s) 402 is connected to the core logic 404 through a host bus 403 . The system RAM 406 is connected to the core logic 404 through a memory bus 405 . The video graphics controller 410 is illustrated connected to the core logic 404 through the AGP bus 407 . The PCI/SCSI bus adapter 414 , PCI/EISA/ISA bridge 416 , and PCI/IDE controller 418 are connected to the core logic 404 through a PCI bus 409 . Also connected to the PCI bus 409 are a network interface card (“NIC”) 422 and a PCI/PCI bridge 424 . Some of the PCI devices such as the NIC 422 and PCI/PCI bridge 424 may plug into PCI connectors on the computer system 400 motherboard 300 (see FIG. 3 ).
Hard disk 430 and tape drive 432 may be connected to the PCI/SCSI bus adapter 414 through a SCSI bus 411 . The NIC 422 is connected to a local area network 419 . The PCI/EISA/ISA bridge 416 connects over an EISA/ISA bus 413 to a ROM BIOS 440 , non-volatile random access memory (NVRAM) 442 , modem 420 , and input-output controller 426 . The modem 420 connects to a telephone line 421 . The input-output controller 426 interfaces with a keyboard 446 , real time clock (RTC) 444 , mouse 448 , floppy disk drive (“FDD”) 450 , a serial port 452 , and a parallel port 454 . The EISA/ISA bus 413 is a slower information bus than the PCI bus 409 , but it costs less to interface with the EISA/ISA bus 413 . The PCI/IDE controller 418 interfaces hard disk 428 and CD ROM drive 434 to the PCI bus 409 .
The present invention, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While the present invention has been depicted, described, and is defined by reference to particular preferred embodiments of the invention, such references do not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alternation, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts. The depicted and described preferred embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects. | A self-contained portable networked computer system having integral storage, power and communications for all components of the networked computer system. The networked computer system comprises a network server fabricated within the walls of a carrying case also having compartments for storing portable (clamshell style) workstations and necessary cabling for power and communications to these workstations. The carrying case may be a brief case, a sample case, a suitcase, a metal case, a fiberglass case, a plastic case or any other type of case used for storage and transporting of papers, and/or equipment. The case may be small enough to slide under an airplane seat or be as large as a steamer trunk. The case may be waterproof, bullet proof, airtight, lockable, etc. The case may also be located in a transportation vehicle or a piece of furniture. | 6 |
INDEX TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent application Ser. No. 60/687,921 filed Jun. 6, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a showerhead holder for use preferably with a commercially available removable showerhead unit, such as model Nature Mist, from LDR Industries, Inc., Chicago, Ill.
[0003] A showerhead is a common fixture for directing the spray of water usually within a shower enclosure having one or more walls to form an enclosure. The enclosure usually has at least one entrance e.g. door. One of the more popular add on showerheads are those that are attached using a hose to a holder at the location of the original showerhead that may be removed at the desire of the user. There are several well-known hand-held showerheads that are commercially available. The heads typically come in a kit comprising a connector, a hose, and the showerhead connected to a handle. Oftentimes, a user will desire, when removing the removable showerhead, to affix it to a different location on a wall within a shower enclosure. In this manner, for example, the spray is directed to a body part or portion of the user's body, while having both of the user's hands free.
[0004] In addition, the showerhead handle often rests in a cradle that is part of the connector at a height of greater than 5-6 feet, often the height is greater than 6 feet. This is because although there is no specific rule, most plumbers install the outlet pipe in a shower 75-78 inches above the floor as a matter of course. This height presents difficulty for children, the elderly, and those that are either not tall enough to reach the handle, or have difficulty unseating the handle from it's cradle. Often, people who have difficulties with the height of the cradle will allow the handle to hang loose. This is often not desirable for many reasons. One reason is if there is any tendency for the showerhead to leak, the hanging position will increase any leaks. Additionally, many will not consider a showerhead handle hanging off the wall to be aesthetically pleasing. One possible solution is to have a cradle that may hold the showerhead handle in a lower position. The problem with an after market cradle is that showerhead handles are not standardized and it would be difficult to provide different cradle sizes and shapes for all of the different brands and sizes. The present invention has addressed this difficulty. The present invention provides for the securing of the removable showerhead utilizing the connector and cradle provided by the original equipment manufacturer (OEM).
[0005] The present invention relates to a showerhead holder, a system, and a kit that is used to hold a removable showerhead at different locations in a shower or bathtub.
[0006] Removable showerheads have an attachment fitting that connects to a supply pipe with a threaded male end, that issues from the wall of the shower. The fitting has a female threaded connection that is screwed onto the supply pipe. The fitting includes a supply line that tees off of the fitting. The supply line connects to a hose that supplies water to the showerhead. Typically the removable showerhead has an elongated handle, which is used for a person to hold in ones hand. The attachment fitting has an adjustable C-shaped retainer or cradle that holds the showerhead by the handle when a person does not want to hold the showerhead (during lathering, shampooing, etc.).
[0007] The disadvantages of the showerhead retainer as described above are that the shower stream can only be directed to the parts of the body where the supply pipe issues from the wall, i.e. if the supply pipe is overhead, the stream is only directed to the upper parts of the body such as the head, neck and shoulders. Furthermore, when disposed opposite the shower entrance, the water stream can deflect out of the shower while waiting for the temperature of the water to reach the desired temperature.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is a showerhead holder that is easy to use and overcomes the disadvantages described above.
[0009] The present invention is a showerhead holder for use with a detachable hand-held showerhead comprising:
(a) a mounting plate; (b) a male connecting means; wherein said male connecting means is attached to said mounting plate and is able to receive the original equipment mounting coupling manufactured and supplied with said detachable showerhead.
[0013] The showerhead holder can be used for therapeutic massage in the shower to allow the removable showerhead e.g. pulsating shower massage to be directed to any body part, eg. sore muscles. This can be done hands free such that the showerhead holder allows the removable showerhead to be aimed at any body part, from a position adjacent to the body part, from the showerhead when held at a wall location, using the showerhead holder of the present invention.
[0014] The showerhead holder mounting plate further comprises means for mounting said plate to the wall of a shower. In one preferred embodiment, the mounting plate is attached to the wall of a shower by suction cups.
[0015] Further, in one embodiment, the showerhead holder male connecting means may be a male threaded attaching means. Although, it is contemplated that any acceptable attaching means may be used as the male connecting means. One such connecting means may be a fluid quick connect/disconnect, a female means or the like.
[0016] In another preferred embodiment, the showerhead holder provides for the male connecting means to hold the OEM connector and allow the showerhead handle to rotate 360° while attached to said mounting plate. Also contemplated as part of the invention is a system for a shower comprising:
(a) a first showerhead which is a detachable hand held showerhead; (b) a connecting means for a second showerhead which is in a fixed position; (c) a directional fluid valve;
[0020] In the system, the user may select a fixed showerhead or the removable showerhead by changing the direction of the water supplied by moving the directional fluid valve.
[0021] In another preferred embodiment, the system further has a detachable hand-held showerhead that is mounted on a showerhead holder for use with a detachable hand-held showerhead comprising:
a. a mounting plate; b. a male connecting means;
[0024] The male connecting means is attached to said mounting plate and is able to receive the original equipment manufacturer's coupling, which was manufactured and supplied with the kit containing the detachable showerhead.
[0025] The mounting plate further comprises means for mounting said plate to the wall of a shower.
[0026] In one preferred embodiment, the mounting plate is attached to the wall of a shower by suction cups. The male connecting means may be a male threaded attaching means.
[0027] In another preferred embodiment, the male connecting means can allow the OEM connector to rotate 360° while attached to said mounting and while said mounting plate is attached to a wall.
[0028] Further contemplated as part of the invention is a kit for converting a single head fixed position showerhead into a configuration for dual head shower operation, wherein the user may select use of a fixed position showerhead or a hand held detachable showerhead. The kit comprises:
(a) a it-type connector wherein said connector attaches to the existing attached plumbing fixture; (b) a showerhead holder for use with a detachable hand-held showerhead comprising:
i. a mounting plate; ii. a male connecting means;
[0033] In one embodiment, the male connecting means is attached to a mounting plate and is able to receive the original equipment manufacturer's mounting coupling manufactured and supplied with said detachable showerhead.
[0034] In a preferred embodiment, the kit has a t-type connector that has one end that may receive a fixed position showerhead and one end to receive a hose for a detachable hand-held showerhead.
[0035] Another embodiment provides that the kit further comprises a cap for affixing to one opening of the t-type connector to configure the system for a single detachable hand-held showerhead.
[0036] In an embodiment where there is a fixed position showerhead and a hose leading to a hand held showerhead, the t-type connector further comprises a directional fluid valve.
[0037] The present invention improves the positionability of a moveable showerhead by allowing the showerhead to be positioned on a holder that can be placed at different locations in the shower.
[0038] It is an object of the present invention to provide a system and kit for securing the handle of a removable showerhead.
[0039] It is another object of the present invention to provide a mounting plate, wherein the plate will accept the OEM connector for a removable showerhead.
[0040] It is another object of the present invention to provide a configuration whereby the user may select a water source from a fixed showerhead or a removable showerhead.
[0041] As used and understood herein, the term removable showerhead refers to a showerhead that is operational when being moved (i.e. not mounted in a fixed immovable position).
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The embodiments of the invention are 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. In the drawings:
[0043] FIG. 1 is a side view of the present invention wherein the t-type connector is attached to the supply pipe that issues from the wall of shower and has a hose running to a movable showerhead handle which is cradled on a connector attached to a mounting plate that is attached to the wall of the shower.
[0044] FIG. 2 is a side view of a t-type connector used in the system and kit of the present invention where the position for the fixed showerhead is plugged with a cap by means of female threads that interact with the threaded male portion of the t-type connector.
[0045] FIG. 3 is an expanded view of the mounting plate wherein the connector is attached to the mounting plate by means of a threaded male connector.
[0046] FIG. 4 is a side view of a t-type connector used in the system and kit of the present invention where the position for the fixed showerhead has a fixed showerhead attached by means of female threads that interact with the threaded male portion of the t-type connector.
[0047] FIG. 5 is a front view of the mounting plate of the present invention.
[0048] FIG. 6 is a sectional view of the OEM showerhead handle and cradle along lines 6 - 6 in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known structures and techniques have not been shown in detail in order not to obscure the understanding of this description. In the illustrated embodiments, the OEM kit shown for a removable shower head comprises;
a showerhead on a handle; a connector, wherein said connector comprises an inlet, which is a female threaded connector to be attached to the supply pipe, an outlet, which is a threaded female connector for attaching a hose, and a cradle, for holding the handle comprising the showerhead; and a hose, which provides water supply from the supply pipe through the connector, through the hose, and to the showerhead attached to the handle.
[0054] As shown, FIG. 1 is an embodiment of the present invention. Supply pipe 10 issues from a wall of a shower enclosure. A shower enclosure typically has at least one wall. Any type of enclosure is contemplated for use with the present invention. In a preferred embodiment, a shower enclosure has 3 walls and some type of entrance. T-type connector 20 attaches to supply pipe 10 by male-female combination. In a preferred embodiment, supply pipe 10 has a terminal end 12 with a male threaded connecting means 13 . T-type connector 20 has a proximal end (proximal to the shower wall) 21 with a threaded female connecting means 22 that interacts with the male threaded connecting means 13 on terminal end 12 of supply pipe 10 to effectuate the connection sufficient such that a watertight seal is formed. The integrity of the seal may further be enhanced through the use of Teflon tape or other means known in the art. T-type connector 20 further has a handle 30 controlling an internal directional fluid control valve as is commonly known. A user may select water flow to continue through fixed showerhead 40 or through exit portal 35 attached to hose 50 , directing the water flow to and through removable showerhead 60 . Hose 50 includes proximal end 52 and distal end 53 .
[0055] Hose 50 connects to showerhead handle 70 which supports movable showerhead 60 . Handle 70 is placed in a cradle 80 that is part of the OEM kit supplied with the removable showerhead product. The cradle 80 is part of the connector 140 that is intended to connect with the shower supply pipe. In the present invention, the OEM connector 140 is attached to a mounting screw 90 that is attached to mounting plate 100 .
[0056] Mounting plate 100 , as shown in FIG. 2 , and FIG. 5 is attached to shower wall 11 with suction cups 110 , 111 , 112 and 113 . Mounting plate 100 has a cavity 101 through which mounting screw 90 may pass. The end of mounting screw 90 proximal to the shower wall has a male threaded end 121 and is secured into place by nut 122 with female threaded attaching means. Mounting screw 90 , includes a shoulder 91 , that abuts plate 100 . The distal end of mounting screw 90 also has a male threaded connecting means 131 . The OEM connector 140 that is typically provided with a removable showerhead assembly has a standardized female threaded connector 141 . The female threaded connector 141 is intended to be mounted on the supply pipe 10 . Because this is a standardized size, the distal end of mounting screw 90 of the present invention has a male threaded connecting means 131 that is congruous with the male threaded connecting means 13 found on terminal end 12 of supply pipe 10 . In this configuration, the distal end of mounting screw 90 of the present invention has a male threaded connecting means 131 that will accept most, if not all OEM connectors that are supplied with removable showerhead kits.
[0057] The present invention does not need to rely on matching a nesting cradle with showerhead handles of varying sizes and shapes. The present invention allows for a system by which the OEM connector 140 , which comprises an appropriately sized cradle 80 for handle 70 in which it is paired and sold, is used as the cradle 80 in the present invention to support showerhead 60 in its new location.
[0058] T-type connector 20 seen in FIG. 3 , has handle 30 for controlling an internal directional fluid control valve and distal end 25 with threaded male connecting means 26 which, in this embodiment is sealed closed with a cap 45 comprising female threaded connector 46 .
[0059] One embodiment of the present invention is shown in FIG. 4 , wherein t-type connector 20 has handle 30 for controlling an internal directional fluid control valve and distal end 25 with threaded male connecting means 26 which, in this embodiment has a fixed showerhead 40 connected to t-type connector 20 by female threaded connector 41 interacting on distal end 25 with threaded male connecting means 26 .
[0060] The present invention relates to the system and kit. The system comprises utilization of a t-type connector. The t-type connector may be easily supplied as a standardized part because the supply pipe used in showers is typically standardized. A vast majority of supply pipes are 0.5 inch internal diameter. Even if other sizes are present, they are typically standard sizes with standard male screw threading and would not pose a difficulty in practicing the invention.
[0061] The user will attach t-type connector 20 supplied with the system and kit of the present invention to shower wall 11 . The user will attach the proximal end 21 to the shower supply pipe 10 . Although it is connected by conventional male-female threaded screw means, it is common practice when working with plumbing fixtures to apply Teflon tape to the threaded male screw threads in order to assist in creating a water tight seal. Alternatively, all connections may be made by quick connect/disconnect, or any other appropriate means.
[0062] The exit port 35 along the length of the body 20 of the t-type connector has a threaded male connecting means 36 similar to the one found on the supply pipe 10 . This threaded male connecting means 36 will accept the threaded female connecting means 51 of hose 50 that is supplied with removable showerheads.
[0063] The user may configure this system in one of several ways. The user may install a threaded cap 45 over the distal end 25 of the t-type connector 20 as seen in FIG. 2 . Optionally, the user may install a fixed showerhead 40 on the distal end 25 of the t-type connector 20 as seen in FIG. 4 . When the user has installed a fixed showerhead 40 on the distal end of the t-type connector, the user may then use handle 30 for controlling an internal directional fluid control valve to select the water flow for the fixed showerhead 40 or to hose 50 to the removable showerhead 60 . Water is supplied to removable showerhead 60 by moving the valve and directing water into hose 50 that has been attached to the t-type connector.
[0064] Mounting plate 100 of the present invention has one side 105 with suction cups 110 , 111 , 112 and 113 for attaching to shower wall 11 . Mounting plate 100 has a cavity 101 through which a mounting screw 90 is placed. Mounting screw 90 is secured to the mounting plate 100 on the suction cup side 105 by a threaded nut 122 or a bolt. Mounting screw 90 has a male threaded screw end 131 of congruous size and shape as the male screw end 13 of the supply pipe 10 . The mounting screw 90 is able to accept the connector 140 supplied with the removable showerhead 60 and handle 70 . The connector 140 supplied with the removable showerhead 140 comprises a ball and socket-type arrangement 141 , whereby the connector assembly 140 may be rotated 360° as desired. Connector 140 , typically includes a male port 142 for attaching the hose 52 in the original OEM configuration. Cap 143 is used in the present arrangement, since this male port 142 is not needed.
[0065] Further, by utilizing the OEM connector assembly 140 , the cradle 80 of the connector assembly 140 is configured for the particular size and shape of removable showerhead handle 70 with which it was supplied. Showerhead handles 70 from OEM suppliers come in many assorted sizes and shapes. In this manner of the present invention, the cradle 80 now supported on mounting plate 100 , will always match handle 70 , since both come from the OEM.
[0066] It is further contemplated that the invention comprises a kit with which the user configures their shower as desired. The kit will contain:
(a) a t-type connector with a directional fluid control valve; (b) a mounting plate, with suction cups to secure the mounting plate to the shower wall, wherein the mounting plate has at least one cavity for receiving a mounting screw; (c) a mounting screw, with a bolt or threaded cap for securing the mounting screw to the mounting plate; (d) a cap for closing one exit port of the t-type connector if the user does not desire to have both a fixed showerhead and a removable showerhead.
[0071] The kit will comprise figures and directions as to the installation and operation of the system.
[0072] Although the illustrated examples and embodiments relate to connections by means of complimentary male-female screw-type connections, any suitable connection for affecting a watertight connection may be used. This may include, but would not be limited to, fluid quick connect/disconnects and the like.
[0073] While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. | The present invention is a showerhead holder for use with an original equipment manufacturer's showerhead connector and cradle to hold the handle of the removable showerhead in a desired position selected by the user. | 4 |
TECHNICAL FIELD
The invention relates to an arrangement for a washing apparatus for washing cellulose pulp, comprising a vertical, column-shaped washing vessel, and a screen unit which is movable in the washing vessel, during a screening phase, at a first speed, from an upper position to a lower position, and, during a return movement, at a substantially higher speed, from the lower position to the upper position. The invention relates in particular to improvements to pressure diffusers.
BACKGROUND TO THE INVENTION
In so-called pressure diffusers used in the cellulose pulp industry for washing pulp in continuously operating washing columns, the screen unit is given a reciprocating movement with the aid of a hydraulic working cylinder via a drag bar. The stroke length is normally up to about one meter. During the downward working stroke, the screen unit is fed slowly downwards at a speed which only slightly exceeds the speed at which the cellulose pulp falls through the column. By contrast, the speed on the return stroke is high: normally about 1-1.5 m/sec. The screen unit which is to be lifted during this rapid return movement can weigh over ten tones, and even bigger installations have been planned. In addition to this, there is the friction between the screen unit and the cellulose pulp in the column. The working cylinder and other parts of the hydraulic unit must therefore be given very large dimensions so as to be able, within a short time, to perform considerable work. This entails, for example, hydraulic oil flow rates of over 10,000 l/min; oil quantities which additionally have to be filtered and cooled during the work cycle of the hydraulic unit. The systems existing at present do not solve these problems in a satisfactory manner, a fact which poses an obstacle to developments within this area of technology towards ever bigger pressure diffusers and, thus, ever heavier screen units.
It is an object of the invention to remedy the above problems and offer a solution aimed at lightening the hydraulic system. It will be appreciated, however, that although the invention has been developed with the aim of solving the problems which are acute in the field of pressure diffusers within the cellulose industry, it is also possible to envisage the invention having another area of application.
These and other objects of the invention can be achieved by the fact that it is characterized by what is stated in the attached patent claims. Further characteristics and aspects of the invention will be evident from the following description of a preferred embodiment.
BRIEF DESCRIPTION OF THE FIGURES
In the following description of a preferred embodiment of the invention, reference will be made to the attached drawing FIGURE which shows a vertical cross-section through a pressure diffuser equipped in accordance with the preferred embodiment. In the FIGURE, certain details and elements have been omitted which are not essential for an understanding of the principles of the present invention, but which represent known details and elements of pressure diffusers.
DETAILED DESCRIPTION OF THE INVENTION
The FIGURE shows a pressure diffuser 1 whose basic construction is generally known. It has the shape of a column comprising an outer pressure vessel 2 with a cylindrical jacket 3 , an upper end wall 4 and a lower end wall 5 . Inside the pressure vessel 2 , and concentric thereto, there is a screen unit 7 which is vertically movable, with the upper and lower ends of the screen unit sliding against an upper inner end wall 8 and a lower inner end wall 9 , respectively. The latter walls are fixed to the pressure vessel 2 by bars or the like. More precisely, the screen unit 7 is movable to and from between upper and lower end positions with the aid of one or more powerful hydraulic cylinders arranged on the top of the column. The hydraulic cylinders are indicated symbolically by the numeral 10 . The cellulose pulp which is to be washed is introduced into the top of the column through an inlet line 12 , continues via the space 13 between the outer and inner upper end walls 4 and 8 to a gap 14 between the cylindrical jacket 3 of the pressure vessel 2 and the screen unit 7 , and is finally led out through an outlet line 15 at the bottom of the column. To make the discharge easier, there are scrapers 16 which are driven by a motor 17 .
Washing liquid is introduced continuously through a series of nozzles 20 distributed around the circumference and length of the jacket 3 , and onwards through the pulp in the gap 14 , and through screen openings in the screen unit 7 , into the space inside the screen unit. Thus, all fillable spaces inside the screen unit 7 between the upper and the lower inner column 8 , 9 are filled with filtrate. From the space inside the upper end wall 8 , the used washing liquid—the filtrate—is sucked out through an outlet line 22 .
The hydraulic cylinder (not shown), or the system of hydraulic cylinders, is connected via a hydraulic bar 23 to a central pipe 24 which extends slidably through the upper end walls 4 and 8 and down into the bottom part of the column. The central pipe 24 is moreover connected to the screen unit via radial, vertical plates 25 . At the top of the column there is a so-called pressure-equalizing chamber 27 intended to be able to receive the cellulose pulp which is continuously fed in the form of a suspension through the inlet line 12 , including during the upward return stroke of the screen unit 7 . The pressure-equalizing chamber 27 communicates with the bottom part of the column through the central pipe 24 . In this context it should be pointed out that the pressure-equalizing chamber 27 and the central pipe 24 are arrangements which only exist in a specific type of pressure diffuser, which is shown in the drawing. Other methods of handling the inflow of cellulose during the upward return stroke are also possible, for example where the piston rod 23 can extend right down to and be connected to the screen unit 7 in the same way as the central pipe 24 .
What has been described above belongs to the prior art. The novel feature consists of a float body 30 . According to the embodiment, the float body 30 consists of an elongate cylindrical vessel which extends along essentially the entire length of the screen unit and narrows at both ends and is securely fixed to the screen body 7 . The float body 30 is also closed and contains air or, if appropriate, foamed plastic in order to give the extra pressure strength. It is concentric to the screen body 7 and has a smaller diameter than the latter, so that an annular gap 31 is formed between the float body 30 and the inside of the screen unit 7 . By virtue of the fact that the float body 30 is fixedly connected to the screen unit 7 , and because the float body 30 is arranged in the filtrate-filled volume inside the screen unit 7 between the inner end walls 8 and 9 , the float body 30 gives the screen unit 7 a buoyancy force which to a large extent compensates the inherent weight of the screen unit, which can amount to many tonnes, for example twenty tonnes in existing cases.
The equipment functions in the following way, with only those parts of the washing process which have to do with the invention being described in detail. The cellulose pulp which is to be washed is, as has already been mentioned, fed continuously through the inlet line 12 and is discharged continuously through the outlet opening 15 . During the washing phase, the screen unit 7 is driven downwards at a speed which only slightly exceeds the speed of the cellulose suspension's downward movement in the annular gap 14 between the outer pressure vessel 2 and the screen unit 7 . The washing liquid is led in through the nozzles 20 , passes through the gap 14 during washing of the pulp in this gap and accumulates in the annular gap 31 between the float body 30 and the screen unit 7 , from where the used washing liquid—the filtrate—which fills all the fillable spaces between the upper and lower end walls 8 and 9 inside the screen unit 7 rises upwards and is gradually led off through the outlet line 22 . This downward movement takes place under the countereffect of the buoyancy which the float body 30 exerts on the screen unit 7 in the liquid-filled volume.
When the screen unit 7 has reached its lower end position, it is driven upwards at high speed during the return stroke with the aid of the hydraulic cylinder (not shown) and under the effect of the buoyancy from the float body 30 . The used washing liquid—the filtrate—in the space inside the upper end wall 8 , displaced by the float body 30 , flows down through the annular gap 31 between the float body 30 and the screen unit 7 to the lower space inside the lower inner end wall 9 and at the same time generates a pressure surge in the radial direction which can contribute to freeing the pulp bed from the screen surface, a fact which facilitates the rapid upward movement of the screen body. By dimensioning the external diameter of the screen body 30 and consequently the width of the gap 31 , it is possible to create optimum conditions in respect of, on the one hand, the desired buoyancy and, on the other hand, the acceptable flow resistance in the gap 31 , and the desired pressure surge for freeing the pulp bed from the screen surface. The displacement of the float body 30 should therefore amount to the weight of the screen unit ±75%, preferably ±50%, expediently ±25%, while the width of the gap 31 will amount to at least 5% of the inner radius of the screen unit 7 , preferably 5-25% and expediently 10-25% of the radius. In absolute figures, the displacement should amount to at least 1 tonne, preferably at least 3 tonnes, but for most existing pressure diffusers expediently at least 5 tonnes, or particularly preferably at least 10 tonnes. | In a washing apparatus for washing cellulose pup, comprising a vertical, column-shaped washing vessel ( 2 ), and a screen unit ( 7 ) which is movable in the washing vessel, during a screening phase, at a first speed, from an upper position to a lower position, and, during a return movement, at a substantially higher speed, from the lower position to the upper position, there is a float body ( 30 ) which exerts a buoyancy force on the screen unit. | 3 |
REFERENCE TO PRIOR APPLICATIONS
The current application is a continuation application of U.S. Utility application Ser. No. 14/020,937, which was filed on 9 Sep. 2013, which is hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates generally to mobile devices, and more particularly, to a mobile device password reset.
RELATED ART
Many methods are available for resetting a forgotten or lost password of a mobile device. One method, typically referred to as a master or factory reset, returns a mobile device to its original, default operating system state. However, this process erases all data (e.g., contacts, applications, personalized settings, etc.) added to the mobile device after purchase. Another method requires a phone call to the phone company that provides service to the mobile device. The present invention addresses these problems allowing users to avoid the data reconstruction of a hard reset and the cost of service provider involvement.
SUMMARY
A first aspect of the invention provides a device password reset method, comprising: receiving a phone call at a locked mobile device from a phone having a privileged phone number; initiating a password reset in response to the receipt of the phone call from the phone having the privileged phone number and the phone call exceeding a predetermined time duration threshold, the password reset comprising: terminating, by the locked mobile device, the phone call from the privileged phone number; generating, by the locked mobile device, a temporary password; establishing, by the locked mobile device, a connection to the phone having the privileged phone number; displaying, by the locked mobile device, a password entry field; communicating, by the locked mobile device, the temporary password via the connection to the phone having the privileged phone number; and unlocking the locked mobile device upon successful entry of the temporary password in the password entry field displayed by the locked mobile device.
A second aspect of the invention provides a device configured to perform a password reset method, the method comprising: receiving a phone call at a locked mobile device from a phone having a privileged phone number; initiating a password reset in response to the receipt of the phone call from the phone having the privileged phone number and the phone call exceeding a predetermined time duration threshold, the password reset comprising: terminating, by the locked mobile device, the phone call from the privileged phone number; generating, by the locked mobile device, a temporary password; establishing, by the locked mobile device, a connection to the phone having the privileged phone number; displaying, by the locked mobile device, a password entry field; communicating, by the locked mobile device, the temporary password via the connection to the phone having the privileged phone number; and unlocking the locked mobile device upon successful entry of the temporary password in the password entry field displayed by the locked mobile device.
A third aspect of the invention provides a computer program product including program code embodied in at least one computer-readable storage medium, which when executed, enables a computer system to implement a device password reset method, the method comprising: receiving a phone call at a locked mobile device from a phone having a privileged phone number; initiating a password reset in response to the receipt of the phone call from the phone having the privileged phone number and the phone call exceeding a predetermined time duration threshold, the password reset comprising: terminating, by the locked mobile device, the phone call from the privileged phone number; generating, by the locked mobile device, a temporary password; establishing, by the locked mobile device, a connection to the phone having the privileged phone number; displaying, by the locked mobile device, a password entry field; communicating, by the locked mobile device, the temporary password via the connection to the phone having the privileged phone number; and unlocking the locked mobile device upon successful entry of the temporary password in the password entry field displayed by the locked mobile device.
Other aspects of the invention provide methods, systems, program products, and methods of using and generating each, which include and/or implement some or all of the actions described herein. The illustrative aspects of the invention are designed to solve one or more of the problems herein described and/or one or more other problems not discussed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the disclosure will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings that depict various aspects of the invention.
FIG. 1 shows a flow diagram of an illustrative process for a mobile device password reset, according to embodiments.
FIG. 2 depicts an illustrative setup process for a mobile device password reset, according to embodiments.
FIG. 3 depicts a user initiating a mobile device password reset by placing a phone call to a locked mobile device, according to embodiments.
FIG. 4 depicts a locked mobile device comparing the phone number of a received phone call to privileged phone numbers on a predefined list, according to embodiments.
FIG. 5 depicts the display of a password reset option to a user via a display of a mobile device, according to embodiments.
FIG. 6 depicts a mobile device placing a return phone call to the phone number of the phone that initiated a mobile device password reset, according to embodiments.
FIG. 7 depicts the initiation of a password reset upon receiving a correct temporary password, according to embodiments.
FIG. 8 shows an illustrative environment for a mobile device password reset according to an embodiment.
It is noted that the drawings may not be to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.
DETAILED DESCRIPTION
The present invention relates generally to mobile devices, and more particularly, to a mobile device password reset.
When a mobile device enters a locked state, operation of the mobile device may be prevented or severely limited. Such a locked state may occur automatically, for example, after a predetermined period of inactivity, or may be activated manually (e.g., via buttons/keys on the mobile device or remotely over the Internet). Typically, the locked state of a mobile device is provided as a security measure to prevent unauthorized or unintended use of the mobile device. However, while in the locked state, most mobile devices allow incoming phone calls, which can be answered by a user of the mobile device, and/or a user of the mobile device may be able to place an outgoing emergency call.
To unlock a mobile device that has entered a locked state, a user typically enters a password into a password entry screen of the mobile device using a virtual or physical keypad of the mobile device. A password may comprise, for example, an alphanumeric passcode, passkey, passphrase, access code, personal identification number (PIN), a pattern entered on the screen, or other type of authentication data. If the user correctly enters the password within a predetermined number of attempts, the mobile device is unlocked and full functionality is restored. Repeated failures to enter the correct password may, in some cases, cause the mobile device to erase all data and perform a master reset.
The present invention provides a mobile device password reset that allows a user to securely regain full authorized access to a locked mobile device. In the present disclosure, such a mobile device may include, for example, a cell phone, smartphone, tablet computer, PDA, laptop computer, or other handheld computing/communication device capable of sending/receiving phone calls.
FIG. 1 shows a flow diagram of an illustrative process for a mobile device password reset according to embodiments. During a setup process S 1 , and as depicted in FIG. 2 , a predefined list 10 of one or more privileged phone numbers 12 is provided and stored in a mobile device 14 by an authorized user 16 (e.g., owner) of the mobile device 14 . For example, the predefined list 10 of privileged phone numbers 12 may include the home and work phone numbers of the user 16 , a friend's cell phone number, a relative's land-line phone number, etc.
The user 16 may provide the predefined list 10 of privileged phone numbers 12 during an initial or subsequent configuration of the settings of the mobile device 14 . Application software 18 loaded and running on the mobile device 14 may also be used to provide the predefined list 10 of privileged phone numbers 12 to the mobile device 14 .
At S 2 , assuming the mobile device 14 is in a locked state and the user 16 has forgotten the password for unlocking the mobile device 14 , the user 16 initiates a mobile device password reset by placing a phone call 20 ( FIG. 3 ) to the mobile device 14 from another phone 22 . The phone 22 can comprise any telecommunication device capable of sending/receiving phone calls, including a mobile device, a land-line phone, a computer with VoIP capabilities, and/or the like. At S 3 , the phone call 20 is received and answered by the mobile device 14 .
At S 4 , the mobile device 14 compares ( FIG. 4 ) the phone number 24 of the phone call 20 to the privileged phone numbers 12 on the predefined list 10 . The phone number 24 of the phone call 20 may be determined via caller ID or using any other suitable technique.
If the phone number 24 of the phone call 20 is not on the predefined list 10 of privileged phone numbers 12 (N at S 4 ), the mobile device password reset process ends and the call proceeds as normal. If, however, the phone number 24 of the phone call 20 is on the predefined list 10 of privileged phone numbers 12 (Y at S 4 ), flow passes to S 5 .
At S 5 , the elapsed duration of the phone call 20 is monitored by the mobile device 14 . If the elapsed duration of the phone call 20 exceeds a predetermined time threshold (e.g., 10-15 seconds) (Y at S 5 ), indicating that the phone call 20 has a high likelihood of being legitimate, a password reset option 26 ( FIG. 5 ) is displayed to the user 16 at S 6 via a display 28 of the mobile device 14 . If the phone call 20 is terminated before the predetermined time threshold has been exceeded (N at S 5 ), the mobile device password reset process ends and the call proceeds as normal. The duration of the phone call 20 will generally be shorter in the case that the mobile device 14 is lost/stolen. In such a case, the user 16 would realize the mobile device 14 has been compromised (e.g., based on who answered the mobile device 14 ) and hang-up before the predetermined time threshold, thereby terminating the mobile device password reset process.
If the user 16 selects the password reset option 26 (Y at S 7 ), the mobile device 14 enters a password reset mode at S 8 . If the user 16 does not select the password reset option 26 (N at S 7 ), the mobile device password reset process ends and the call proceeds as normal. Selection of the password reset option 26 may be provided, for example, via YES and NO buttons 30 , 32 , respectively, or in any other suitable manner.
Upon entering the password reset mode at S 8 , the mobile device 14 terminates the phone call 20 at S 9 . Thereafter, at S 10 , the mobile device 14 generates a random, one-time, temporary password 34 ( FIG. 6 ).
At S 11 , and as shown in FIG. 6 , the mobile device 14 establishes a connection (e.g., via a return phone call 36 ) to the phone number 24 of the phone 22 that initiated the mobile device password reset. If the return phone call 36 is not answered by the user 16 (N at S 12 ) the mobile device password reset process ends. If the return phone call 36 is answered by the user 16 (Y at S 12 ), the mobile device 14 , at S 13 , displays a password entry field 38 and speaks the temporary password 34 to the user 16 (e.g., using text-to-speech) one or more times for a predetermined period of time (e.g., 30 seconds). In other embodiments, the mobile device 14 may communicate the temporary password 34 to the user 16 in a non-vocal manner. For example, the mobile device 14 may communicate the temporary password 34 to the user 16 via a short message service (SMS) text message, an email, and/or the like.
If the user 16 does not enter the correct temporary password 34 into the displayed password entry field 38 within the predetermined period of time (N at S 14 ), the mobile device password reset process ends. If the user 16 enters the correct temporary password 34 into the displayed password entry field 38 within the predetermined period of time (Y at S 14 ), flow passes to S 15 . As depicted in FIG. 6 , a timer 40 may be displayed on the mobile device 14 to indicate the time remaining during which the user 16 can enter the correct temporary password 34 into the displayed password entry field 38 .
At S 15 , upon receiving the correct temporary password 34 , the mobile device 14 immediately initiates a password change process ( FIG. 7 ), after which the user 16 is required to enter a new password 42 into the mobile device 14 . After successful completion of the password change process (Y at S 16 ), the mobile device 14 is unlocked at S 17 and is ready for use. If the password reset is not completed (N at S 16 ), the mobile device 14 remains locked and the mobile device password reset process ends. In this case, the user 16 must return to S 2 to restart the mobile device password reset process.
An illustrative environment 100 for providing a mobile device password reset is shown in FIG. 8 . The environment 100 includes at least one computer system 101 and a mobile device password reset program 130 that can perform processes described herein in order to provide a mobile device password reset in accordance with embodiments. The environment 100 may be provided, for example, within a mobile device 14 .
The computer system 101 is shown including a processing component 102 (e.g., one or more processors), a storage component 104 (e.g., a storage hierarchy), an input/output (I/O) component 106 (e.g., one or more I/O interfaces and/or devices), and a communications pathway 108 . In general, the processing component 102 executes program code, such as the mobile device password reset program 130 , which is at least partially fixed in the storage component 104 . While executing program code, the processing component 102 can process data, such as a list 10 of privileged phone numbers 12 and/or the like, which can result in reading and/or writing transformed data from/to the storage component 104 and/or the I/O component 106 for further processing. The pathway 108 provides a communications link between each of the components in the computer system 101 . The I/O component 106 can include one or more human I/O devices, which enable a human user 112 to interact with the computer system 101 and/or one or more communications devices to enable a system user 112 to communicate with the computer system 101 using any type of communications link. To this extent, the mobile device password reset program 130 can manage a set of interfaces (e.g., graphical user interface(s), application program interfaces, communication interface(s), and/or the like) that enable human and/or system users 112 to interact with the mobile device password reset program 130 . Furthermore, the mobile device password reset program 130 can manage (e.g., store, retrieve, create, manipulate, organize, present, etc.) the data, such as the list 10 of privileged phone numbers 12 and/or the like, using any solution.
The computer system 101 can include one or more general purpose computing articles of manufacture (e.g., computing devices) capable of executing program code, such as the mobile device password reset program 130 , installed thereon. As used herein, it is understood that “program code” means any collection of instructions, in any language, code or notation, that cause a computing device having an information processing capability to perform a particular action either directly or after any combination of the following: (a) conversion to another language, code or notation; (b) reproduction in a different material form; and/or (c) decompression. To this extent, the mobile device password reset program 130 can be embodied as any combination of system software and/or application software.
Furthermore, the mobile device password reset program 130 can be implemented using a set of modules 132 . In this case, a module 132 can enable the computer system 20 to perform a set of tasks used by the mobile device password reset program 130 , and can be separately developed and/or implemented apart from other portions of the mobile device password reset program 130 . As used herein, the term “component” means any configuration of hardware, with or without software, which implements the functionality described in conjunction therewith using any solution, while the term “module” means program code that enables a computer system 101 to implement the actions described in conjunction therewith using any solution. When fixed in a storage component 104 of a computer system 101 that includes a processing component 102 , a module is a portion of a component that implements the actions. Regardless, it is understood that two or more components, modules, and/or systems may share some/all of their respective hardware and/or software. Furthermore, it is understood that some of the functionality discussed herein may not be implemented or additional functionality may be included as part of the computer system 101 .
When the computer system 101 includes multiple computing devices, each computing device can have only a portion of the mobile device password reset program 130 fixed thereon (e.g., one or more modules 132 ). However, it is understood that the computer system 101 and the mobile device password reset program 130 are only representative of various possible equivalent computer systems that may perform a process described herein. To this extent, in other embodiments, the functionality provided by the computer system 101 and the mobile device password reset program 130 can be at least partially implemented by one or more computing devices that include any combination of general and/or specific purpose hardware with or without program code. In each embodiment, the hardware and program code, if included, can be created using standard engineering and programming techniques, respectively.
When the computer system 101 includes multiple computing devices, the computing devices can communicate over any type of communications link. Furthermore, while performing a process described herein, the computer system 101 can communicate with one or more other computer systems using any type of communications link. In either case, the communications link can include any combination of various types of optical fiber, wired, and/or wireless links; include any combination of one or more types of networks; and/or utilize any combination of various types of transmission techniques and protocols.
While shown and described herein as a method and system for detecting illegal activity through interpersonal relationship resolution, it is understood that aspects of the invention further provide various alternative embodiments. For example, in one embodiment, the invention provides a computer program fixed in at least one computer-readable storage medium, which when executed, enables a computer system to for detect illegal activity through interpersonal relationship resolution. To this extent, the computer-readable storage medium includes program code, such as the mobile device password reset program 130 , which enables a computer system to implement some or all of a process described herein. It is understood that the term “computer-readable storage medium” includes one or more of any type of tangible medium of expression, now known or later developed, from which a copy of the program code can be perceived, reproduced, or otherwise communicated by a computing device. For example, the computer-readable medium can include: one or more portable storage articles of manufacture; one or more memory/storage components of a computing device; paper; and/or the like.
Another embodiment of the invention provides a method of providing a copy of program code, such as the mobile device password reset program 30 , which enables a computer system to implement some or all of a process described herein. In this case, a computer system can process a copy of the program code to generate and transmit, for reception at a second, distinct location, a set of data signals that has one or more of its characteristics set and/or changed in such a manner as to encode a copy of the program code in the set of data signals. Similarly, an embodiment of the invention provides a method of acquiring a copy of the program code, which includes a computer system receiving the set of data signals described herein, and translating the set of data signals into a copy of the computer program fixed in at least one computer-readable medium. In either case, the set of data signals can be transmitted/received using any type of communications link.
Still another embodiment of the invention provides a method for providing a mobile device password reset. In this case, a computer system, such as the computer system 101 , can be obtained (e.g., created, maintained, made available, etc.) and one or more components for performing process(es) described herein can be obtained (e.g., created, purchased, used, modified, etc.) and deployed to the computer system. To this extent, the deployment can include one or more of: (1) installing program code on a computing device; (2) adding one or more computing and/or I/O devices to the computer system; (3) incorporating and/or modifying the computer system to enable it to perform a process described herein; and/or the like.
The foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to an individual skilled in the art are included within the scope of the invention as defined by the accompanying claims. | The disclosure is directed to a device password reset. A method in accordance with an embodiment includes: receiving a phone call at a locked mobile device from a phone having a privileged phone number; initiating a password reset in response to the receipt of the phone call from the privileged phone number and the phone call exceeding a predetermined time duration threshold by: terminating, by the locked mobile device, the phone call from the phone having the privileged phone number; generating, by the locked mobile device, a temporary password; establishing, by the locked mobile device, a connection to the phone having the privileged phone number; displaying, by the locked mobile device, a password entry field; communicating, by the locked mobile device, the temporary password via the connection to the phone having the privileged phone number; and unlocking the locked mobile device upon successful entry of the temporary password in the password entry field displayed by the locked mobile device. | 7 |
BACKGROUND OF THE INVENTION
The invention concerns a contact unit for a card-shaped carrier element of electronic components, especially in accordance with PCMCIA standards, comprising a plug-in or insertable card-shaped housing that comprises a base plate and a cover plate that is congruent thereto at least in the transverse direction, between which is formed a slot-like insertion channel that opens on one side of the housing for accommodating a chip-card, and that at the opposing side is provided a plug-in strip, and furthermore comprising arranged parallel to the insertion channel in the housing a printed circuit board that is connected electrically to the plug-in strip and that is provided on its surface with a contact field for contact with the chip-card.
Given the increasing miniaturization in the field of computer technology, electronic components are more and more frequently arranged on or in card-shaped carrier elements with a view toward variability and transportability. Frequently encountered are carrier elements in accordance with PCMCIA standards that are cards that comprise a standard-compliant matrix-like connector strip and can accommodate a great variety of electronic components, depending on application. For instance, such cards are employed as memory expansion cards, drive cards, modem cards, etc. The interface to a data processing system (e.g., a notebook computer) is created by means of the plug-in strip, which effects a mechanical and electrical contact with a PCMCIA slot in the data processing system.
Widely used are chip-cards that have integrated circuits and comprise flush contact fields arranged for contact with, e.g., correspondingly designed reading units. Known areas of application for this type of chip-cards are currently telephone cards, authorization cards, or what are known as “SmartCards”.
Known in the current art are contact units that make it possible to connect a chip-card to a PCMCIA standard interface in a data processing system. The combination of a PCMCIA card and a chip-card contact unit that can be inserted into a corresponding modular insertion slot in a computer and then read is useful in a wide variety of applications (e.g., electronic banking, pay TV, authenticating access authorization to data networks, etc.). The disadvantage is that known chip-card readers of this type comprise an extension in the housing in the form of an enlarged insertion guide for the chip-card that extends beyond the insertion area of the modular insertion slot in the computer and that simultaneously provides a grip for the user. This means the readers are substantially longer than standard PCMCIA cards so that when in the operating position this extension projects out of the insertion slot, e.g., in a notebook computer, so that during mobile operation there is a risk that the contact unit will jam in the slot or might even be bent or damaged. This extension has thus far been considered necessary for safely guiding the chip-card into and out of the slot-type insertion channel without the risk of inserting the card improperly—that is, for introducing, retaining, and removing a chip-card.
As the usage of transportable computers (e.g., laptop and notebook computers) continues to increase, there is a technical requirement that a chip-card reader situated in the operating position be completely insertable into the slot in the computer without projecting parts interfering with usage. This becomes important, e.g., when a chip-card must be inserted for personal authorization to use the computer. Although contact elements are known that do not comprise an extension and thus correspond to the PCMCIA standard, these are provided at least partially with closed sides in order to achieve lateral guidance for the chip-card. However, a significant market requirement is that the width of a contact unit also comply exactly with the PCMCIA standard so that even the wall thickness, {fraction (1/10)}mm, for the sides does not deviate substantially from the PCMCIA standard. An additional disadvantage of very thin-walled sides is that the slightest misplacement of the chip-card when it is inserted into the contact unit can damage the card. An additional disadvantage results when the thin sides are deformed and it is then no longer possible to insert the chip-card.
The object of the invention is to further develop a contact unit for a card-shaped carrier element in electronic components such that the contact unit can be completely inserted into a PCMCIA slot in a computer without parts projecting therefrom and the object is furthermore also to ensure that proper insertion is still possible and that there is sufficient mechanical stability and simple manufacture.
This object is achieved in a contact unit of the type cited in the foregoing in that the insertion channel is continuously open over its entire length in the direction the chip-card is inserted and in that the base plate and cover plate are securely attached to each other solely in the region adjacent to the insertion channel in the direction of insertion.
The features in accordance with the invention make it possible to provide a contact unit the length and width of which comply precisely with the PCMCIA standard, e.g., Type II, and which can be inserted in its entirety into the PCMCIA slot of a computer (e.g., a notebook computer) without parts projecting therefrom. The complete insertability precludes any risk of damage, especially during transport, wherein a protective flap can also be provided that closes the PCMCIA slot when the contact unit is inserted. Of course, in this case it is not possible to leave a chip-card in the contact unit since, corresponding to the length of the region adjacent to the insertion channel, it projects from the contact unit when in its inserted position.
In a preferred embodiment of the invention, the connection of base plate and cover plate in the region adjacent to the insertion channel in the direction of insertion is also a swivelling axis relative to which the base plate and cover plate can swivel slightly such that the height of the insertion channel can be changed against the effect of a restoring force. The advantage of this is that when inserted into the insertion channel the chip-cards can be retained clamp-like in the channel. It is particularly advantageous when the height of the insertion channel declines as the distance from the connection increases when there is no chip-card inserted therein. When the chip-card is inserted into the insertion channel, the latter expands and the chip-card is held securely in the channel by means of inherent elastic return deformation. At the same time a high degree of form stability in the contact unit and compensation of production tolerances can be achieved in this manner.
Furthermore, a particular advantage is that the printed circuit board is connected at its end opposing the plug-in strip to a metal strip that is affixed to the printed circuit board in the housing and that comprises flexibly extending tabs that electrically conductively adjoin the metal cover plate. The metal strip in this manner keeps the printed circuit board level in the housing and also provides a grounded transition to the printed circuit board. With regard to this latter, it is necessary that the metal strip is connected to grounded contact surfaces in the printed circuit board. In order to facilitate simple assembly, in accordance with an additional feature of the invention the metal strip is arranged on a plastic profile that is connected to the cover and that constitutes an upper insertion guide for the chip-card. The plastic profile can be provided on its side facing the insertion channel guides for a chip-card and can be joined to the metal strip, e.g., by clamping, adhesive, or locking means.
In accordance with a further advantageous development of the invention, provided in the insertion channel is at least one spring element, the one end of which is securely joined to the cover plate and the other, free end of which can be detachably attached to the base plate. The spring element fulfills a plurality of roles. When no chip-card is inserted, the spring element ensures that the height of the insertion channel remains the same against the action of the restoring force so that the chip-card can be easily introduced. Since the free end of the spring element is detachably attachable to the base plate, the insertion channel is simultaneously protected against outward expansion. This provides the contact unit additional form stability. Introducing the chip-card releases the free end and the spring element is bent in the insertion channel in the direction of the cover plate so that due to this spring-effect the chip-card is subjected to increased pressure which also ensures the contact. Advantageously the spring element is produced integral to the metal strip and when a chip-card is inserted extends to the cover plate through cut-outs in the printed circuit board so that chip-card and metal cover plate are conductively connected to each other, whereby static charging of the chip-card can be prevented. Securing the free end of the spring element on the base plate also makes it possible to achieve a bonding point between cover plate, printed circuit board, and base plate when there is no chip-card inserted. The metal strip and the spring element are cost-effective to produce by means of stamping and bending as strip-type goods and can be joined to the cover plate or to the plastic profile constituting the upper insertion guide in a single step by means of caulking, adhesive, welding, or ultrasound welding.
In order to obtain the compression/tension effect with the spring element, it is useful to embody the spring element in an approximate S-shape and to provide at its free end a claw-shaped extension that engages a mating lock element for securing the spring element. In accordance with an additional feature of the invention, it is advantageous to provide the lock element an undercut in which the claw-shaped extension of the spring element is releasably held. In an advantageous embodiment of the invention it is furthermore suggested that the lock element is embodied in a reinforcing plate made of plastic or metal that is joined to the base plate. While a reinforcing plate made of plastic can be joined to the metal base plate by means of injection molding, a metal reinforcing plate can be joined to the base plate by means of welding or adhesive. Advantageously the lock element is employed as a separate component in the reinforcing plate or as a cut-out in the reinforcing plate that is at least single-layer. In the latter case the undercut in the lock element can be produced by punching or stamping a single-layer reinforcing plate or by the offset arrangement of two reinforcing plates, one above the other and provided with openings. If, however, the lock element comprises a separate component, it is useful to prefabricate this component and press it into an opening in the reinforcing plate.
In accordance with an additional feature of the invention, the base plate at its end opposing the plug-in strip is provided with a plastic profile that functions as a lower insertion guide in order to ensure that the chip-card can be easily inserted. The plastic profile can be provided guides analogous to those for the upper insertion guide.
In an advantageous embodiment of the invention it is furthermore suggested that the base plate and cover plate are each provided at said plug-in strip with plastic holders arranged on the edge for fastening thereto that can be securely joined by means of a plastic bond like adhesive, ultrasound welding, or heat pressing. Base plate and cover plate can be securely joined in this manner. Alternatively, or in addition thereto, in accordance with an additional feature of the invention the base plate and cover plate are congruent and are welded to each other at lateral welded brackets. In this case it is particularly advantageous when the length of the secure joining of base plate and cover plate is approximately 30% of the overall length of the contact unit because this results in high form stability in the contact unit. Finally, it is suggested that an end stop comprising a stop angle is provided for limiting the insertion of the chip-card. Depending on requirements, insertion of the chip-card can also be limited by the lateral welding brackets or by the plastic holders, which are then provided with appropriate rounded stop surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional details, features, and advantages of the subject of the invention can be appreciated from the following description of two exemplary embodiments, with reference to the associated drawings, in which:
FIG. 1 is a perspective view of a contact unit that does not have a chip-card inserted therein;
FIG. 1 a is a perspective view of the contact unit in accordance with FIG. 1 into which a chip-card has been inserted;
FIG. 1 b is a perspective view of the contact unit in accordance with FIG. 1 showing swiveling of the base plate and the cover plate relative to one another.
FIG. 2 illustrates the individual parts of the contact unit in accordance with FIG. 1 in a perspective view of housing members that have been flipped open and taken apart and their internal composition;
FIG. 3 illustrates the individual parts of the contact unit in accordance with FIG. 2 in an intermediate stage of assembly;
FIG. 3 a is a perspective exploded view of the attachment of a metal strip to a plastic profile;
FIG. 3 b is a perspective view of the attachment of the metal strip in accordance with FIG. 3 a to a printed circuit board;
FIG. 4 illustrates a side view of the contact unit in accordance with FIG. 1;
FIG. 4 a illustrates a side view of the contact unit in accordance with FIG. 1 a;
FIG. 5 illustrates the individual parts of an alternative embodiment of a contact unit in a perspective view of the housing members that have been flipped open and taken apart and their internal composition;
FIG. 6 illustrates the individual parts of the contact unit in accordance with FIG. 5 in an intermediate stage of assembly;
FIG. 7 shows a side view of the contact unit in accordance with FIG. 5 that does not have a chip-card inserted therein; and
FIG. 7 a illustrates a side view in accordance with FIG. 6 into which a chip-card has been inserted.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The exemplary embodiment of the invention illustrated in FIG. 1 shows a contact unit 1 designed as a chip-card reader that is provided for contact with a notebook computer by means of a standard PCMCIA interface. The contact unit 1 comprises a two-member external housing 2 having a base plate 3 , a PCMCIA interface field in the form of a plug-in strip 4 with 68 poles at the front end (relative to the direction in which it is inserted into the notebook computer, as indicated by the arrow), an upper and lower insertion guide 5 , 5 a on the opposing end for introducing a chip-card 9 , e.g., in accordance with ISO 78 16, and a cover plate 6 that extends parallel to and at a distance from the base plate 3 and that is rigidly joined to the base plate 3 in the region of the plug-in strip 4 . The parts of the contact unit cited are carried by the interior plastic profile elements made of PCB and illustrated in FIGS. 2 and 3, which furthermore hold a PCMCIA printed circuit board 7 spaced parallel to the base plate 3 in such a manner that formed therebetween is an insertion channel 8 for the ISO 78 16 chip-card 9 that is insertable into the contact unit via an insertion slot 10 between the insertion guides 5 , 5 a . The chip-card 9 can be inserted into and withdrawn from the contact unit 1 in the direction of the double arrow shown in FIG. 1, wherein contact can be created by means of the chip field 11 arranged on the surface of the chip-card 9 and a contact field 11 ′ on the underside of the PCMCIA printed circuit board 7 , which contact makes it possible to process the chip-card via the PCMCIA card when the contact unit 1 is inserted into the notebook and is connected to its PCMCIA interface via the plug-in strip 4 .
FIG. 2 illustrates the two individual members of the external housing 1 , i.e., the base plate 3 in a perspective view of the interior and the cover plate 6 , flipped 180°, also in a perspective view of the interior. Base plate 3 and cover plate 6 are separate pieces of sheet that are not joined to each other and that have clips 12 bent inward on the longitudinal sides 13 , 14 and in the back side 15 (relative to direction of insertion), while the front side (relative to direction of insertion) remains free so that the plug-in strip 4 can be arranged there later. In the exemplary embodiment illustrated in FIG. 2, the base plate 3 is provided with a welded reinforcing plate 16 that makes it possible to employ an extraordinarily thin housing sheet of approximately {fraction (2/10)}mm thickness. It should be appreciated that instead of metal, a reinforcing plate 16 made of plastic can be used that can be manufactured, along with other plastic parts described below, in a single process step by means of injection molding.
The clips 12 comprise an L shape and it is provided that these be punched from the sheet of the base plate 3 and cover plate 6 , bent upward 90° out of the plane toward the interior and then be bent again 90° inward so that there is a free leg that projects into the subsequent interior of the contact unit 1 parallel to the base plate 3 and cover plate 6 at the clips 12 , which represents a particularly advantageous fastening device for coating the clips 12 , also described below. The number and arrangement of the clips 12 on the base and cover plates 3 , 6 are coordinated to provide a housing that is as torsion-proof as possible, wherein it has proved useful to provide a plurality of clips 12 on the cover plate 6 , while on the base plate 3 , the plastic profile 18 that constitutes the lower insertion guide 5 a is held in place with clips 12 on the side 15 and with hooks 17 . The hooks 17 are likewise punched from the sheet for the base plate 3 and bent upward and inward in an L shape. In principle, instead of using clips 12 and hooks 17 punched out of the material of the base and cover plates, it is also possible to use separate fastening elements that then must be mechanically joined to the housing members.
FIG. 2 furthermore illustrates the plastic profiles employed in the interior of the contact unit 1 , which profiles in the preferred embodiment are not however manufactured separately and introduced into the housing but rather are manufactured in connection with the corresponding metal parts of the housing in a single process step in the injection molding process. Provided in the front region of the base plate 3 (relative to the direction of insertion) for holding the plug-in strip 4 are plastic holders 19 , 20 that simultaneously constitute axial stops for limiting the insertion of the chip-card 9 and that comprise corresponding rounded stop surfaces 24 .
The plastic holders 19 correspond to correctly shaped holders 25 , 26 on the free ends of a U-shaped plastic frame 27 that belongs to the cover plate 6 and that at its closed side comprises a strip 28 constituting the upper insertion guide 5 and provided with a platform-type tier 21 for attaching a metal strip 22 . The longitudinal legs of the plastic frame 27 comprise a guide that is open toward the interior and that is in the form of a step 29 for engaging and holding the printed circuit board 7 , which when assembled is fixed by the plastic frame 27 , wherein the holders 25 , 26 together with the plastic holders 19 , 20 fix the plug-in strip 4 connected to the printed circuit board 7 . The plastic elements illustrated in FIGS. 2 and 3 are furthermore provided various positioning projections and recesses 30 for positioning purposes.
The printed circuit board 7 shown adjacent thereto is arranged on the cover plate 6 , flipped 180°, such that at the front the knobs 31 on the side of the plug-in strip 4 engage in the corresponding recesses on the plastic holders 25 , 26 and opposing grounded contact surfaces 23 in the printed circuit board 7 are pushed flush under the clamp contacts 32 in the metal strip 22 . The base plate 3 is arranged flipped 180° on the cover plate 6 . This means that formed between the base plate 3 and the cover plate 6 with the printed circuit board 7 is the insertion channel 8 that remains free for introducing the chip-card 9 and that makes it possible for the chip field 11 to contact the PCMCIA card through the contact field 11 ′.
The base plate 3 and the printed circuit board 7 in FIGS. 2 and 3 are not shown in their assembled positions, but flipped 180° in order to make it possible to see the interior. It shall be appreciated that allocated to the cover plate 6 is the U-shaped plastic frame 27 , which is held to the cover plate 6 by the corresponding clips 12 and upon which the prepared base plate 3 is placed after assembly with the printed circuit board 7 in the manner described.
In addition, in contrast to FIG. 2, FIG. 3 illustrates the correct arrangement of the plastic elements on the base plate 3 and cover plate 6 , wherein it can be seen that the clips 12 are no longer visible. This is due to the preferred manufacturing process used during the manufacture of the contact unit 1 in which the exterior housing members in the form of base plate 3 and cover plate 6 are punched as separate pieces of sheet that are not connected to each other, the clips 12 and hooks 17 being punched and bent inward at the same time; in a second process step the base plate 3 is provided with the plastic holders 19 , 20 and the plastic profile 18 and the cover plate 6 is provided with the plastic frame 27 , this being done separately using an injection molding process in the form of a unit. The printed circuit board 7 and its plug-in strip 4 are then flipped 180° and placed onto the cover plate 6 , positioned on the metal strip 22 and the plastic holders 25 , 26 , and in a final process step the housing members pre-assembled in this manner with interior plastic elements are arranged upon each other and joined to each other by means of a plastic joining technique, particularly adhesive or ultrasound welding.
FIG. 3 a illustrates the assembly of the metal strip 22 with the upper insertion guide 5 and FIG. 3 b illustrates its [the metal strip's] assembly with the printed circuit board 7 . The clamping contacts 32 in the metal strip 22 are arrested on the grounded contact surfaces 23 on the printed circuit board 7 . Spring elements 33 that are integral to the metal strip 22 engage in the cut-outs 34 of the printed circuit board 7 , as can be seen especially in FIG. 3 b . The metal strip 22 is also provided with bores 35 and grounded contact springs 36 . The bores 35 cooperate with corresponding pins 37 on the tier 21 in the strip 28 , the metal strip 22 and the printed circuit board 7 connected to the metal strip 22 via the clamp contacts 32 being centered on the cover plate 6 . The metal strip 22 is fixed by subsequent ultrasound welding.
The functionality of the spring elements 33 integral to the metal strip 22 can be seen in FIGS. 4 and 4 a . FIG. 4 illustrates the contact unit 1 with no chip-card 9 inserted, while as can be seen in FIG. 4 a , the chip-card 9 has been inserted into the insertion channel 8 up to the rounded stop surfaces 24 , the chip field 11 of the chip-card 9 coming to rest at the contact field 11 ′ in the printed circuit board 7 . The spring element 33 is essentially S-shaped and is provided at its free end with a claw-shaped extension 39 that engages under prestress when there is no inserted chip-card 9 a lock element 40 embodied as a recess in the reinforcing plate 16 . As can be seen in FIG. 4 a , the lock element 40 comprises an undercut that ensures that the spring element 33 is arrested. The cover plate 6 and the base plate 3 are connected to each other by the plastic holders 19 , 20 , 25 , 26 such that they are subject to a clamping force. The spring element 33 ensures that the height of the insertion channel 8 does not change, which facilitates simple insertion of the chip-card 9 . When the chip-card 9 is inserted into the insertion channel 8 , the front of the chip-card 9 (relative to direction of insertion) presses the spring element 33 in the direction of the cover plate, the spring element 33 being pressed through the cut-out 34 in the printed circuit board 7 against the metal cover plate 6 . Thus the chip-card 9 can be inserted into the insertion channel 8 up to the rounded stop surfaces 24 and is clamped therein by the internal stress inherent in the base and cover plates 3 , 6 . In addition, the spring element 33 presses on the chip-card 9 so that contact is assured between chip-card 11 and contact field 11 ′. When the chip-card 9 is removed from the insertion channel 8 , the spring element 33 returns to the lock element 40 , this also creating a connection between metal strip 22 respectively to cover plate 6 and base plate 3 .
The alternative embodiment of the contact unit 1 illustrated in FIGS. 5 through 7 a comprises on the base plate 3 and cover plate 6 in the region adjoining the insertion channel 8 in the direction of insertion additional welded brackets 41 by means of which the base plate 3 and cover plate 6 are joined together and the clamping internal stress in the contact unit 1 is obtained. In contrast to the embodiment in accordance with FIGS. 2 through 4 a , the metal strip 22 does not comprise the spring element 33 so that when no chip-card 9 is inserted the insertion channel 8 in the contact unit 1 tapers from the welded brackets (which are also the swivelling axis) in the direction of the upper and lower insertion guides 5 , 5 a . When a chip-card 9 is inserted, the insertion channel 8 expands while generating a restoring force, this holding the chip-card 9 in the insertion channel 8 in a clamping manner. The welded brackets 41 on the cover plate 6 are offset for enabling the brackets 41 to be welded without infringing on the width dimensions in the PCMCIA standard. In addition, the plastic holders 19 , 20 , 25 , and 26 can be welded together in a known manner.
From FIGS. 2 and 5 it can be seen that the reinforcing plate 16 can be provided with an insulating film or element 42 that is used particularly when the reinforcing plate 16 is made of metal so that short-circuits can be prevented between the contact field 11 ′ on the printed circuit board 7 and the reinforcing plate 16 arranged opposed thereto. In addition, a wear-resistant insulating film can be applied to the underside of the printed circuit board 7 to prevent wear on the chip-card 9 and to simultaneously insulate the conductors and through-contacts on the printed circuit board 7 on the side facing the insertion channel 8 . It can also be seen from FIG. 2 that the lock element 40 can also embody a separate component that is pressed into recesses in the reinforcing plate 16 . This is particularly simple and cost-effective. In order to make it simple to introduce a chip-card 9 into the insertion channel 8 , the lower insertion guide 5 a can in addition be embodied in the form of a lower lip (relative to the upper insertion guide 5 in the direction in which the chip-card 9 is inserted).
With the contact unit 1 described in the foregoing a chip-card reader is created that precisely corresponds to PCMCIA dimensions when a chip-card is not inserted and that provides assured contact and sufficient mechanical stability. In addition, security is increased in that the cover plate 6 and base plate 3 are congruent so that when inserted into the PCMCIA slot in a computer the base plate 3 and cover plate 6 are conducted into the lateral guides in the PCMCIA slot. This prevents the cover plate 6 from being forcibly bent upward or downward relative to the base plate 3 in an adjacent PCMCIA slot in the computer. Furthermore, the metal embodiment of the base plate 3 and cover plate 6 provides shielding and a high degree of functional stability and stability in the contact unit 1 , even at high stagnation and ambient temperatures above 100° C. Finally, the contact unit 1 is also distinguished by simple and cost-effective manufacture.
The specification incorporates by reference the disclosure of German priority document 298 11 425.9 of Jun. 29, 1998 and European Patent Application priority document PCT/EP99/03560 of May 25, 1999.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
1
Contact unit
2
Exterior housing
3
Base plate
4
Plug-in strip
5
Upper insertion guide
5a
Lower insertion guide
6
Cover plate
7
PCMCIA printed circuit
board
8
Insertion channel
9
Chip-card
10
Insertion slot
11
Chip field
11′
Contact field
12
Clips
13
Longitudinal side
14
Longitudinal side
15
Side
16
Reinforcing plate
17
Hook
18
Plastic profile
19
Plastic holder
20
Plastic holder
21
Platform or tier
22
Metal strip
23
Ground contact surface
24
Stop surfaces
25
Plastic holder
26
Plastic holder
27
Plastic holder
28
Strip
29
Step
30
Positioning
projection/recess
31
Knobs
32
Clamp contact
33
Spring element
34
Cut-out
35
Bore
36
Grounded contact spring
37
Pin
38
End stop
39
Extension
40
Lock element
41
Welded bracket
42
Insulating element | A contact unit for a card-shaped carrier element of electronic components is provided. The contact unit includes an insertable card-shaped housing that has a base plate and a cover plate that is congruent to the base plate at least in the transverse direction. Formed between the base plate and the cover plate is a slot-like insertion channel that opens on one side of the housing for accommodating a chip-card. At the opposite side is provided a plug-in strip. Disposed parallel to the insertion channel, in the housing, is a printed circuit board that is electrically connected to the plug-in strip and that is provided on its surface with a contact field for contact with the chip-card. The insertion channel is continuously open on both sides over its entire length in the direction in which the chip-card is inserted. The base plate and the cover plate are securely attached to one another solely in the region adjacent to the insertion channel in the direction of insertion. | 7 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 62/250,251 which was filed on Nov. 3, 2015.
FIELD OF THE INVENTION
[0002] The present invention generally relates to vehicles. More particularly, it relates to a support bar for heat exchangers including oil coolers and radiators.
BACKGROUND OF THE INVENTION
[0003] In many front part body structures of vehicles, an engine compartment is generally provided in front of a cabin. A front part of the vehicle shown in FIG. 1 contains the engine compartment and is provided with front side members 2 , 4 positioned at right and left sides in a lateral direction of the vehicle, a plurality of cross members 6 , 8 that bridge the side members, suspension support elements 12 , 14 attached to the front side members, and upper frame members 16 , 18 fixed at one end at the cabin side, the other ends of the upper frame members are fixed to respective front pillars members 20 , 22 . Front suspension elements are respectively fixed to the right and left suspension support elements. The upper frame members 16 , 18 positioned at the right and left sides in the lateral direction of the vehicle are extended in a longitudinal direction of the vehicle and formed a closed sectional structure. The upper frame members 16 , 18 are joined opposite cabin side by upper cross member 10 . Respective outer body panels are mounted to the various members. The respective members are joined by bolts or welds, typically arc welds.
[0004] A radiator 100 for an automotive engine cooling system is affixed to the front pillar members 20 , 22 , cross member 6 and the upper member 10 . The radiator 100 typically includes a top tank, bottom tank, and a core. Alternatively, the radiator can be constructed with left and right tanks for cross-flow. Resilient mounts may be used because the radiator may be subject to vibrations, high forces, and shocks during normal use due to jolts, accelerations, or decelerations of the vehicle as it is driven over rugged terrain. Although the frame formed by the various members is advantageous in that rigidity can be obtained, the upper frame bears a load from the front suspension of the vehicle. This load is transferred to the radiator 100 . This load, which may be transferred as torque, can damage the radiator 100 .
SUMMARY OF THE INVENTION
[0005] A radiator mounting arrangement on a vehicle includes a frame member having a center assembly, left and right end caps, and radiator mounting brackets. The radiator has respective mounts that mate with the mounting brackets. The radiator mounting arrangement is inexpensive, requires few parts and is fast and easy to assemble and does not transfer damaging forces to the radiator.
[0006] A radiator assembly comprises a radiator and a support bar. The support bar is configured to be attached to a vehicle by respective end caps and brackets. The support bar, end caps, and brackets are produced from die cast steel components, steel plate, and steel tubing. Each of the pieces is about 0.05-2 inches (1.7-5 mm) thick. The entire support bar, end caps and brackets are fully welded to minimize flex and torque transfer from the vehicle to the radiator. The radiator is mounted to the support bar using pegs. The pegs have a threaded bolt portion that is co-molded with a flexible material such as rubber, or the like. The peg threads into the radiator and is secured to the support bar by a retaining clamp. The support pegs further minimize flex and torque transfer from the vehicle to the radiator.
[0007] The radiator assembly comprises a support bar comprising, a center portion and respective end portions welded to the center portion, wherein the end portions having respective flared ends that mate with the center portion; and a pair of support mounts; at least two pegs con figured to mate with the support mounts, the pegs having a rubber portion that mates with the support mounts and a comolded bolt; and a radiator having receiving mounts configured to receive the comolded bolt of the peg.
[0008] According to one embodiment, the center portion is a rectangular tube.
[0009] According to one embodiment, the rectangular tube is substantially 0.07 inches (2 mm) thick.
[0010] According to one embodiment, the respective end portions are cast steel.
[0011] According to one embodiment, the respective end portions mate with the center portion with about 0.03 inches (1 mm) of clearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a front part of the vehicle containing;
[0013] FIG. 2 is a perspective view of a radiator support bar;
[0014] FIG. 3 is a front view of the radiator support bar;
[0015] FIG. 4 is a top view of the radiator support bar;
[0016] FIG. 5 is a perspective view of a center assembly of the radiator support bar;
[0017] FIG. 6 is a front view of a center assembly of the radiator support bar;
[0018] FIG. 7 is an end view of a center assembly of the radiator support bar;
[0019] FIG. 8 is a blank for a notch in the center assembly of the radiator support bar;
[0020] FIG. 9 is a perspective view of the formed notch in the center assembly of the radiator support bar;
[0021] FIG. 10 is a tab for the center assembly of the radiator support bar;
[0022] FIG. 11 is a left end cap for the radiator support bar;
[0023] FIG. 12 is a right end cap for the radiator support bar;
[0024] FIG. 13 is a bracket for the radiator;
[0025] FIG. 14 is the radiator mounted to a support bar;
[0026] FIG. 15 is the radiator and mounting peg;
[0027] FIG. 16 is the mounting peg attached to the radiator
[0028] FIG. 17 is the mounting peg; and
[0029] FIG. 18 is a cross section of the mounting peg; and
[0030] FIG. 19 is a cross section of the mounting peg.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] FIG. 2 is a perspective view of a radiator support bar. The radiator support bar comprises a center assembly 200 , a left end cap 300 , and a right end cap 400 . The left end cap 300 and right end cap 400 are attached to the center assembly 200 by welding, bolts, or the like. Also shown in FIG. 2 brackets 250 and 255 are affixed to the left end cap 300 and the right end cap 400 . Given a specific application for the support bar, notches 500 , 600 may be present that accommodate hood latches, cables, and the like.
[0032] In one embodiment, the support bar has an anti-corrosive finish, is powder coated, plated, or the like. Alternatively, the support bar is painted. The threads of nuts 202 are preferably protected during any finishing process. By protecting the threads, the threads are able to receive a bolt.
[0033] FIG. 3 is a front view of the radiator support bar and FIG. 4 is a top view of the radiator support bar. In the front view of the support bar, mounting tabs 270 , 275 are shown. Mounting tabs 270 , 275 are welded to center assembly 200 . The left end cap 300 includes mounting ear 302 that extends substantially longitudinally with respect to the center assembly 200 . Another mounting ear 304 extends substantially perpendicular with respect to center assembly 200 . The right end cap 400 includes mounting ear 402 that extends substantially longitudinally with respect to the center assembly 200 . Another mounting ear 404 extends substantially perpendicular with respect to center assembly 200 .
[0034] FIG. 5 is a perspective view of a center assembly of the center assembly 200 . As shown, there is a weld fillet 550 for the weld that attaches the notch 500 to the center assembly 200 . A weld fillet 650 attaches the notch 600 to the center assembly 200 . A weld fillet 273 attaches the mounting tab 270 to the center assembly 200 . A weld fillet 277 attaches the mounting tab 275 to the center assembly 200 . A weld fillet 212 attaches the nut 202 to the center assembly 200 . In one embodiment, the welds are ground smooth as part of the assembly process.
[0035] FIG. 6 is a front view of the center assembly 200 of the radiator support bar. FIG. 6 shows the center assembly 200 with dimension lines for a specific application. As one skilled in the art would readily appreciate, these dimensions can be adjusted for specific vehicles as required. The placement of the nuts 202 and notches can be adjusted as required for different applications. Further, the mounting tabs 270 , 275 can be adjusted as required.
[0036] FIG. 7 is an end view of the center assembly 200 of the radiator support bar. As shown, the nuts 202 are welded by weld 212 to the center assembly 200 . The nuts 202 are arranged inside the rectangular tube that forms the center assembly 200 . In one embodiment, the nuts 202 are self-clinching fasteners. The self-clinching fasteners install permanently in metal sheets by pressing them into properly sized holes. This forces displaced sheet material to cold flow into an annular recess in the shank or pilot of the fastener, locking it in place. A serrated clinching ring, knurl, ribs, or hex head prevents the fastener from rotating in the metal when technicians apply tightening torque to the mating hardware. The fasteners can be installed during fabrication or final assembly.
[0037] FIGS. 8 and 9 are an example of the notch 500 . FIG. 8 is a blank used to form the notch 500 . Edge portions 504 , 406 , and 508 are folded at substantially 90 degrees on fold lines 502 . As shown in FIG. 9 , the seam 515 at which edge portions 504 and 506 meet is welded and the seam 515 at which edge portions 506 and 508 meet is welded. This assembly is then welded into the center assembly 200 . In another embodiment, the blank has tabs that can be attached to the center assembly 200 by screws, nuts and bolts, and the like.
[0038] FIG. 10 is an example of mounting tabs 270 and 275 . The tabs are typically made from 0.1 inches (3 mm) thick mild steel plate. The tabs are dimensioned as required for mounting in a given application. The mounting tabs 270 and 275 are dimensioned as required for various mounting configurations.
[0039] FIG. 11 is an example of the left end cap 300 for the radiator support bar. The left end cap 300 is cast mild steel. After casting, the part is finished by sandblasting. The left end cap 300 has a mating portion 306 that mates with the center assembly 200 . The mating portion 306 is configured to mate with the center assembly 200 so that it can be welded. The mounting ears 302 , 304 are configured to mount with the frame members that form the engine cabin of the vehicle.
[0040] FIG. 12 is an example of the right end cap 400 for the radiator support bar. The right end cap 400 is cast mild steel. After casting, the second part is finished by sandblasting. The right end cap 400 has a mating portion 406 that mates with the center assembly 200 . The mating portion 406 is configured to mate with the center assembly 200 so that it can be welded. The mounting ears 402 , 404 are configured to mount with the frame members that form the engine cabin of the vehicle.
[0041] FIG. 13 is an example of the brackets 250 , 255 . Typically, the brackets 250 , 255 are made from flat mild steel plate. The piece of steel is appropriately punched and folded at fold lines 251 . Nuts 202 are welded into the brackets 250 , 255 . Alternatively, self-clinching fasteners are used. The brackets 250 , 255 have a mounting face 252 that is configured to mate with the left end cap 300 , right end cap 400 , or center assembly 200 .
[0042] FIG. 14 is a view of the radiator 100 and support bar from the engine compartment. The radiator 100 is mounted to the support bar via mounting pegs 700 . The mounting peg 700 is held in bracket 250 by strap 290 . The mounting peg 700 is screwed into the radiator and retained in the bracket 250 . The assembly prevents torque from being transmitted through the vehicle to the radiator 100 .
[0043] FIG. 15 is a view of the radiator 100 and the mounting peg 700 prior to the mounting peg 700 being installed on the radiator 100 . The radiator 100 has a threaded mount 110 configured to accept the mounting peg 700 . Alternatively, the mounting peg 700 is welded to the mount 110 or attached in another suitable manner. The mounting peg 700 has a threaded portion 710 that mates with the threaded portion of the threaded mount 110 .
[0044] FIG. 16 is the mounting peg 700 attached to the radiator 100 . The mounting peg 700 is a comolded metal bolt 710 and rubber portion. Typically, the mounting peg 700 is approximately 3 inches (45 mm). The bolt has a head and a threaded portion. The threaded portion is about 0.4 inches (10 mm) long. Alternatively, the threaded portion does not have a bolt head.
[0045] FIG. 17 is the mounting peg 700 . The mounting peg 700 is a comolded metal bolt 710 and rubber portion. The mounting peg 700 is a flexible material, typically a rubber material. In one embodiment, the durometer of the rubber is 80 Shore A. The mounting peg 700 is generally circular and has a diameter of about 1.12 inches (28.5 mm). In one embodiment, the metal bolt 710 is an M8×1.25 bolt. In one embodiment, the metal bolt is grade 10.9 zinc coated steel. It should be noted that other material, finishes, and threads can be used, depending on the application. In one embodiment, in place of the threaded bolt, the mounting peg 700 has a comolded nut and a corresponding bolt is affixed to the radiator.
[0046] FIG. 18 is a cross section of the mounting peg 700 . The head 715 of the comolded metal bolt 710 is shown as being about 0.2 inches (5 mm). It should be noted that the steel insert which comprises the metal bolt 715 and head 715 can have any shape that provides adequate strength. In one embodiment, the head 715 has a diameter of about 0.8 inches (20 mm).
[0047] FIG. 19 is a cross section of the mounting peg 700 . The mounting peg has a nut 725 that mates with a bolt on the radiator. A clearance 730 is formed in the peg to receive the bolt on the radiator. In one embodiment, the clearance 730 is substantially the same diameter as the bolt on the radiator.
[0048] Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | A radiator assembly having a support bar, mounting pegs, and a radiator. The support bar has a center portion and respective end portions welded to the center portion. The end portions have respective flared ends that mate with the center portion and a pair of support mounts. The mounting pegs mate have a flexible portion that mates with the support mounts and a comolded fastener that mates with the radiator. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of Taiwan application serial no. 93118236, filed Jun. 24, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electrostatic discharge (ESD) protection circuit, and more particularly to ESD protection circuit of level shifters.
[0004] 2. Description of the Related Art
[0005] Mixed-voltage integrated circuits apply system voltages with different voltage levels to internal circuits. FIG. 1A is a partial circuit block diagram of a prior art mixed-voltage integrated circuit. The operating voltages of the internal circuit 110 comprises the system voltage VDD 1 , e.g. 3.3 V, and the ground voltage VSS 1 , e.g. 0 V. The operating voltages of the internal circuit 130 comprises the system voltage VDD 2 , e.g. 12 V, and the ground voltage VSS 2 , e.g. 0 V. The logic level of the internal circuit 110 does not match that of the internal circuit 130 . A level shifter 110 is required and serves as an interface of these circuits. For example, the level shifter 120 receives the signal 111 output from the internal circuit 110 , transforms the signal 111 , e.g. 3.3 V. into a corresponding signal 131 and outputs the signal 131 to the internal circuit 130 , e.g. 12 V.
[0006] When ESD occurs at a terminal of the mixed-voltage integrated circuit, the ESD current flows along a low impedance path. Due to the ESD current, the devices on such a path will be damaged. FIG. 1B is a drawing showing the ESD paths of the level shifter 120 shown in FIG. 1A . Referring to FIG. 1B , when ESD occurs at the ground voltage VSS 2 and the system voltage VDD 1 is grounded, the ESD current flows from the ground voltage VSS 2 to the system voltage VDD 1 through the gate capacitor of the transistor 121 , i.e. the dot line ESD 1 . When the ground voltage VSS 1 is grounded, the ESD current flows from the ground voltage VSS 2 to the ground voltage VSS 1 through the gate capacitor of the transistor 121 , i.e. the dot line ESD 2 . Accordingly, the transistors 121 and 122 may be damaged.
[0007] The damage on the devices is caused due to the fact that the ground voltage VSS 1 and the ground voltage VSS 2 are not coupled to each other. The ESD current cannot reach the ground voltage VSS 2 through the ground voltage VSS 1 , but through the silicon bulk. Due to the low impedance of the silicon bulk, the ESD current damages the transistor 121 . Because of the short period of time of the ESD pulse, the impedance of the gate capacitor under ESD operation is lower than the impedance under normal operation.
[0008] FIG. 1C is a drawing showing another ESD path of the level shifter 120 shown in FIG. 1A . Referring to FIG. 1C , the ESD damage becomes more serious when ESD occurs at the system voltage VDD 2 , rather than on the ground voltage VSS 2 . This phenomenon is observed due to no discharge path existing in the N-well when ESD occurs at the system voltage VDD 2 . To the contrary, a discharge path can be implemented by connecting the ground voltage VSS 1 and the ground voltage VSS 2 through the silicon bulk. When ESD occurs at the system voltage VDD 2 , and because the system voltage VDD 1 is grounded, the ESD current flows from the system voltage VDD 2 to the system voltage VDD 1 through the gate capacitor of the transistor 123 , i.e. the path of ESD 1 . When the ground voltage VSS 1 is grounded, the ESD current flows from the system voltage VDD 2 to the ground voltage VSS 1 through the gate capacitor of the transistor 123 , i.e. the path of ESD 2 . Accordingly, the transistors 123 and 124 may be damaged.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is directed to a electrostatic discharge (ESD) preventing-able level shifter capable of preventing an ESD current flowing from a set of power terminals to another set of power terminals and thereby reducing damage to the level shifter.
[0010] The present invention is directed to another ESD preventing-able level shifter capable of providing other ESD route for discharging charges so as to protect the level shifter from damage.
[0011] The present invention is directed to the a ESD preventing-able level shifter capable of providing another ESD route between sets of power terminals so as to protect the level shifter from damage.
[0012] The present invention discloses a ESD preventing-able level shifter for receiving a first signal and outputting a second signal with a level corresponding to a level of the first signal. The first signal is transmitted between a first system voltage and a first ground voltage, and the second signal is transmitted between a second system voltage and a second ground voltage. The level shifter comprises an inverter, a voltage converter, a first ESD clamp circuit and a second ESD clamp circuit. The inverter receives the first signal and outputs a first reverse signal, wherein the first reverse signal is reverse with respect to the first signal and is transmitted between the first system voltage and the first ground voltage. A first input terminal of the voltage converter receives the first reverse signal. A second input terminal of the voltage converter receives the first signal. An output terminal of the voltage converter outputs the second signal. A first terminal of the first ESD clamp circuit is coupled to the first input terminal of the voltage converter. A second terminal of the first ESD clamp circuit is coupled to the second ground voltage. A first terminal of the second ESD clamp circuit is coupled to the second input terminal of the voltage converter. A second terminal of the second ESD clamp circuit is coupled to the second ground voltage.
[0013] The present invention discloses another ESD preventing-able level shifter for receiving a first signal and outputting a second signal with a level corresponding to a level of the first signal. The first signal is transmitted between a first system voltage and a first ground voltage, and the second signal is transmitted between a second system voltage and a second ground voltage. The level shifter comprises an inverter, a voltage converter, a first ESD clamp circuit and a second ESD clamp circuit. The inverter receives the first signal and outputs a first reverse signal, wherein the first reverse signal is reverse with respect to the first signal and is transmitted between the first system voltage and the first ground voltage. A first input terminal of the voltage converter receives the first reverse signal. A second input terminal of the voltage converter receives the first signal. An output terminal of the voltage converter outputs the second signal. A first terminal of the first ESD clamp circuit is coupled to the second system voltage. A second terminal of the first ESD clamp circuit is coupled to the first input terminal of the voltage converter. A first terminal of the second ESD clamp circuit is coupled to the second system voltage. A second terminal of the second ESD clamp circuit is coupled to the second input terminal of the voltage converter.
[0014] According to another embodiment of the present invention, a ESD preventing-able level shifter for receiving a first signal and outputting a second signal with a level corresponding to a level of the first signal is provided. The first signal is transmitted between a first system voltage and a first ground voltage, and the second signal is transmitted between a second system voltage and a second ground voltage. The level shifter comprises an inverter, a voltage converter and ESD clamp circuit. The inverter receives the first signal and outputs a first reverse signal, wherein the first reverse signal is reverse to the first signal and transmitted between the first system voltage and the first ground voltage. A first input terminal of the voltage converter receives the first reverse signal. A second input terminal of the voltage converter receives the first signal. An output terminal of the voltage converter outputs the second signal. A first terminal of the ESD clamp circuit is coupled to the second system voltage. A second terminal of the ESD clamp circuit is coupled to the first ground voltage.
[0015] According to the exemplary ESD preventing-able level shifters of the present invention, the ESD clamp circuit comprises, for example, an N-type transistor. A drain of the N-type transistor is coupled to a first input terminal of the voltage converter. The gate, the source and the bulk of the N-type transistor are coupled to the second ground voltage. The ESD clamp circuit may comprise, for example, a diode. A cathode of the diode is coupled to the first input terminal of the voltage converter, and an anode of the diode is coupled to the second ground voltage.
[0016] By using the ESD clamp circuit, the present invention provides a current route for releasing ESD currents flowing between sets of the power terminals so as to reduce the damage to the internal circuits, such as level shifter, of the integrated circuit.
[0017] The above and other features of the present invention will be better understood from the following detailed description of the preferred embodiments of the invention that is provided in communication with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a partial circuit block diagram of a prior art mixed-voltage integrated circuit.
[0019] FIG. 1B is a drawing showing the ESD paths of the level shifter 120 shown in FIG. 1A .
[0020] FIG. 1C is a drawing showing another ESD path of the level shifter 120 shown in FIG. 1A .
[0021] FIG. 2A is a schematic drawing showing a level shifter according to an embodiment of the present invention.
[0022] FIG. 2B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0023] FIG. 3A is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0024] FIG. 3B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0025] FIG. 4A is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0026] FIG. 4B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0027] FIG. 5A is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0028] FIG. 5B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0029] FIG. 6A is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0030] FIG. 6B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0031] FIG. 7A is a schematic drawing showing a level shifter according to another embodiment of the present invention.
[0032] FIG. 7B is a schematic drawing showing a level shifter according to another embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0033] FIG. 2A is a schematic drawing showing a level shifter according to an embodiment of the present invention. Referring to FIG. 2A , the level shifter 220 receives the first signal 211 output from the internal circuit 210 of the integrated circuit. The level shifter 220 outputs a second signal 231 with a level corresponding to the level of the first signal 211 , which is received by the internal circuit 230 of the integrated circuit. The first signal 211 is transmitted between the first system voltage VDD 1 , e.g. 3.3 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 231 is transmitted between the second system voltage VDD 2 , e.g. 12 V, and the second ground voltage VSS 2 , e.g. 0 V.
[0034] In this embodiment, the level shifter 220 comprises an inverter 240 , a voltage converter 250 , a first electrostatic discharge (ESD) clamp circuit 260 and a second ESD clamp circuit 270 . The inverter 240 receives the first signal 211 and outputs a first reverse signal 241 . The first reverse signal 241 is reverse to the first signal 211 . The first reverse signal 241 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 .
[0035] The inverter 240 comprises, for example, a P-type transistor 242 and an N-type transistor 244 . The source of the transistor 242 is coupled to the first system voltage VDD 1 . The gate of the transistor 242 receives the first signal 211 . The drain of the transistor 242 outputs the first reverse signal 241 . The gate of the transistor 244 receives the first signal 211 . The drain of the transistor 244 is coupled to the drain of the transistor 242 . The source of the transistor 244 is coupled to the first ground voltage VSS 1 .
[0036] The first input terminal of the voltage converter 250 receives the first reverse signal 241 . The second input terminal of the voltage converter 250 receives the first signal 211 . The output terminal of the voltage converter 250 outputs the second signal 231 . The voltage converter 250 comprises, for example, the P-type transistors T 1 and T 3 , and the N-type transistors T 2 and T 4 .
[0037] The first source/drain, for example, a first source hereafter, of the first transistor T 1 is coupled to the second system voltage VDD 2 . The gate of the second transistor T 2 receives the reverse signal 241 . The first source/drain, for example, a drain hereafter, of the second transistor T 2 is coupled to the second source/drain, for example, a drain hereafter, of the first transistor T 1 . The second source/drain, for example, a source hereafter, of the second transistor T 2 is coupled to the second ground voltage VSS 2 . The first source/drain, for example, a source hereafter, of the third transistor T 3 is coupled to the second system voltage VDD 2 . The second source/drain, for example, a drain hereafter, of the third transistor T 3 is coupled to the gate of the first transistor T 1 . The gate of the third transistor T 3 is coupled to the drain of the first transistor T 1 . The gate of the fourth transistor T 4 receives the first signal 211 . The first source/drain, for example, a drain hereafter, of the fourth transistor T 4 is coupled to the drain of the third transistor T 3 . The second source/drain, for example, a source hereafter, of the fourth transistor T 4 is coupled to the second ground voltage VSS 2 . The signal on the drain of the fourth transistor T 4 is the second signal 231 .
[0038] The first terminal of the first ESD clamp circuit 260 is coupled to the first input terminal of the voltage converter 250 . The second terminal of the first ESD clamp circuit 260 is coupled to the second ground voltage VSS 2 . The first terminal of the second ESD clamp circuit 270 is coupled to the second input terminal of the voltage converter 250 . The second terminal of the second ESD clamp circuit 270 is coupled to the second ground voltage VSS 2 .
[0039] In this embodiment, the first ESD clamp circuit 260 comprises, for example, an N-type transistor. The drain of the N-type transistor is coupled to the first input terminal of the voltage converter 250 . The gate, the source and the bulk of the N-type transistor are coupled to the second ground voltage VSS 2 . One of ordinary skill in the art will understand that the first ESD clamp circuit 260 may comprise a diode. FIG. 2B is a schematic drawing showing a level shifter according to an another embodiment of the present invention. Referring to FIG. 2B , a diode is used in the first ESD clamp circuit 260 . The cathode of the diode is coupled to the first input terminal of the voltage converter 250 . The anode of the diode is coupled to the second ground voltage VSS 2 . In this embodiment, the second clamp circuit 270 is similar to the first clamp circuit 260 . Detailed descriptions are not repeated.
[0040] When ESD occurs at the terminal of the second ground voltage VSS 2 , and because the first system voltage VDD 1 is grounded, the ESD current will flow from the second ground voltage VSS 2 to the first system voltage VDD 1 through the first ESD clamp circuit 260 and the transistor 242 . If the terminal of the first ground voltage VSS 1 is grounded, the ESD current flows from the second ground voltage VSS 2 to the first ground circuit VSS 1 through the first ESD clamp circuit 260 and the transistor 244 . Accordingly, the damage to the level shifter 220 can be reduced.
[0041] Following are the descriptions of another embodiment of the present invention. FIG. 3A is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 3A , the level shifter 320 receives the first signal 311 outputted from the internal circuit 310 of the integrated circuit. The level shifter 320 outputs a second signal 331 with a level corresponding to the level of the first signal 311 , which is received by the internal circuit 330 of the integrated circuit. The first signal 311 is transmitted between the first system voltage VDD 1 , e.g. 3.3 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 331 is transmitted between the second system voltage VDD 2 , e.g. 12 V, and the second ground voltage VSS 2 , e.g. 0 V. The level shifter 320 comprises an inverter 340 , a voltage converter 350 , a first electrostatic discharge (ESD) clamp circuit 360 and a second ESD clamp circuit 370 .
[0042] The inverter 340 receives a first signal 311 and outputs a first reverse signal 341 . The first reverse signal 341 is reverse with respect to the first signal 311 . The first reverse signal 341 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 . In this embodiment, the inverter 340 comprises, for example, a P-type transistor 342 and an N-type transistor 344 . The source of the transistor 342 is coupled to the first system voltage VDD 1 . The gate of the transistor 342 receives the first signal 311 . The drain of the transistor 342 outputs the first reverse signal 341 . The gate of the transistor 344 receives the first signal 311 . The drain of the transistor 344 is coupled to the drain of the transistor 342 . The source of the transistor 344 is coupled to the first ground voltage VSS 1 .
[0043] The first input terminal of the voltage converter 350 receives the first reverse signal 341 . The second input terminal of the voltage converter 350 receives the first signal 311 . The output terminal of the voltage converter 350 outputs the second signal 331 . The first terminal of the first ESD clamp circuit 360 is coupled to the second system voltage VDD 2 . The second terminal of the first ESD clamp circuit 360 is coupled to the first input terminal of the voltage converter 350 . The first terminal of the second ESD clamp circuit 370 is coupled to the second system voltage VDD 2 . The second terminal of the second ESD clamp circuit 370 is coupled to the second input terminal of the voltage converter 350 .
[0044] The voltage converter 350 comprises, for example, the P-type transistors T 1 , T 2 , T 4 and T 5 , and the N-type transistors T 3 and T 6 . The first source/drain, for example, a source hereafter, of the first transistor T 1 is coupled to the second system voltage VDD 2 . The gate of the second transistor T 2 receives the reverse signal 341 . The first source/drain, for example, a source hereafter, of the second transistor T 2 is coupled to the second source/drain, for example, a drain thereafter, of the first transistor T 1 . The gate of the third transistor T 3 receives the first reverse signal 341 . The first source/drain, for example, a drain thereafter, of the third transistor T 3 is coupled to the second source/drain, for example, a drain hereafter, of the second transistor T 2 . The second source/drain, for example, a source hereafter, of the third transistor T 3 is coupled to the second ground voltage VSS 2 . The first source/drain, for example, a source hereafter, of the fourth transistor T 4 is coupled to the second system voltage VDD 2 . The gate of the fourth transistor T 4 is coupled to the drain of the second transistor T 2 . The gate of the fifth transistor T 5 receives the first signal 311 . The first source/drain, for example, a source, of the fifth transistor T 5 is coupled to the second source/drain, for example, a drain, of the fourth transistor T 4 . The second source/drain, for example, a drain, of the fifth transistor T 5 is coupled to the gate of the transistor T 1 . The gate of the sixth transistor T 6 receives the first signal 311 . The first source/drain, for example, a drain, of the sixth transistor T 6 is coupled to the drain of the fifth transistor T 5 . The second source/drain, for example, a source, of the sixth transistor T 6 is coupled to the second ground voltage VSS 2 . The signal on the drain of the sixth transistor T 6 is the second signal 331 .
[0045] In this embodiment, the first ESD clamp circuit 360 comprises, for example, a P-type transistor. The drain of the P-type transistor is coupled to the first input terminal of the voltage converter 350 . The gate, the source and the bulk of the P-type transistor are coupled to the second system voltage VDD 2 . One of ordinary skill in the art will understand that the first ESD clamp circuit 360 may comprise a diode. FIG. 3B is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 3B , a diode is used in the first ESD clamp circuit 360 . The anode of the diode is coupled to the first input terminal of the voltage converter 350 . The cathode of the diode is coupled to the second system voltage VDD 2 . In this embodiment, the second ESD clamp circuit 370 is similar to the first ESD clamp circuit 360 . Detailed descriptions are not repeated.
[0046] When ESD occurs at the terminal of the second system voltage VDD 2 and the first system voltage VDD 1 is grounded, the ESD current will flow from the second system voltage VDD 2 to the first system voltage VDD 1 through the first ESD clamp circuit 360 and the transistor 342 . If the terminal of the first ground voltage VSS 1 is grounded, the ESD current will flow from the second system voltage VDD 2 to the first ground circuit VSS 1 through the first ESD clamp circuit 360 and the transistor 344 . Accordingly, damage to the level shifter 320 can be reduced.
[0047] Following are the descriptions of another embodiment of the present invention. FIG. 4A is a schematic drawing showing another level shifter according to an embodiment of the present invention. Referring to FIG. 4A , the level shifter 420 receives the first signal 411 outputted from the internal circuit 410 of the integrated circuit. The level shifter 420 outputs a second signal 431 with a level corresponding to the level of the first signal 411 , which is received by the internal circuit 430 of the integrated circuit. The first signal 411 is transmitted between the first system voltage VDD 1 , e.g. 3.3 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 431 is transmitted between the second system voltage VDD 2 , e.g. 12 V, and the second ground voltage VSS 2 , e.g. 0 V.
[0048] In this embodiment, the level shifter 420 comprises an inverter 440 , a voltage converter 450 and an electrostatic discharge (ESD) clamp circuit 460 . The inverter 440 receives the first signal 411 and outputs a first reverse signal 441 . The first reverse signal 441 is reverse with respect to the first signal 411 . The first reverse signal 441 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 .
[0049] The voltage converter 450 and the inverter 440 are similar to the voltage converter 350 and the inverter 340 shown in FIG. 3A , respectively above. Detailed descriptions are not repeated.
[0050] The first terminal of the ESD clamp circuit 460 is coupled to the second system voltage VDD 2 , and the second terminal of the ESD clamp circuit 460 is coupled to the first ground voltage VSS 1 . In this embodiment, the ESD clamp circuit 460 comprises, for example, a transistor. The collector of the transistor is coupled to the second system voltage VDD 2 . The emitter and base of the transistor is coupled to the first ground voltage VSS 1 . One of ordinary skill in the art will understand that the ESD clamp circuit 460 may comprise a diode. FIG. 4B is a schematic drawing showing another level shifter according to an embodiment of the present invention. Referring to FIG. 4B , a diode is used in the ESD clamp circuit 460 . The anode of the diode is coupled to the first ground voltage VSS 1 . The cathode of the diode is coupled to the second system voltage VDD 2 .
[0051] When ESD occurs at the terminal of the second system voltage VDD 2 , and because the first ground voltage VSS 1 is grounded, the ESD current will flow from the second system voltage VDD 2 to the first ground voltage VSS 1 through the ESD clamp circuit 460 . Accordingly, damage to the level shifter 420 can be reduced.
[0052] Following are the descriptions of another embodiment present invention. FIG. 5A is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 5A , the level shifter 520 receives the first signal 511 outputted from the internal circuit 510 of the integrated circuit. The level shifter 520 outputs a second signal 531 with a level corresponding to the level of the first signal 511 , which is received by the internal circuit 530 of the integrated circuit. The first signal 511 is transmitted between the first system voltage VDD 1 , e.g. 12 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 531 is transmitted between the second system voltage VDD 2 , e.g. 3.3 V, and the second ground voltage VSS 2 , e.g. 0 V.
[0053] In this embodiment, the level shifter 520 comprises an inverter 540 , a voltage converter 550 and electrostatic discharge (ESD) clamp circuits 560 and 570 . The inverter 540 receives the first signal 511 and outputs a first reverse signal 541 . The first reverse signal 541 is reverse with respect to the first signal 511 . The first reverse signal 541 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 .
[0054] In this embodiment, the inverter 540 is similar to those described above. Detailed descriptions are not repeated.
[0055] In this embodiment, the voltage converter 550 comprises, for example, the P-type transistors T 1 and T 3 , and the N-type transistors T 2 and T 4 . The first source/drain, named as a source thereafter, of the transistor T 1 is coupled to the second system voltage VDD 2 . The gate of the transistor T 1 receives a reverse signal 541 . The first source/drain, for example, a drain hereafter, of the transistor T 2 is coupled to the second source/drain, for example, a drain hereafter, of the transistor T 1 . The second source/drain, for example, a source hereafter, of the transistor T 2 is coupled to the second ground voltage VSS 2 . The first source/drain, for example, a source hereafter, of the transistor T 3 is coupled to the second system voltage VDD 2 . The second source/drain, for example, a drain hereafter, of the transistor T 3 is coupled to the gate of the transistor T 2 . The gate of the transistor T 3 receives the signal 511 . The gate of the transistor T 4 is coupled to the drain of the transistor T 1 . The first source/drain, for example, a drain hereafter, of the transistor T 4 is coupled to the drain of the transistor T 3 . The second source/drain, for example, a source hereafter, of the transistor T 4 is coupled to the second ground voltage VSS 2 . The signal on the drain of the transistor T 4 is the second signal 531 .
[0056] The first terminal of the first ESD clamp circuit 560 is coupled to the second system voltage VDD 2 . The second terminal of the first ESD clamp circuit 560 is coupled to gate of the first transistor T 1 . In this embodiment, the first ESD clamp circuit 560 comprises, for example, a P-type transistor. The drain of the P-type transistor is coupled to the first input terminal of the voltage converter 550 , i.e. the gate of the first transistor T 1 . The gate, the source and the bulk of the P-type transistor are coupled to the second system voltage VDD 2 . One of ordinary skill in the art will understand that the first ESD clamp circuit 560 may comprise a diode. FIG. 5B is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 5B , a diode is used in the first ESD clamp circuit 560 . The cathode of the diode is coupled to the second system voltage VDD 2 . The anode of the diode is coupled to the first input terminal of the voltage converter 550 , i.e. the gate of the transistor T 1 .
[0057] In this embodiment, the ESD clamp circuit 570 is similar to the first ESD clamp circuit. Detailed descriptions are not repeated.
[0058] FIG. 6A is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 6A , the level shifter 620 receives the first signal 611 outputted from the internal circuit 610 of the integrated circuit. The level shifter 620 outputs a second signal 631 with a level corresponding to the level of the first signal 611 , which is received by the internal circuit 630 of the integrated circuit. The first signal 611 is transmitted between the first system voltage VDD 1 , e.g. 12 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 631 is transmitted between the second system voltage VDD 2 , e.g. 3.3 V, and the second ground voltage VSS 2 , e.g. 0 V.
[0059] In this embodiment, the level shifter 620 comprises an inverter 640 , a voltage converter 650 and electrostatic discharge (ESD) clamp circuits 660 and 670 . The inverter 640 receives the first signal 611 and outputs a first reverse signal 641 . The first reverse signal 641 is reverse with respect to the first signal 611 . The first reverse signal 641 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 .
[0060] In this embodiment, the inverter 640 is similar to those described above. Detailed descriptions are not repeated.
[0061] The voltage converter 650 comprises, for example, the P-type transistors T 1 and T 4 , and the N-type transistors T 2 , T 3 , T 5 and T 6 . The gate of the first transistor T 1 receives the reverse signal 641 . The first source/drain, for example, a source hereafter, of the transistor T 1 is coupled to the second system voltage VDD 2 . The gate of the transistor T 2 is coupled to the gate of the transistor T 1 . The first source/drain, for example, a drain hereafter, of the transistor T 2 is coupled to the second source/drain, for example, a drain hereafter, of the transistor T 1 . The first source/drain, for example, a drain hereafter, of the transistor T 3 is coupled to the second source/drain, for example, a source thereafter, of the transistor T 2 . The second source/drain, for example, a source thereafter, of the transistor T 3 is coupled to the second ground voltage VSS 2 . The first source/drain, for example, a source thereafter, of the transistor T 4 is coupled to the second system voltage VDD 2 . The second source/drain, for example, a drain hereafter, of the transistor T 4 is coupled to the gate of the transistor T 3 . The gate of the transistor T 4 receives the first signal 611 . The gate of the transistor T 5 is coupled to the gate of the transistor T 4 . The first source/drain, for example, a drain, of the transistor T 5 is coupled to the drain of the transistor T 4 . The gate of the transistor T 6 is coupled to the drain of the transistor T 1 . The first source/drain, for example, a drain, of the transistor T 6 is coupled to the source of the transistor T 5 . The second source/drain, for example, a source, of the transistor T 6 is coupled to the second ground voltage VSS 2 . The signal on the drain of the transistor T 6 is the second signal 631 .
[0062] The first terminal of the ESD clamp circuit 660 is coupled to the second system voltage VDD 2 , and the second terminal of the ESD clamp circuit 660 is coupled to the gates of the first and the second transistors T 1 and T 2 , respectively. In this embodiment, the first ESD clamp circuit 660 comprises, for example, a P-type transistor. The drain of the P-type transistor is coupled to the first input terminal of the voltage converter 650 , i.e. the gates of the first and the second transistors T 1 and T 2 . The gate, the source and the bulk of the P-type transistor are coupled to the second system voltage VDD 2 . One of ordinary skill in the art will understand that the first ESD clamp circuit 660 may comprise a diode. FIG. 6B is a schematic drawing showing another level shifter according to an embodiment of the present invention. Referring to FIG. 6B , a diode is used in the ESD clamp circuit 660 . The anode of the diode is coupled to the first input terminal of the voltage converter 650 . The cathode of the diode is coupled to the second system voltage VDD 2 .
[0063] In this embodiment, the second ESD clamp circuit 670 is similar to the ESD clamp circuit 660 . Detailed descriptions are not repeated.
[0064] FIG. 7A is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 7A , the level shifter 720 receives the first signal 711 outputted from the internal circuit 710 of the integrated circuit. The level shifter 720 outputs a second signal 731 with a level corresponding to the level of the first signal 711 , which is received by the internal circuit 730 of the integrated circuit. The first signal 711 is transmitted between the first system voltage VDD 1 , e.g. 12 V, and the first ground voltage VSS 1 , e.g. 0 V. The second signal 731 is transmitted between the second system voltage VDD 2 , e.g. 3.3 V, and the second ground voltage VSS 2 , e.g. 0 V.
[0065] In this embodiment, the level shifter 720 comprises an inverter 740 , a voltage converter 750 and electrostatic discharge (ESD) clamp circuits 760 and 770 . The inverter 740 receives the first signal 711 and outputs a first reverse signal 741 . The first reverse signal 741 is reverse to the first signal 711 . The first reverse signal 741 is transmitted between the first system voltage VDD 1 and the first ground voltage VSS 1 .
[0066] The voltage converter 750 and the inverter 740 are similar to the voltage converter 650 and the inverter 640 shown in FIG. 6A , respectively. Detailed descriptions are not repeated.
[0067] The first terminal of the ESD clamp circuit 760 is coupled to gates of the first and the second transistors T 1 and T 2 , respectively, and the second terminal of the ESD clamp circuit 760 is coupled to the second ground voltage VSS 2 . In this embodiment, the first ESD clamp circuit 760 comprises, for example, an N-type transistor. The drain of the N-type transistor is coupled to the first input terminal of the voltage converter 750 , i.e. the gates of the first and the second transistors T 1 and T 2 . The gate, the source and the bulk of the N-type transistor are coupled to the second ground voltage VSS 2 . One of ordinary skill in the art will understand that the first ESD clamp circuit 760 may comprise a diode. FIG. 7B is a schematic drawing showing a level shifter according to another embodiment of the present invention. Referring to FIG. 7B , a diode is used in the ESD clamp circuit 760 . The cathode of the diode is coupled to the first input terminal of the voltage converter 750 . The anode of the diode is coupled to the second ground voltage VSS 2 .
[0068] In this embodiment, the second ESD clamp circuit 770 is similar to the ESD clamp circuit 760 . Detailed descriptions are not repeated.
[0069] It can be noted that the voltage converter 450 shown in FIGS. 4A and 4B can be replaced by any other voltage converter, such as the voltage converters 250 , 550 and 650 shown in FIGS. 2A, 5A and 6 A, respectively.
[0070] Although the present invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be constructed broadly to include other variants and embodiments of the invention which may be made by those skilled in the field of this art without departing from the scope and range of equivalents of the invention. | ESD preventing-able level shifter, for receiving a first signal and outputting a second signal is provided. The level shifter comprises an inverter, a voltage converter, a first ESD clamp circuit and a second ESD clamp circuit. The inverter receives the first signal and outputs a first reverse signal. The voltage converter having a first input terminal for receiving the first reverse signal, a second input terminal for receiving the first signal and an output terminal for outputting the second signal. A first and second terminal of the first ESD clamp circuit is coupled to the first input terminal of the voltage converter and a second ground voltage, respectively. A first and a second terminal of the second ESD clamp circuit is coupled to the second input terminal of the voltage converter and the second ground voltage, respectively. | 7 |
BACKGROUND TO THE INVENTION
[0001] THIS invention relates to a toilet cistern dual flush valve which is capable of discharging different volumes of water from the cistern at the election of the operator.
[0002] Toilet cisterns generally have a fixed volume of water, the full content of which is discharged to the toilet bowl when flushing is initiated. In many instances, a full discharge is not required and effective flushing of the toilet bowl could be achieved by discharging a smaller volume from the cistern. In this way wastage of water could be minimised resulting in reduced water consumption and associated costs to the consumer.
[0003] A number of dual flush toilet cistern valves have been devised with a view to providing the user of the toilet with a choice between a full flush in which the full content of the cistern is discharged into the toilet bow), and a partial flush in which only part of the cistern content is discharged. Many of the known dual flush valves are either complicated and expensive to manufacture or are unreliable in operation. Another problem with some known dual flush valves is their use of two separate floats each at the end of a relatively long, transverse float arm to achieve selective locking of a valve stem carrying the valve closure which controls the discharge of water from the cistern to the bowl. The long float arms make such valves unsuitable for use in the compact cisterns which are currently in favour. The present invention seeks to provide a compact, simple and relatively inexpensive dual flush valve.
SUMMARY OF THE INVENTION
[0004] According to the invention there is provided a toilet cistern dual flush valve operable selectively in a full flush mode in which a relatively large volume of water is discharged from the cistern or a partial flush mode in which a relatively small volume of water is discharged from the cistern, the valve comprising;
[0005] a valve stem carrying a valve closure seatable on an outlet from the cistern and movable between a raised, open position in which the closure is spaced from the outlet and a lowered, closed position in which the closure seats on the outlet,
[0006] means operable in both full and partial flush modes to raise the stem,
[0007] operatively buoyant means attached to the stern which in the full flush mode maintains the stem in the open position until the relatively large volume of water has been discharged and the buoyant means loses buoyancy whereafter the stem descends under gravity to the closed position, and
[0008] means which operates in the partial flush mode to add sufficient further mass to the stem when the relatively small volume of water has been discharged, to cause the stem to descend to the closed position.
[0009] A preferred embodiment of the invention includes actuators which are selectively, manually operable to initiate the full or partial flush mode, an upper float unit, upper and lower collars on the stem, and linkages extending between the actuators and the upper float unit such that operation of either actuator raises the upper float unit into abutment with an upper collar on the stem thereby raising the stem to the open position. The linkages may include a toggle attached pivotally to the upper float unit and carrying a detent, the arrangement being such that operation of the relevant actuator to initiate a partial flush causes the toggle to pivot to a position in which the detent engages the lower collar and adds the mass of the upper float unit to the stem when the water in the cistern has dropped to a level at which the upper float unit loses buoyancy. The upper float unit may include a water reservoir to accommodate a volume of water providing gravitational mass.
[0010] Both the main float and the upper float unit may include inverted cup-shapes to accommodate air which renders both the main float and upper float units buoyant in water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0012] [0012]FIG. 1 shows a partially exploded perspective view of a dual flush valve according to this invention;
[0013] [0013]FIG. 2 shows a side view of the stem, main float and closure assembly of the dual flush valve of FIG. 1;
[0014] [0014]FIG. 3 shows a side view of the secondary float unit of the dual flush valve of FIG. 1;
[0015] [0015]FIG. 4 shows a side view of relevant components of the dual flush valve of FIG. 1 when a full flush is initiated;
[0016] [0016]FIG. 5 shows a vertical cross-sectional view of relevant components of the dual flush valve of FIG. 1 when a partial flush is initiated;
[0017] [0017]FIG. 6 shows a horizontal cross-section at the line 6 - 6 in FIG. 4;
[0018] [0018]FIG. 7 shows a horizontal cross-section at the line 7 - 7 in FIG. 5;
[0019] [0019]FIG. 8 shows a side view of a second embodiment of the dual flush valve according to the invention;
[0020] [0020]FIG. 9 shows an exploded perspective view of components for suspending the dual flush valve of FIG. 8 in a cistern; and
[0021] [0021]FIG. 10 shows a perspective view of actuating buttons of the dual flush valve of FIG. 8.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] [0022]FIG. 1 shows a dual flush valve 10 according to this invention. The valve 10 includes an outlet structure 12 having a threaded spigot 14 , a nut 16 mateable with the spigot, a flange 18 and three legs 20 extending vertically from the flange and carrying enlargements 22 at their upper ends.
[0023] The valve 10 also includes a housing 24 of generally inverted cup shape. The housing has a cylindrical skirt 25 carrying circumferentially spaced locking formations 26 and an annular upper wall 28 from which a cylindrical sleeve 30 projects vertically.
[0024] When installed in a toilet cistern 31 the spigot 14 is passed downwardly through an opening in the base 33 of the cistern and the outlet structure 12 is locked in place by engaging the nut 16 with the spigot beneath the base. The housing 24 is then located over the outlet structure 12 with the enlargements 22 received through enlarged zones 32 of the locking formations 26 . The housing is then rotated relative to the outlet structure to locate the enlargements 22 over relatively narrow zones 34 of the locking formations 26 . It will accordingly be understood that the housing 24 is locked to the outlet structure 12 by what is, in effect, a bayonet action.
[0025] The dual flush valve 10 also includes a vertical, hollow stem 36 carrying a closure 38 at its lower end which can seat on the rim of the outlet opening 40 through the outlet structure 12 . The stem passes slidably through the sleeve 30 of the housing 24 and carries a relatively large collar 42 and a relatively small collar 44 at spaced apart positions near to its open upper end. Beneath the upper wall 28 of the housing the stem passes through, and is fixed to, a central sleeve 46 extending downwardly from the horizontal upper wall 48 of a main float 50 . The float 50 is in the form of an inverted cup and has a cylindrical skirt 52 depending downwardly from the periphery of the upper wall 48 . The outside diameter of the float skirt 52 is somewhat less than the inside diameter of the housing skirt 25 so the float 50 , which is fixed to the stem 36 , is capable of free vertical movement within the housing.
[0026] Another component of the valve 10 is a secondary or upper float unit 54 which has an upper cup-shaped reservoir section 56 , a lower float section 58 of inverted cup-shape and a horizontal wall 60 serving both as a base of the section 56 and an upper wall of the section 58 . A central, vertical sleeve 62 extends upwardly from the wall 60 . The stem 36 extends freely through this sleeve which has an internal diameter greater than the external diameter of the lower collar 44 but smaller than the external diameter of the upper collar 42 . The upper edge of the sleeve 62 is formed with a cut-out 64 shaped as shown in FIG. 3.
[0027] Pivoted externally to the side of the sleeve 62 , at a pivot axis 66 located generally beneath the cut-out 64 , is a toggle 68 having the shape of a sector of a circle. The upper edge of the toggle carries a detent 70 which projects transversely into the cut-out 64 in a direction towards the stem 36 .
[0028] Attached pivotally to the toggle at spaced apart points on opposite sides of the pivot axis 66 are upright arms 72 and 74 . At their upper ends, the arms 72 and 74 are pivoted to respective transverse arms 76 and 78 . The arm 76 , which is a full flush arm, extends from a collar 80 fixed on a hollow shaft (not shown) which in use extends through the front wall 81 of the cistern and to which a full flush actuating handle 82 is connected. The arm 78 , which is a partial flush arm, extends from a collar 84 fixed on a shaft 85 which extends rotatably through the hollow shaft and to which a partial flush actuating handle 86 is connected. An element 88 extends from the collar 84 and overlies the collar 80 .
[0029] When the valve 10 is installed in the cistern in use, the actuating handles 82 and 86 are located externally on the front wall 81 of the cistern for selective operation by the user. When the full flush actuating handle 82 is depressed, i.e. pivoted in a clockwise direction as illustrated, the hollow shaft to which it is attached will rotate in a clockwise direction, thereby raising the arm 72 via the collar 80 and full flush arm 76 . Because of the presence of the element 88 , this action also rotates the collar 84 and hence the shaft 85 to which the partial flush actuating handle 86 is connected. As a consequence, the arm 74 is also raised via the partial flush arm 78 . The arms 72 and 74 apply balanced lifting forces to opposite sides of the toggle 68 which is itself lifted but does not rotate.
[0030] When the partial flush actuating handle 86 is depressed, the shaft to which it is connected rotates accordingly. The arm 74 is therefore raised via the collar 84 and partial flush arm 78 . However in this case, there is no corresponding movement of the arm 72 . The arm 74 applies an unbalanced force to the toggle and causes it to pivot, in an anticlockwise direction as viewed in FIG. 1, on the axis 66 . The detent 70 moves to a position in which it extends directly towards the axis of the stem 36 .
[0031] The operation of the dual flush valve 10 will now be explained with reference to a full flush action and a partial flush action. In both instances a flushing action will commence when the cistern is full of water, volumes of air are trapped in the main float 50 and in the float section 58 of the upper float unit 54 , the reservoir section 56 of the upper float unit is full of water, and the valve closure 38 is seated in sealing manner on the rim of the outlet opening 40 .
[0032] Full Flush
[0033] As just explained a full flush is initiated by depressing and then releasing the actuating handle 82 . Depression of the actuating handle has the effect of raising both arms 72 and 74 . Because the toggle 68 is attached to the upper float unit 54 at the pivot axis 66 , the upper float unit is pulled upwardly. When the upper edge of the sleeve 62 encounters the upper collar 42 on the stem 36 , the stem is also raised. This lifts the valve closure 38 off the rim of the outlet 40 , allowing water to discharge from the cistern through the spigot 14 and into the toilet bowl to perform a flushing action. During flushing the stem is kept in a raised position by the buoyancy of the main float 50 , attributable to the pocket of air trapped therein. Flushing will continue until the water level in the cistern has dropped to a level where the float 50 loses buoyancy, allowing the stem 36 and with it the closure 38 to drop. The closure reseats on the rim of the outlet opening 40 , thereby closing the valve again.
[0034] The upper float unit 54 is kept in a raised position during an initial part of the full flush by the air pocket trapped in the lower float section 58 . When the water level in the cistern drops beneath the lower edge of the float section 58 , the float unit 54 will descend with the water level until it eventually comes to rest on the upper wall 28 of the housing 24 . As described previously, the stem 36 and closure 38 are kept in the raised position by the buoyancy of the main float 50 until the full flush is completed
[0035] It is to be noted that because the toggle does not pivot when the full flush is initiated, the detent 70 remains in a position off-set laterally from the axis of the stem 36 , and so does not interfere with the collar 44 , as shown in FIG. 6.
[0036] Partial Flush
[0037] The partial flush is initiated by depressing the actuating handle 86 . As described previously, this has the effect of raising the arm 74 only. The unbalanced force on one side of the toggle causes the toggle to pivot as it is pulled upwardly by the arm 74 . As in the full flush mode of operation, the upper edge of the upper float unit 54 encounters the upper collar 42 and raises the stem 36 and closure 38 , initiating the flush. However in this case, the pivotal movement of the toggle aligns the detent 74 with the axis of the stem, with the result that the detent locates over the collar 44 , as shown in FIG. 7.
[0038] As in the full flush mode the stem 36 is kept raised and the closure 38 remains in an open position because of the buoyancy of the main float 50 . The upper float unit is also kept raised by the buoyancy attributable to the air pocket trapped in the float section 58 .
[0039] When a partial flush has taken place, the water in the cistern has dropped to the level of the lower edge of the float section 58 . At this point, the float unit 54 loses buoyancy and starts dropping. Because the detent 70 has located over and moves into contact with the collar 44 , the gravitational force on the float unit 54 is transferred to the stem 36 . While the unit 54 is itself relatively light, its mass is considerably increased by the volume of water in the reservoir section 56 . The combined mass of the float unit 54 and the volume of water in the reservoir section is sufficient to overcome the buoyancy of the main float 50 , so the stem is forced downwardly for the closure 38 to reseat on the rim of the opening 40 and close the valve. At this stage, only a part of the cistern contents have been discharged.
[0040] As the float unit 54 drops the toggle 68 is reset to a neutral or balanced position, in which the detent is free of the collar 44 , by the upward force on the toggle applied by the arm 72 .
[0041] In both the full and partial modes of operation, the cistern is refilled in the normal way via a cistern inlet valve which forms no part of the present invention and which is not shown in the drawings.
[0042] The design of the valve 10 described above is suitable for use in modern, compact toilet cisterns in which internal space is at a premium. It will also be appreciated that the valve 10 is of sufficiently simple construction to enable it to be manufactured at relatively modest cost.
[0043] A feature of the design is the use of the mass of water in the reservoir section 56 to apply a valve closing force in the partial flush mode. It is however within the scope of the invention for the required mass to be provided by, for instance, a weight attached to the float unit, although this would increase the overall cost of the valve.
[0044] A second embodiment of a dual flush valve is depicted in FIG. 8 and indicated by the reference numeral 110 . In this instance actuating buttons 112 and 114 replace the pivoted actuating handles 82 and 86 on the front wall of the cistern as described in the first embodiment.
[0045] The actuating buttons 112 and 114 are clearly illustrated in FIG. 10. It will be noted that they have flat portions at their sides allowing them to be placed juxtaposed within the flat portions facing one another.
[0046] [0046]FIG. 8 shows that the actuating buttons 112 and 114 are located in a sleeve 118 and are moveable relative to each other in the sleeve 118 . It will be noted that the sleeve is a carried by a support beam 120 .
[0047] The support beam 120 is suspended within the cistern by two brackets 122 and 124 . The connection between the support beam 120 and the brackets 122 and 124 is illustrated in FIG. 9. The support beam 120 has a tongue 126 locatable in a cavity 128 of the bracket 122 . Once the tongue 126 is located in the cavity 128 , it can be secured with a bolt 134 , shown in FIG. 8 , that is placed through holes 130 and 132 which are located in the tongue 126 and the bracket 122 respectively. The support beam 120 is connected to the support bracket 124 in a similar manner.
[0048] Various different options are available for suspending the brackets in position. FIG. 9 illustrates one possibility in which the bracket 122 has two protruding members 136 and 138 at its ends. The protruding member 136 is slidably locatable in a slot 140 defined by a support frame 142 that is attached to the inside of the front wall (not illustrated) of the cistern with adhesive. The protruding member 138 is attached to the back wall of the cistern in a similar fashion. Placing the cistern's lid in position will prevent the protruding members being removed from their respective slots.
[0049] It is envisaged that slots similar to the slot 140 can be formed in the walls of the cistern itself. However, the dual flush valve 110 should also be capable of use in existing cisterns and in such situations will require the use of frames as described above.
[0050] Turning again to FIG. 8, it will be noted that the sleeve 118 has two lugs 144 and 146 connected thereto, each support frame having a pivot pin indicated by the reference numerals 148 and 150 respectively.
[0051] The pivot pin 148 pivotally connects the button 112 via an arm 151 with an arm 152 , which is in turn connected to an arm 156 . A portion of the arm 151 is located in a cavity 153 shown in FIG. 10. In operation the linear movement of the button 112 in a downward direction will cause the arm 152 to pivot on the pivot pin 148 thereby moving the arm 156 in an upward direction. This movement, illustrated in broken lines in FIG. 8, will initiate a partial flush as described previously. Depressing both buttons simultaneously will lead to a full flush, also as described previously,
[0052] A further feature of the second embodiment is also illustrated in FIG. 8. It is know that toilet cisterns are normally manufactured in two standard sizes, i.e. 6 I and 9 I. In different embodiments of these cisterns the height of the cistern may vary. From an economic perspective it would therefore be desirable if a single dual flush valve 110 could be installed and used in cisterns having either of these standard sizes and varying cistern heights.
[0053] This objective is addressed by having arms 156 and 158 of telescopic construction. Telescopic movement is achieved in that the arms 156 and 158 include ratchets 160 and 162 as well as catches 164 and 166 respectively. Telescopic construction is well known in the art and it will suffice to say that each catch can be moved on the associated ratchet in such a manner that the effective length of the arms 156 and 158 can be either increased or decreased depending on the cistern size.
[0054] In FIG. 8 both the lower float section 58 of the upper float unit 54 and the float 50 are filled with closed cell foam. It has been mentioned that the floats 50 and 54 are kept in a raised position due to the buoyancy attributable to air pockets trapped therein. Using closed cell foam manufactured air pockets trapped therein will lead to a more constant degree of buoyancy of the floats thereby enhancing the overall performance of the dual flush valve 110 .
[0055] As indicated previously, the stem 36 is hollow. Its open upper end serves as a cistern overflow to allow water to escape from the cistern in the event of overfilling. In another modification, the stem could be of telescopic construction to allow its upper end to be raised or lowered to suit a particular cistern and the desired flush volume. | The invention provides a toilet cistern dual flush valve ( 10 ) operable selectively in a full flush mode in which a relatively large volume of water is discharged from the cistern or a partial flush mode in which a relatively small volume of water is discharged from the cistern. The dual flush valve ( 10 ) comprises a stem ( 36 ) carrying a valve closure ( 38 ) seatable on an outlet from the cistern, means to raise the stem ( 70, 72,74 ), buoyant means ( 50 ) attached to the stem ( 36 ) which in the full flush mode maintains the stem ( 36 ) in the open position until the relatively large volume of water has been discharged and the buoyant means ( 50 ) loses buoyancy whereafter the stem ( 36 ) descends under gravity to the closed position, and means ( 54 ) which operates in the partial flush mode to add sufficient mass to the stem when the relatively small volume of water has been discharged causing the stem ( 36 ) to descend to the closed position. | 4 |
BACKGROUND
This invention relates in general to the measurement of water vapor or dew point in a gas, and more particularly to such measurement using a compact solid state sensor which provides rapid measurement of absolute humidity or dew point over a wide range of temperature and pressure conditions.
The technique for performing a measurement of this sort has evolved, from the nineteenth century approach of plotting the temperature differential between dry and wet bulb thermometers, to modern systems wherein a small well-defined circuit element or structure which changes its resistance or capacitance in response to the surrounding humidity, is adapted to sense humidity in diverse process or measurement environments. By making the active circuit element thin or small, one is able to provide an instrument which reaches equilibrium with the atmosphere relatively quickly, and by utilizing films of material such as polymer or ceramic, these instruments may be relatively long-lived, such that the compilation of a table of operating parameters is readily carried out and can remain in effect or be recalibrated to achieve accuracy, or at least repeatability, for extended periods of time.
One example of this approach to humidity sensing instrumentation is shown in U.S. Pat. No. 3,523,244. That patent shows a sensor element in which an aluminum oxide layer approximately one quarter of a micron thick is formed on a conductive substrate and covered with a thin conductive but porous top surface electrode. The oxide layer, a hard hydrated form of aluminum oxide with an irregular pore structure, allows water vapor to permeate or diffuse through its thickness. This material takes on water in proportion to its partial pressure in the surrounding atmosphere, and changes in both its resistance and its capacitance are readily measured between the substrate and the surface electrode. As noted above, because of the relatively small thickness of the active layer, the element responds quickly to the surrounding humidity, with a response time normally ranging from a fraction of second to several minutes, depending on degree of saturation, and has a wide range for humidity levels that change over a range of three or more orders of magnitude.
Readout of such a device is accomplished with conventional circuitry of the type used for a great number of capacitive or resistive sensors, such as load cells, diaphragm-type capacitive differential pressure measuring instruments, and others. This may be done with a capacitance measuring bridge, or other such circuit. For example, a square or sawtooth wave oscillation of a few hundred to a few thousand Hz may be provided across the element to cyclically charge and discharge the sensor, and the voltage developed on the sensor may be synchronously sampled, amplified, rectified, and output as a normalized (e.g., zero to one volt) signal. In various embodiments, the direct voltage readout may be strictly proportional to absolute humidity or otherwise reflect the humidity reading in a particularly simple fashion. More generally, the capacitance will vary both with humidity and with temperature of the element, and readout is accomplished by having first compiled a table of the output values, and stored the table, and then applying the correct calibration scale from the stored table for the given temperature, pressure or other directly measured condition.
In addition to hydrated ceramic films as described in the above-referenced '244 patent, a number of films of a polymer, such as a polysulphone film, and other materials have been used as the water-sensitive layer to enhance the response, stability or other characteristics of the sensor.
One method for using such sensors is to first obtain a sensor calibration curve of the sensor capacitance for each relative humidity at a fixed temperature. Then, when a sample gas with an unknown relative humidity or dew point is applied to the sensor and the corresponding capacitance value is measured, the unknown relative humidity can be found by finding the corresponding value on the previously compiled capacitance versus relative humidity calibration curve. When the relative humidity and sensor temperature are both known, the corresponding dew point is also uniquely determined and may be found or interpolated empirically from widely available tables of saturated water vapor pressure versus temperature. However, since the sensor is in general quite small, the above methodology implicitly measures the sensor capacitance or resistance at the temperature of the test gas, and this requires that the calibration curve be obtained and stored for all temperature levels at which the element is to be used.
While in theory this measurement can be made quite accurate, in practice, a number of possible sources of error are inherent in the methodology. First, any temperature detection error leads to reliance on an inappropriate calibration curve. Second, as a practical matter calibration curves are compiled at the time the sensor is built or installed, so that sensor "aging" over time may cause its characteristics to depart from those originally measured. Third, some hysteresis error may arise because the process of detection relies on the absorption or desorption of water from the thin layer, and the driving forces for the mechanics of equilibration may be affected by the previous level of humidity measured, so that the calibration curve will depend on the previous relative humidity and the time interval during which the new and different level has been applied to the sensor. This memory effect may last for days or weeks. Furthermore, systematic errors of the measuring instrument such as errors in capacitance measuring bridges, in volt meters, parasitic capacitance of connecting cables, or changes in capacitance due to bending or realignment of wires, or other changes in circuit parameters that occur with temperature, may all contribute to inaccuracies of the fundamental signals or of their conversion to humidity measurements.
A number of these sources of error can be overcome in a sophisticated measurement environment by processes of recalibrating or reinstalling the equipment, protocols for baking out or zeroing the sensor, and by initializing or purging processes such as applying a reference dry gas for a known period of time, or other processes which may be specific to the sensor or electronics under consideration. Furthermore when operated with a microprocessor-controlled circuit, as is commonly done, tables of normal aging characteristics may be built into the device, allowing an estimated correction factor to be applied for some of these effects.
Overall it may be said that the development of solid state humidity sensors and associated instrumentation have led to relatively hardy and compact embodiments capable of making repeated measurements, but these measurements, because of the underlying physics of the sensor and electrical signal processing, possess limitations that should be addressed.
It would therefore be desirable to provide a humidity sensor of enhanced accuracy, stability or ease of calibration.
SUMMARY OF THE INVENTION
This is achieved in accordance with a method of humidity measurement of the present invention wherein a humidity responsive element is subjected to the measuring environment and its thermal capacitance or resistance coefficient is measured. A representative device operates by cycling the sensor element between a first temperature and a second temperature and determining the sensor capacitance at each temperature. The sensor capacitance difference, or thermal coefficient of capacitance, is then compared to a previously compiled table of gas dew point versus capacitance increment calibration curves. The differential measurement thus made is free from systematic error originating in equipment drift, cable capacitance change and various aging and slow hysteresis or sensor capacitance variations. Furthermore, initial calibration requires only a set of ΔC curves rather than a full matrix of calibration points.
In one embodiment, a capacitive type relative humidity sensor is placed in thermal contact with an electric heater, a thermoelectric cooler, or both, and the heater and/or cooler are operated to drive the sensing element from a first temperature to a second temperature which is preferably done under control of a digital device such as a microprocessor control chip, or under control of simple analog devices such as thermal cut-off or cut-in switches. Depending on the ambient temperature, the device may return to its initial temperature passively, or be actively driven by the heater or cooler. The frequency or cycle time of these temperature changes is selected to correspond to the time constant of the sensor in the ranges of temperature and relative humidity of the intended sample gas, and measurement is preferably made at each temperature end point. In illustrative embodiments, a platinum film may be deposited in or on the substrate below the sensing film and energized at a controlled power level to heat the film. A Peltier device may be employed as the cooler. These are driven to change the sensor temperature and effect upper and lower readings, with a time constant or cycle time of approximately 1-3 minutes, or may operate at greater intervals or a more prolonged period of time, depending on the measurement protocol.
In one preferred measurement protocol, a fixed cycle time is employed, and capacitance is measured at lower and upper temperatures successively in each cycle with the sensor immersed in the sample environment. The measured capacitance difference is then compared to that of a previously compiled table of ΔC vs. dew point for a range of dew point values.
In another measurement protocol a more prolonged interval elapses between ΔC differential measurements, and during the interval conventional measurements are employed to determine moisture content. Effectively, recalibration is done by measuring the capacitance C of separate or preferably the same humidity sensor employed in the ΔC measurement as described above at a fixed or continuously monitored (i.e., measured) temperature to compile a new calibration table which is corrected by the more accurate ΔC measurement. The updated C vs. dew point table so obtained is then used alone for a time, applying a standard conversion procedure to determine dew point measurement result.
Both measurements (i.e., the conventional one based on C measurement, and ΔC differential measurement in accordance with this invention) are assumed to be made practically at the same time and with the same gas portion, so humidity data obtained from each single ΔC differential measurement is sufficient to provide one point calibration of the conventional C vs. dew point calibration curve. In other words, the same current value of sample gas humidity is simultaneously measured by two different methods, a ΔC differential measurement method to determine the correct calibration curve, followed by a one point C measurement and look up, in the conventional manner, on a stored humidity curve. The conventional method is then used for some time alone e.g. over a period of hours or days, after which another ΔC difference measurement result is obtained and used for another calibration as described above.
The ΔC differential measurement is readily performed in a very short time, e.g., within a 5 to 15 second time interval, so this automatic calibration is practically transparent i.e., not noticeable and does not delay the conventional method of humidity measurement. In this embodiment, the time period between calibrations depends on the time period during which the conventional measurement remains stable, e.g., one hour.
The invention also contemplates that a more sophisticated algorithm be embodied into a microprocessor based controller. By way of example, the ΔC different measurement protocol can be temporarily omitted as long as change in the consecutive conventional measurements remains less than a preset threshold. This minimizes ΔC differential measurement dynamic error.
In one embodiment of a device for carrying out the method, a heater is provided to heat the sensor and the sensor is operated in two cycles or at two different power levels to drive the sensor to a first temperature T 1 above ambient temperature, and to a second higher, temperature T 2 . The temperature then returns to T 1 by passive cooling, and is again driven to T 2 . In another embodiment a Peltier cooler is placed in thermal contact with the sensor, and it is operated to decrease the temperature of the sensor element to one or more levels T- 1 , T- 2 below ambient. Again, the sensors return to the higher temperature by passive interaction with the surroundings. In yet a third embodiment the system includes both a heater and a cooler, and the sensor element is actively driven between the two temperatures at which its capacitance is measured. By actively driving the device to T 1 , then to T 2 , then back to T 1 in a known cycle time, the memory effects are made repeatable, and are a function of the cycling conditions which are accurately represented in the ΔC-dew point calibration table.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be understood from the description below, taken together with the background art and the Figures herein representing illustrative embodiments and operation of the invention, wherein
FIG. 1 illustrates a prior art humidity sensor;
FIG. 2 is a table showing humidity as a function of temperature and dew point;
FIG. 3 is a graph showing sensor capacitance as a function of dew point at various temperatures;
FIG. 3A is a graph showing sensor capacitance as a function of temperature at various dew points;
FIGS. 4 and 4A illustrate sensor embodiments of the invention with a heater and a cooler, respectively; and
FIG. 5 illustrates a system operating according to the method of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a general schematic drawing of a humidity sensor applicable to the present invention and to the prior art. As shown, the system 10 includes a sensing element 1 comprising at least a substrate 2 and an active humidity sensing layer 3, and an environmental chamber 5 illustrated in phantom in which the sensing element 1 resides. Electrodes 7a, 7b connect to opposing sides of the active layer 3 which, as illustrated is a thin film which responds to humidity in the environment. The sensing element 1 is placed in a measurement circuit which, simply by way of example, is illustrated as including an oscillating signal source 8, a timer and switching unit 9, such as a flip flop or microprocessor controlled switch or switch array, and an amplifier 11 which may be operated in various embodiments synchronously or with a partial duty cycle to produce an output signal representative of the capacitance or other electrical characteristic of the sensor 1. As shown in FIG. 1, this output is digitized and fed to a microprocessor or controller 13 which compares the output signal to signals stored in a look-up table 14 and determines the corresponding values of relative humidity or dew point to which the sensor is subjected. This humidity value is produced as an output signal on line 15 and may for example be fed to a panel display or be output to a printer, digital storage device or other form of recorder or display.
In general, the measured sensor property such as capacitance of the active layer 3 will be proportional to the dielectric constant ε of the material times its surface area divided by its thickness, and as noted above, the thickness is generally small, well under one mil to assure a fast response time. For alumina or typical polymer films, a dielectric constant ε is about 3 to 5, while that of water is 81, so that as water is gained or lost in the active layer, the capacitance of the element will increase or decrease respectively. In general, the level of moisture in the plastic film will be proportional to the pressure of moisture in the air and will also be a function of surrounding temperature. The final output may be calibrated either in absolute terms of grams of water per cubic meter, as a partial pressure of water vapor in the total gas, or as a dew point measurement; that is, as a temperature T at which the saturated water vapor pressure would be equal to the measured water vapor pressure. The moisture measurement may also be reported out in relative units, i.e. as a relative humidity.
FIG. 2 shows a representative portion of a table of aqueous vapor pressure over ice in millimeters of mercury for a temperature range of 0 to 20 degrees centigrade. These empirical tables are conventionally used for straightforward conversions between the various forms of humidity output measurement. However, as an initial step, the capacitance of the sensor must be compiled over the expected range of temperature and humidity operating conditions.
As applied to a sensor described above, a typical film capacitance may be around 200 pF at zero humidity, and would generally rise with increasing water vapor in the surrounding air. In general, the taking in or release of water may be physically modeled as an equilibrium process going on at the surface of the polymer sensing film, between water molecules on the surface having a relatively low energy and water molecules in the surrounding vapor. In general, the energy of water molecules in the gas is higher, and the bound molecules are able to escape from the surface as the temperature rises and a greater proportion of the surface molecules acquire a higher energy.
The saturation pressure may be represented as P S =P So e.sup.ΔE 1 /RT where ΔE 1 corresponds to the difference in energy of a free water molecule and a bound (liquid) molecule, and R is the Boltzmann constant. Because of this equilibrium process, while the saturation pressure of humidity in a gas will increase sharply with temperature, the capacitance of the sensor will decrease with temperature due to the shift in distribution between liquid and gaseous water, decreasing the amount of water residing in or on the sensing film. The horizontal asymptote makes it difficult to obtain accurate readings at high temperatures and saturation.
The general form of these curves is a nested family of curves, which are invertible, in the sense that a capacitance reading at a known temperature can be converted to a specific humidity or dew point value.
As noted above, the humidity sensor resistance and/or capacitance is a function of both humidity and temperature. This function is customarily represented as a family of capacitance vs. gas dew point curves for a set of different temperatures, as shown in FIG. 3, or capacitance vs. temperature curves for several different sample gas dew point values as shown in FIG. 3A. The gas temperature may be assumed to coincide with the sensor temperature at least on the sensor surface.
Empirical tables of aqueous vapor pressure over ice at different temperatures as shown in FIG. 2 are conventionally used for straightforward conversions between the various units of humidity output measurement. Using such tables, the capacitance vs. dew point and temperature function as shown in FIG. 3 and FIG. 3A can be transformed into capacitance vs. pressure, relative humidity or any other unit of moisture measurement which is desired for the measurement application involved. An additional parameter may be measured for effecting some of these conversions, and this is readily provided by a separate sensor, such as a pressure sensor. For example a gas pressure reading is needed to transform dew point or partial pressure into units of grams per kilogram.
However, as an initial step, the capacitance of the sensor vs. humidity/temperature function must first be empirically obtained over the range of expected operating conditions, and must be represented in terms of at least one of the units of the moisture measurement.
FIG. 3 shows a typical such family of calibration curves for effecting prior art measurement, with sensor capacitance in picofarads plotted against sample gas dew point, for a range gas temperatures between ten and fifty degrees. Using these stored curves, measured sensor capacitance is readily converted, for a given gas temperature, into a dew point measurement of sample gas, and this, in turn may be converted using a table (FIG. 2) to an absolute or relative humidity measurement. Other curves may be used in particular ranges of conditions to simplify measurements, such as capacitance vs. relative humidity, which is largely temperature-independent in a restricted range of conditions.
The aforementioned drifts due to sensor aging, hysteresis and systematic errors of the measurement instrument affect the actual sensor response curve by shifting the family of curves shown in FIG. 3 upward or downward. This shift is substantially isometric--that is, it translates the curve without changing its shape or distance between points along the curve. In practical terms such calibration curve drift results in measurement error of about ±1% or more for a commercially available relative humidity sensor. A similar shift occurs in the calibration curves expressed in other common units.
In one embodiment of the invention shown in FIG. 3A applicant utilizes as calibration curves an empirically tabulated set of sensor capacitance vs. temperature curves for different dew points. These curves FIG. 3A may be regarded as a "vertical slice" of the curve family shown in FIG. 3.
As can be seen in FIG. 3A, the vertical distance between two points on each curve, represented by sensor capacitance increment ΔC and taken at two different temperatures (30° C. and 60° C. in FIG. 3A), will remain the same in spite of the upward/downward drift of a curve. At the same time, the increment ΔC between two fixed temperature points is an increasing function of dew point. More generally, a one-to-one correlation between capacitance increment and dew point can be established at any two given temperature points within the range of expected operating conditions.
Applicant uses this correspondence to initially establish by direct measurement and tabulation, and then apply, a family of calibration curves to obtain differential measurements which are unaffected by "aging" and other sources of error mentioned above. Using this capacitance increment measurement technique a cumulative relative humidity measurement error of less that ±0.02% has been achieved over a one year time without re-calibration. Applicant exploits this property in new measurement protocols, and corresponding apparatus, shown in FIGS. 4, 4A and 5. The apparatus drives the sensor between two temperatures and develops a ΔC measurement, which is then converted via the stored calibration curves.
FIG. 4 shows a sensor in accordance with the present invention for improved humidity detection. As shown, the sensor includes a sensing film 3 on a substrate or support 2 wherein electrode contacts 3a, 3b are provided to the upper and lower surfaces of the sensor. A heating element 20 which may for example be formed by a metalized film within the body of or on the surface of support 2 is adapted to provide heat to the assembly for driving the temperature upward, while a thermocouple or other temperature sensing device 25 is formed on or mounted in close proximity to the sensing element 3 to provide a signal which accurately reflects the temperature at the surface. Other forms of heater control are also contemplated. For example, when using a thin platinum film as the heater, temperature control may be achieved by placing the heater in a bridge with two different precision resistors, e.g., via a switch or switch array operating under control of a microprocessor. The resistance values are selected such that their resistance is equivalent or proportional to that of the heater resistance at the specified temperature T 1 or T 2 , and the imbalance voltage developed across the bridge controls the gain of a power supply connected to the heater, so that power is provided to the heater in proportion to its variation from this set resistance value. Thus, the platinum heater is powered until it reaches the desired resistance set point. At this point the computer switches in the other resistor and powers the heater to reach a different temperature. The platinum film lies closely under or may be deposited on one surface of, the sensing film and thus accurately represents the sensing film temperature, although, as noted above, one or more thermocouples may be provided to allow more accurate control, for example to introduce temperature dependent or environment dependent corrections.
FIG. 4A illustrates another embodiment of a humidity sensor in accordance with the present invention. In this embodiment, a thermoelectric cooler or Peltier effect cooler 16 is provided as the support for the sensing film 3. As before, surface electrodes are provided for detection of changes in the sensor capacitance and a temperature sensor (not shown) may be mounted in an appropriate position to allow determination of the surface temperature. It will be understood that several thermocouples may be provided to allow an automated controller to detect a temperature gradient and extrapolate or interpolate the actual surface temperature. The invention also contemplates embodiments where both a cooler and a heater are provided and each may be energized at different times to separately drive the temperature up or down. It will be understood that each sensor is to be employed in a system wherein an electric circuit or microprocessor controller sets the two different temperatures T 1 and T 2 to which the relative humidity sensor will be driven and controls another circuit as discussed above, to measure capacitance.
It will further be understood that when a thermoelectric cooler is provided for the sensor, heating may be simply accomplished by reversing the current direction to reverse the heat-cold temperature distribution in the cooler element. Thus, for example, a preset current, for example 200 mA may be continuously supplied to the cooler element and the temperature change may be achieved by reversing the current polarity. At one current direction the sensor is cooled below ambient temperature, while a reversal of current causes the thermoelectric element 16 to work as a heat pump and increase the temperature of the sensor. By monitoring the thermocouple output, the current may be reversed, and sensor capacitance measurements taken at appropriate times.
FIG. 5 shows the general form of capacitance measurement effected by the present invention. Temperature of the sensor is plotted on the vertical axis against time, and a representative capacitance measurement point indicated in each interval. As the sensor toggles back and forth between temperatures, the sensor capacitance measurement C1, C2, C3 . . . are taken and the processor forms the difference C1-C2, C3-C4 . . . as these differences converge to a stable value. The stable value ΔC is then looked up in a previously stored table in which the sensor capacitance difference between these temperatures has been stored for the range of dew points encountered in practice. The processor then outputs the dew point measurement, or the desired equivalent (e.g. relative humidity at ambient) by empirical conversion.
It has been assumed that at least two capacitance measurements are performed at two different temperatures but with the same sample gas portion or at least at the same moisture contents. To avoid dynamic error when the moisture concentration is changing in time, moisture sensors with relatively small time response are preferably used, so that the temperature change of the sensor and two consecutive measurements before and after this change thus can be made in a short period of time. One suitable sensor is the commercially available MiniCap2 sensor sold by Panametrics, Inc. of Waltham, Mass. These sensors have a response time less than two seconds in the range of 0° to 180° C., and their small size allows the required temperature change and two consecutive capacitance measurements to be made in about a 5 to 20 second time interval using a relatively low power heater, less than one Watt. In most cases this is fast enough for dynamic error to be neglected.
More sophisticated data processing algorithms utilizing more than two data points are also known to those experienced in the field of instrumentation and can be appropriately used with this invention in order to minimize dynamic error. Thus the invention further contemplates systems wherein automated numerical filtering, averaging, fitting, convergence or estimation protocols are applied to the data points, for example with digital measurement signal processing to develop a precise ΔC measurement, or to correct the measured humidity value in the presence of changing temperature, pressure or humidity conditions.
Furthermore, while the foregoing description relates to a measurement wherein the sensor characteristic is measured at two temperatures and the difference is converted, via stored curves, to a humidity measurement, the salient feature of the invention lies in the accuracy of this measurement, since any shifting or drift, whether due to sensor aging, stray capacitance or other common effect, is canceled by the differencing step.
In a further aspect of the invention, the measurement so taken is applied to update or recalibrate a conventional system, such as a single-point sensor system employing the calibration curves of FIG. 3. According to this aspect, a microprocessor controller controls the temperature driver to perform a ΔC measurement, then compares the humidity value with the values given by the stored curves for a single-temperature sensor reading. The error function is applied to update the stored curves, which may involve simply shifting the curve up or down, after which the system then continues to operate in a single-temperature reading mode for a period of days, weeks or months. As noted above, the ΔC correction protocol may be quickly implemented to provide a corrective shift of a single measurement curve in a few seconds. Such a correction protocol obviates the various calibration or correction protocols required in the prior art, such as the periodic provision of a calibration sample gas at known relative humidity.
The invention has been described with reference to specific embodiment and preferred implementations shown in the FIGURES above. However, it will be understood that a great many circuit, control systems and methods and devices for operation and correction of humidity sensors have been developed in the past and are all usable with, and may be incorporated with the improved method and sensors of the present invention. The invention being thus disclosed and described, further variations and modifications will occur to those skilled in the art, and all such modifications and variations are considered to be within the scope of the invention, as set forth in the claims appended hereto. | A method of humidity measurement wherein a humidity responsive element is subjected to the measuring environment and its temperature coefficient is measured. A system operates a sensor element between a first temperature and a second temperature, determining its temperature coefficient, which is then compared to a previously compiled table. The differential measurement thus made automatically corrects for system error originating in equipment drift, cable capacitance change and various aging and slow hysteresis or sensor capacitance variations. In another embodiment, an occasional differential measurement is performed to detect errors in a set of stored curves and update the tables used for single-point humidity measurements, thus obviating the need for protocols involving reference gases or recalibration. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for use in the manufacture of semiconductors, and more particularly, to a method and an apparatus for reuse of an abrasive fluid used in the manufacture of semiconductor devices.
A chemical-mechanical polishing (CMP) device is used in flattening a wafer surface in a semiconductor manufacturing step. The CMP device employs an abrasive slurry, and accordingly, as the quantity of products manufactured increases, the quantity of used abrasive slurry also increases. The quantity of abrasive slurry used influences the manufacturing cost, and hence an efficient reuse of the used abrasive slurry or fluid is required.
In the conventional practice of flattening a wafer surface, an abrasive slurry in liquid form which comprises a commercially available abrasive stock having a weight percentage of approximately 25 wt % and diluted by deionized water to nearly 13 wt % is used. Used abrasive fluid is further diluted within the polishing device to produce an effluent which may have a concentration on the order of about 0.1 to 0.2 wt %, for example. It will be understood that the abrasive effluent contains fragments of films abraded from the wafer and impurities produced by a polishing table (or pad) of the polishing device. Abrasive effluents are generally passed through a neutralization treatment before disposal or delivered to an industrial waste disposal undertaker in the form of sludges which result from a drainage treatment. The abrasive fluid represents a significant proportion of the wafer processing cost, but the abrasive effluent has been disposed of without a reuse thereof.
Abrasive grains contained in the abrasive effluent are agglomerated to larger sizes. However, a single grain in the agglomeration has a grain diameter which remains substantially unchanged from the grain size which it exhibited before it was fed to the polishing step, and thus retains a grain size which is still useable in the abrasive operation. Nevertheless, the grain agglomerations are disposed of without being recycled.
The cost of disposing sludges delivered to the industrial waste disposal undertaker adds to the semiconductor manufacturing cost. Thus, reuse of the abrasive effluent is of importance in reducing the semiconductor manufacturing cost.
It is an object of the invention to provide a method and an apparatus which allow reuse of an abrasive effluent.
SUMMARY OF THE INVENTION
In a first aspect of the present invention, a method is provided that reuses a slurry effluent containing agglomerations of abrasive grains which has been used in a polishing step in the manufacture of a semiconductor. First, the agglomerations of abrasive grains contained in the slurry effluent are crushed. Then, an abrasive fluid is regenerated using the slurry effluent containing the crushed abrasive grains.
In a second aspect of the present invention, an apparatus is provided that reuses a slurry effluent containing agglomerations of abrasive grains which has been used in a polishing step in the manufacture of a semiconductor. The apparatus includes a crusher for crushing the agglomerations of abrasive grains contained in the slurry effluent and a regeneration unit for regenerating an abrasive fluid using the slurry effluent containing the crushed abrasive grains.
In a third aspect of the present invention, a crusher is provided that crushes agglomerations of abrasive grains contained in a slurry effluent which has been used in the manufacture of a semiconductor. The crusher includes a tank for storing the slurry effluent and at least one of a mill, an ultrasonic oscillator and a pressurizing circulation unit attached to the tank.
In a fourth aspect of the present invention, an apparatus for concentrating a slurry effluent is provided. The apparatus includes a concentrating unit including a concentrating membrane for separating the slurry effluent into a concentrate fluid and a permeate fluid; a temperature regulator for adjusting the temperature of the slurry effluent; and a concentration controller for controlling the temperature regulator to control the concentration of the concentrate fluid.
In a fifth aspect of the present invention, an apparatus for regulating the quality of a slurry effluent including abrasive grains is provided. The apparatus includes a tank for storing the slurry effluent and a specific gravity adjusting unit for adjusting the concentration of the abrasive grains in the slurry effluent.
In a sixth aspect of the present invention, an apparatus for regulating the quality of a slurry effluent including abrasive grains is provided. The apparatus includes a tank for storing the slurry effluent and a pH adjusting unit for adjusting the pH of the slurry effluent.
In a seventh aspect of the present invention, an apparatus for cleansing a concentrating membrane used in concentrating a slurry effluent is provided. A concentrate fluid and a permeate fluid are generated by concentrating the slurry effluent. The apparatus includes a chamber for temporarily storing the permeate fluid and a back washing unit for cleansing the concentrating membrane using the permeate fluid stored in the chamber.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a schematic diagram of an abrasive effluent regeneration plant according to one embodiment of the present invention;
FIG. 2 is a schematic diagram of a slurry effluent regeneration unit of the plant of FIG. 1; and
FIG. 3 is a schematic diagram of a crusher of the plant of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An abrasive effluent regeneration plant according to one embodiment of the present invention will now be described with reference to FIGS. 1 to 3 .
FIG. 1 is a schematic diagram of the abrasive effluent regeneration plant 1 , which includes a circulation system including a feed system for feeding an abrasive solution to a plurality of polishing devices 2 , which may be three in number, and a regeneration system which regenerates an abrasive effluent or a slurry effluent discharged from the polishing devices 2 . Specifically, the plant 1 comprises a stock solution drum cabinet 4 containing a stock solution drum 3 , a slurry feeder 5 , and a slurry effluent regeneration unit 6 . The polishing devices 2 preferably comprise a chemical-mechanical polishing (CMP) device, which is used to abrade a metal layer or oxide layer of aluminium, for example, formed on a semiconductor wafer.
The stock solution drum 3 contains a stock solution containing abrasive grains, for example, fine particles of alumina. Preferably, the stock solution has a concentration of about 25 wt %. The stock solution drum 3 is connected to the slurry feeder 5 via a channel 7 , and is also connected to the slurry effluent regeneration unit 6 via a channel 8 . The stock solution is fed to the feeder 5 and the unit 6 by opening valves 9 , 10 which are disposed in the channels 7 , 8 , respectively.
While not shown, the slurry feeder 5 includes a mixing tank. A given proportion of stock solution which is fed from the drum 3 is diluted by and mixed with deionized water (DIW) to prepare a slurry fluid. At this end, deionized water used for the dilution is fed to the slurry feeder 5 . Preferably, the prepared slurry fluid has a concentration of about 13 wt %. It is preferred that a pair of mixing tanks are provided to be used in an alternate fashion. The slurry feeder 5 is connected to each of the polishing devices 2 via a feed channel 11 , and a valve 12 is provided in the feed channel 11 to allow the slurry fluid from the slurry feeder 5 to be fed to each of the polishing devices 2 when it is opened. The quantity of the slurry fluid fed to each polishing device 2 is regulated by the opening of the valve 12 .
Each polishing device 2 feeds the slurry fluid onto a polishing pad disposed on a rotary table, and polishes a wafer by urging the wafer against the pad. Used slurry fluid is diluted by water and is then discharged as a slurry effluent, thus preventing loading or plugging of a clearance around the table by abrasive grains. The slurry effluent has a concentration of preferably about 0.1-0.2 wt %. The slurry effluent is discharged from each polishing device 2 to the slurry effluent regeneration unit 6 through a discharge channel 13 .
The slurry effluent regeneration unit 6 regenerates the slurry effluent by separating it into a regenerated and concentrated slurry fluid (hereafter simply referred to as regenerated slurry fluid) which is concentrated to a given concentration which is the same as that of an initial or original slurry fluid, and a permeate fluid. The regenerated slurry fluid is fed from the slurry effluent regeneration unit 6 through a circulation channel 14 which merges with the feed channel 11 so as to be circulated through the individual polishing devices 2 . Intermediate its length, the circulation channel 14 has a branch connecting it to the slurry feeder 5 . The regenerated slurry fluid is fed to each polishing device 2 by opening valves 15 , 16 disposed in the circulation channel 14 , and is also fed to the slurry feeder 5 by opening a valve 17 disposed in the branched channel. In the manner, by controlling the opening of the valves 15 - 17 , the regenerated slurry fluid can be selectively fed to the polishing devices 2 and the slurry feeder 5 . The permeate fluid is passed from the regeneration unit 6 to the slurry feeder 5 through a permeate channel 18 , where it is used to dilute the stock solution used to prepare the slurry fluid. Each of the valves 9 , 10 , 12 and 15 - 17 is controlled by a controller, not shown.
FIG. 2 is a schematic diagram of the slurry effluent regeneration unit 6 , which comprises a crusher 21 , a fluid quality regulator 22 , a concentration unit 23 , a coarse filter 24 , a back washer 25 , a concentrated fluid tank 26 and a permeate fluid tank 27 .
The purpose of the crusher 21 is to crush agglomerations of abrasive grains contained in the slurry effluent. A schematic diagram of the crusher 21 is shown in FIG. 3 . Specifically, the crusher 21 includes a crushing tank 32 having a crushing chamber 31 therein, and a mill 33 , an agitator 34 and a ultrasonic vibrator plate 35 which are disposed within the crushing tank 32 . A pressurizing circulation unit comprising a circulating pipe 36 and a pressurizing pump 37 is connected to the crushing chamber 31 . The ultrasonic vibrator plate 35 is connected with an ultrasonic oscillator 38 which energizes the plate 35 for vibration at a high frequency. The combination of the vibrator plate 35 and the oscillator 38 defines an ultrasonic oscillation system.
The slurry effluent from the discharge channel 13 is initially injected into the mill 33 at a pouring port 39 . The agglomerations of abrasive grains contained in the slurry effluent are crushed by the mill 33 , and are then further crushed and dispersed by the ultrasonic vibration of the vibrator plate 35 , which is energized by the oscillator 38 . The slurry effluent which accumulates in the crushing chamber 31 is agitated by the agitator 34 . Injection of the slurry effluent into the crushing chamber 31 is via the pump 37 and through the circulating pipe 36 , which causes an impingement of the slurry effluent against the internal wall of the crushing chamber 31 , thus crushing the agglomerations into individual abrasive grains.
It is not always necessary to use all three of the mill 33 , the pressurizing pump 37 and the ultrasonic oscillator 38 , but any one of these three may be chosen as required. However, it is effective to use a combination of a pressurizing circulation crushing technique using the pressuring tank 37 and an ultrasonic oscillation crushing technique using the ultrasonic oscillator 38 . After the crushing step, the slurry effluent is discharged from the crushing tank 32 through a discharge port 40 into a channel 41 to a stock solution tank 42 (see FIG. 2) of the fluid quality regulator 22 .
Referring to FIG. 2, the purpose of the fluid quality regulator 22 is to regulate the quality of the slurry effluent crushed by the crusher 21 , and/or to perform a pretreatment, including a specific gravity adjustment and a pH adjustment, which enables an efficient concentrating operation within the concentrating unit 23 . The fluid quality regulator 22 comprises a stock solution tank 42 , an agitator 43 , a desitometer 44 , a pH meter 45 , a specific gravity controller 46 and a pH controller 47 . The pretreatment is performed while agitating the slurry effluent by means of the agitator 43 . The combination of the desitometer 44 and the specific gravity controller 46 defines a specific gravity regulator while the combination of the pH meter 45 and the pH controller 47 defines a pH regulator.
The adjustment of the specific gravity is performed using the desitometer 44 and the gravity controller 46 . The specific gravity of the slurry effluent within the stock solution tank 42 is measured by the desitometer 44 . The specific gravity controller 46 adjusts if the specific gravity or concentration of the slurry effluent has reached a given value on the basis of a measured value of the specific gravity. If the measured value of the specific gravity does not reach the given value, the specific gravity controller 46 controls the specific gravity of the slurry effluent by adding a fresh slurry fluid or regenerated slurry fluid thereto. In this manner, the concentration of the slurry effluent is adjusted so that a regenerated slurry fluid having a desired concentration may be obtained.
The adjustment of the pH value is performed using the pH meter 45 and the pH controller 47 . The pH value of the slurry effluent within the stock solution tank 42 is measured by the pH meter 45 . The pH controller 47 determines if the pH value of the slurry effluent has reached a given value on the basis of the measured pH value. If the measured pH value does not reach the given value, the pH controller 47 adjusts the pH of the slurry effluent by adding an alkali solution or an acid thereto. The slurry effluent, as it is discharged from the polishing devices 2 , has a pH value of about 9. The pH controller 47 adjusts the pH value of the slurry effluent so that a slurry effluent having a pH value of about 10.5 is obtained. When the pH value of the slurry effluent is adjusted in this manner, the agglomerations of abrasive grains which have not yet been crushed become likely to be disintegrated, thus improving the dispersibility of abrasive grains in the slurry effluent.
The concentration unit 23 comprises a pair of concentrating membrane units 49 , 50 , a heat exchanger 52 which is used in controlling the degree of concentration of the regenerated slurry fluid, a flow rate controller 63 and a flowmeter 71 . The concentrating membrane units 49 and 50 are connected to the stock solution tank 42 via a channel 48 , in which a pump 51 and the heat exchanger 52 , serving as a temperature regulator, are disposed. The pump 51 feeds the slurry effluent from the stock solution tank 42 to the concentrating membrane units 49 , 50 through the channel 48 . The heat exchanger 52 adjusts the temperature of the slurry effluent before it is fed to the concentrating membrane units 49 , 50 . Two valves 53 , 54 are disposed in the channel 48 to control the flow of the slurry effluent to the concentrating membrane units 49 , 50 .
Each of the concentrating membrane units 49 , 50 separates the slurry effluent, after the regulation of the fluid quality thereof, into a concentrate fluid and a permeate fluid. The concentrate fluid is passed from the concentrating membrane units 49 , 50 through channels 55 , 56 , respectively, to a pair of microfilters 57 where it is coarsely filtered. After the coarse filtration, the concentrate fluid is discharged to the concentrate fluid tank 26 through a discharge channel 58 . The microfilters 57 removes abrasive grains which have not been crushed from the concentrate fluid. In this manner, any damage of the wafer by the concentrate fluid is prevented when the concentrate fluid which accumulates in the concentrate fluid tank 26 is used as the regenerated slurry fluid. The concentrate fluid fed to the tank 26 has substantially the same concentration as the concentration of the slurry fluid used in the polishing device 2 . Accordingly, the concentrate fluid can be directly used as the regenerated slurry fluid. One of the pair of microfilters 57 can be selected by opening or closing valves 59 - 62 associated with the respective microfilters 57 . It will be noted that the flow rate controller 63 is disposed in the discharge channel 58 in order to control the flow rate of the concentrate fluid.
The back washer 25 comprises a pair of back wash chambers 64 , 65 , a pair of control valves 74 , 75 and a pair of gas purgers 76 , 77 . The purpose of the back washer 25 is to cleanse the concentrating membranes in the units 49 , 50 utilizing the permeate fluid. The pair of back wash chambers 64 , 65 each operate to receive and temporarily store the permeate fluid from the respective concentrating membrane unit 49 or 50 through channels 66 , 67 . Valves 68 , 69 are disposed in the channels 66 , 67 at locations downstream of the back wash chambers 64 , 65 , respectively, and are closed when these chambers 64 , 65 store the permeate fluid. When the valves 68 , 69 are opened, the permeate fluid is passed through a discharge channel 70 to the permeate fluid tank 27 .
The flow rate of the permeate fluid is measured by the flowmeter 71 disposed in the discharge channel 70 . The flow rate controller 63 controls the flow rate of the permeate fluid, as measured by the flowmeter 71 , using the heat exchanger 52 . That is, when the temperature of the slurry effluent rises, the speed of the slurry effluent passing through the concentrating membrane increases, while in the opposite instance, the speed of the slurry effluent decreases. Thus, the flow rate controller 63 controls the flow rate of the permeate fluid by controlling the temperature fluid using the heat exchanger 52 , so that the flow rate is maintained at a given value. When the flow rate controller 63 fails to maintain the flow rate of the permeate fluid at a given value, it determines that the concentrating membranes are to be cleansed, and a back wash is performed. A combination of the heat exchanger 52 , the flow rate controller 63 and the flowmeter 71 defines the degree of concentration control.
The back wash chambers 64 , 65 are connected via channels 72 , 73 to gas purgers 76 , 77 , respectively. Control valves 74 , 75 are disposed in the channels 72 , 73 , respectively, thereby allowing the gas purgers 76 , 77 to feed a high pressure inert gas (such as nitrogen or argon, for example) into the back wash chambers 64 , 65 , respectively. The inert gas prevents oxidation of the permeate fluid. The gas which is fed into the back wash chambers 64 , 65 causes a back flow of the permeate fluid within the back wash chambers 64 , 65 through the channels 66 , 67 , respectively, such that the permeate fluid is strongly ejected onto the concentrating membranes in the units 49 , 50 , thus cleansing the concentrating membranes. It will be noted that the concentrating membrane units 49 , 50 are connected to the stock solution tank 42 via the channels 55 , 56 as well as a channel 78 . When back washing the concentrating membranes in the units 49 , 50 , both of the valves 53 , 54 disposed upstream of the units 49 , 50 and the valves 79 , 80 disposed downstream of the units 49 , 50 are closed, while valves 81 , 82 disposed in the return channel 78 are opened. In this manner, the permeate fluid used in the back wash process is returned to the stock solution tank 42 through the return channel 78 . It is to be noted that the back wash process for cleansing the membranes in the units 49 , 50 is performed separately for each unit.
The concentrate fluid in the concentrate fluid tank 26 is discharged into the circulating channel 14 and fed to the polishing devices 2 or the slurry feeder 5 . On the other hand, the permeate fluid from the permeate fluid tank 27 is discharged through the channel 18 to the slurry feeder 5 .
The operation of the plant 1 will now be described.
The slurry effluent which has been used in the polishing process in each polishing device 2 is transferred to the crushing chamber 31 of the crusher 21 . It is to be understood that agglomerations of abrasive grains which have diameters on the order of about 500 nm are present in the slurry effluent. It is also to be understood that abrasive grains in a fresh fluid have diameters of around 100 nm, and thus an agglomeration is formed of about 125 abrasive grains. It is possible that the agglomeration also contains fragments of films abraded from the wafer and impurities such as exfoliation from the polishing pad. However, the amount of such fragments of films and impurities is negligible compared with the quantity of the abrasive grains.
The slurry effluent containing agglomerations of abrasive grains is introduced into the crushing chamber 31 through the pouring port 39 , shown in FIG. 3, and the agglomerations in the effluent are crushed by the mill 33 . After the crushing operation, any remaining agglomerations of abrasive grains are subject to a crushing and dispersion effected by the ultrasonic vibration of the ultrasonic vibrator plate 35 . In addition, the slurry effluent which is pressurized by the pump 37 is passed through the circulating pipe 36 and ejected into the crushing chamber 31 , whereby the remaining agglomerations of abrasive grains contained in the slurry effluent impinge upon the internal wall of the crushing chamber 31 and are crushed.
The abrasive grains which are crushed in such manner are dispersed evenly throughout the slurry effluent in a floating condition as a result of the agitating effect by the agitator 34 , and are then passed through the discharge port 40 and the channel 41 and transferred into the stock solution tank 42 shown in FIG. 2 .
The desitometer 44 and the pH meter 45 measure the specific gravity and the pH value of the slurry effluent in the stock solution tank 42 , and the specific gravity controller 46 and the pH controller 47 regulate the quality of the slurry effluent in accordance with such measurements. After the regulation of the fluid quality, the slurry effluent is pumped by the pump 51 through the heat exchanger 52 to the respective concentrating membrane units 49 , 50 .
The slurry effluent is separated into a permeate fluid and a concentrate fluid by the concentrating membrane in each unit 49 , 50 . The concentrate fluid is passed through the channels 55 , 56 and fed to the microfilters 57 where it is filtered coarsely. The filtered concentrate fluid passes through the flow rate controller 63 and the discharge channel 58 to the concentrate fluid tank 26 . On the other hand, the permeate fluid passes through the channels 66 , 67 and is stored temporarily in the back wash chambers 64 , 65 , and is subsequently transferred from the back wash chambers 64 , 65 to the permeate fluid tank 27 while the flow rate of the permeate fluid is being measured by the flowmeter 71 .
When using the permeate fluid which is temporarily stored in the back wash chamber 64 to cleanse the concentrating membrane in the unit 49 , the valves 53 , 79 are closed while the valve 81 is opened together with the control valve 74 , thus allowing the inert gas from the gas purger 76 to be blown into the back wash chamber 64 . The time interval during which the inert gas is blown into the chamber 64 is chosen so that the permeate fluid within the back wash chamber 64 is completely removed. The cleansing action of the concentrating membrane in the unit 50 similarly is performed by blowing the inert gas from the gas purger 77 into the back wash chamber 65 . When the cleansing or back wash of the concentrating membrane of one of the units 49 , 50 is being effected, the concentrating membrane of the other unit ( 50 , 49 ) is used to continue the concentrating operation. In this manner, the concentrating operation is continuously performed using the pair of concentrating membrane units 49 , 50 in an alternate fashion. It is also to be noted that there are provided two microfilters 57 . This allows for continuous operation of the plant 1 such that when one of the microfilters is being changed, the remaining microfilter may be used to continue the concentrating operation.
The concentration of the concentrate fluid stored in the concentrate fluid tank 26 is adjusted by changing the temperature of the slurry effluent by means of the heat exchanger 52 , which controls the speed at which the slurry effluent passes through the concentrate membrane in the units 49 , 50 . When the temperature of the heat exchanger 52 is raised, which increases the speed of the slurry effluent, the concentration of the concentrate fluid is increased. On the other hand, the concentration of the concentrate fluid is decreased when the temperature of the heat exchanger is controlled to reduce the flow speed of the slurry effluent. The flow speed is controlled by the flow rate controller 63 on the basis of the flow rate of the permeate fluid as measured by the flowmeter 71 .
The permeate fluid stored in the permeate fluid tank 27 is fed to the slurry feeder 5 , where it is used to dilute the stock solution used to prepare a fresh slurry fluid.
The abrasive effluent regeneration plant 1 of the present embodiment has the following advantages:
1. Agglomeration of abrasive grains contained in the slurry effluent which has been used to polish a semiconductor wafer are crushed during the crushing step and separated into a concentrate fluid and a permeate fluid, with the concentrate fluid being reused as a regenerated slurry fluid in polishing the semiconductor wafer. Accordingly, the amount of polishing stock solution used and the amount of sludge produced are significantly reduced. This reduces the manufacturing cost of a semiconductor device.
2. The crushing step allows a regenerated slurry fluid to be obtained which has abrasive grains of grain diameters comparable to the single abrasive grains in the fresh slurry fluid.
3. The use of the mill 33 enhances the effect of crushing the agglomerations of abrasive grains. A pressurizing circulation process enabled by the pressurizing tank 37 and/or ultrasonic oscillation process enabled by the ultrasonic oscillator 38 may be used in combination with the mill 33 , thus allowing the agglomeration of abrasive grains to be crushed in a reliable manner.
4. Since the concentration or the specific gravity of the slurry effluent is adjusted, a concentrate fluid having a desired concentration is obtained. The pH value of the slurry effluent is also adjusted, and accordingly any remaining agglomerations of abrasive grains which were not been crushed during the crushing step are easily disintegrated in the process of being fed to the concentrating membrane units 49 , 50 , thus improving the dispersibility of the abrasive grains in the slurry effluent.
5. An agitation of the slurry effluent by the agitator 34 allows the crushed abrasive grains to be evenly dispersed throughout the fluid.
6. A coarse filtering of the concentrate fluid by the microfilter 57 prevents damage of a semiconductor wafer from occurring as it is polished using the regenerated slurry fluid.
7. The use of the permeate fluid in diluting the stock solution allows a fresh slurry fluid to be obtained with an improved dispersibility of abrasive grains. Temporary storage of the permeate fluid in the chambers 64 , 65 allows a back wash process of the concentrating membrane using the permeating fluid at the time when contamination of the concentrating membrane is aggravated, thus allowing the concentrating membrane to be cleansed in a simple manner using the permeate fluid.
8. The flow rate of the permeate fluid is detected by the flowmeter 71 , and the temperature of the heat exchanger 52 is controlled by the flow rate controller 63 on the basis of the detected flow rate, whereby the speed of flow of the slurry effluent before it is subject to the concentrating operation can be controlled, allowing a concentrate fluid having a desired concentration to be obtained.
9. The provision of the pair of concentrating membrane units 49 , 50 and the pair of back wash chambers 64 , 65 allows one of the concentrating membrane units to be used even during the time the other unit 49 or 50 is being cleansed, such that a continuous operation is enabled without requiring an interruption of the slurry fluid regeneration operation.
10. The provision of the pair of microfilters 57 allows a continuous operation by allowing one of the microfilters to be used while the other microfilter is being changed.
11. Since the concentration unit 23 is controlled such that a concentrate fluid having the same concentration as the slurry fluid which is used in the polishing device 2 can be obtained, the concentrate fluid can be directly used as the regenerated slurry fluid for the polishing device 2 .
12. A fully automatic regeneration and the circulation system can be constructed since the concentrate fluid is fed to the polishing device 2 through the circulation channel 14 .
It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly it should be understood that the invention may be embodied in the following forms:
a) The crusher may include any combination of the mill 33 , the ultrasonic oscillation system 35 , 38 and the pressurizing circulation system 36 , 37 . For example, the crusher may comprise the ultrasonic oscillation system and the pressurizing circulation system.
b) A dispersant may be used in the crushing step to promote crushing action upon the agglomerations of abrasive grains.
c) The concentrating operation is not limited to the separation into a concentrate fluid and a permeate fluid. By way of example, a concentrate fluid may be produced by causing an evaporation of moisture in the slurry effluent. When the separation process is used, it may be implemented by a centrifuging process, for example, rather than using a concentrating membrane. In addition, the concentrate fluid may be obtained by removing a supernatant liquid after the separation by flocculation such as by precipitation.
d) A concentrate fluid having a higher concentration than that used in the polishing device 2 may be produced. In this instance, the permeate fluid may be used in the slurry feeder 5 to dilute the concentrate fluid, thereby preparing a regenerated slurry fluid.
e) A step of discarding the slurry effluent as a sludge by controlling abrasive grain diameters, when the number of reuses has increased to result in abrasive grain diameters which are below a given value, may be used. In this instance, a high polishing capability of the slurry fluid is maintained.
f) The back wash process may be performed after a given number of concentrating operations. In such instance, the number of concentrating operations is counted, and the back wash process is carried out when the count reaches a given value. Alternatively, an operator may control the degree of contamination of the concentrating membrane using a suitable instrument, and may determine a timing when the membrane is to be cleansed on the basis of a value obtained by the instrument, thus manually effecting the back wash process.
g) One, two, three or more concentrating membrane units may be used.
h) One, two, three or more microfilters may be used.
i) The abrasive grains in the slurry fluid or polishing fluid are not limited to alumina, but may comprise colloidal silicon or diamond.
j) The present invention may be implemented as a system for feeding the concentrate fluid to the polishing device after the concentrate fluid in the concentrate fluid tank is transferred to a feeding tank.
k) The present invention is not limited in its application to the regeneration of an effluent which has been used in the polishing step for a semiconductor wafer, but may also be used in the regeneration of an effluent which has been used in the polishing of a package.
Therefore, the present examples and embodiment are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope and the equivalence of the appended claims. | An apparatus and method recycles the abrasive fluid or slurry effluent used in the polishing step in the manufacture of semiconductors. Agglomerations of abrasive grains built up in the slurry effluent are crushed using a mill, ultrasonic oscillation, or pressurized circulation. The slurry effluent is then regenerated and reused. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/235,648 filed on Oct. 1, 2015, the disclosure of which is hereby incorporated by reference in entirety.
BACKGROUND
[0002] Railroads are typically constructed to include a pair of elongated, substantially parallel rails, which are coupled to a plurality of laterally extending rail ties. The rail ties are disposed on a ballast bed of hard particulate material such as gravel and are used to support the rails. Over time, normal wear and tear on the railroad may cause the rails to deviate from a desired profile based on movement of the underlying ballast, and as such voids or gaps under the rail ties may appear.
[0003] The traditional method of fixing voids that appeared under rail ties was very labor and time intensive, as it required measurement of the voids under each individual rail tie, manually lifting the rail ties, and then spreading a pre-measured quantity of ballast under the rail ties to raise the rails. In the 1970s, British Rail developed a mechanization of the traditional method by modifying a tamper and installing a system for distributing ballast under the rail tie with blasts of compressed air, creating the first stoneblower.
[0004] Modern stoneblowers are typically wheeled cars that comprise a track lifting device, a supply of crushed ballast rock, a source of compressed air, and a number of workheads. Each workhead carries a pair of blowing tubes. In operation, the track lifting device raises the track rails and the underlying rail ties to which the rails are secured. The workhead forces the blowing tubes into the ballast adjacent the raised rail ties with each pair of blowing tubes straddling a track rail. Stone is then blown through the blowing tubes into the voids beneath the raised rail ties. The workhead withdraws the blowing tubes and the track rail and rail ties are lowered. The stoneblower then advances to the next set of rail ties and repeats this procedure.
[0005] Modern stoneblowers are designed to restore a track's vertical and lateral alignment to an accuracy of 1.0 mm without disturbing the pre-existing compacted ballast layer. Vehicle bogies allow stoneblowers to measure a loaded track profile, and therefore measure the voids in the ballast under each rail tie. Computers then calculate the quantity of ballast to be “blown” under each rail tie, thus minimizing stone usage based on the track category or speed limit.
[0006] Compared with tamping, stoneblowers advantageously can be used on high speed track lines, treat only the areas of the track that need treatment, and reduce ballast damage. Further, after stoneblowing, the track does not become more rigid because the stoneblower only treats areas that need treatment, while the majority of the rail ties are supported on the original ballast and railroad bed. In addition, a new rock supplier is not needed to use a stoneblower for track maintenance. The injected ballast often comes from the same quarries and has the same attrition values as normal ballast. Additionally, using small, crushed stones as ballast causes less damage to the underside of the rail ties because the small stone is less likely to fail under heavy axle load based on increased surface area.
[0007] Current stoneblowers have some drawbacks, however, based on the current design incorporating pairs of parallel blowing tubes. For example, modern stoneblowers cannot efficiently blow ballast under non-uniform sections of rails, such as at railroad frogs or crossings, because the pairs of blowing tubes are only configured to have blowing tubes on each side of a rail and/or on each side of a rail tie, but they cannot blow ballast directly under the frog and/or under the rail tie area directly under the frog. However, in the continually changing world of track maintenance, it is essential that rail companies be able to provide quality track maintenance and alignment equipment that can service all sections of rail, not just uniform sections of rail. Moreover, conventional stoneblowers are large vehicles that are expensive to manufacture, deploy and operate. Smaller stoneblower machines, including those that can be deployed to work small areas of rail, such as frogs, are needed. Therefore, an improved stoneblower is desired.
BRIEF SUMMARY
[0008] The present disclosure generally relates to an improved stoneblower system comprising a railroad chassis for performing ballast maintenance on sections of non-uniform railroad track, such as railroad frogs or other intersections. The railroad chassis includes a plurality of workheads that are independently operable (e.g., movable). Each of the workheads includes one or more blowing tubes for dispensing ballast stones into a bed of ballast stones underlying rail ties of a railroad track. The one or more blowing tubes may be lowered into the bed of ballast stone so that new ballast stone may be dispensed into cavities in the bed of ballast stone below the rail ties. Dispensing new ballast stone into the bed of ballast stone raises the height of the bed of ballast stone, thereby raising the height of the overlying rail ties and rails of the railroad tracks. In this manner, alignment of the railroad tracks may be improved and/or maintained. The blowing tubes may similarly be independently operable with respect to the workheads (e.g., rotatable with respect to the workheads) so that new ballast may be accurately dispensed in difficult-to-reach locations of the non-uniform railroad track. Various hardware elements may be used to control positioning of the workheads and the blowing tubes. Additionally, a computing system may be utilized to collect and analyze measurements associated with the railroad track to ensure appropriate amounts of ballast stone are dispensed in particular locations. Related methods for operating the railroad chassis are also described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
[0010] FIG. 1 illustrates a perspective view of an exemplary stoneblower system according to the present disclosure.
[0011] FIG. 2 illustrates a perspective view of an exemplary railroad chassis of the stoneblower system of FIG. 1 .
[0012] FIG. 3 illustrates a perspective view of a workhead and associated blowing tube associated with the associated with the railroad chassis of FIG. 2 .
[0013] FIG. 4 illustrates a perspective view of a track reference device associated with the railroad chassis of FIG. 2 .
[0014] FIG. 5 illustrates a perspective view of a third point lifting arm associated with the railroad chassis of FIG. 2 .
[0015] FIG. 6 illustrates a perspective view of a railroad chassis associated with the railroad stoneblower system of FIG. 1 .
[0016] FIG. 7 illustrates a top view of an exemplary railroad frog intersection according to the present disclosure.
[0017] FIG. 8 illustrates a cross-sectional side view of an exemplary stoneblowing process according to the present disclosure.
[0018] FIG. 9 illustrates a computing system for carrying out processes described herein.
DETAILED DESCRIPTION
[0019] Various embodiments of an improved stoneblower are described according to the present disclosure. It is to be understood, however, that the following explanation is merely exemplary in describing the devices and methods of the present disclosure. Accordingly, several modifications, changes, and substitutions are contemplated.
[0020] In an embodiment, and as shown in FIG. 1 , an improved stoneblower system 100 may comprise a rail maintenance vehicle 102 and a railroad chassis 104 . In some embodiments, the railroad chassis 104 may be towed behind the rail maintenance vehicle 102 as the rail maintenance vehicle 102 propels itself along rails 106 of a railroad track. In other embodiments, the railroad chassis 104 may be self propelled and thus may include an engine 107 (e.g., a propulsion system and/or operating system) for propelling the railroad chassis 104 along the rails 106 of the railroad track. In still other embodiments, the railroad chassis 104 may be operated as a drone vehicle with no on-board personnel. In further embodiments, the railroad chassis 104 may take the form of a road-rail chassis or by-rail vehicle, which may be operated on both roads and rail. The rail maintenance vehicle 102 and/or the railroad chassis 104 of the stoneblower system 100 may include a plurality of wheels for engaging and moving along a top surface of the rails 106 .
[0021] As described throughout, the railroad track may include a pair of elongated, substantially parallel rails 106 , which may be coupled to a plurality of laterally extending rail ties 108 . In some embodiments, a top surface of each rail tie 108 may be coupled to a bottom surface of the rails 106 . The rail ties 108 may be disposed on a ballast bed 110 of hard particulate material such as gravel (e.g., ballast, rocks, and/or the like) and may be used to support the rails 106 .
[0022] FIG. 2 illustrates a more detailed view of the railroad chassis 104 of FIG. 1 . In some embodiments, the railroad chassis 104 may include a wheeled car comprising a ballast supply 112 , a track lifting device (not shown), at least one source of compressed air 116 (e.g., air compressor), and a plurality of workheads 118 . The railroad chassis 104 also may include various framing elements (e.g., frame 111 ) for coupling with elements described herein, as well as an operator cab.
[0023] In some embodiments, ballast stones may include crushed rock, gravel, and/or other small, hard particulate material. Ballast stones may be held in the ballast supply 112 (e.g., a containing device, a hopper, a bin, and/or the like) of the railroad chassis 104 . In some embodiments, the ballast supply 112 may include a dispenser and/or conveyor belt for transporting and/or distributing ballast stones to various workheads 118 of the railroad chassis 104 . In some embodiments, this dispenser and/or conveyor belt may be mechanized and/or controlled by a computing system. Additionally, the ballast supply 112 may include one or more sensors for determining an amount (e.g., a volume, a weight, and/or the like) of ballast stones remaining in the ballast supply 112 and/or an amount of ballast stones to be dispensed to (and/or dispensed by) one or more workheads 118 . In some embodiments, determining an amount of ballast stones remaining in the ballast supply 112 may initiate, by the computing system, generation of an automated request for refilling the ballast supply 112 with a predetermined amount of ballast stones. In other embodiments, determining an amount of ballast stones to be dispensed to one or more workheads 118 may be performed by the computing system and/or may occur in response to a measurement associated with the ballast bed 110 as described in more detail below.
[0024] In an embodiment, and as shown in FIG. 3 , each workhead 118 may be configured to disperse and/or distribute ballast stones through blowing tubes 120 . A lower end of each workhead 118 may comprise one or more blowing tubes 120 . The blowing tubes 120 may be arranged on a workhead 118 as a single blowing tube 120 , a pair of blowing tubes 120 , and/or any other arrangement of blowing tubes 120 .
[0025] Each blowing tube 120 may comprise a vertically elongated opening through which ballast stone is distributed. For example, during operation, a blowing tube 120 may be lowered into the ballast bed 110 so that ballast stones may be blown (e.g., inserted and/or injected) into gaps (e.g., voids, cavities, and/or the like) in the ballast bed 110 beneath rail ties 108 . This insertion of ballast stones into the ballast bed 110 may raise the rail ties 108 to a desired height so as to stabilize the rail ties 108 and increase alignment of the rails 106 .
[0026] Each blowing tube 120 may further be configured to be independently inserted into the ballast bed 110 . For example, each workhead 118 (and thus each blowing tube 120 ) may independently pivot, move, and/or traverse laterally relative to a rail 106 and/or a rail tie 108 . In this manner, ballast stones may be distributed in the ballast bed 110 at precise angles and/or locations. This is particularly advantageous at intricate track intersections and/or switches in the railroad track.
[0027] Additionally, in some embodiments, a blowing tube 120 may be independently operable (e.g., movable, adjustable, and/or the like) relative to its associated workhead 118 . For example, the blowing tube 120 may be independently rotatable, angularly adjustable, and/or extendable relative to the workhead 118 to which it is coupled. In some embodiments, a housing may be coupled to a distal end of the workhead 118 to accommodate insertion of the blowing tube 120 into the housing. A motor, or other activation device may be provided in the housing for causing rotation of the blowing tube 120 relative to the workhead 118 based on instructions received from a computing system associated with the rail vehicle 102 . The housing may contain one or more thrust bearings that accommodate rotation of the blowing tube 120 and ensure that the motor does not receive the thrust. Further, an anti-rotational pin may be deployed to lock the blowing tube 120 in place once it rotates to the desired position. Of course, the aforementioned description of the rotation mechanism for the blowing tube 120 is merely exemplary, and other embodiments are contemplated so long as the blowing tube 120 is independently rotatable relative to the workhead 118 .
[0028] In some embodiments, the blowing tubes 120 may be capable of rotating about a vertical axis specifically designed to match a curvature of one or more non-uniform rail locations, such as at a railroad frog track intersection (e.g., railroad frog 126 of FIG. 7 ). By allowing the blowing tubes 120 to rotate about the vertical axis, the elongated opening in each blowing tube 120 that deposits the ballast may face a side of the rail 106 in order to deliver ballast stone under a rail tie 108 and/or another track section. In some embodiments, the blowing tubes 120 may be curved.
[0029] During operation, the track lifting device may be utilized to lift a portion of the rails 106 and/or rail ties 108 so that ballast stones may be blown into the ballast bed 110 underlying the rail ties 108 . The track lifting device may lift the rail 106 and/or underlying rail ties 108 to a predetermined distance above of the ballast bed 110 so that a desired amount of ballast stones may be inserted underneath the lifted rail ties 108 . In some embodiments, the movements of the track lifting device may be controlled by the computing system as described herein.
[0030] Also during operation, air from an air compressor 116 associated with the workhead 118 may be utilized to insert and/or inject ballast stones through the blowing tube 120 and into the ballast bed 110 . In some embodiments, each workhead 118 may include an air compressor 116 . In other embodiments, workheads 118 may share a common air compressor 116 and/or may comprise multiple air compressors 118 . The computing system may determine an amount of air to be blown into each workhead 118 and through the blowing tube 120 as described in more detail below.
[0031] In an embodiment, and as depicted in FIG. 5 , the railroad chassis 104 may further comprise one or more third point lifting arms 124 operable to enable the blowing of ballast stones under portions of railroad tracks that are not uniform, such as railroad switches and/or crossing panels of adjacent railroad tracks, railroad frog track intersections, and/or the like. For example, a third point lifting arm 124 may be configured to move a workhead 118 , and in turn, an associated blowing tube 120 , laterally relative to the railroad chassis 104 . In this manner, the workhead 118 and the associated blowing tube 120 may move outwardly from the railroad chassis 104 along the third point lifting arm 124 so that the blowing tube 120 may be lowered into the ballast bed 110 underneath a rail tie 108 of an adjacent rail 106 (e.g., a rail 106 adjacent to the rail 106 on which the railroad chassis 104 is positioned).
[0032] The third point lifting arm 124 may extend outwardly from the railroad chassis 104 using a hydraulic system. The third point lifting arm 124 may also be foldable and/or pivotable in relation to the railroad chassis 104 .
[0033] In some embodiments, the third point lifting arm 124 may be operated by a maintenance professional located inside the railroad chassis 104 and/or by a second maintenance professional located outside the railroad chassis 104 . The workhead 118 may be configured to move a predetermined distance along the third point lifting arm 124 so that the workhead 118 (and thus the blowing tube 120 ) is positioned as desired near a rail tie 108 of an adjacent rail 106 and/or track section. Movements of the third point lifting arm 124 and/or the workhead 118 along the third point lifting arm 124 may also be controlled by the computing system as described herein.
[0034] In an embodiment, and as depicted in FIG. 6 , the railroad chassis 104 may be utilized at a rail switch. As shown in FIG. 6 , the blowing tube 120 may be deployed at an angle relative to the vertical axis of the rail 106 . Importantly, utilizing multiple workheads 118 on the railroad chassis 104 and/or third point lifting arms 124 as described above may enable a railroad maintenance crew to blow ballast stones under rail ties 108 of rails 106 at non-uniform locations and angles, thereby raising the rails 106 at locations previously unserviceable by standard stoneblowers.
[0035] As shown in FIG. 7 , a railroad frog 126 may include a railroad track structure that is used at an intersection of two running rails 106 to provide support for railcar wheels and passageways for wheel flanges, thus permitting wheels on either rail 106 to cross over the rails 106 . On a rail wheel, the flange may be the inside rim which projects below the tread. Each railroad frog 126 may have about fifteen rail ties 108 under the rails 106 of the railroad frog 126 , and as such, tamping equipment and current stoneblowers cannot adequately maintain a railroad line at the railroad frog 126 because of the non-uniform nature of the rails 106 at the railroad frog 126 . Advantageously, the disclosed improved stoneblower 100 is operable to blow ballast stones under rail ties 108 of the rails 106 of the railroad frog 126 , as well as many other non-uniform sections of rail 106 .
[0036] In operation, each independent workhead 118 may work in a similar manner as the ballast stone depositing process 128 depicted in FIG. 8 . In a first step, the railroad chassis 104 may move along the rails 106 to a desired position on a particular section of railroad track. While moving along the rails 106 , one or more sensors associated with the railroad chassis 104 may collect track profile data associated with the rails 106 . These sensors may measure a height, a width, an orientation, a shape, a contour, an angle, a condition, and/or other factors associated with the rails 106 .
[0037] A track design computer (e.g., the computing system as described herein) associated with the railroad chassis 104 and in communication with the one or more sensors may generate a track profile of the rails 106 along the particular section of rail 106 . Based on the generated track profile, the computer system may calculate an amount of ballast stone required to be blown into the ballast bed 110 underneath one or more rail tie(s) 108 along the particular section of the rail 106 to achieve a desired or optimum track profile.
[0038] The computing system may then, based on the determined amount of ballast stone to be blown into the ballast bed 110 , determine a height to which the rails 106 and/or the rail ties 108 need to be raised so that the determined amount of ballast stone may be blown underneath the rail ties 108 . The computing system may instruct the track lifting device to lift the rail(s) 106 to at least the predetermined height so that adequate space in the ballast bed 110 is present (e.g., see step 1 of FIG. 8 ).
[0039] The computing system may also, based on the determined amount of the ballast stone to be blown into the ballast bed 110 , determine an amount of ballast stone held in the ballast supply 112 to be distributed to the one or more workheads 118 for injection into the ballast bed 110 . The computing system may instruct the ballast supply 112 to distribute the determined amount of ballast stone to the one or more workheads 118 . In some embodiments, the determined amount of ballast stone may be distributed to the one or more workheads 118 according to the computer system instructions continuously during the stoneblowing process and/or at a time prior to stoneblowing.
[0040] The computing system may further, based on the determined amount of the ballast stone to be blown into the ballast bed 110 , determine an amount of compressed air to be blown by the air compressor(s) 116 for injecting the determined amount of ballast stone into the ballast bed 110 . The computing system may instruct the air compressor(s) 116 to distribute the determined amount of compressed air stone to the one or more workheads 118 and/or the blowing tubes 120 .
[0041] The computing system may additionally, based on the determined amount of the ballast stone to be blown into the ballast bed 110 , determine a position of the one or more workheads 118 for optimally blowing the ballast stones into desired locations in the ballast bed 110 . In this manner, the computing system may instruct various movements and/or adjustments of at least one of the one or more workheads 118 , the associated blowing tubes 120 , and the third point lifting arm 124 so that the workheads 118 , and importantly the blowing tubes, are accurately and independently positioned for dispensing the ballast stones into the ballast bed 110 as desired. For example, the one or more workheads 118 (and thus the associated blowing tubes 120 ) may be independently lowered (e.g., inserted) into the ballast bed 110 at a predetermined location along the rail 106 and at a calculated angle relative to the rail 106 and/or rail tie 108 . Once inserted into the ballast bed 110 , the blowing tubes 120 may be rotated and/or adjusted with respect to the workheads 118 .
[0042] The computing system may then instruct the one or more workheads 118 to independently blow the determined amount of compressed air and ballast stone through the blowing tubes 120 so that it is injected into the ballast bed 110 at one or more desired locations (e.g., see step 2 of FIG. 8 ). For example, ballast stones may be blown underneath the rail tie 108 associated with the lifted rail 106 , thereby accumulating new ballast stones in the ballast bed 110 under the rail(s) 106 and/or rail tie(s) 108 (e.g., see step 3 of FIG. 8 ).
[0043] Once the determined amount of ballast stones is injected into the ballast bed, the computer system may instruct the track lifting device to lower the rails 106 and/or the rail ties 108 so that the rail ties 108 rest on the ballast bed 110 (e.g., see step 4 of FIG. 8 ). Because of the ballast stones being injected into the ballast bed 110 to raise the ballast bed 110 , the rail(s) 106 and/or rail tie(s) 108 may similarly be raised, thereby leveling the rails 106 to a desired height and/or alignment (e.g., track profile). The railroad chassis 104 may then move along to another section of the rails and repeat the aforementioned stoneblowing process.
[0044] Advantageously, the improved stoneblower system 100 described herein may be especially helpful at locations where two rails merge or intersect, such as at a railroad frog 126 and/or other non-uniform sections of railroad tracks. In addition, by allowing each workhead 118 (and therefore each blowing tube 120 ) to move, pivot, and/or be inserted independently, the railroad maintenance crews may be enabled to blow ballast stones under non-uniform sections of rails 106 , such as at railroad frogs 126 and/or railroad crossings. By allowing maintenance crews to raise rail ties 108 supporting these non-uniform sections of rails 106 by executing the aforementioned stoneblowing process, railroad frogs 126 and other crossings may have extended lifespans. For example, the rail ties 106 of these crossings may be raised to uniform heights at these locations by adjusting the height of the underlying ballast bed 110 , thereby reducing the wear and tear on the rails 106 .
[0045] Referring to FIG. 9 , the computing system may take the form of a computer or data processing system 200 that includes a processor 220 configured to execute at least one program stored in memory 222 for the purposes of performing one or more of the processes disclosed herein. The processor 220 may be coupled to a communication interface 224 to receive remote sensing data as well as transmit instructions to receivers distributed throughout the rail vehicle 102 and/or chassis 104 . The processor 220 may also receive and transmit data via an input/output block 225 . In addition to storing instructions for the program, the memory may store preliminary, intermediate and final datasets involved in techniques that are described herein. Among its other features, the data processing system 200 may include a display interface 226 and a display 228 that displays the various data that is generated as described herein. It will be appreciated that the data processing system 200 shown in FIG. 9 is merely exemplary in nature and is not limiting of the systems and methods described herein.
[0046] While various embodiments in accordance with the disclosed principles have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages. | The present disclosure generally relates to a railroad chassis vehicle having independently operable workheads for carrying out rail maintenance operations on non-uniform sections of railroad tracks. Related methods of operation of the railroad chassis and associated maintenance of ballast beds underlying railroad tracks are also described. | 4 |
TECHNICAL FIELD
The present disclosure relates to communication between intermittently connected devices, and more specifically to a protocol for secure communications between field equipment and a computer server.
BACKGROUND
Field equipment, or more simply, machines, such as earthmoving equipment, mining equipment, fixed installation generators, etc., are increasingly outfitted with programming and monitoring capabilities. By nature, however, such equipment is subject to both intermittent operation and intermittent network access so that reliable access to the equipment for exchange of relevant data is difficult.
SUMMARY OF THE DISCLOSURE
In a first embodiment, a system for securely communicating requests and responses between a workstation and a machine uses a task list server that includes the machine that is communicatively coupled to the task list server and that receives, from the task list server, an instruction corresponding to a request from the workstation, the instruction being a task instruction or a status instruction corresponding to the request. The machine may develop a response to the instruction without human operator intervention. The system may also include the task list server having executable instructions that when executed by a processor causes the task list server to establish a first communication session between the task list server and the workstation, the first communication session being mutually authenticated and encrypted. The first communication session communicates the request from the workstation to the task list server and the request includes at least one of a task or job request or a status request. Asynchronously to the first communication session, a second communication session may be established between the task list server and the machine, the second communication session is mutually authenticated and encrypted. The second communication session communicates the response to the instruction from the machine to the task list server.
In another embodiment, a system for securely communicating requests and responses between a workstation and a machine includes a task list server that has a server processor and a communication port coupled to the server processor. The communication port supports secure and authenticated session-based communications between the task list server and the workstation and between the task list server and the machine. The task list server also includes a memory configured to store operational data, keys, and executable commands for execution on the server processor that cause the task list server to store data and communicate data traffic over the communication port. The system also includes a machine that has a machine processor, a machine communication port coupled to the machine processor and is communicatively coupled to the communication port of the task list server. The machine further includes a memory configured to store executable commands for execution on the machine processor that implement i) a communication routine that receives an instruction from the task list server, ii) a queue storing the instruction received from the task list server and a response to the instruction for sending sent to the task list server, and iii) a dispatch routine that causes the instruction to be executed and determines the response to the instruction.
In yet another embodiment, a method of asynchronous communication between a plurality of workstations and a plurality of machines using a task list server includes establishing a first communication session between the task list server and a workstation, receiving, at the task list server, a request from the workstation, where the request includes at least one of a status request for a status at one or more of the plurality of machines or a job request to be executed at the one or more of the plurality of machines and storing the request in a queue at the task list server. The method further includes establishing a second communication session between the task list server and a one machine of the plurality of machines, determining that the queue has a stored request for the one machine, dispatching, to the one machine, an instruction corresponding to the stored request in the queue, marking the stored request in the queue as pending, and disconnecting the second communication session. The method may also include establishing a third communication session between the task list server and the one machine, receiving from the one machine a response to the instruction, storing the response in the queue at the task list server, and sending, from the task list server to an authenticated workstation, a status message corresponding to the response stored in the queue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram illustrating components supporting a secure machine-to-machine protocol;
FIG. 2 is a block diagram illustrating message flow in the system of FIG. 1 ;
FIG. 3 is a block diagram of an exemplary task list server;
FIG. 4 is a block diagram of an exemplary workstation;
FIG. 5 is a block diagram of an exemplary processing module of a machine; and
FIGS. 6 and 7 are a flow chart of an exemplary method of secure machine-to-machine communication.
DETAILED DESCRIPTION
FIG. 1 illustrates a system 10 that supports a secure machine-to-machine protocol. The system 10 may include a task list server 12 and one or more workstations 14 , 16 . The system 10 may also include a machine 18 that may include a processing module 20 . A second machine 22 and its associated processing module 24 are used to illustrate that any number of machines may be supported by the system 10 . The task list server 12 and workstation 16 may be connected by a network 26 that may include a public or private local area network. The task list server 12 may be connected to the workstation 14 by a wide area network 28 , that may include the Internet. A wireless link 30 may directly connect the task list server 12 to machine 18 . Alternatively, the task list server 12 may communicate with a machine, such as machine 22 , via a wireless link 32 coupled to the wide area network 28 , and may include a cellular telephone network, a satellite network, a private data system, etc. In other embodiments, a hardwired connection 34 may couple the machine 22 to the task list server 12 either via the wide area network 28 or directly with the task list server 12 (not depicted).
FIG. 2 is a block diagram illustrating message flow between elements of the system 10 of FIG. 1 . Four general categories of communication are depicted in FIG. 2 representing bidirectional communication between the task list server 12 and workstation 16 or between the task list server 12 and machine 18 . It will be understood that a plurality of workstations, task list servers, and machines are supported by the system 10 but for the sake of clarity of illustration the descriptions will generally be confined to a single instance of each element.
Communication from the workstation 16 to the task list server 12 is referred to as a request 42 . Communication from the task list server 12 to the machine 18 is referred to as an instruction 44 . It is understood that the contents of a particular request 42 and its corresponding instruction 44 may be identical and are at least related, but are separately named for ease of referencing in the following description. Communication from the machine 18 to the task list server 12 is referred to as a response 46 . Communication from the task list server 12 to the workstation 16 is referred to as a status message 48 . Similarly, it is understood that the contents of the response 46 and the status message 48 may be identical and are at least related but are separately named for the purpose of description.
The task list server 12 may include one or more machine specific queues 50 , 52 . As described in more detail below, the queues 50 , 52 are used to manage communication traffic between workstation 16 and one or more machines, such as machine 18 , particularly in view of the intermittent access by the either the workstation 16 or the machine 18 . Similar queues 54 , 56 for traffic intended for one or more workstations may also be supported at the task list server 12 .
One or more additional task list servers 58 may be included in the system for the sake of redundancy, backup, load sharing, etc. In the following description for the sake of clarity, the task list server 12 will be described in the singular with the understanding that one or more task list servers 58 may be used in some embodiments.
FIG. 3 is a block diagram of an exemplary task list server 12 . The task list server 12 may include a processor 72 and a memory 74 coupled by an internal bus 76 . The internal bus 76 may further connect the processor 72 to a communication port 78 as well as user interface elements such as a display 80 and user input 82 , for example, a keyboard and mouse. The communication port 78 may be coupled to the network 26 . As discussed in FIG. 1 , the communication port 78 may optionally support communication via a wireless network 30 such as Wi-Fi, Zigbee, etc.
The memory 74 may include one or more modules such as an operating system 84 and utilities 86 that may be used in diagnostics, maintenance, status reporting, etc. The memory 74 may also include one or more modules that when executed by the processor 72 may implement functions associated with secure machine-two-machine communication. These modules may include, but are not limited to, task list management 88 , a Web server 90 , and optional data such as machine configuration 92 and/or support for a workstation user interface 94 . The memory 74 may also include keys and certificates 96 used for secure channel set up, endpoint authentication, and user authentication as required.
Task list manager 88 may include executable code that receives and sends communications between the workstation 16 and the machine 18 . For example, in one embodiment, a request may be stored on a machine-specific outbound queue at the task list server 12 and responses may be stored in a workstation-specific outbound queue at the task list server 12 . In another embodiment, only machine-specific inbound or workstation-specific inbound queues may be used and the task list manager 88 may query each queue when looking for messages destined for a particular workstation 16 or machine 18 . In such an embodiment, communications are stored in queues specific to where the communication came from, rather than queues specific to where the communications are destined, as discussed above. The task list manager 88 , or a similar function, may log the date and time of communication sessions with the machine 18 and may flag a machine that is overdue for a communication session either based on previous communication patterns or on a pre-determined schedule.
The web server 90 may offer a web presence to support asynchronous communication between either a machine 18 or a workstation 16 . Web services are not the only communication base that is available and others may include remote procedure call (RPC), file transfer protocol (FTP), etc. However, the asynchronous nature of a web service is particularly well-suited to this type of operation.
In embodiments where communication is supported via a web service, a web server 90 may be implemented. The web server 90 may support unsolicited asynchronous communication requests from either the machine 18 or the workstation 16 and may serve web pages or web-based data. In some embodiments, the web server 90 , or a utility 86 may support push communications after determining that a target machine 18 or workstation 16 is online and available.
Several optional functions may also be supported. Machine configuration information 92 may be maintained at the task list server 12 for each machine 18 supported. It is expected that each machine type, for example, an earthmover will support a different set of task or job requests and status requests compared to, for example, a power generator. Even within a particular machine type, different models may support slightly different job or status requests. Therefore, it is expected that such a repository of machine-specific configuration information is present somewhere in the system 10 . As shown here in FIG. 3 , the information may reside in the task list server 12 . As discussed below, machine-specific configuration information may be stored in the workstation 16 . Alternatively, each machine 18 may store its own configuration information and may supply a list of capabilities in response to a discovery request.
The memory 74 may also store a workstation user interface 94 . As is known, there are many options for where the code for a workstation user interface 94 may be stored. As shown here, the workstation user interface 94 may be stored at the task list server 12 . The workstation user interface 94 may be embodied in many known formats and when the workstation client is a generic browser may include HTML, Java, or JavaScript. In other embodiments where the workstation user interface 94 is embodied in a different form, such as a thin client or a thick client, the workstation user interface 94 may be a compiled executable code that is downloaded and installed on the workstation 16 .
Keys and/or certificates 96 may also be stored in the memory 74 for use in establishing authenticated sessions between the task list server 12 and the workstation 16 as well as between the task list server 12 and the machine 18 . The establishment of secure communication sessions may use any of several known techniques and may include Diffie-Hellman key exchange, public and private key pairs using a trusted certificate authority (CA), derived keys based on commonly known shared keys, etc. In some embodiments, more than one CA may be involved, such as a manufacturer CA and an operator CA. In these cases, some form of mutual trust may be established between the CAs. There are two primary reasons, among many, for securing communication between endpoints and for performing authentication and authorization procedures. First, status information regarding operation of a particular machine or machines may represent highly confidential business information that a business would seek to protect from disclosure to a competitor either through direct query or by eavesdropping. Second, and of perhaps greater concern, is protection from potentially malicious access that seeks to disrupt productivity or even sabotage operation by, for example, placing the targeted machine in a maintenance mode.
FIG. 4 is a block diagram of an exemplary workstation 16 . The workstation 16 may be any conventional computer that for some embodiments supports at least a browser. This may include servers and desktop units as well as laptops, tablets, smart phones etc. The workstation 16 may include a processor 102 connected to a memory 104 by an internal data bus 106 . The processor 102 may also be connected to a communication port 108 for use in communication with the task list server 12 via a network, for example, network 26 . The workstation 16 may include a display 110 and other user input equipment 112 such as, but not limited to, a keyboard, a mouse, or a touchscreen (not depicted).
In some embodiments, removable media 114 may be used to install various configuration elements to the memory 104 , to transport results information, or for data backup. The memory 104 may include an operating system 116 , various utilities 118 that may also include a browser, and several optional elements. Particularly in those embodiments where local executable code is stored in the memory 104 , those optional elements may include data such as a response log 120 , a request queue 122 , machine configuration 124 , and user interface code 126 , although other configurations may be supported.
The response log 120 may include information status message information received from one or more machines, such as machine 18 . In some embodiments, previously submitted requests may be stored locally so that an analysis of outstanding requests can be performed locally and/or to allow various metrics to be collected after a particular status message corresponding to a previously submitted request is received. This analysis may include response times, successful completions of task or job requests, etc.
When off-line operation is supported, the request queue 122 may store both job requests and status requests for transmission to the task list server 12 after a network connection with the task list server is established. Machine configuration information 124 may be the same as or similar to machine configuration information 92 found in some embodiments at the task list server 12 . In an embodiment, machine-specific configuration information 124 may only be downloaded to the workstation 16 at the time a user expresses an interest in sending a request to a particular machine 18 . The user interface code 126 may be downloaded code, such as JavaScript associated with a browsing session, or permanently installed code associated with, for example, off-line generation of task or status message requests that would be communicated to the task list server 12 upon establishment of a network connection. As above, keys and/or certificates 128 may be used to perform authorization, authentication, and transmission security functions.
FIG. 5 is a block diagram of an exemplary processing module 20 of a machine 18 . The processing module 20 may include a processor 152 and a memory 154 that is coupled to the processor 152 via a bus 156 . Also coupled to the processor 152 via the bus 156 may be a communication port 158 for communication via a network 28 or another similar network.
In an embodiment, one or more engine or body electronics or sensors 160 may be coupled to the processing module 20 either directly to the bus 156 , via communication port 158 , or via another connection (not depicted). The engine or body electronics or sensors 160 may include engine control modules, chassis control modules, load sensors, temperature sensors, pressure sensors, voltage or current sensors, etc. Communication between the processing module 20 and these various elements of machine 18 may be used to develop responses to instructions received from the task list server 12 .
The memory 154 may include, as discussed above, an operating system 162 and utilities 164 . The memory 154 may also include a communication routine 166 for use in communicating both between the processing module 20 and the task list server 12 as well as the module 20 and the various engine or body electronics and sensors 160 . A priority manager 168 may be used to prioritize the sequence in which instructions received from the task list server 12 are executed, based on a priority associated with a particular instruction, a date and time prioritization, or a combination of the two. In other embodiments, additional prioritization characteristics may be included, such as the time required to develop a response so that a simple data gathering such as a coolant temperature may be performed before a calculated response such as drawbar pull. In another embodiment, execution of an instruction for which there is not enough data may be de-prioritized. To illustrate, a request for work cycle productivity may need to be delayed until the first work cycle is completed.
An instruction/response queue 172 may be used to store instructions received from the task list server 12 , to store prioritization information about the instructions, and to store response information pending transmission to the task list server 12 . In another embodiment, separate queues (not depicted) may be used for inbound and outbound data. The instruction/response queue 172 may include a time reference (not depicted) for use in logging instructions received for use by the priority manager 168 in prioritizing execution order. Other sources of time may be used. After connection to the task list server, response information stored in an outbound queue may be cleared after a confirmation of receipt message is received from the task list server 12 . As discussed above, keys and certificates 174 may be used to perform authorization, authentication, and transmission security functions.
FIG. 6 is a flow chart of an exemplary method 200 of secure machine-to-machine communication. The portion of the method 200 illustrated in FIG. 6 may be particularly relevant to an initial round of communication when no previous requests have been made and no responses may be pending. However, other embodiments of the method 200 may perform the steps in a slightly different order. At block 202 , a communication session is established between task list server 12 and the workstation 16 . The communication session may be initiated at the workstation 16 responsive to user activity at the workstation 16 , for example, by connecting a browser to the web server 90 . Other activities that support establishment of a communication session between the task list server 12 and the workstation 16 may also be supported.
In creating the communication session, several steps may be followed to help ensure that the session is secure. For example, a secure channel using, for example, HTTPS may first be established to prevent eavesdropping. Then, for authentication purposes, a nonce may be generated at each end and signed by the local device's private key and through a number of exchanges may be verified at the remote device using the local device's public key. Verification of the certificate containing the public key at a certificate authority (not depicted) may also be performed. Alternatively, a shared secret may be used to authenticate both parties in the communication session. Once each side has authenticated the other, authorization information such as user login credentials may be supplied by the workstation 16 and verified at the task list server 12 . In an alternate embodiment, each machine 18 may have trusted user information programmed into the processing module 20 , so that the task list server may save and forward some form of user authentication information during that portion of the method 200 .
At block 204 the task list server 12 may receive a request from the workstation 16 . Numerous kinds of requests may be supported and may include a request for a status at the machine 18 or a request for a task to be executed at the machine 18 . For example, a status request may include a request for operating hours, payload information, fuel status, etc. Exemplary task or job requests may include resetting a log value, initiating a catalytic converter recharge cycle, or even downloading updates to an engine controller. Each request may have a priority assigned to the request at the time the request is created at the workstation 16 . In an embodiment, the priority may be assigned or changed any time after the request is received at the task list server 12 up until the associated instruction is executed at the machine 18 , given the appropriate communication session availability. Grouping of machines may also be supported to allow mass requests by a workstation 18 targeting a number of machines. In such an embodiment, the task list server 12 would have to manage each request separately due to possible differences in connectivity between the task list server 12 and individual machines.
At block 206 the task list server 12 may store the request received from the workstation 16 in a machine specific-queue at the task list server 12 . In another embodiment, the request may be stored in a workstation-specific queue or even just a general delivery queue where either of the latter are reviewed upon connection with a specific machine 18 . At this point, the communication session between the task list server 12 and the workstation 16 may be ended, although in some embodiments the communication session may be relatively persistent and last through several cycles of communication based on network availability and session timeout requirements. In other embodiments, certain communication session related data may be stored, such as session identifiers, so that when a communication channel is available, the communication session may be restored more quickly than negotiating a new session. However, when referred to here, ending or disconnecting a communication session is associated with completion of one or more rounds of communication and, in general, tearing down the communication session. Ending a communication session may also include a positive step taken at either the machine 18 or the workstation 16 to disconnect from a particular network, either in response completion of all pending communications or to a change in machine status that affects the ability to communicate. One example may be disconnecting a tether used for communication in preparation for transport to a worksite.
The dashed line between block 206 and block 208 and other similar dashed lines connecting blocks in FIGS. 6 and 7 are provided to indicate an asynchronous action, that is, that some passage of time may occur between the execution of the blocks or that other communication sessions may occur during this time. For example, a second communication session between the workstation 16 and the task list server 12 may occur before any communication is established between the task list server 12 and the machine 18 .
At block 208 , a communication session may be established between the task list server 12 and the machine 18 . The communication session may be established responsive to a request from the machine 18 to establish a communication session, for example, at the completion of a workday when the machine is brought to a service center, or when a wireless connection between the machine 18 and a wireless service provider capable of supporting the session becomes available. As above, this may involve creation of a secure channel and mutual authentication. Although authorization, such as a user login, would not be expected, the machine 18 may, in some embodiments, supply additional proof of identity information beyond that used for mutual authentication.
For the processing module 20 to function autonomously, the processing module 20 must be network aware and capable of periodic testing of wireless connections (if any) to determine if any approved network becomes available. The processing module 20 may also need to be sensitive to physical network connections becoming available, for example, when the machine 18 is returned to a work center and a tether attached. The processing module 20 may be initially programmed for a particular set of networks and operating conditions and then must operate independently to establish network connections, manage priorities, determine whether instructions were completed successfully or not, report responses, and implement downloaded programming changes. Programming changes may include changes to the configuration of the processing module 20 as well as changes to components of the machine 18 , such as operating limits at an engine control module (not depicted).
At block 210 , the task list server 12 may check a machine-specific queue for any requests pending at the task list server for the machine 18 . As discussed above, different queue configurations may be used. If, at block 210 , one or more requests have been queued for the machine 18 , the “yes” branch from block 210 may be taken to block 212 .
At block 212 , queued requests may be reformatted as necessary and dispatched to the machine 18 in the form of instructions. As noted above, the use of the terms request and instruction are semantic and used in illustrating of the concepts disclosed.
At block 214 , the request in the queue may be marked as pending, indicating that the request has been dispatched to the machine 18 but that no response has been received.
At block 216 , any responses or other status information pending at the machine 18 may be forwarded from the machine 18 to the task list server 12 and placed in an appropriate queue on the task list server 12 . In an exemplary embodiment, responses may be stored in a queue specific to the workstation 16 that either placed the request or which has been designated by the machine 18 . As to the latter, the machine 18 may generate some outbound responses that are machine initiated, such as an alarm condition. In that case, the machine 18 may designate a destination for the message. In an embodiment, the destination may be name only, such as “urgent maintenance” and the task list server 12 may resolve the name to a particular destination.
Returning to block 210 , if there are no queued requests for the machine 18 , the “no” branch from block 210 may be taken to block 216 and executed as described above.
The method illustrated in FIG. 6 continues at FIG. 7 as noted by the “A” designator. FIG. 7 illustrates a continuation of method 200 of FIG. 6 and may be directed to subsequent communication sessions between the task list server 12 and the endpoints, machine 18 and workstation 16 .
At block 218 , communication may be established between the task list server 12 and the machine 18 . At block 220 , a determination may be made as to whether there are responses queued at the machine 18 for uploading to the task list server 12 . If so, the “yes” branch from block 220 may be taken to block 222 .
At block 222 , responses corresponding to request/instructions previously delivered from the task list server 12 may be uploaded to the task list server 12 . At block 224 , following confirmation of the receipt of the response, items in the response queue 172 of FIG. 5 may be cleared or otherwise marked as delivered. At block 226 , any instructions pending at the task list server 12 may be delivered to the machine 18 , and, optionally, the communication session may be ended.
If, at block 220 , there are no queued responses at the machine 18 , execution may take the “no” branch from block 220 to block 226 , where execution continues as described above with respect to block 226 .
Asynchronously to block 226 , at block 228 , when a network connection is available, a communication session may be established between the task list server 12 and the workstation 16 as described above.
At block 230 , when responses are queued at the task list server 12 for the workstation 16 , the “yes” branch may be taken to block 232 . At block 232 , the responses in the form of status messages may be sent to the workstation 16 . At block 234 , the task list server 12 may mark the queued responses as sent following confirmation of delivery. The queued responses may be deleted following delivery, but in other embodiments, the delivered responses may be archived at the task list server 12 .
At block 236 , any requests pending at the workstation 16 may be delivered to the task list server 12 and, as discussed above with respect to block 206 , those requests may be queued for delivery to the machine 18 .
INDUSTRIAL APPLICABILITY
In general, the ability to ability to asynchronously queue requests/instructions and responses/status messages between a workstation and a machine gives a new level of flexibility to machine owners, operators and other authorized parties for communication with the machine. Many worksites are inherently under construction and may not have a mature communication infrastructure in place. In other applications, such as mining, a machine may be in such a harsh communication environment that no data transfers are possible at all until the machine is physically moved to a different location, such as above ground.
Similarly, on the workstation side, modem communications equipment such as tablets and smart phones allow mobility among workers that was previously unheard of. However, even with these advances, coverage gaps, building interiors, tunnels, airplane restrictions, etc., make ubiquitous and uninterrupted communication access unachievable. Therefore, the services offered by the above-disclosed system and method may provide an important link between a human user and a machine with no user interface or, in some cases, with no user.
Unlike a simple email client, or other supervisory control and data acquisition (SCADA) equipment such as a smart electric meter, a processing module in the machine may be capable of determining network availability, establishing connections, performing authentication and authorizations as needed, and manage its own instruction queue, as well as manage collecting data and sending the data, all without human user involvement. These features allow machine diagnostics, work site information transfers, and programming changes to be accomplished, in many cases without the machine being taken out of service and without distracting an operator or on-site maintenance technician. Because a machine may have limited computational power or may have a limited number of free cycles for execution and reporting of instructions received from the task list server, the processing module benefits from the ability to manage its own queue and arrange the sequence in which instructions are performed according to an assigned priority, the date and time of the request, or other assignable criteria. | A task list server supports secure asynchronous communications between both a workstation and one or more machines. The task list server stores requests and responses initiated by either side and establishes secure communication channels used to forward the data between parties. The communication between workstation and machine may be delayed by hours or even days, depending on the work schedule and network access of both the workstation operator and machine. The machine may process requests in order from highest priority to lowest priority and from oldest to newest. Public key encryption may be used to establish secure channels between the task list server and the workstation or the one or more machines using a combination of certificate authorities including both manufacturers and owner/operators. | 7 |
FIELD OF THE INVENTION
This invention relates a false twist processing apparatus principally for chemical fiber filament yarns.
RELATED ART STATEMENT
There has been known an apparatus for applying a predetermined false twisting process to a yarn supplied from a yarn supply device by passing the yarn through a plurality of yarn treating devices provided on a frame sideway of said yarn supply device (For example, Japanese Utility Model Application Laid-Open No. 21084/1987).
In the above-described yarn treating devices for the false twist processing apparatus, a heater, a cooling plate, a false twisting member (a false twisting spindle) and a take-up device are provided in order of processing steps, and as the case may be, a second heater for removing torque is provided between the false twisting member and the take-up device.
Since the aforesaid second heater is for removing torque, and therefore, a long heater is not required, but a heater (a first heater) arranged at upstream of the false twisting member need be relatively long. The reason why is that in the case where the yarn speed is increased in an attempt of increasing the processing speed of the yarn, the length of the heater need be extended to increase contact time between the yarn and the heater in order to apply sufficient heating to the yarn. In the aforesaid heater, smoke generated during processing is discharged along the heating surface thereof, and therefore, normally, the heater is supported vertically or with a suitable inclination. However, this increases a mounting height (a height of center of gravity) of the heater in line with an increased length of the heater itself.
On the other hand, those which are driven at high speeds and comprise a vibrating source among the aforementioned yarn treating devices are mainly the false twisting member (spindle for the false twisting member) and the take-up device.
The take-up device is normally provided at a relatively low position on a floor because an operator himself need to doff the wound package, and the spindle for the false twisting member is often provided thereabove.
Accordingly, a mechanical vibration induced by the vibration of the take-up device itself in the vicinity of a low position on the floor on which the take-up device is installed comprises no significant problem but a vibration of the spindle and a vibration induced by the transmission of the vibration of take-up device in the vicinity of the heater mounted at a relatively high level tend to be amplified. The amplified vibration induces a looseness in a fastening portion of bolts and nuts or the like during a long time of service, resulting in an unexpected trouble, and in an occurrence of trouble in processing of yarn.
OBJECT AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a false twist processing apparatus whereby transmission of vibrations induced by a false twisting member and a take-up device toward a heater can be minimized.
According to an embodiment of the present invention, there is provided a false twist processing apparatus for applying a predetermined processing to a yarn supplied from a yarn supply device by passing it through treating devices such as a yarn feed device provided on a frame, a heater, a twist member, a take-up device, and the like, wherein said frame is composed of at least two support columns which are independent from each other and stood upright on a floor surface, said treating devices are mounted on said support columns so that a yarn processing route is formed between said two support columns, and said heater is so mounted on the support column as transmission of vibrations of the support column, on which the false twisting member and the take-up device are mounted, toward the heater is minimized.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of a twist processing apparatus according to a first embodiment of this invention;
FIG. 2 is a side view of a second embodiment thereof; and
FIGS. 3 and 4 are respectively sectional views showing a damper device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a side view of a false twist processing apparatus as a first embodiment, showing a right half portion thereof, the whole being symmetrical to left and right with a center line indicated at dottedcontour lines (CL). A description will be made of the right half portion alone.
Reference numeral 1 designates a known creel which is a yarn supply device for supporting a number of yarn supply packages P1. Yarns drawn from the yarn supply packages P1 are gathered leftward of the creel through a guide pipe not shown and then introduced into treating devices which will be mentioned hereinbelow.
A first support column 2 is stood upright on the floor in close proximity of the creel 1, and a second support column 3 is stood upright on the floor apart therefrom. Accordingly, since this apparatus is symmetrical to left and right, the structure is that as viewed from the side, one support column 3 is stood upright, and two support columns 2 and 3 are stood upright to left and right, and the creel 1 is arranged externally thereof. The frame is constituted by the aforesaid support columns 2 and 3.
The above-described explanation was made by way of a side view. Actually, a suitable number of support columns 2 and 3 corresponding to the length of the machine bed are stood upright as viewed in front.
Reference numerals 4, 5 and 6 denote horizontal beams disposed over the full length of the machine bed as viewed from front.
There is a passage space 7 for an operator between the support columns 2 and 3 having a width so that a person may pass therethrough.
The treating devices are mounted in the following order so that a yarn may be extended between two support columns 2 and 3.
That is, the first support column 2 has a first feed roller 8 and a heater 9 mounted thereon, and the second support column 3 has a cooling plate 11, a belt type twist device 12 as a twist member, a second feed roller 13 and a take-up device 14 mounted thereon. 15 is a yarn guide. These devices will be described hereinafter.
The heater 9 is secured at 16, substantially at a position of center of gravity, to the upper portion of the first support column 2, and the cooling plate 11 is secured through a bracket 18 to the end of a horizontal beam 17 horizontally extended from the upper portion of the second support column 3. No connecting means is present between the lower end of the heater 9 and the cooling plate 11, which are completely separated.
A belt type false twisting device 12 is mounted at a front position of a reinforcing plate 18 extended sideway from the second support column 3, which is a well known construction. The second feed roller 13 is mounted on the horizontal beam 6. The take-up device 14 is composed of cradles 19 for supporting packages P2, friction rollers 21 and traverse devices not shown, as well known.
In the false twist processing apparatus according to this embodiment, a yarn Y from the creel 1 is subjected to false twist processing passing through said devices in said order and wound as a package P2 on the take-up device 14. Vibrations when the take-up device 14 and the false twisting member 12 are operated are not transmitted to the first support column 2, that is, to the heater 9.
Next, the second embodiment will be described with reference to FIG. 2.
In FIG. 2, the creel 1, the first and second support columns 2 and 3 are arranged in the same manner as that of the first embodiment, and a passage space 7 for an operator is likewise formed between the support columns 2 and 3.
Horizontal beams are indicated at 22, 23, 24, 25 and 26.
In the second embodiment, the treating devices are mounted as described below so that a yarn is extended between the two support columns 2 and 3.
That is, the first support column 2 has first and second feed rollers 27, 28 and one end of a heater 29 mounted thereon, and the second support columns 3 has a cooling plate 31, a belt type false twisting device 32 as a false twisting member, a third feed roller 33 and a take-up device 34.
These devices will be described hereinafter.
The first and second feed rollers 27 and 28 are mounted on the horizontal beams 22 and 23, and the heater 29 is pivoted at 36 at one end thereof on a bracket 35 extended from the first support column 2 while the other end being free with respect to the first support column 2.
The cooling plate 31 is fixedly suspended from a support bracket 38 secured to the front surface of a reinforcing plate 37 horizontally extended from the upper portion of the second support column 3. The end of the cooling plate 31 and the lower end of the heater 29 are not connected but the lower end of the heater 29 is connected to the end of the support bracket 38 through a damper device 39 so as to be discontinuous with relative to vibrations.
That is, as shown in FIG. 3, a hard rubber member 41 is bolted at 42 to the end of the support bracket 38, and the other end of the rubber member 41 is secured to a bolt 43 projected from the heater 29. Accordingly, approximately half the weight of the heater 29 is supported by the hard rubber member 41 of the damper device 39.
Preferably, the hard rubber member 41 is preferably selected to have properties which absorb the number of vibrations generated particularly on the side of the take-up device 34 and false twisting member 32.
Furthermore, the damper device 39 may be constituted by a bolt 44 screwed into the heater 29 extending through the end of the support bracket 38 and an annular rubber member 45 inserted into the bolt 44, as shown in FIG. 4. In this case, the stability of supporting the heater 29 is enhanced, and this arrangement is suitable for the case of supporting the heater 29 having a relatively large weight.
The supporting position 36 of the heater 29 to the bracket 35 may be of approximately the position of center of gravity as in the first embodiment. In this case, a resilient member such as a spring, an air cushion or the like can be used in place of the rubber member 41 of the damper device 39.
The belt type false twisting device 32 is secured to the lower surface of the reinforcing plate 37, and the take-up device 34 is composed of cradles 46 for supporting packages P2, friction rollers 47 and traverse devices not shown, as is well known.
Also, in the false twist processing apparatus according to the second embodiment, similarly to the first embodiment a yarn Y from the creel 1 is subjected to false twist processing in the aforesaid order and wound as a package P2 on the take-up device 34. Vibrations when the take-up device 34 and twist member 32 are operated are shut off by the damper device 39 and not transmitted to the first support column 2, that is, the heater 29.
As described above, in the false twist processing apparatus according to the present invention, the transmission of vibrations toward the heater in which vibrations tend to be amplified can be minimized. Therefore, an unexpected trouble resulting from a looseness of a fastening portion or the like can be avoided, and an occurrence of trouble in processing yarns caused by the vibrations can also be avoided. | A false twist processing apparatus for applying a predetermined processing to chemical fiber filament yarns supplied from a yarn supply device by passing it through treating devices such as a yarn feed device provided on a frame, a heater, a false twisting member, a take-up device, and the like, wherein the frame is composed of at least two support columns which are independent from each other and stood upright on a floor surface, and the treating devices are mounted on the support columns so that a yarn processing route is formed between the two support columns. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 12/726,761, which is a divisional of application Ser. No. 12/003,559 filed Dec. 28, 2007, now U.S. Pat. No. 7,709,310, which is a divisional of application Ser. No. 11/713,599 filed Mar. 5, 2007, now U.S. Pat. No. 7,335,542, which is a divisional of application Ser. No. 10/768,092 filed Feb. 2, 2004, now U.S. Pat. No. 7,223,645, which is a divisional of application Ser. No. 10/084,924, now U.S. Pat. No. 6,717,271, filed Mar. 1, 2002, which is based on Japanese Patent Applications No. 2001-236301, filed on Aug. 3, 2001, and No. 2002-019361, filed on Jan. 29, 2002, the whole contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] A) Field of the Invention
[0003] The present invention relates to a semiconductor device and its manufacture method, and more particularly to a semiconductor device having a so-called mushroom electrode and its manufacture method.
[0004] B) Description of the Related Art
[0005] The operation speed of a field effect transistor depends upon the gate length along the current path direction. In order to speed up a field effect transistor, it is desired to shorten the gate length. If the resistance of the gate electrode increases, a high speed operation of the transistor is restrained. In order to lower the gate electrode resistance, it is desired to set the cross sectional area of the gate electrode to a predetermined value or larger.
[0006] These requirements can be met by a mushroom type gate electrode which has a limited size of a lower part and a magnified size of the upper part. A generally upright lower part of the mushroom electrode is called a stem and the upper part with the magnified cross sectional area is called a head. A mushroom gate electrode is formed by vapor-depositing a gate electrode layer on a photoresist layer having a lower opening with vertical side walls and an upper expanded opening, and lifting off the resist layer.
[0007] As the aspect ratio of a vertical opening to be formed in a resist layer becomes large, it becomes difficult to uniformly bury the lower vertical opening with a gate electrode layer. In order to mitigate this difficulty, it has been proposed to form an upwardly broadening lower opening of a forward taper shape in a resist layer, and vacuum-deposit an upwardly broadening gate electrode stem of a forward taper shape without forming any void.
[0008] In forming an upward broadening gate electrode stem of a forward taper shape, it is important to reliably control a gate length and a contact cross section between semiconductor and the gate electrode in order to improve the performance and reliability of the device. A conventional tapering method is, however, insufficient in that a uniform opening shape and a gate electrode cross-sectional shape at the contact area between semiconductor and the gate electrode cannot be formed reliably.
[0009] If a field effect transistor to be formed has a gate length longer than 0.15 μm, a mushroom gate electrode can be formed without any problem by forming a lower opening with generally vertical side walls in a photoresist layer. If a device having a gate length equal to or shorter than 0.15 μm is formed by a conventional method, a manufacture yield of gate electrodes lowers.
[0010] It is desired to form an upwardly broadening resist opening of a forward taper shape for forming the stem of the gate electrode.
[0011] In forming an upwardly broadening gate electrode of a forward taper shape by a conventional method, a gate electrode stem opening is formed in a resist layer and is forwardly tapered by utilizing glass transition. This conventional method has, however, poor controllability so that a uniform gate length is difficult to be set. Because of poor controllability, the cross section at the contact between semiconductor and the gate electrode is difficult to be controlled and an operation speed and reliability of devices cannot be improved.
[0012] A fine gate opening for a conventional mushroom gate having a high aspect ratio is upwardly broadened by utilizing resist glass transition. This method has, however, poor controllability and is difficult to obtain a uniform opening length, i.e., gate length. Because of poor controllability, it is difficult to control the cross section of the contact area between semiconductor and the gate electrode and improve the operation speed and reliability of devices.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a semiconductor device having a fine gate capable of being manufactured with a high yield.
[0014] It is another object of the invention to provide a method of highly reliably manufacturing a semiconductor device with a fine gate.
[0015] It is another object of the invention to provide a semiconductor device having electrodes with various characteristics, the electrodes being made of the same layer.
[0016] It is another object of the invention to provide a semiconductor device manufacture method capable of forming electrodes with various characteristics by the same process.
[0017] According to one aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a pair of current input/output regions via which current flows; a first insulating film formed on the semiconductor substrate and having a gate electrode opening; and a mushroom gate electrode structure formed on the semiconductor substrate via the gate electrode opening, the mushroom gate electrode structure having a stem and a head formed on the stem, the stem having a limited size on the semiconductor substrate along a current direction and having a forward taper shape upwardly and monotonically increasing the size along the current direction, the head having a size expanded stepwise along the current direction, and the stem contacting the semiconductor substrate in the gate electrode opening and riding the first insulating film near at a position of at least one of opposite ends of the stem along the current direction.
[0018] According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising the steps of: (a) preparing a semiconductor substrate having a pair of current input/output regions; (b) forming an insulating layer on the semiconductor substrate; (c) forming a resist laminate on the insulating layer; (d) forming an upper opening through an upper region of the resist laminate, the upper opening having a laterally broadened middle space; (e) forming a lower opening through a lower region of the resist laminate, the lower opening communicating the upper opening, having a limited size along a current direction, and having generally vertical side walls; (f) etching the insulating film exposed in the lower opening; (g) performing a heat treatment of the resist laminate to deform the side walls of the lower opening so that at least one of opposite ends of the lower opening is retracted or retarded from a corresponding end of the insulating layer and that the lower opening has a forward taper shape upwardly and monotonically increasing a size of the lower opening along the current direction; and (h) filling a gate electrode stem in the lower opening and forming a head in the upper opening, the head having an expanded size along the current direction.
[0019] According to another aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a plurality of transistor regions; and a plurality of mushroom gate electrode structures formed on the semiconductor substrate in the plurality of transistor regions, the mushroom gate electrode structure having a stem and a head formed on the stem, the stem having a limited size on the semiconductor substrate along a current direction, and the head having a size expanded stepwise along the current direction, wherein at least some of the mushroom gate electrode structures have each a taper shape upwardly and monotonically increasing a size along the current direction, and the taper shapes have different angles in different transistor regions.
[0020] According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising the steps of (a) preparing a semiconductor substrate having a plurality of element regions; (b) forming a resist laminate on the semiconductor substrate; (c) applying an energy beam to an upper region of said resist laminate for defining an upper opening in each of said plurality of element regions, and applying an energy beam to a lower region of said resist laminate in at least part of said plurality of element regions at a dose depending on the element region; (d) forming the upper opening through the upper region of the resist laminate in each of the plurality of element regions, the upper opening having a laterally broadened middle space; (e) forming a lower opening through the lower region of the resist laminate in each of the element regions, the lower opening communicating the upper opening, having a limited size along a first direction, and having generally vertical side walls; (f) performing a heat treatment of the resist laminate to deform the side walls of the lower opening in at least some of the element regions in accordance with doses so that the lower opening has a taper shape upwardly and monotonically increasing a size of the lower opening along the first direction; and (g) filling a conductive stem in the lower opening and forming a head in the upper opening, the head having an expanded size along the first direction.
[0021] According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising the steps of: (a) preparing a semiconductor substrate having a plurality of element regions; (b) forming a resist laminate on the semiconductor substrate; (c) forming an upper opening through an upper region of the resist laminate in each of the plurality of element regions, the upper opening having a laterally broadening middle space; (d) applying an energy beam to a lower region of the resist lamination layer in at least some of the element regions at a dose corresponding to each element region; (e) forming a lower opening through the lower region of the resist laminate in each of the element regions, the lower opening communicating the upper opening, having a limited size along a first direction, and having generally vertical side walls; (f) performing a heat treatment of the resist laminate to deform the side walls of the lower opening in at least some of the element regions in accordance with doses so that the lower opening has a taper shape upwardly and monotonically increasing a size of the lower opening along the first direction; and (g) filling a conductive stem in the lower opening and forming a head in the upper opening, the head having an expanded size along the first direction.
[0022] As above, a semiconductor device having mushroom gate electrodes can be manufactured highly reliably. Even if the gate length is short, a mushroom gate electrode can be formed with a high yield.
[0023] If an insulating film is used as the lowest layer of a gate electrode structure, the semiconductor surface and metal gate electrode can be separated by the insulating film and direct contact therebetween can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIGS. 1A to 1J are cross sectional views of a semiconductor substrate illustrating a method of manufacturing a semiconductor device according to an embodiment of the invention.
[0025] FIGS. 2A to 2D are cross sectional views of the semiconductor device illustrating characteristic points of the embodiment shown in FIGS. 1A to 1J .
[0026] FIGS. 3A to 3D are cross sectional views of a semiconductor substrate illustrating a method of manufacturing a semiconductor device according to another embodiment of the invention.
[0027] FIGS. 4A to 4E are cross sectional views of a semiconductor substrate illustrating a method of manufacturing a semiconductor device according to another embodiment of the invention.
[0028] FIGS. 5A to 5E are cross sectional views of a semiconductor substrate illustrating a method of manufacturing a semiconductor device according to another embodiment of the invention.
[0029] FIGS. 6A to 6E are cross sectional views of resist layers and graphs illustrating the study results made by the present inventors.
[0030] FIG. 7 is a graph showing a dose dependency upon a forward taper angle illustrating the study results made by the present inventors.
[0031] FIG. 8 is a cross sectional view of a semiconductor substrate illustrating a method of manufacturing a semiconductor device according to another embodiment of the invention.
[0032] FIGS. 9A to 9E are plan views and cross sectional views illustrating another embodiment of the invention.
[0033] FIGS. 10A to 10D are plan views and cross sectional views illustrating another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Prior to describing the embodiments of the invention, the study results made by the inventors will be described.
[0035] In order to form a fine mushroom gate electrode, it is desired to form an opening of an upwardly broadened taper shape in a resist layer. As resist capable of forming such an opening, polymethylmethacrylate (PMMA) is used by way of example.
[0036] As shown in FIG. 6A , on the surface of a semiconductor substrate 50 , a resist layer 51 of PMMA is formed to a desired thickness by spin coating. Baking is performed at a temperature near the boiling point of resist solvent to evaporate the solvent. The resist layer 51 after baking is subjected to electron beam (EB) drawing and developed to form an opening 52 having generally vertical side walls.
[0037] As shown in FIG. 6B , as the developed resist layer 51 is subjected to heat treatment, the side wall of the opening 52 changes to have an upwardly broadening forward taper shape. A forward taper opening 52 x is therefore obtained.
[0038] For example, if the boiling point of PMMA solvent is about 140° C., baking is preformed at 145° C. after resist coating and before exposure, and heat treatment is performed at 135° C. after development. In this case, a forward taper angle θ of about 70 degrees can be formed. As shown in FIG. 6A , the forward taper angle is an angle less than 90 degrees between the opening side wall and the substrate surface.
[0039] During the forward taper process of the resist opening, the upper part of the opening is expanded and the size of the opening at the bottom changes. This size change (at the bottom) is dependent upon the heat treatment temperature. FIG. 6C is a graph showing an opening length change with a heat treatment temperature after development. The abscissa represents a heat treatment temperature in the unit of ° C., and the ordinate represents a ratio of a change in the opening length to the opening length before heat treatment. Although the opening length becomes longer at low heat treatment temperatures, it becomes shorter at higher heat treatment temperatures. In other words, an opening having a length either longer or shorter than the original length can be formed.
[0040] The graph of FIG. 6D shows a change in the taper angle with a heat treatment temperature after development. The abscissa represents a heat treatment temperature in the unit of ° C., and the ordinate represents a taper angle in the unit of degree. At a low heat treatment temperature, the taper angle is nearly 90 degrees and the effects of the forward taper process are not obtained. As the heat treatment temperature rises, the taper angle becomes small and the considerable effects of the forward taper process can be obtained. For example, in order to obtain a forward taper angle of about 75 degrees, heat treatment is performed at about 133° C.
[0041] The characteristics shown in FIGS. 6C and 6D are obtained by setting a constant temperature of baking after resist coating and before exposure. If the baking temperature is changed, the characteristics shown in FIGS. 6C and 6D are changed. Generally, as the baking is performed at a higher temperature, the effects of the forward taper process obtained at the later heat treatment are small. It can be considered that at a higher baking temperature, bridging of resist molecules is enhanced so that deformation of the resist becomes difficult at the later heat treatment. In a practical case, in order to form an opening of 0.1 μm in length, it is desired to use a taper angle of 80 degrees or smaller so that the process yield can be maintained high.
[0042] FIG. 6E is a graph showing a difference of the forward tapering effect between relatively low and high temperatures of pre-baking after resist coating and before exposure. The abscissa represents a heat treatment temperature in the unit of ° C., and the ordinate represents a taper angle in the unit of degrees. As the pre-baking is performed at a high temperature, the effects of the forward taper process obtained by heat treatment after development become small. As the pre-baking is performed at a lower temperature, the effects of the forward taper process obtained by heat treatment after development become larger.
[0043] It can be understood from these characteristics that a desired opening length change and a desired taper angle can be obtained by selecting a pre-baking temperature after resist coating and before exposure and a heat treatment temperature after development.
[0044] Generally, a resist opening for a fine gate electrode is formed by EB exposure. When EB exposure is also carried out on the region adjacent to the gate opening at such a dose level that the resist will not be developed, high forward tapering effect can be obtained at a lower heat treatment temperature. This can be ascribed to a smaller molecular weight of resist whose bonds are broken upon application of an energy beam such as an electron beam.
[0045] FIG. 7 is a graph showing a change in the taper angle obtained when auxiliary EB radiation is performed for a region near the fine gate opening. The abscissa represents a dose in the region near a fine gate opening in the unit of μC, and the ordinate represents a taper angle in the unit of degree. As the dose is increased, the taper angle becomes smaller at the same heat treatment temperature and the large forward tapering effect can be obtained. Since EB exposure can be selectively performed in a desired region, a desired region near the gate opening subjected to EB exposure can be changed to have a forward taper angle.
[0046] PMMA resist can be coated repetitively to form two or more PMMA resist layers each of which can be baked at different temperature. If a lower level layer is baked at a high temperature and a higher level layer is baked at a low temperature, the effects of the high temperature baking are given only to the lower level layer. Therefore, the lower level layer is difficult to have a large forward taper angle, whereas the upper level layer is likely to have a larger forward taper angle because the upper level layer was subjected only to the low temperature baking. If the upper level layers of the laminated resist layers are baked at lower temperatures, the taper process effects become large at the upper level layers.
[0047] Embodiments of the invention will be described in connection with the above-described study results.
[0048] FIGS. 1A to 1J are cross sectional views of a semiconductor substrate illustrating the manufacture processes for a semiconductor device according to a first embodiment of the invention. FIGS. 2A to 2D are cross sectional views of the semiconductor substrate illustrating the characteristics of the embodiment shown in FIGS. 1A to 1J .
[0049] As shown in FIG. 1A , for example, on the surface of a GaAs substrate 1 , a GaAs buffer layer 2 is grown to a thickness sufficient for relaxing the influence of dislocation of the substrate, by a growth method such as metal organic chemical vapor deposition (MOCVD) and molecular beam epitaxy (MBE). On this GaAs buffer layer 2 , an electron transit layer 3 of InGaAs is grown to a thickness of, for example, 14 nm. On the electron transit layer 3 , an electron supply layer 4 of AlGaAs is grown to a thickness of about 25 nm. On the electron supply layer 4 , a low resistance layer 5 of GaAs doped with Si is grown to a thickness of about 50 nm. A semiconductor substrate S is therefore formed on which a semiconductor device is formed.
[0050] In order to define element regions in a conductive semiconductor substrate surface layer, semi-insulating regions are formed by implanting elements such as oxygen into regions other than active regions and inactivating donors in the ion implanted regions.
[0051] As shown in FIG. 1B , a resist layer PR 1 is coated on the surface of the semiconductor substrate S, exposed and developed to form openings for ohmic electrodes. After a resist pattern PR 1 with the ohmic electrode openings is formed, an ohmic electrode layer 11 is formed in a high vacuum vapor deposition system, the ohmic electrode layer 11 having a lamination structure of an AuGe layer of about 20 nm in thickness and an Au layer of about 300 nm in thickness. As the resist pattern PR 1 is removed, the ohmic electrode layer deposited on the resist pattern PR 1 is also lifted off and removed. Ohmic electrodes 11 are therefore left on the semiconductor substrate S.
[0052] As shown in FIG. 1C , an SiN film 13 of about 20 nm in thickness is formed on the semiconductor substrate S, covering the ohmic electrodes 11 . This SiN film 13 improves tight contactness between the substrate and a resist layer to be formed over the substrate.
[0053] As shown in FIG. 1D , a resist layer PR 2 is coated on the SiN film 13 , and an opening for a gate recess region is formed through the resist layer PR 2 by EB drawing. The gate recess region is, for example, a gate area added with an area of about 0.1 μm along the gate length direction on both sides of the gate area.
[0054] After the resist pattern PR 2 with the gate recess region opening is formed, by using this resist pattern as a mask, the SiN film 13 is etched by dry etching using SF 6 gas and then the low resistance GaAs layer 5 is etched by dry etching using SiCl 4 gas. The electron supply layer 6 is therefore exposed in the gate recess region. The resist pattern PR 2 is thereafter removed.
[0055] As shown in FIG. 1E , after the gate recess region is etched, an SiN film 15 having a thickness of about 20 nm is deposited on the substrate surface to protect the uppermost surface and improve tight contactness with a resist layer to be next formed. On the SiN film 15 , a PMMA positive type electron beam resist layer PR 10 is spin-coated on the SiN film 15 to a thickness of about 300 nm and is subjected to a heat treatment for 10 minutes at 160° C. On this electron beam resist layer PR 10 , an alkali-soluble resist layer R is spin-coated to a thickness of about 600 nm, and baked for 4 minutes at 160° C. On this alkali-soluble resist layer R, a polystyrene electron beam resist layer PR 20 is spin-coated to a thickness of about 200 nm, and baked for about 4 minutes at 160° C.
[0056] EB drawing is performed for the electron beam resist layer PR 20 to define an opening A 1 having a width of about 0.8 μm.
[0057] As shown in FIG. 1F , the exposed region A 1 of the electron beam resist layer PR 20 is developed by mixed solution of methylisobutylketone (MIBK) and methylethylketone (MEK). By using the developed electron beam resist layer PR 20 as a mask, the underlying resist layer R is etched by alkaline developing liquid. With this etching, an opening is formed through the resist layer R, the opening being retracted by about 0.2 μm or laterally deeper from the opening of the electron beam resist layer PR 20 .
[0058] A gate electrode opening having a width of about 0.1 μm is defined by EB drawing through the electron beam resist layer PR 10 exposed in the opening. An EB exposed region A 3 is developed by mixed solution of MIBK and isopropyl alcohol (IPA) to form a gate electrode opening through the electron beam resist layer PR 10 .
[0059] As shown in FIG. 1G , by using the electron beam resist layer PR 10 as a mask, the exposed SiN film 15 is etched by dry etching using SF 6 gas. A substrate surface having a width of about 0.1 μm is therefore exposed in the gate electrode opening having generally vertical side walls SW 1 .
[0060] As shown in FIG. 1H , a heat treatment is performed for about 10 minutes at a temperature which forms a forward taper and elongates the opening length, for example, at 130° C. With this heat treatment, while the opening length becomes longer, the forward taper upward broadening the opening is formed. A gate electrode opening A 4 having slanted side walls SW 2 is therefore formed in the gate electrode opening. The side walls SW 2 of the electron beam resist layer have the shape retracting from the edges of the underlying SiN film 15 , for example, by 0.01 μm.
[0061] As shown in FIG. 1I , an insulating metal oxide film, e.g., TiO x , is deposited in a high vacuum vapor deposition system from the upper side of the semiconductor substrate S subjected to the forward taper process. Then, a Ti layer, a Pt layer and an Au layer are laminated to form a gate electrode layer 17 .
[0062] The function of the forward taper process for a gate electrode opening before the gate electrode layer depositing step will be described.
[0063] As shown in FIG. 2D , if the resist layer PR 10 has vertical side walls, although a vapor deposition layer 17 a vapor-deposited from the upper side of the substrate S can be reliably deposited in the central area of the opening bottom, it becomes difficult to be deposited in the peripheral area of the opening bottom because of the shading influences of the side walls of the resist layer PR 10 . The vapor deposition layer becomes thin in the peripheral area of the opening bottom and in some cases, the surface of the substrate S is exposed in this area. If the TiO x is formed in this state and a Ti layer is vapor-deposited thereon, the Ti layer may directly contact the substrate S surface in the peripheral area of the opening bottom. As Ti contacts the semiconductor surface, Ti and semiconductor chemically react under the condition that an energy such as an electric field is applied, and the desired device characteristics cannot be obtained. This phenomenon is likely to occur on the drain side to which a strong electric field is applied.
[0064] As shown in FIG. 2B , although a insulating layer D (SiN layer 15 ) on the semiconductor substrate S has generally vertical side walls, the height of the side wall is very low. The electron beam resist layer PR 10 on the insulating layer D has a forward taper upward extending the width of the opening. A vapor deposition layer deposited from the upper side is not obstructed by the side walls of the resist layer PR 10 , and can be generally uniformly deposited in the opening of the insulating layer D. The TiO x layer 17 a first deposited reliably covers the exposed substrate S surface to prevent a metal layer to be later deposited from contacting the semiconductor layer.
[0065] As shown in FIG. 2C , in the gate electrode opening defined by the insulating layer D and electron beam resist layer PR 10 , a TiO x 17 a having a thickness of, for example, several nm, a Ti layer 17 b having a thickness of, for example, 10 nm, and a Pt layer 17 c having a thickness of, for example, 10 nm are sequentially formed. Thereafter, an Au layer 17 d having a sufficient thickness of, for example, about 500 nm is deposited.
[0066] As shown in FIG. 1I , in the opening defined by the laminated resist structure, a mushroom gate electrode 17 is therefore formed.
[0067] As shown in FIG. 1J , the semiconductor substrate is immersed into heated organic solution to dissolve the laminated resist layers to lift off the gate electrode layer 17 deposited on the resist lamination structure. A mushroom gate electrode 17 is therefore left on the semiconductor substrate S.
[0068] As shown in FIG. 2A , the mushroom gate electrode obtained has the structure that the opposite ends of the gate electrode ride the insulating film D. As shown in FIG. 2C , the surface of the semiconductor substrate S exposed in the opening of the insulating film D is securely covered with the TiO x film. The semiconductor layer S and a metal layer such as a reactive Ti layer formed on the TiO x layer 17 a can be prevented from direct contact.
[0069] The gate electrode riding the insulating film D extends outward from the gate electrode in contact with the semiconductor layer. An electric field near the opposite ends of the gate electrode can be relaxed.
[0070] With the gate electrode structure of the embodiment, the effective gate electrode length is determined by the opening length defined the insulating film D. The gate electrode G has a stem broader than the opening length of the insulating film D and rides the insulating film D. For example, even if an electrode having a gate length of 0.1 μm rides the insulating film D by 0.01 μm, generally the same electric characteristics of the gate electrode structure can be retained. Since the contact area of the gate electrode increases and the gate electrode covers the steps, the mechanical stability of the gate electrode can be improved.
[0071] FIGS. 3A to 3D are cross sectional views of a semiconductor substrate illustrating the semiconductor device manufacture method according to another embodiment of the invention.
[0072] In the processes shown in FIGS. 1A to 1G , the process of depositing the SiN layer 15 after the gate recess region is formed is omitted, and the other processes are performed in similar manners.
[0073] As shown in FIG. 3A , an opening is defined by the laminated resist layers in the gate recess region where the semiconductor substrate S is exposed. A TiO x layer 17 a is vapor-deposited from the upper side of this structure. On the bottom of the gate electrode opening having generally vertical side walls, the TiO x layer 17 a is therefore deposited.
[0074] As shown in FIG. 38 , a heat treatment is performed, for example, for 10 minutes at 145 c′C under the conditions that the gate electrode opening has a forward taper and the opening length is shortened. The gate electrode opening has a forward taper shape upward broadening its opening, the opening length at the bottom of the opening is shortened, and the resist layer PR 10 rides the deposited TiO x layer 17 a.
[0075] As shown in FIG. 3C , a Ti layer, a Pt layer and an Au layer are sequentially deposited in a high vacuum state to form a gate metal layer GM.
[0076] As shown in FIG. 3D , the semiconductor substrate is immersed into heated organic solution to leave a gate electrode G through lift-off.
[0077] With the gate electrode structure of the embodiment, the metal gate electrode structure GM is formed inside the surface area of the insulating metal oxide film 17 a on the semiconductor substrate. Since the opposite ends of the metal gate electrode structure GM are positioned inside the surface area of the insulating metal oxide film 17 a , it is possible to prevent a direct contact between reactive metal and the semiconductor surface.
[0078] Next, another embodiment will be described in which an additional dose is used to enhance the forward taper process.
[0079] FIG. 7 is a graph showing a taper angle dependency upon a dose obtained by experiments made by the present inventors. If an electron beam having an energy equal to or larger than a threshold value is applied to an EB exposure resist, the molecular weight of the resist lowers so that the resist can be developed by resist developer liquid. If the radiation amount of an electron beam is lowered to a proper value, the state that resist has a smaller molecular weight can be realized although the resist is not developed. If such a resist layer is subjected to a heat treatment, the resist layer can have an upward broadening taper shape at a lower temperature than an electron beam is not applied.
[0080] In FIG. 7 , the abscissa represents a dose of an electron beam applied to a region near the fine gate, and the ordinate represents a taper angle. The heat treatment temperature is set to such a value that a taper shape is hardly obtained if an electron beam was not applied. As the dose increases, the taper angle relative to the substrate surface becomes small starting from 90 degrees. Namely, the opening side walls broaden and the taper degree becomes large.
[0081] As shown in FIG. 4A , a lamination structure of a insulating layer D, an electron beam resist layer PR 10 , a resist layer R, and an electron beam resist layer PR 20 is formed on a semiconductor substrate S, in the manner similar to those processes shown in FIGS. 1A to 1J .
[0082] A gate electrode opening A 3 is drawn by an electron beam E 1 at a predetermined dose. For example, a gate electrode opening having a width of 0.1 μm is EB-drawn. An auxiliary EB radiation whose energy is set equal to or lower than a development limit, e.g., about a half of the threshold value, is applied to the region near the gate electrode opening, in the example shown in FIG. 4A , a right region having a width of about 0.05 μm. As shown in FIG. 4B , the electron beam resist layer PR 10 is developed by mixed solution of MIBK and IPA. With this development, although the exposed region A 3 for a gate electrode is removed, the auxiliary exposed region Ax is left. The insulating film D, e.g., an SiN film exposed on the bottom of the gate electrode opening is removed by dry etching using, for example, SF 6 gas.
[0083] In this embodiment, two types of electron beam radiation are sequentially performed and then the development is performed. Development may be performed after the electron beam radiation is performed, and then the auxiliary EB exposure is performed for the developed resist pattern. Also, EB exposures for the upper and lower apertures and for affording tapering can be performed through the upper resist layer at the same stage.
[0084] As shown in FIG. 4C , a forward taper heat treatment is performed for 10 minutes in a temperature range allowing the opening length to be elongated, e.g., at 130° C. The region, on the left side of the opening, of the electron beam resist layer PR 10 auxiliary applied with an electron beam changes its shape to the taper shape with a priority over the other regions. The left side wall of the electron beam resist layer PR 10 is maintained being relatively less influenced.
[0085] As shown in FIG. 4D , in a high vacuum vapor deposition system, an insulating metal oxide film (TiO x film), a Ti layer, a Pt layer and an Au layer are sequentially deposited in the opening to form a gate electrode 17 .
[0086] As shown in FIG. 4E , the semiconductor substrate is immersed into heated organic solution to leave a gate electrode G through lift-off. With the gate electrode structure of the embodiment, the gate electrode G rides the insulating film D only on one side thereof, e.g., on the drain side. Since the gate electrode rides the insulating film D on the drain side, an electric field in a strong electric field intensity region where reaction is likely to progress can be relaxed. Since the insulating metal oxide film securely covers the semiconductor substrate S surface, a direct contact between reactive metal and the semiconductor substrate can be avoided.
[0087] Another embodiment will be described in which the forward taper shape is controlled by changing the baking temperature of a laminated resist layer structure.
[0088] As shown in FIG. 5A , a semiconductor substrate S is prepared by performing the processes similar to the first embodiment shown in FIGS. 1A to 1J before the gate recess region is formed. On the surface of the semiconductor substrate S, a insulating film D such as an SiN film is formed. Thereafter, a first electron beam resist layer PR 11 is coated to a thickness of about 200 nm by using PMMA or the like, and baked, for example, for 5 minutes at 185° C. On the first electron beam resist, a second electron beam resist layer PR 12 is coated to a thickness of about 200 nm by using PMMA or the like, and baked, for example, for 5 minutes at 145° C. The lower resist lamination is constituted of a lower layer baked at a high temperature and an upper layer baked at a low temperature.
[0089] On the second electron beam resist layer PR 12 , for example, an alkali-soluble resist layer R is coated to a thickness of about 600 nm, and baked for 4 minutes at 145° C. On the alkali-soluble resist layer R, a polystyrene electron beam resist layer PR 20 as an upper electron beam resist layer is coated to a thickness of about 200 nm, and baked for about 4 minutes at 145° C.
[0090] As shown in FIG. 5B , EB drawing is performed for the upper electron beam resist layer PR 20 to define an opening A 1 having a width of about 0.8 μm, and the upper electron beam resist layer PR 20 is developed by mixed solution of MIBK and MEK. By using the upper electron beam resist layer PR 20 as a mask, the underlying resist layer R is etched by alkaline developing liquid. With this etching, an opening is formed through the resist layer R, the opening being retracted by about 0.2 μm or laterally deeper from the opening of the upper electron beam resist layer PR 20 .
[0091] An opening having a width of about 0.1 μm is defined by EB drawing through the laminated electron beam resist layers PR 12 and PR 11 . The resist layers are then developed by mixed solution of MIBK and IPA. After the opening is formed through the electron beam resist layers, the exposed insulating film D is dry-etched by SF 6 or the like.
[0092] As shown in FIG. 5C , a heat treatment is performed for the lower laminated resist layers PR 12 and PR 11 for about 10 minutes at a temperature which forms a forward taper, for example, at 140° C. The first electron beam resist layer PR 11 baked at a relatively high temperature has a low forward taper degree, whereas the second electron beam resist layer PR 12 baked at a relatively low temperature has a large forward taper degree. In this manner, the forward taper broadening more at an upper position can be obtained.
[0093] As shown in FIG. 5D , similar to the above-described embodiment, in a high vacuum vapor deposition system, an insulating metal oxide film (TiO x film), a Ti layer, a Pt layer and an Au layer are sequentially deposited in the opening to form a gate electrode structure 17 .
[0094] As shown in FIG. 5E , the semiconductor substrate is immersed into heated organic solution to leave a gate electrode G through lift-off.
[0095] With the gate electrode structure of the embodiment, the lower stem of the fine gate has relatively vertical side walls, and the upper stem has a forward taper upward broadening the opening. The insulating film D on the semiconductor surface may be omitted.
[0096] Various modifications of the embodiments are possible. For example, although the insulating oxide film is used as the lowest layer of the gate electrode structure, a gate electrode structure that a Schottky metal layer directly contacts the semiconductor surface may be formed. The cross section of a taper shape is not necessarily a straight line, but any other lines may be possible so long as they change monotonously. Although an SiN film is used as the insulating film, other insulating films may be used. Instead of an insulating metal oxide film, other insulating films may also be used. The composition of a gate electrode is not limited to those described earlier.
[0097] In the embodiments, an opening in a PMMA resist film is changed to have a forward taper shape. Instead, in manufacturing semiconductor devices, other resist layers may also be used whose opening shape can be adjusted with good controllability in a temperature range where an abrupt opening shape change to be caused by glass transition or the like does not occur (in a temperature range lower than a glass transition temperature).
[0098] In forming the recess region, other methods may be used. For example, a semiconductor layer may be wet-etched, an SiN film may not used, or a semiconductor layer may be etched by using an opening for a mushroom gate.
[0099] In the embodiments, the head of a mushroom gate electrode is formed by using three electron beam resist layers. Instead, the head of a mushroom gate electrode may be formed by using a backward taper resist layer opening in a photoresist layer or the like. In FIG. 8 , a resist layer PR 20 is formed on an electron beam resist layer PR 10 , and the resist layer PR 2 is formed with a backward taper opening downward broadening its opening. The other structures are similar to those shown in FIG. 1F . The head of a mushroom gate electrode may be formed through milling by using an inverted pattern.
[0100] Various semiconductor elements are formed in a semiconductor integrated circuit. A high speed operation is required for some transistors and not required for other transistors. It is preferable that the gate length of a transistor operating at high speed is short, and the gate length of a transistor operating at not so high speed is not so much required to be short.
[0101] FIGS. 9A to 9E are plan views and cross sectional views of a semiconductor device according to another embodiment of the invention.
[0102] FIG. 9A is a schematic plan view showing the structure of a semiconductor integrated circuit device. On the surface of a semiconductor chip SP, a high speed circuit HP and a low speed circuit LP are formed.
[0103] FIG. 9B is a schematic plan view showing gate resist openings for a transistor formed in the low speed circuit LP. An opening AW is a gate stem opening formed through the uppermost to lowermost surfaces of the laminated resist layers. An upper opening GW is an opening formed only through upper layers of the laminated resist layers.
[0104] FIG. 9C is a schematic plan view showing gate resist openings for a transistor formed in the high speed circuit HP. An opening AN is a gate stem opening formed through the uppermost to lowermost surfaces of the laminated resist layers. An opening GN is an opening formed only through upper layers of the laminated resist layers. A region AD is a region where auxiliary EB exposure is performed. Although the resist layer is not developed by auxiliary EB exposure, the later heat treatment forms a forward taper shape upward broadening the opening.
[0105] As shown in FIG. 9D , the auxiliary EB exposure is not performed for the low speed circuit, but it is performed only for the high speed circuit. For example, the auxiliary EB exposure is performed at an acceleration energy of 50 keV and a dose of 20 μC.
[0106] Thereafter, a heat treatment is performed, for example, for 5 minutes at 130° C. Since the average molecular weight of resist in a region subjected to the auxiliary EB exposure is low, this heat treatment forms a forward taper shape upward broadening its opening. The region not subjected to the auxiliary EB exposure has no significant forward taper shape. After the gate electrode is deposited, the resist layer is removed to lift off the gate electrode layer on the resist layer.
[0107] FIG. 9E shows the outline shapes of gate electrodes. The gate electrode GW in the low speed circuit has a relatively long gate length and its stem is defined by generally upright side walls. This gate electrode has a high mechanical strength. The gate electrode GN in the high speed circuit has a stem of a taper shape upward extending the size along the gate length direction, the gate length being defined at the bottom and being short. Such a gate electrode is suitable for a high speed operation.
[0108] A semiconductor integrated circuit is formed not only with transistors but also with other electronic components such as capacitors and wiring lines. A mushroom structure is also applied to circuit components other than transistors.
[0109] FIGS. 10A to 10D show the structure of a semiconductor device according to another embodiment of the invention.
[0110] FIG. 10A is a schematic plan view showing the structure of a semiconductor chip SP. Similar to the structure shown in FIG. 9A , a high speed circuit area HP and a low speed circuit area LP are disposed in the semiconductor chip HP. In the high speed circuit area HP, a transistor Q operating at high speed and a circuit component P other than a transistor having a thick finger are disposed.
[0111] FIG. 10B is a schematic plan view showing resist openings for the circuit component P in the high speed circuit area.
[0112] FIG. 10C is a schematic plan view showing gate resist openings for the transistor Q in the high speed circuit area The shapes of these resist openings are similar to those shown in FIGS. 9B and 9C . The resist openings for the circuit component P have an opening PW formed through the upper resist layer and an opening formed through the upper and lower resist layers. The resist openings for the transistor Q in the high speed circuit area have an opening GN formed through the upper resist layer and an opening AN formed in correspondence with the gate electrode stem. Auxiliary EB exposure regions AD are defined on both sides of the opening AN.
[0113] Similar to the embodiment shown in FIGS. 9A to 9E , the EB exposure is performed for the regions AD, and thereafter the processes for heat treatment, electrode layer deposition and resist layer removal are executed.
[0114] FIG. 10D shows the outline shapes of the gate electrode and thick finger. The circuit component P has a thick stem defined by generally upright side walls and constitutes, for example, a wiring line. The gate electrode GN of the transistor Q operating at high speed has a stem of a taper shape upward elongating the gate length.
[0115] In the embodiments shown in FIGS. 9A to 9E and FIGS. 10A to 10D , the laminated resist layers may be either three layers shown in FIG. 1E or two layers shown in FIG. 8 . A resist pattern may be formed by exposure and development or by etching after the laminated resist layers are formed, or it may be formed by forming the lowest resist layer, pattering it, and thereafter forming the upper resist layer.
[0116] In the above embodiments, after a broad region is exposed as shown in FIG. 1E and developed as shown in FIG. 1F , a narrow region is exposed and developed as shown in FIG. 1G . Instead, a plurality of exposures may be performed first and thereafter the upper and lower resist layers are developed.
[0117] In the above embodiments, a resist layer to be tapered is made of PMMA. PMMA has a glass transition temperature of, for example, 165° C. As solvent of this resist material, ethyl cellosolve acetate (ECA, boiling point: about 170 to 180° C.), 140° C.+α), propylene glycol monomethyl ether acetate (PGMEA), boiling point: about 140° C.+α) and the like are known. Even if solvent having a high boiling point is used, it is preferable that baking and heat treatment of resist are performed at a glass transition temperature or lower of resist.
[0118] By using PGMEA as solvent, baking before exposure and heat treatment after development were performed in a temperature range of 120° C. to 150° C. In the whole temperature range, the taper shapes were formed. From these results, it can be considered that a desired taper shape can be obtained by performing baking and heat treatment at a glass transition temperature or lower.
[0119] The embodiments of the invention have been described in connection with the preferred embodiments. The invention is not limited only to the above embodiments. It is apparent that various modifications, improvements, combinations, and the like can be made by those skilled in the art. | A semiconductor device has: a semiconductor substrate having a pair of current input/output regions via which current flows; an insulating film formed on the semiconductor substrate and having a gate electrode opening; and a mushroom gate electrode structure formed on the semiconductor substrate via the gate electrode opening, the mushroom gate electrode structure having a stem and a head formed on the stem, the stem having a limited size on the semiconductor substrate along a current direction and having a forward taper shape upwardly and monotonically increasing the size along the current direction, the head having a size expanded stepwise along the current direction, and the stem contacting the semiconductor substrate in the gate electrode opening and riding the insulating film near at a position of at least one of opposite ends of the stem along the current direction. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/378,130 filed Aug. 30, 2010.
FIELD OF THE INVENTION
[0002] This invention concerns a synergistic herbicidal composition containing (a) penoxsulam and (b) bentazon for controlling weeds in crops, especially rice, cereal and grain crops, pastures, rangelands, industrial vegetation management (IVM), aquatics and turf. These compositions are disclosed as providing improved post-emergence herbicidal weed control and improved safening on rice.
BACKGROUND OF THE INVENTION
[0003] The protection of crops from weeds and other vegetation which inhibit crop growth is a constantly recurring problem in agriculture. To help combat this problem, researchers in the field of synthetic chemistry have produced an extensive variety of chemicals and chemical formulations effective in the control of such unwanted growth. Chemical herbicides of many types have been disclosed in the literature and a large number are in commercial use.
[0004] In some cases, herbicidal active ingredients have been shown to be more effective in combination than when applied individually and this is referred to as “synergism.” As described in the Herbicide Handbook of the Weed Science Society of America, Ninth Edition, 2007, p. 429 “‘synergism’ [is] an interaction of two or more factors such that the effect when combined is greater than the predicted effect based on the response to each factor applied separately.” The present invention is based on the discovery that penoxsulam and bentazon, already known individually for their herbicidal efficacy, display a synergistic effect when applied in combination.
SUMMARY OF THE INVENTION
[0005] The present invention concerns a synergistic herbicidal mixture comprising an herbicidally effective amount of (a) penoxsulam and (b) bentazon. The compositions may also contain an agriculturally acceptable adjuvant and/or carrier.
[0006] The present invention also concerns herbicidal compositions for and methods of controlling the growth of undesirable vegetation, particularly in monocot crops including rice, wheat, barley, oats, rye, sorghum, corn, maize, pastures, grasslands, rangelands, fallowland, turf, IVM and aquatics, and the use of these synergistic compositions.
[0007] The species spectra of penoxsulam and bentazon, i.e., the weed species which the respective compounds control, are broad and highly complementary. It has now been found that a combination of penoxsulam and bentazon exhibits a synergistic action in the control of rice flatsedge ( Cyperus iria ; CYPIR); arrowhead ( Sagittaria trifolia ; SAGTR); and barnyardgrass ( Echinochloa crus-galli ; ECHCG) at application rates equal to or lower than the rates of the individual compounds. It has also been found that a combination of penoxsulam and bentazon exhibits a safening effect on rice ( Orysa sativa ; ORYSA).
DETAILED DESCRIPTION OF THE INVENTION
[0008] Bentazon is the common name for 3-(1-methylethyl)-1H-2,1,3-benzothiadiazin-4(3H)-one 2,2-dioxide. Its herbicidal activity is described in The Pesticide Manual , Fifteenth Edition, 2009. Bentazon controls a wide range of economically important broadleaf and sedge weeds. It can be used as the acid itself or as an agriculturally acceptable salt or ester. Use as a salt is preferred, with the sodium salt being most preferred. Bentazon is also known as bentazone and bendioxide.
[0009] Penoxsulam is the common name for 2-(2,2-difluoroethoxy)-N-(5, 8-dimethoxy-[1,2,4]triazolo[1,5-c]pyrimidin-2-yl)-6-(trifluoromethyl)benzenesulfonamide. Its herbicidal activity is described in The Pesticide Manual , Fifteenth Edition, 2009. Penoxsulam controls Echinochloa spp., as well as many broadleaf, sedge and aquatic weeds in rice, and Apera spp. grass in cereals, as well as many broadleaf weeds in aquatics, many cereal crops, range and pasture, IVM and turf.
[0010] The term herbicide is used herein to mean an active ingredient that kills, controls or otherwise adversely modifies the growth of plants. An herbicidally effective or vegetation controlling amount is an amount of active ingredient which causes an adversely modifying effect and includes deviations from natural development, killing, regulation, desiccation, retardation, and the like. The terms plants and vegetation include germinant seeds, emerging seedlings, plants emerging from vegetative propagules, and established vegetation.
[0011] Herbicidal activity is exhibited by the compounds of the synergistic mixture when they are applied directly to the plant, to the locus of the plant at any stage of growth or before planting or emergence or after emergence. The effect observed depends upon the plant species to be controlled, the stage of growth of the plant, the application parameters of dilution and spray drop size, the particle size of solid components, the environmental conditions at the time of use, the specific compound employed, the specific adjuvants and carriers employed, the soil type, and the like, as well as the amount of chemical applied. These and other factors can be adjusted as is known in the art to promote non-selective or selective herbicidal action. Generally, it is preferred to apply the composition of the present invention postemergence to relatively immature undesirable vegetation to achieve the maximum control of weeds.
[0012] In the composition of this invention, the weight ratio of bentazon-sodium to penoxsulam at which the herbicidal effect is synergistic lies within the range of between about 13:1 and about 667:1. The rate at which the synergistic composition is applied will depend upon the particular type of weed to be controlled, the degree of control required, and the timing and method of application. In general, the composition of the invention can be applied at an application rate of between about 303 grams per hectare (g/ha) and about 2050 g/ha based on the total amount of active ingredients in the composition. Penoxsulam is applied at a rate between about 3 g/ha and about 50 g/ha and bentazon is applied at a rate between about 300 g/ha and about 2000 g/ha.
[0013] The components of the synergistic mixture of the present invention can be applied either separately or as part of a multipart herbicidal system.
[0014] The synergistic mixture of the present invention can be applied in conjunction with one or more other herbicides to control a wider variety of undesirable vegetation. When used in conjunction with other herbicides, the composition can be formulated with the other herbicide or herbicides, tank mixed with the other herbicide or herbicides or applied sequentially with the other herbicide or herbicides. Some of the herbicides that can be employed in conjunction with the synergistic composition of the present invention include: 2,4-D, acetochlor, acifluorfen, aclonifen, AE0172747, alachlor, ametryn, amidosulfuron, aminocyclopyrachlor, aminopyralid, aminotriazole, amitrol, ammonium thiocyanate, anilifos, asulam, atrazine, azimsulfuron, beflubutamid, benazolin, benefin, benfuresate, bensulfuron, bensulide, benthiocarb, benzobicyclon, benzofenap, bifenox, bispyribac, bromacil, bromobutide, bromoxynil, butachlor, butafenacil, butralin, cafenstrole, carbetamide, carfentrazone, chlorflurenol, chlorimuron, chlormequat, chlorpropham, chlortoluron, cinidon, cinosulfuron, clethodim, clodinafop, clomazone, clomeprop, clopyralid, cloransulam, cumyluron, cyanazine, cyclosulfamuron, cycloxydim, cyhalofop, daimuron, dicamba, dichlobenil, dichlorprop, diclofop, diclosulam, diflufenican, diflufenzopyr, dimefuron, dimepiperate, dimethametryn, dimethenamid, dimethenamid, diquat, dithiopyr, diuron, EK2612, EPTC, erioglaucine, esprocarb, ET-751, ethofumesate, ethoxysulfuron, ethbenzamide, etobenzanid, F7967, fenoxaprop, fentrazamide, flazasulfuron, florasulam, fluazifop, flucarbazone, flucetosulfuron (LGC-42153), flufenacet, flufenpyr, flumetsulam, flumiclorac, flumioxazin, fluometuron, flupyrsulfuron, fluroxypyr, flurtamone, fosamine, fomesafen, foramsulfuron, fumiclorac, glufosinate, glyphosate, halosulfuron, haloxyfop, hexazinone, imazamethabenz, imazamox, imazapic, imazapyr, imazaquin, imazethapyr, imazosulfuron, indanofan, indaziflam, iodosulfuron, ioxynil, ipfencarbazone (HOK-201), IR 5790, isoproturon, isoxaben, isoxaflutole, KUH-071, lactofen, linuron, MCPA, mecoprop, mefenacet, mesosulfuron, mesotrione, metamifop, metazosulfuron (NC-620), metolachlor, metosulam, metribuzin, metsulfuron, molinate, monosulfuron, MSMA, napropamide, nicosulfuron, norflurazon, OK-9701, orthosulfamuron, oryzalin, oxadiargyl, oxadiazon, oxazichlomefone, oxyfluorfen, paraquat, pendimethalin, pentoxazone, pethoxamid, picloram, picolinafen, pinoxaden, piperophos, pretilachlor, primisulfuron, prodiamine, profluazol, profoxydim, prohexadione, prometon, pronamide, propachlor, propanil, propisochlor, propoxycarbazone, propyrisulfuron (TH-547), propyzamide, prosulfocarb, prosulfuron, pyrabuticarb, pyraclonil, pyraflufen, pyrazogyl, pyrazolynate, pyrazosulfuron, pyrazoxyfen, pyribenzoxim (LGC-40863), pyridate, pyriftalid, pyriminobac, pyrimisulfan (KUH-021), pyrithiobac, pyroxasulfone (KIH-485), pyroxsulam, quinclorac, quinmerac, quinoclamine, quizalofop, rimsulfuron, S-3252, saflufenacil, sethoxydim, simazine, simetryne, SL-0401, SL-0402, sulcotrione, sulfentrazone, sulfometuron, sulfosate, sulfosulfuron, tebuthiuron, tefuryltrione (AVH-301), terbacil, thenylchlor, thiazopyr, thiencarbazone, thifensulfuron, thiobencarb, topramezone, tralkoxydim, triasulfuron, tribenuron, triclopyr, trifloxysulfuron, trifluralin, trinexapac, tritosulfuron and salts, esters, optically active isomers and mixtures thereof.
[0015] The synergistic composition of the present invention can, further, be used in conjunction with glyphosate, glufosinate, dicamba, imidazolinones, sulfonylureas, or 2,4-D on glyphosate-tolerant, glufosinate-tolerant, dicamba-tolerant, imidazolinone-tolerant, sulfonylurea-tolerant and 2,4-D-tolerant crops. It is generally preferred to use the synergistic composition of the present invention in combination with herbicides that are selective for the crop being treated and which complement the spectrum of weeds controlled by these compounds at the application rate employed. It is further generally preferred to apply the synergistic composition of the present invention and other complementary herbicides at the same time, either as a combination formulation or as a tank mix.
[0016] The synergistic composition of the present invention can generally be employed in combination with known herbicide safeners, such as benoxacor, benthiocarb, brassinolide, cloquintocet (mexyl), cyometrinil, daimuron, dichlormid, dicyclonon, dimepiperate, disulfoton, fenchlorazole-ethyl, fenclorim, flurazole, fluxofenim, furilazole, isoxadifen-ethyl, mefenpyr-diethyl, MG 191, MON 4660, naphthalic anhydride (NA), oxabetrinil, R29148 and N-phenyl-sulfonylbenzoic acid amides, to enhance their selectivity.
[0017] The synergistic mixture of penoxsulam and bentazon of the present invention also provides a safening effect when applied to rice.
[0018] In practice, it is preferable to use the synergistic composition of the present invention in mixtures containing an herbicidally effective amount of the herbicidal components along with at least one agriculturally acceptable adjuvant or carrier. Suitable adjuvants or carriers should not be phytotoxic to valuable crops, particularly at the concentrations employed in applying the compositions for selective weed control in the presence of crops, and should not react chemically with herbicidal components or other composition ingredients. Such mixtures can be designed for application directly to weeds or their locus or can be concentrates or formulations that are normally diluted with additional carriers and adjuvants before application. They can be solids, such as, for example, dusts, granules, water dispersible granules, or wettable powders, or liquids, such as, for example, emulsifiable concentrates, solutions, emulsions or suspensions.
[0019] Suitable agricultural adjuvants and carriers that are useful in preparing the herbicidal mixtures of the invention are well known to those skilled in the art. Some of these adjuvants include, but are not limited to, crop oil concentrate (mineral oil (85%)+emulsifiers (15%)); nonylphenol ethoxylate; benzylcocoalkyldimethyl quaternary ammonium salt; blend of petroleum hydrocarbon, alkyl esters, organic acid, and anionic surfactant; C 9 -C 11 alkylpolyglycoside; phosphated alcohol ethoxylate; natural primary alcohol (C 12 -C 16 ) ethoxylate; di-sec-butylphenol EO-PO block copolymer; polysiloxane-methyl cap; nonylphenol ethoxylate+urea ammonium nitrate; emulsified methylated seed oil; tridecyl alcohol (synthetic) ethoxylate (8EO); tallow amine ethoxylate (15 EO); PEG(400) dioleate-99.
[0020] Liquid carriers that can be employed include water and organic solvents. The organic solvents typically used include, but are not limited to, petroleum fractions or hydrocarbons such as mineral oil, aromatic solvents, paraffinic oils, and the like; vegetable oils such as soybean oil, rapeseed oil, olive oil, castor oil, sunflower seed oil, coconut oil, corn oil, cottonseed oil, linseed oil, palm oil, peanut oil, safflower oil, sesame oil, tung oil and the like; esters of the above vegetable oils; esters of monoalcohols or dihydric, trihydric, or other lower polyalcohols (4-6 hydroxy containing), such as 2-ethyl hexyl stearate, n-butyl oleate, isopropyl myristate, propylene glycol dioleate, di-octyl succinate, di-butyl adipate, di-octyl phthalate and the like; esters of mono, di and polycarboxylic acids and the like. Specific organic solvents include toluene, xylene, petroleum naphtha, crop oil, acetone, methyl ethyl ketone, cyclohexanone, trichloroethylene, perchloroethylene, ethyl acetate, amyl acetate, butyl acetate, propylene glycol monomethyl ether and diethylene glycol monomethyl ether, methyl alcohol, ethyl alcohol, isopropyl alcohol, amyl alcohol, ethylene glycol, propylene glycol, glycerine, N-methyl-2-pyrrolidinone, N,N-dimethyl alkylamides, dimethyl sulfoxide, liquid fertilizers and the like. Water is generally the carrier of choice for the dilution of concentrates.
[0021] Suitable solid carriers include talc, pyrophyllite clay, silica, attapulgus clay, kaolin clay, kieselguhr, chalk, diatomaceous earth, lime, calcium carbonate, bentonite clay, Fuller's earth, cottonseed hulls, wheat flour, soybean flour, pumice, wood flour, walnut shell flour, lignin, and the like.
[0022] It is usually desirable to incorporate one or more surface-active agents into the compositions of the present invention. Such surface-active agents are advantageously employed in both solid and liquid compositions, especially those designed to be diluted with carrier before application. The surface-active agents can be anionic, cationic or nonionic in character and can be employed as emulsifying agents, wetting agents, suspending agents, or for other purposes. Surfactants conventionally used in the art of formulation and which may also be used in the present formulations are described, inter alia, in “McCutcheon's Detergents and Emulsifiers Annual,” MC Publishing Corp., Ridgewood, N.J., 1998 and in “Encyclopedia of Surfactants,” Vol. I-III, Chemical Publishing Co., N.Y., 1980-81. Typical surface-active agents include salts of alkyl sulfates, such as diethanolammonium lauryl sulfate; alkylarylsulfonate salts, such as calcium dodecylbenzenesulfonate; alkylphenol-alkylene oxide addition products, such as nonylphenol-C 18 ethoxylate; alcohol-alkylene oxide addition products, such as tridecyl alcohol-C 16 ethoxylate; soaps, such as sodium stearate; alkylnaphthalene-sulfonate salts, such as sodium dibutyl-naphthalenesulfonate; dialkyl esters of sulfosuccinate salts, such as sodium di(2-ethylhexyl) sulfosuccinate; sorbitol esters, such as sorbitol oleate; quaternary amines, such as lauryl trimethylammonium chloride; polyethylene glycol esters of fatty acids, such as polyethylene glycol stearate; block copolymers of ethylene oxide and propylene oxide; salts of mono and dialkyl phosphate esters; vegetable or seed oils such as soybean oil, rapeseed/canola oil, olive oil, castor oil, sunflower seed oil, coconut oil, corn oil, cottonseed oil, linseed oil, palm oil, peanut oil, safflower oil, sesame oil, tung oil and the like; and esters of the above vegetable oils, particularly methyl esters.
[0023] Oftentimes, some of these materials, such as vegetable or seed oils and their esters, can be used interchangeably as an agricultural adjuvant, as a liquid carrier or as a surface active agent.
[0024] Other additives commonly used in agricultural compositions include compatibilizing agents, antifoam agents, sequestering agents, neutralizing agents and buffers, corrosion inhibitors, dyes, odorants, spreading agents, penetration aids, sticking agents, dispersing agents, thickening agents, freezing point depressants, antimicrobial agents, and the like. The compositions may also contain other compatible components, for example, other herbicides, plant growth regulants, fungicides, insecticides, and the like and can be formulated with liquid fertilizers or solid, particulate fertilizer carriers such as ammonium nitrate, urea and the like.
[0025] The concentration of the active ingredients in the synergistic composition of the present invention is generally from 0.1 to 98 percent by weight. Concentrations from 10 to 90 percent by weight are often employed. In compositions designed to be employed as concentrates, the active ingredients are generally present in a concentration from 5 to 98 weight percent, preferably 10 to 90 weight percent. Such compositions are typically diluted with an inert carrier, such as water, before making a postemergence, foliar application to exposed weed and crop foliage, or applied as a dry or liquid formulation directly into flooded rice fields. The diluted compositions usually applied as a postemergence, foliar application to weeds or the locus of weeds generally contain 0.25 to 20 weight percent active ingredient and preferably contain 0.4 to 14 weight percent.
[0026] The present compositions can be applied to weeds or their locus by the use of conventional ground or aerial dusters, sprayers, and granule applicators, by addition to irrigation or paddy water, and by other conventional means known to those skilled in the art.
[0027] The following examples illustrate the present invention.
[0028] Evaluation of Postemergence Herbicidal Activity of Mixtures in the Greenhouse
[0029] Seeds of the desired test plant species were planted in 80% mineral soil/20% grit planting mixture, which typically has a pH of 7.2 and an organic matter content of approximately 3 percent, in plastic pots with a surface area of 128 square centimeters (cm 2 ). The growing medium was steam sterilized. The plants were grown for 7-19 days (d) in a greenhouse with an approximate 14-hour (h) photoperiod which was maintained at about 29° C. during the day and 26 ° C. during the night. Nutrients and water were added on a regular basis and supplemental lighting was provided with overhead metal halide 1000-Watt lamps as necessary. The plants were treated with postemergence foliar applications when they reached the second to fourth true leaf stage. All treatments were applied using a randomized complete block trial design, with 4 replications per treatment.
[0030] Treatments consisted of the compounds as listed in Tables 1 and 3, each compound applied alone and in combination. Formulated amounts of penoxsulam and bentazon, were placed in 60 milliliter (mL) glass vials and dissolved in a volume of 60 mL of a water solution containing Agri-dex crop oil concentrate in a 1% v/v ratio. Compound requirements are based upon a 12 mL application volume at a rate of 187 liters per hectare (L/ha). Spray solutions of the mixtures were prepared by adding the stock solutions to the appropriate amount of dilution solution to form a 12 mL spray solution with active ingredients in single and two way combinations. Formulated compounds were applied to the plant material with an overhead Mandel track sprayer equipped with 8002E nozzles calibrated to deliver 187 L/ha at a spray height of 18 inches (43 centimeters (cm)) above average plant canopy.
[0031] The treated plants and control plants were placed in a greenhouse as described above and watered by sub-irrigation to prevent wash-off of the test compounds. Treatments were rated at 7 to 21 d after application as compared to the untreated control plants. Visual weed control was scored on a scale of 0 to 100 percent where 0 corresponds to no injury and 100 corresponds to complete kill.
[0032] Evaluation of Postemergence Herbicidal Activity of Mixtures in the Field
[0033] Field trials were conducted in rice using standard herbicide small plot research methodology. Plots varied from 3×3 meter (m) to 3×10 m (width×length) with 4 replicates per treatment. The rice crop was grown using normal cultural practices for fertilization, seeding, watering, flooding and maintenance to ensure good growth of the crop and the weeds.
[0034] All treatments in the field trials were applied using a CO 2 backpack sprayer calibrated to apply 187 L/ha spray volume. Commercially available products of penoxsulam and bentazon were mixed in water at appropriate formulated product rates to achieve the desired rates based on a unit area of application (hectare) to achieve the desired rates as shown. Treatments were rated at 6 to 45 d after application as compared to the untreated control plants. Visual weed control was scored on a scale of 0 to 100 percent where 0 corresponds to no injury and 100 corresponds to complete kill.
[0035] Tables 1 and 2 demonstrate the herbicidal synergistic efficacy of penoxsulam+bentazon-sodium tank mixes on weed control. Table 3 demonstrates the herbicidal synergistic safening of two crops to mixtures of penoxsulam+bentazon-sodium. All treatment results, both for the single product and mixtures, are an average of 3 to 4 replicates and the tank mix interactions are significant at the P>0.05 level.
[0036] Colby's equation was used to determine the herbicidal effects expected from the mixtures (Colby, S.R. Calculation of the synergistic and antagonistic response of herbicide combinations. Weeds 1967, 15, 20-22.).
[0037] The following equation was used to calculate the expected activity of mixtures containing two active ingredients, A and B:
[0000] Expected= A+B −(A×B/100)
[0038] A=observed efficacy of active ingredient A at the same concentration as used in the mixture.
[0039] B=observed efficacy of active ingredient B at the same concentration as used in the mixture.
[0040] Some of the compounds tested, application rates employed, plant species tested, and results are given in Tables 1-3. All comparisons are an average of 3 to 4 replicates and are significant at the P>0.05 level.
[0000]
TABLE 1
Synergistic Activity of Herbicidal Compositions on Sedge Weeds
( Cyperus iria ; CYPIR) in the Greenhouse at 21 Days after Application
Application Rate (g/ha)
% Control
Bentazon-
CYPIR
Penoxsulam
Sodium
Ob
Ex
3
0
20
0
500
55
3
500
85
64
3
0
20
0
1000
72
3
1000
98
78
[0000]
TABLE 2
Synergistic Activity of Herbicidal Compositions on Broadleaf and
Grass Weeds Sagittaria trifolia (SAGTR) and Echinochloa crus -
galli (ECHCG) in the Field at 6 to 45 Days after Application
% Control
Application Rate (g/ha)
Bentazon-
SAGTR
ECHCG
Penoxsulam
Sodium
Ob
Ex
Ob
Ex
15
0
38
—
—
—
0
1100
78
—
—
—
15
1100
100
87
—
—
23
0
45
—
—
—
0
1100
78
—
—
—
23
1100
100
88
—
—
38
0
—
—
30
—
0
2000
—
—
0
—
38
2000
—
—
53
30
[0000]
TABLE 3
Activity of Herbicidal Compositions on Safening of Injury in
Rice (ORYSA) in the Greenhouse at 21 Days after Application
Application Rate (g/ha)
% Control
Bentazon-
ORYSA
Penoxsulam
sodium
Ob
Ex
7.5
0
0
—
0
500
14
—
7.5
500
2.5
14
15
0
0
—
0
500
14
—
15
500
0
14
7.5
0
0
—
0
1000
16
—
7.5
1000
0
16
15
0
0
—
0
1000
16
—
15
1000
0
16 | A synergistic mixture of penoxsulam and bentazon controls weeds in crops, especially rice and other cereal and grain crops, pastures, rangelands, IVM and turf. In addition to providing improved post-emergence herbicidal weed control, the mixture safens damage to rice. | 0 |
FIELD OF THE INVENTION
The invention relates to the general field of semiconductor packaging with particular reference to increasing the lengths of solder bumps.
BACKGROUND OF THE INVENTION
This invention discloses a technique to generate stretched solder columns (bumps) at the wafer level, suitable for wafer level packaging and having the following desirable characteristics: Low cost, excellent test and burn-in ability, and high thermal cycling reliability. More specifically, the invention describes (1) a technique of forming stretched solder columns on a functional wafer using a mechanical process (2) techniques to separate these stretched solder columns from a dummy wafer, leaving the stretched solder attached to only the functional wafer, and (3) the technique of forming the super stretched solder through controlled solidification.
Integrated Circuit (IC) devices, be they microprocessor or memory devices, will, in general, need to be connected to a printed circuit board (PCB). Besides providing electrical interconnection, microelectronic packaging also provides mechanical support and protection to the delicate IC and the interconnections, as well as providing thermal paths for heat dissipation. Microelectronic packaging, especially those used in commercial products, is also driven by lower cost and reduced size. Chip Scale Package (CSP) with small silicon-to-package area ratio is widely used in commercial portable products where size is of paramount importance.
Recently, there has been very high interest in Wafer Level Packaging (WLP). WLP, as the name implies, involves packaging at the wafer level and then mounting individual packages onto printed circuit boards (PCBs) using solder interconnections. WLP offers the lowest silicon-to-package area ratio possible. However, the main driver for WLP is the reduced cost associated with the integration of test and burn-in procedures at the wafer level, eliminating costly burn-in and test (BT) at the package level.
The main obstacle to implementing a WLBT process has been the problem of developing a full-wafer contact technology that has the process capability required for manufacturing [1]. In other words, the hundreds of test pins from the tester must be able to make contact with the corresponding solder bumps on the wafer. This requires a new approach to the design of test pins as well as very high co-planarity of the solder bumps.
Besides cost and testability, a good WLP design must also address an important issue in microelectronic assembly, namely thermal cycling reliability. A microelectronic assembly will experience millions of cycles of temperature excursion during field application due to power on-off. During each such temperature cycle, the silicon chip and the organic substrate/board expand and contract by different amounts due to different coefficients of thermal expansion. This thermal mismatch applies a high stress/strain to the solder that is interconnecting the silicon chip and the organic substrate/board, as illustrated in FIGS. 1 a and 1 b . FIG. 1 a shows a schematic view of a chip 11 that has been attached to PCB 13 through solder bumps 12 while FIG. 1 b shows 1 a after it has been heated through arrows 14 ), as a result of which PCB 13 has expanded, relative to chip 11 , by an amount d resulting in stress/strain on solder bumps 12 . With the industry trend towards the use of larger dies (over 400 mm 2 ) and miniaturized interconnections, the thermal cycling reliability of the interconnections has become more critical.
It is intuitive from FIG. 1 b that the stress/strain on the interconnection can be reduced by increasing the length of standoff 12 and/or increasing the rotational freedom of the interconnection ends that are attached to the chip or the substrate.
A number of wafer level packaging schemes have been pursued by the industry to enhance the thermal cycling reliability of the solder interconnections. These include:
(1) Stacked Solder technique [2-4] where the standoff between the chip and the substrate is increased by multiple stacking of solder bumps/balls. However, this technique suffers from low process efficiency due to the sequential stacking processes.
(2) Copper Post technique [5-7] where the standoff between the chip and the substrate is increased through use of a copper column that is electroplated upwards from the under bump metalization (UBM) of the wafer. The main drawback of this process is the long electroplating duration as well as the expensive (material and capital) lithography process required to electroplate the copper column.
(3) Stress Buffer technique [8-10] where the UBM is formed on compliant polymeric layers that increase the rotational freedom of the solder interconnection. Besides the expensive lithography process, the improvement in thermal cycling reliability from enhanced rotational free is limited compared to that from an increasing standoff. All the above techniques also suffer from poor test and burn-in ability due to poor wafer level co-planarity of the solder bumps.
REFERENCES
[1] Larry Gilg, Die Products Consortium, Austin, Tex.—EP&P, Jul. 1, 2002
[2] U.S. Pat. No. 5,251,806, “Method of forming dual height solder interconnections”, IBM, October 1993.
[3] Beth Keser, et al. “Encapsulated double-bump WL-CSP: Design & reliability”, Proc. 51 st Electronic Component Technology Conference, pp 35-39, 2001.
[4] J. Simon, “Development and board level reliability of a wafer level CSP”, Proc. 41 st IEMT/IMC, pp. 22-27, 2000.
[5] S. I. Denda, et al., “Wafer level packaging technology in Japan”, Proc. 4 th IEMT/IMC, pp. 4-9, (FIG. 2), 2000.
[6] Advanced IC packaging markets and trends, pp 4-49 to 4-51, Electronic Trend Publication, 6 th Edition, 2002.
[7] U.S. Pat. No. 5,790,377, “Integral copper column with solder flip chip”, Packard Hughes Interconnect, August 1998.
[8] Bakir, et al., “Sea of leads ultra high-density compliant wafer-level packaging technology”, Proc. 52 nd Electronic Component Technology Conference, pp. 1087-1094, 2002.
[9] P. Garrou, et al., “Cyclotene BCB resin for bumping and wafer level chip scale packaging (WLCSP), Proc. 3 rd IEMT/IMC, pp. 206-211, 1999.
[10] S. I. Denda, et al., “Wafer level packaging technology in Japan”, Proc. 4 th IEMT/IMC, pp. 4-9, (FIG. 10), 2000.
A routine search of the prior art was performed with the following additional references of interest being found:
U.S. Pat. No. 5,441,195 Tustaniwskyj et al. August 1995—method of stretching solder joints. U.S. Pat. No. 5,964,396 Brofman et al. October 1999—enhanced ceramic ball grid array using in-situ solder stretch with clip. U.S. Pat. No. 5,975,409 Brofman et al. November 1999—ceramic ball grid array using in-situ solder stretch. U.S. Pat. No. 6,442,831 Khandros et al. September 2002—method for shaping spring elements.
SUMMARY OF THE INVENTION
It has been an object of at least one embodiment of the present invention to provide a method for forming elongated solder bumps.
Another object of at least one embodiment of the present invention has been to apply said method to wafer level packaging.
Still another object of at least one embodiment of the present invention has been that said method be inexpensive and rapid.
A further object of at least one embodiment of the present invention has been that solder bumps produced as the end product of said method have flat co-planar ends.
These objects have been achieved by using two wafers—the standard (functional) wafer that contains the integrated circuits and a master (dummy) wafer on whose surface are provided an array of solder bumps that is the mirror image of that on the functional wafer. After suitable alignment, both sets of solder bumps are melted and then slowly brought together till they merge. Then, at constant temperature, they are slowly pulled apart thereby stretching the merged solder columns to the desired length. We have employed two general approaches to dealing with the problem of how to separate the two wafers:
(1) Weak Metalization:
The distance between the wafers is maintained until the solder columns have fully solidified and acquired their full mechanical strength. The functional wafer is then displaced slightly causing the more weakly bonded end to separate.
(2) Leveling Techniques:
The functional wafer is cooled to at least 50 C below the hot working temperature of the solder while the master wafer is brought to the appropriate hot working temperature. While maintaining the latter temperature, the wafers are gradually separated. The associated temperature gradient causes the stretching of the solder to be greatest at the master wafer end, the solder eventually breaking off there.
After separation from the functional wafer surface, the elongated solder bumps tend to have uneven ends. This is corrected by pressing a flat heated plate against said ends which causes them to flatten out and become coplanar. This flattening process is performed while maintaining the functional wafer at a low temperature and while the leveling press is heated to the hot working temperature of the solder. This ensures that the solder columns do not collapse during the leveling process. Note that the surface of the leveling press is non-wetting with respect to the solder.
As an alternative to the preferential separation of the elongated solder bumps at the functional wafer surface, a sacrificial layer may be deposited onto the master wafer's surface prior to the formation of the mirror image bump array. Separation of the elongated solder bumps is then achieved through preferential etching away of said sacrificial layer.
A third alternative method to achieve separation of the elongated bumps is to sacrifice the functional wafer in its entirety. This can be done either through etching or through grinding and polishing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b illustrate the problem of solder bump stressing during thermal cycling.
FIGS. 2 a and 2 b show a key feature of the invention, namely the use of two wafers to achieve elongation of solder bumps.
FIG. 3 shows how the solder bumps on the two wafers are merged into a single column.
FIG. 4 shows the elongation of the solder bumps.
FIG. 5 illustrates how the solder bumps may be separated from one of the two substrates to which they initially adhere.
FIG. 6 schematically illustrates wafer level test and burn-in.
FIG. 7 shows attachment of a chip to a PCB.
FIG. 8 shows how a sacrificial layer may be used to facilitate separation of the extended bumps from one of the wafers.
FIGS. 9 and 10 illustrate how solder bump separation may be effected through full consumption of the entire functional wafer.
FIGS. 11 a , 11 b , and 12 show a method for making the solder bumps' ends flat, dovetailed in shape, and co-planar.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The key novel feature of the invention is that two wafers are used. As shown in FIG. 2 , one of them, wafer 21 , the functional wafer, is a standard VLSI wafer including connections to its interior that have been made by forming contact pads over openings in the top insulation layer, followed by the attachment of solder bumps, one per pad. Wafer 22 is a master (dummy) wafer that is blank except for the presence on its top surface of an array of solder bumps that is an exact mirror image of that on wafer 21 .
For both wafers, the bumps are formed from a high melting solder (melting point above 260 C) using standard processes. Examples of the solder include (but are not limited to) 95Pb5Sn, 90Pb10Sn, and 80Pb2OSn. The adhesion of the metalization to silicon oxide is designed to be weak. An example of weak metallization is gold or copper. The degree of adhesion can be further modified through modification of the surface morphology by means of plasma etching, chemical etching (dry or wet), mechanical roughening; etc.
As shown in FIG. 3 , both the functional and the master wafers are gripped by means of vacuum chucks 31 and 32 . At least one of the wafer chucks includes a heating element 34 with precision temperature control. One of the wafer chucks is held securely in place while the other is attached to a machine spindle, similar to a standard flip chip attacher, that has full positional and angular adjustment capability. The solder bumps in the top wafer are then positioned above the bottom wafer and aligned relative to the lower wafers solder bumps, at a distance apart, while heat is applied to melt the solder bumps on both wafers. The top wafer is then lowered gradually (arrows 33 ) until the solder bumps on the wafers merge (shown as merged bumps 35 in the figure).
At constant temperature, the top wafer is raised in a controlled manner (arrows 41 ), thereby stretching the merged solder bumps so that they become elongated bumps 45 , as seen in FIG. 4 . The separation between the wafers is stopped when the desired elongated profile of the solder is reached and before any breakage of the elongated bumps can occur.
While maintaining the distance between the two wafers, the temperature of the wafer chuck(s) is reduced to allow cooling of the elongated solder columns 45 . Upon solidification, the solder acquires a bulk strength that is significantly higher than the adhesion strength of the weaker metalization on the functional wafer. The chuck that grips the functional wafer ( 21 in FIG. 5 ) is then given a minute upward displacement that will result in separation of the weaker metalization and its associated solder columns from the master wafer. The ends of the solder columns are now exposed.
The weaker adhesion to the surface of the functional wafer is achieved by using metalization that has inherently poor adhesion to the silicon substrate. For example, one might use Cr/Cu/plated Cu/Ni (UBM) on the master wafer. The bulk strength of the solder is around 30 MPa. The net result is that the force required to cause separation of the master pads is less than 50% of what is needed to initiate damage in the stretched solder. Assuming an area ratio 5:1 between the pad and the solder column at its minimum cross-section, the adhesion strength of the metalization to the pad needs to be 0.1 to 3 MPa. This minimum adhesion strength is necessary to ensure that the metalization survives the fabrication processes.
As a consequence of the above-described process, the exposed ends of the solder columns will have acquired the high level of co-planarity necessary for wafer level burn-in and test (shown schematically in FIG. 6 ).
As seen in FIG. 7 , the functional wafer is now diced into individual chips 71 that are ready to be attached to a PCB which is pre-mated with a finish layer of solder 75 that has a melting point about 80-100° C. below that of the solder columns, for example, 63Sn37Pb eutectic solder. This ensures that the solder columns do not collapse during mounting of the chip to the PCB. The master wafer can now be recycled by chemical cleaning or mechanical polishing, followed by the deposition of fresh, weakly adhering metalization.
This new technique offers several attractive features:
Low cost—Low material cost; short processing time (less than 2 minutes excluding time to recycle the functional wafer). Maximum bump co-planarity—A critical feature for wafer level test and burn-in. High thermal cycling reliability—Because of the high standoffs Elimination of under-fill—Lowers cost and eliminates popcorn cracking Design flexibility—Degree of solder column elongation readily varied.
We now describe some possible variations of the basic invention that was disclosed above:
1. Alternative solder alloy systems: Instead of the system of high temperature solder column (melting temperature above 280° C.) used with near eutectic SnPb solder joining, an alternative system of Pb-free solder (melting temperature about 220° C.) and a near eutectic SnBi solder joint may be used.
2. Alternative techniques for separating and exposing the solder columns:
2.1. As shown in FIG. 8 , sacrificial layer 81 (typically between about 0.2 and 0.4 microns thick) is first deposited onto the surface of functional wafer 22 . After the elongated solder bumps have been formed, as described above, layer 81 is selectively removed through chemical etching, thereby allowing the separation of the elongated solder columns. The sacrificial layer may be organic, such as a high temperature polymer, or inorganic, such as amorphous silicon, polysilicon, or silicon oxide.
2.2 As shown schematically in FIG. 9 , the entire functional wafer 92 may be removed through chemical etching, thus exposing the solder columns.
2.3 As shown in FIG. 10 , the entire functional wafer 92 may be removed through mechanical grinding and polishing, or through chemical-mechanical polishing (CMP). Upon cooling, and prior to grinding/polishing, the space between the master and the functional wafers is impregnated with a wax-like material 95 such as Nikka Seiko's Skycoat. The wax servers to protect the delicate solder columns from damage during the grinding process. Once the functional wafer has been ground away, the wax may be removed, if desired, with simple heating or chemical etching.
As an alternative to wax, a thermoplastic material may be used. In this case, the reinforcing thermoplastic will be left in the master wafer and will be part of the diced chip. The thermoplastic will soften and make good adhesion with the PCB during solder reflow, thereby serving as a reinforcement for the solder interconnections, similar to an under-fill material.
2.4 Leveling Technique
After achieving the desired stretched height, the functional wafer is cooled to at least 50° C. below the hot working temperature of the solder while the master wafer is brought to the appropriate hot working temperature. While maintaining the latter temperature, the wafers are gradually separated. The associated temperature gradient causes the stretching of the solder to be greatest at end near the master wafer 112 and eventually breaks off ( FIG. 11 a ). After separation from the master wafer, the elongated solder bumps tend to have uneven ends ( FIG. 11 b ). This is corrected through a leveling process. In the leveling process, the functional wafer is held with a chuck, which may be the same as that during the stretching, with the free-standing stretched solder (with uneven ends) facing down. The temperature of the wafer is maintained at 50 to 100° C. below the hot working temperature of the solder. This is to prevent collapsing of the solder column during leveling. The wafer is lowered and pressed against a leveling plate (non wetting to solder) which is maintained at the hot work temperature of the solder. The temperature gradients results in local deformation in the solder at the end in contact with the leveling plate. This local deformation results in dovetailing of the solder which serves as a good anchor when attached to the printed circuit board. On the wafer level, the leveling process enforces coplanarity among all the solder columns in the wafer.
2.5 Flexible Laminate Technique
This technique differs from the above techniques in that a flexible laminate is used in place of the master wafer to provide for the stretching.
Stage 1: Pattern flexible laminate. The process starts with a copper foil—dry film flexible laminate that is supplied in a roll form. The laminate is then patterned to expose the copper foil with the desired pattern of solder bumps.
Stage Ia: Formation of solder bumps on a flexible laminate. If so desired, the patterned flexible laminate, may be coated with a solder pattern by using either printing, plating, or jetting. Dry film serves as mask during any of these processes.
Stage 2: Mounting and solder merging: The functional wafer as well as the flexible laminate with patterned pad (or solder bumps) are held by a set of vacuum chucks, equipped with heating, using vacuum. The chuck for the function wafer is attached to a machine spindle that has x-y-z-φ degrees of freedom, similar to a standard flip chip attach machine. Using the x-y-φ degrees of freedom, the functional wafer is aligned and positioned at a distance over the flexible tape while heat is applied to melt the solder bumps on the functional wafer as well as on the flexible tape (if there is one). Using the vertical degree of freedom, the functional wafer is lowered gradually until the solder bumps are merged.
Stage 3: Stretching. While maintaining the temperature to keep the merged solder in the molten state, the top wafer is raised in a controlled manner, stretching the solder in the process. The displacement of the top wafer is stopped when the desired elongated profile of the solder is reached.
Stage 4: Cooling. While maintaining the distance between the two wafers, the temperature of the wafer chuck is reduced to allow cooling and solidification of the stretched solder columns. The assembly is then released from the holders.
Stage 5: Exposure of solder columns. The solder columns on the assembly are released from the flexible laminate by chemically etching away the copper foil on the flexible laminate.
Discussion:
The theoretical stretchability of the solder column is a function of pad dimension, the volume, surface energy as well as the density of the solder. The theoretical limit of stretching two 100 micron diameter eutectic solder bumps has been evaluated using Evolver (a computer program that uses the principle of minimum gravitational and surface energy) at 290 microns, or a length to diameter aspect ratio of 2.9 assuming the solders were completely in the molten state. By controlling the temperatures of the two substrates to achieve progressive solidification of the solder column, a practical aspect ratio, of 4.5 has been achieved. This is possible because, during stretching, solidification of the solder column is initiated and advances progressively from one end so that at any given time the aspect ratio in the liquid portion of the solder column is less than the theoretical limit of 2.9.
Advantages Over Prior Art
A comparison of this wafer level packaging process with other established processes is tabulated in the table below:
Wafer Level Packaging Processes
Critical
Stacked
Stress buffer
Factors
WLS 3
Solder
Cu Post
layer
Processibility
2
4
3
1
(Cost)
(fast action)
(sequential
(long plating
(Additional
solder
duration)
layer)
stacking)
Reliability
1
3
2
4
(compliant,
(multiple
(weakness
(Least
no stress
stress
along Cu
compliant)
concentra-
concentra-
solder
tion sites)
tion sites)
interface)
Testability
1 (max co-
3 (non-
3 (non-
3 (non-
planarity)
coplanar)
planar)
coplanar)
Electrical
3
4
2
1
performance
(smooth
(large cross
(better
(shortest
cross section
sectional
electrical
height)
variation)
variation)
property
of Cu)
Overall
4 (+3)
10 (+4)
8 (+2)
8 (+1)
The WLS 3 technique presents the most balanced qualities.
More significantly, the WLS technique presents superior reliability, thereby overcoming what has been the main weakness of conventional WLP processes, namely limiting its die size. | We disclose a technique to generate stretched solder columns (bumps) at the wafer level, suitable for wafer level packaging. This is accomplished through use of using two wafers—the standard (functional) wafer that contains the integrated circuits and a master (dummy) wafer on whose surface is provided an array of solder bumps that is the mirror image of that on the functional wafer. After suitable alignment, both sets of solder bumps are melted and then slowly brought together till they merge. Then, as they cool, they are slowly pulled apart thereby stretching the merged solder columns. Once the latter have fully solidified, they are separated from the master wafer only. | 8 |
BACKGROUND OF THE INVENTION
The present invention pertains to a power amplifier and control apparatus therefore.
Power amplifiers are common items in modern day radio telephony. Because of their excellent performance at high frequencies, their small size and light weight, solid state transistor amplifiers using GaAs semiconductors are preferred for portable applications requiring radio frequency (RF) power amplifiers. However, in order to operate safely and efficiently, a complex arrangement for supplying power to and controlling operation of the amplifier has frequently been required. A further complication is that the manner in which the amplifier is turned on and off must be carefully pre-determined in order to minimize non-linear effects which lead to generation of spurious signals in channels outside of that being used for communication. A still further complication is that, in most instances, it is desired to operate the power amplifier from a single voltage power source. As a consequence of these and other requirements, complex, bulky and inefficient circuits have been needed, in the prior art, to control and operate such amplifiers. Thus, the overall amplifier function has been less attractive than is desired in one or more aspects of size, weight, cost and power consumption.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE shows a simplified schematic circuit diagram of a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The sole FIGURE shows in simplified schematic form, and according to a preferred embodiment of the present invention, circuit 100 incorporating power amplifier 102. While power amplifier 102 is conveniently a GaAs power amplifier, those of skill in the art will understand that amplifiers of other materials and properties can also be used and that amplifier 102 may have a single stage or multiple stages of amplification. Accordingly, as used herein the term "amplifier" and "power amplifier" are intended to include such other amplifying structures.
Coupled in series with amplifier 102 is switch 103. Switch 103 is conveniently an N-channel MOSFET but this is not essential. Other forms of switches are also suitable and switch 103 can be a single stage or a multiple stage switch according to the needs of the user. The purpose of switch 103 is to couple and decouple amplifier 102 from power source 105. Switch 103 turns amplifier 102 on and off in a controlled manner.
Circuit 100 is desired to operate from single, unipolar power source 105. While power source 105 is shown as being a battery, which is especially convenient for portable applications, this is not essential. Any form of power source can be used and the word "battery" is intended to include such alternatives.
Circuit 100 has portion 104 shown within dashed lines 106, 108. Portion 104 is conveniently incorporated within a single monolithic integrated circuit (IC) so as to minimize one or more of size, weight, cost and power consumption. This is especially desirable for portable applications. Unless otherwise noted, the abbreviation "IC" or "IC 104" is intended to refer to the combination of elements within dashed outlines 106, 108 and having external terminals 110-134 or equivalent.
In most cases, it is desirable to have both positive and negative voltages for supplying amplifier 102 and switch 103. Portion 106 of IC 104 provides power conditioning, that is, it derives from single voltage Vb supplied by battery 105 via terminal 110, the voltages needed to properly operate amplifier 102. Portion 108 of IC 104 provides control functions to insure the proper operation and safety of amplifier 102 and switch 103. The combination of power conditioning portion 106 and control portion 108 which can be readily integrated in common IC 104 is a particular feature of the present invention.
Power conditioning portion 106 conveniently includes oscillator 135, positive charge pump 136, positive regulator 138, negative charge pump 140 and negative regulator 142. Oscillators, charge pumps and regulators are electronic functions individually well known in the art. Oscillator 135 conveniently provides a square wave output with approximately 50% duty cycle, although this is not essential. Oscillator 135 conveniently operates at about 100kHz, but higher or lower frequencies can also be used. The exact frequency is not critical. Oscillator 135 provides the square wave output to positive charge pump 136 and negative charge pump 140 via line 137.
Positive charge pump 136 receives power from Vb-in terminal 110 which is coupled to power source 105 via line 144. External capacitors C2 and C3 (e.g., external to IC 104) are coupled via terminals 112, 114, 116 to positive charge pump 136. Capacitors C2 and C3 are used by positive charge pump 136 in a conventional manner to provide voltage doubling and voltage tripling. Positive doubled voltage Vd is coupled to terminal 118 via line 146 and stored on (e.g., external) capacitor Cd. Positive tripled voltage Vt is coupled to terminal 134 via line 148 and stored on (e.g., external) capacitor Ct. Those of skill in the art will understand based on the description herein that the terms "doubled"and "tripled"refer approximately to the magnitude of power supply voltage Vb but are not intended to be exact since losses occur in the switching and rectifying functions needed to perform the voltage doubling and tripling and the magnitude of Vd and Vt also depend upon the regulating signal being provided from positive regulator 138 to positive charge pump 136 via line 150.
Positive regulator 138 is conveniently a differential amplifier comparing the voltage received at (e.g. negative) input 151 with the voltage received at (e.g., positive) input 153 to provide an output on line 150 to control the magnitude of the voltages being generated by positive charge pump 136. Input 151 is conveniently coupled to common node 155 of back-to-back diodes 154, 156 which are in turn coupled, respectively, by resistor 158 to line 148 and by resistor 160 to common ground 162. Diode 154 is conveniently a Zener diode. Input 153 is coupled to line 152 on which appears master reference voltage Vm. Thus, the action of positive regulator 138 is to compare a portion of Vt appearing on line 148 from positive charge pump 136 to master reference voltage Vm appearing on line 152 and adjust the output of charge pump 136 until Vt has the proper value relative to Vm. The generation of Vm is discussed later.
Negative charge pump 140 works in an analogous manner, receiving square wave signals from oscillator 135 via line 137, and being coupled via terminals 120, 122 to (e.g., external) voltage doubling capacitor C4. Negative charge pump 140 receives Vt from positive charge pump 136 via lines 148, 145, 147 and a control signal from negative regulator 142 via line 143. Negative regulator 142 is conveniently a differential amplifier comparing the voltage at (e.g. positive) input 161 to the common (ground 162) potential appearing at (e.g., negative) input 163, to provide an output on line 143 to control the magnitude of voltage Vss being generated by negative charge pump 140. Input 161 is conveniently coupled to common node 169 of resistors 168, 170. Resistor 168 is further coupled to line 152 supplying master reference voltage Vm and resistor 170 is further coupled to Vss-out terminal 124 and, via line 160, to the output of negative charge pump 140. Thus, the action of negative regulator 142 is to compare a portion of Vss appearing on line 160 from negative charge pump 140 to master reference voltage Vm appearing on line 152 and adjust the output of charge pump 140 until Vss has the desired value relative to Vm. Node 192 is coupled to Vss-out terminal 124. Schottky diode 194 is coupled from node 192 to capacitor C4 and terminal 122. Capacitor Cn is coupled from node 192 to ground 162. Vss appears across capacitor Cn. A feature of the present invention is that regulators 138, 142 enable circuit 104 to operate over a significant range of temperature and Vb-in voltages, for example, as might be encountered due to changing environmental conditions for a portable phone or as battery 105 discharges.
The optimal values of Vss-out and Vg-out at terminals 124 and 130 depend upon the characteristics of amplifier 102 and switch 103 selected by the user. Persons of skill in the art will understand, based on the particular amplifier and switch chosen for their application, how to vary the values of resistors 158, 160, 168, 170 and the related voltage references in order to achieve the proper Vss-out and Vg-out voltages levels.
Control circuit portion 108 comprises stand-by circuit 172, voltage reference 174, upper voltage lock-out (UVLO) circuit 176 and gate driver amplifier 178. Stand-by circuit 172 receives power from battery 105 via terminal 110 and line 171 and sends power via line 173 to voltage reference 174. Control line 175 extends from V(idle-in) terminal 132 to stand-by circuit 172. Stand-by circuit 172 acts as a switch to disable circuit 100 when the system does not require amplifier 102 to function. This is done by cutting off battery power to oscillator 135 and other elements coupled to voltage reference 174. In the preferred embodiment, stand-by circuit 172 is "open" when V(idle-in) applied at terminal 132 is equal to zero volts relative to ground 162. In this condition, no significant power is consumed by circuit 100 and amplifier 102 is in an "off" state (i.e., RF input signals presented at terminal 180 are not amplified). When V(idle) is greater than or equal about two volts, stand-by circuit 172 is "closed", power is applied to circuit 100 and amplifier 102 is in an "on" state and able to amplify signals presented at input terminal 180 and deliver the amplified signal to output terminal 182. Stand-by circuit 172 is desirable but not essential.
Voltage reference 174 receives power from battery 105 via stand-by circuit 172 and line 173. The function of element 174 is to provide on line 152, master reference voltage Vm. A convenient value of Vm is about 1.27 volts, which is readily obtained using a Widlar band-gap reference circuit well known in the art. While this value and choice of reference circuit are preferred, other means of generating a predetermined master reference voltage may also be used and other values of Vm chosen, according the type of amplifier 102 and switch 103 that the user desires to employ. Persons of skill in the art will understand, based on the description herein, how to select a master reference voltage and reference circuit for their particular application.
UVLO circuit 176 is conveniently a differential amplifier with (e.g., positive) input 175 coupled to node 185 between resistors 184, 186, and (e.g., negative) input 177 coupled to ground 162. Resistor 184 is further coupled to Vm line 152 and resistor 186 is further coupled via line 187 to V(sense) terminal 126. V(sense) terminal 126 is desirably coupled via line 189 to node 188 adjacent to amplifier 102 in line 190 running from amplifier 102 to Vss-out terminal 124 of IC 104 via node 192.
Output 179 of UVLO circuit 176 is coupled to gate amplifier 178 so as to control, in part, the operation of amplifier 178. Gate amplifier 178 has (e.g., negative) input 195 coupled to node 199 between resistors 200, 202. Resistor 200 is further coupled to node 198 in output lead 196 of gate amplifier 178 and resistor 202 is further coupled to ground 162. Gate amplifier 178 receives tripled power supply voltage Vt via lead 145 from node 149. Gate amplifier 178 has (e.g., positive) input 197 coupled to Tx-on/off input terminal 128. Assuming that the action of UVLO circuit 176 has not disabled gate amplifier 178, applying an "on" signal to Tx-on/off input terminal 128 causes amplifier 178 to provide a signal on lead 196 sufficient to energize gate 204 of switch 103 so that current can flow between source-drain leads 206, 208 and thereby energize amplifier 102. Persons of skill in the art will understand that the type of device used for switch 103 and the polarity of the driving signals to energize switch 103 will vary depending upon the particular choice of amplifier 102 and, based on the description herein, such variations are within the competence of persons of ordinary skill in the art.
The function of UVLO circuit 176 in combination with gate amplifier 178 is to prevent amplifier 102 from being connected to battery 105 if Vss is not present and negative. For example, if a negative voltage (e.g., Vss or the like) is present at node 188, then input 175 of UVLO circuit 176 is pulled negative and UVLO circuit 176 produces no output on lead 179, thereby permitting amplifier 178 to function normally. Conversely, if a negative voltage is not present at node 188, then input 175 drifts positive to Vm and a large output is provided by UVLO 176 thereby cutting off amplifier 178 so that switch 103 cannot be turned on even if Vtx-on is present at terminal 128. Node 188 is desirably electrically close to amplifier 102 so that spurious signals and other errors are avoided. While it is preferred to couple V(sense) terminal 126 to node 188, this is not essential. V(sense) terminal 126 can be connected to Vss-out terminal 124.
A further feature of the present invention is that amplifier 178 conveniently provides a controlled rise and fall time. When presented with, for example, an abrupt Off-On Vtx transition signal at terminal 128, the output voltage on lead 196 from amplifier 178 follows a predetermined and more gradual rise time, and conversely, when Vtx undergoes an abrupt On-Off transition, amplifier 178 provides a predetermined and more gradual fall-time. This is important because it substantially reduces the generation of high frequency transients and out-of-band modulation products which would otherwise result from rapid transition of amplifier 102 between "off" and "on" states. The rise and fall time of amplifier 178 are readily predetermined by appropriate RC time constants built into amplifier 178.
Alternatively, amplifier 178 can be provided with a rapid response characteristics and the rise and fall time of the turn on/off of amplifier 102 controlled by the rise and fall time of the applied Tx-on/off signal. Either method works.
When in the "on" state, amplifier 102 receives a signal, e.g., an RF signal, at terminal 180 and provides an amplified output at terminal 182. The RF signal can be continuously supplied to terminal 180 and the operation of amplifier 102 controlled by the combination of V(idle) applied to terminal 132 and V(Tx-on/off) applied to terminal 128.
Based on the foregoing description, it will be apparent that the invented combination provides an efficient, compact and effective apparatus for controlling an amplifier, especially a GaAs RF amplifier. By virtue of the ability to integrate nearly all of the required components in a single IC, low cost, high performance and small size can be simultaneously achieved. The combination of on-board power conditioning circuits combined with on-board control and protection circuits provides an overall amplifier control apparatus of great utility.
Although the preferred embodiment of the invention has been illustrated, and that form described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | An amplifier controller (104) is described for operating from a single voltage power supply (105). A switch (103) is coupled between the amplifier (102) and the power supply (105). The controller (104) includes a power conditioning circuit (106) for generating doubled and tripled voltages and positive and negative voltages for operating the controller (104) and the amplifier (102). Internal voltage regulators (138, 142) control the magnitude of the generated voltages. The controller (104) further includes: (i) a circuit (172) for disabling the controller (104) and amplifier (102) in response to an idle signal presented thereto, (ii) a circuit (178) for energizing the switch in response to a turn-on signal (128) so that the amplifier (102) can amplify, and (iii) a circuit (176) for sensing the presence or absence of negative polarity (Vss) on a second lead (188) of the amplifier (102) and, if not present, disabling the switch (103) despite the presence of the turn-on signal. The controller (104) can be integrated in a single IC. | 7 |
BACKGROUND OF THE PRESENT INVENTION
1. Field of the Invention
This invention relates to the field of hard disk controller systems that are compatible with the IBM AT BIOS (Basic Input/Output System) and in particular the AT interface between host and microprocessor.
2. Background Art
Computers and their associated disk drives are used for storing large amounts of data. Typically, data is stored on a magnetic disk in a series of concentric tracks on the surface of the disk. A read/write head moves back and forth radially on the disk so that it can be selectively positioned over one of the tracks. To effectively read and write data, it is necessary that the position of the tracks in relation to the head be known. In addition to knowing which track the head is over, it is necessary to know where on that particular track the head is positioned. A servo pattern is used to provide position information. One type of servo pattern is the sector servo, which comprises bursts of servo information disposed on a disk surface in between data areas.
Also, it is necessary to know at which circumferential position in the track the head is located. This is done by an "index" which is generally defined at a specific circumferential location in the servo pattern to indicate the start/end location of each data track. Also necessary for proper addressing is cylinder information which is a combination of all the tracks that are currently accessed by the heads in a drive. Once in position over a track, the head remains in place as the track rotates beneath it, allowing the head to read or write data on the track.
The host computer communicates with the disk drive through an interface such as the AT Bus interface. An AT Bus interface often contains several registers that the host uses to communicate with the disk drive controller. The entire set of registers is collectively referred to as an AT Task File. The control registers of the interface are used for writing and reading data and also issuing commands between the host and the disk microprocessor. The control registers also provide status information including error status to the host. Other registers of the AT Task File specify the physical address for a read or write command. All of these registers that comprise the interface are necessary for proper coordination between the host and drive.
Thus, data information as well as status information from the disk is then provided to the AT Bus interface before the data information is provided to the host computer. The AT task file registers within the AT interface receives the status information from the drive for updating the registers. After each data sector is transferred, AT task file registers of the AT interface are updated in order to indicate the physical address of the sector of data being transferred.
A block diagram of the AT interface is given in FIG. 4. The host computer block 120 and disk drive microprocessor 110 are coupled to AT interface 130 through bus line 160. AT interface block 130 is also coupled to AT task file block 140 which is a part of AT interface 130. AT task file 140 is coupled to microprocessor 110. AT interface is coupled to other electronics block 170 which is coupled to Head Drive Assembly (HDA) 150. Head Drive Assembly 150 is also coupled to microprocessor 110. The other electronics block 170 along with AT interface 130 make up the disk controller of the disk drive. In operation, commands are sent to the disk drive to read or write data. This data is transferred back to the computer. When the data information is transferred through the AT interface 130 and bus 160 to the host 120 or microprocessor 110, AT task file block 140 is updated by the microprocessor with the status information. These task file registers (that are updated after each data block or sector is transferred for providing the physical address of data sectors being transferred) comprise a sector count register, a sector number register, a drive/head number register, a cylinder low register and a cylinder high register.
The AT sector number register is a dual-ported, read/write register available to both the host and microprocessor. This register is an 8 bit parameter register used to provide the sector ID. This register is used to specify the starting sector number for the current/read write sector command. This register is usually incremented by the local microcontroller after each sector is transferred by the host and controller, or transferred from the controller to the host (read operation).
When the sector number register is incremented high enough so that the register value reaches the largest sector ID on the track, (the upper bound of the sector number register), the next time a data sector is transferred, the microprocessor must reset the register for proper updating. The microprocessor stores this upper bound value and prevents the register from incrementing above this value.
The AT sector count register is used to specify the number of sectors to be transferred during a read/write sector command. This register is decremented by the local microcontroller usually after each sector is transferred. If this register is loaded with zero then 256 sectors are transferred.
The AT drive/head register is an 8 bit register used by the host to specify the head number and the drive number. In addition, bit four of this register is used to select one of the two drive status registers, drive zero status register or drive one status register, accessible from the host. Bits 3-0 contain the binary coded address of the head to be selected. In previous AT task files, the microprocessor changes the head address as each track or cylinder boundary is crossed.
The AT cylinder low register is used to specify the lower eight bits of the disk cylinder address. This register, in conjunction with the cylinder high register, constitutes a 16-bit cylinder address. This register is incremented by the local microcontroller usually as each cylinder boundary is crossed. At the end of the command, this register is updated to reflect the current cylinder number.
The cylinder high register contains the high order bits of the starting cylinder address for any disk access. At the end of the command, this register is updated to reflect the current cylinder number. The most significant bits of the cylinder address are loaded into the cylinder high register.
Upon completion of each data sector transfer, the registers described above must be updated with the current sector, head, and cylinder information. This process, in prior art, is typically performed by the system microprocessor. This requires that the microprocessor maintain, increment and reload each of the task file registers for each block of data transferred. Unfortunately, this reduces the available microprocessor bandwidth and increases the time over-head in transferring data from the disk drive to the host computer. It is desirable to have the microprocessor bandwidth free from maintaining the task file register values. If a single microprocessor is used in disk drives to support all the drive functions, including task file updates, microprocessor bandwidth may not be available to maintain the task file register values. It is desirable to free the microprocessor from updating the task file registers.
SUMMARY OF THE INVENTION
The present invention automates the operation of the AT task file registers used in hard disk drives and hard disk controller systems. The present invention provides registers that interface between the disk controller circuit and the host computer. The invention utilizes four 8-bit digital upcounters, one 4-bit digital upcounter, an 8-bit data register and a 4-bit data register. These counters indicate the physical address of the sector of data being transferred and are incremented or reloaded as required as each sector of data is transferred. The present invention employs the 8-bit data register, the maximum sector register, to hold the number of sectors per track on the drive and the 4-bit register, the maximum head register, to hold the number of heads on the disk drive. Then the counters are reloaded or incremented as required based upon the contents of the maximum head and maximum sector registers without microprocessor support after each sector is transferred.
The sector counter register of the present invention is decremented automatically after each data sector has been transferred to or from the host to or from the disk drive. The sector number register value is updated automatically in the present invention by being compared with the value in the maximum sector register after each sector is transferred. After each comparison the sector number register is loaded with one if its value is equal to the maximum sector register. Otherwise, it is incremented. The drive/head register is also updated automatically in the present invention by being compared to the value in the maximum head register when the sector count register is reloaded. After each comparison the drive/head register is loaded with zero, if the lower 3 bits of the drive/head register equal the maximum head register. Otherwise it is incremented. The cylinder low and cylinder high register values are also updated automatically in the present invention. The cylinder low register value is updated based on the value stored in the drive/head register, and the cylinder high register value is subsequently updated based on the value stored in the cylinder low register. External circuitry (typically a microprocessor) is not required in any of these operations. Having an automatic update of the AT task file is desirable for it reduces the command overhead and microprocessor bandwidth requirement in supporting the AT task file. The present invention is compatible with the ATA (AT Attachment) Specification, (ANSI standardization or BIOS compatibility).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram describing the updating process of the sector number register value.
FIG. 2 is a flow chart describing the updating process of the head register value as well as the cylinder low and cylinder high register values.
FIG. 3 is a block diagram illustrating the preferred embodiment of the automatic task file of the present invention.
FIG. 4 is a block diagram of a host computer/AT bus/disk drive system.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to an apparatus for providing registers that interface between a disk controller circuit and a host computer. In the following description, numerous specific details, such as type of registers, number of tracks, etc., are described in detail to provide a more thorough description of this invention. It will be apparent, however, to one skilled in the art, that the invention may be practiced without these specific details. In other instances, well known features have not described in detail so as not to unnecessarily obscure the present invention.
The present invention provides circuitry to improve the performances of the controller by reducing the number of functions performed by the microprocessor. This circuitry includes automatic updating of the task file registers. The task file registers collectively indicate the physical address of the sector of data being transferred, and these registers are incremented or reloaded as required as each sector of data is transferred. For example, when executing the write multiple or read multiple commands, the sector number register of the task file is automatically incremented as each sector is transferred, up to the sector number specified by the maximum sector register. After this value is reached, the sector number register rolls over to one, and the drive/head register is incremented.
FIG. 4 is a block diagram of a host computer/AT bus/disk drive system. In FIG. 4, host 120 is coupled to bus line 160 which is coupled to AT interface 130. Within AT interface block 130 is AT task file registers block 140. AT interface 130 is also coupled to disk drive microprocessor 110 through bus 160. Disk drive processor 110 is coupled to HDA 150. FIG. 4 illustrates how the host and disk drive processor communicate with each other when data sectors are transferred to or from the host to or from the disk drive. The AT task file registers 140 of AT interface 130 provide the physical address of the data sectors being transferred. As can be seen in FIG. 4, both disk drive processor 110 and host 120 access AT interface 130 through bus 160. The system of FIG. 4 is designed so that host 120 and disk drive processor 110 can only access AT interface 130 at separate times. In the present invention, AT interface 130 has been designed so that the AT task file registers in block 140 are automatically updated without any microprocessor support.
Referring to FIG. 1, a flow chart describing the update of the sector number register value as well as the relationship of the head register to the sector number register is illustrated. The update begins at start block 10. At step 12, a data sector is transferred from the disk drive to the host. At decision block 14, the argument "does sector number register value equal maximum sector register value?" is made. If the argument is true, the system proceeds to step 16.
At step 16, the sector number register value is reset at step 16. Also at step 16, the drive/head register is incremented automatically.
If the argument at decision block 14 is false, the system proceeds to step 18. At step 18, the sector number register is incremented automatically and the system proceeds to step 20, the end.
The maximum sector register of the present invention stores the largest sector ID on the track written by the microprocessor. Since the maximum sector register is the upper bound of the sector number register, if the argument at decision block 14 is false, the sector number register is incremented. When the sector number register value is equal to the maximum sector register value, this implies that the sector number register has reached the upper bound of tracks and therefore the sector number register is automatically reset to 1. At the same time the sector number register is reset, this causes a carry to be generated to increment the drive/head register as specified by operation block 16.
Referring to FIG. 2, a flow chart describing the automatic updating of the drive/head register, as well as the cylinder low and cylinder high registers is illustrated.
The operation of FIG. 2 begins at start block 21 or from the host to the disk drive. At step 22, a data sector is transferred from the disk drive to the host or from the hose to the disk drive. At this point, the system proceeds to decision block 23 and the argument "does head register value equal maximum head register value?" is made. If the argument is true, the system proceeds to step 24. At step 24, the head register is reset and the cylinder low register is incremented. The system then proceeds to decision block 26. At decision block 26, the argument "does cylinder low overflow to zero?" is made. If the argument is false, the system proceeds to step 32.
If the argument at decision block 26 is true, the cylinder high register is incremented at step 28 and the system then proceeds to end block 32.
Returning to decision block 23, if the argument at decision block 23 is false, the system proceeds to step 30 and the head register is incremented. The system then proceeds to the end block 32.
A block diagram for the automation of the task file registers of the present invention is described in FIG. 3. FIG. 3 includes a data bus, 4 8-bit digital up counters (registers/counters), 1 4-bit digital up counter (register/counter), an 8-bit data register, and a 4-bit data register. The maximum sector register is an 8-bit data register, the maximum drive-head register is a 4-bit data register, the sector counter register, sector number register, cylinder low and cylinder high registers are 8-bit digital up counters, and the drive/head register is a 4-bit digital up counter.
In FIG. 3, microprocessor address/data bus 72 provides data input to and receives data output from all of the registers including maximum sector register 40, maximum drive/head register 42, sector count register 44, sector number register 46, drive/head register 48, cylinder low register 50 and cylinder high register 52. Sector count register 44 provides output signal 45 to the microprocessor address/data bus 72. Sector number register 46 also provides an output signal 47 to microprocessor address/data bus 72. Drive/head register 48 provides output signal 49 to microprocessor address/data bus 72. Cylinder low register 50 provides output signal 51 to microprocessor address/data bus 72. Cylinder high register 52 provides output signal 53 to microprocessor address/data bus 72. Maximum sector register 40 provides output signal 41 to microprocessor address/data bus 72. Maximum drive/head register 42 provides output signal 43 to microprocessor address/data bus 72. Output signals 41, 43, 45, 47, 49, 51 and 53 are all tri-state inverted outputs of their respective registers. Bus 72 is accessible by either the microprocessor or the Host Computer.
Reset signal 70 is provided to maximum sector register 40, maximum drive/head register 42, sector count register 44, sector number register 46, drive/head register 48, cylinder low register 50 and cylinder high register 52. Sector signal 74 provides a clocking signal to sector count register 44, sector number register 46, drive/head register 48, cylinder low register 50 and cylinder high register 52. Auto task file enable signal 80 is provided to sector count register 44, sector number register 46, drive/head register 48, cylinder low register 50 and cylinder high register 52. Sector count load signal 76 is provided to sector count register 44. Drive/head load signal 78 is provided to drive/head register 48.
Cylinder low load signal 82 is provided to cylinder load register 50. Cylinder high load signal 84 is provided to cylinder high register 52. Sector number load signal 86 is provided to sector number register 46. Signals 62 and 68 are provided to maximum drive/head register 42 to enable read and write operations, respectively. Signals 64 and 66 are provided to maximum sector register 40 to enable read and write operations, respectively. Each bit from 8-bit output signal 88 from maximum sector register 40 is coupled to eight separate 2-input exclusive NOR gates which are represented in FIG. 3 by exclusive NOR gate 54. Each bit of 8-bit output signal 92 from sector number register 46 is also coupled to the eight separate 2-input exclusive NOR gates 54. The eight outputs from the eight exclusive NOR gates 54 are then provided to the eight input AND gate 56. The output signal 96 from the AND gate 56 is provided to the drive/head register 48 as a "count enable" signal.
Each bit of the 4-bit output signal 90 from maximum drive/head register 42 is provided to the four separate 2-input exclusive NOR gates which are represented in FIG. 3 by exclusive NOR gate 58. Also, each bit of the 4-bit output signal 94 from drive/head register 48 is coupled to the four 2-input exclusive NOR gates 58. The four separate outputs from exclusive NOR gates 58 are then provided to the four input AND gate 60. Output signal 98 from AND gate 60 is then provided to the cylinder low register 50 as a "count enable" signal.
When the task file is in its initial state, external circuitry (usually a microprocessor) loads the number of sectors that the drive uses into the maximum sector register 40 and the number of heads into maximum drive/head register 42. A data transfer is then initiated by the external circuitry. After each sector is transferred, external circuitry generates a pulse on the sector signal 74. The sector count register 44 is decremented by one on the falling edge of sector pulse 74. As shown in decision block 14 of FIG. 1, the value of sector number register 46 received from microprocessor address/data bus 72 is compared to the value stored in maximum sector register 40 using the eight exclusive NOR gates 54. Exclusive NOR gates 54 receive an 8-bit input from sector number register 46 as well as from maximum sector register 40. The eight exclusive NOR gates 54 represent the decision block 14 of FIG. 1. If all 8 bits of sector number register 46 are equal to the 8 bits of maximum sector register 40 (all eight exclusive NOR gate outputs are logic one), then the sector number register 46 has reached its upper bound and is loaded with one and the drive/head register 48 is incremented. This decision represents block 16 of FIG. 1 which states that the sector number is reset to one and the head register is incremented.
As shown in FIG. 3, if all eight inputs received by AND gate 56 are logic one, then output signal 96 from AND gate 56 provides a signal to drive/head register 48 for the register to be incremented. If all eight inputs to AND gate 56 are not logic one, this indicates that the sector number register has not reached its upper bound. Then the sector number register 46 is incremented, as shown in block 18 of FIG. 1, and output 96 does not enable drive/head register 48 to count. At the same time, the value stored in maximum drive/head register 42 bits 0-3 are compared to the value of the bits 0-3 of drive/head register 48. This comparison is described in the flow chart of FIG. 2 which describes the updating process for the head, cylinder low and cylinder high registers. This comparison is made by using the four exclusive NOR gates 58 in conjunction with 4-input AND gate 60. NOR gates 58 are represented by decision block 22 of FIG. 2.
If all 4-bits of drive/head register 48 are equal to the bits of maximum drive/head register 42 (all four exclusive NOR gates output a logic one), this then implies that the drive/head register value is equal to the maximum drive/head register value. Then, AND gate 60 outputs signal 98 which enables cylinder low register 50 to increment by one. Also, drive/head register 48 bits 3-0 are cleared as represented by block 24 in FIG. 2. If the last increment of the cylinder low register forces the cylinder low register 50 to overflow to zero, then cylinder low register 50 asserts output signal 100 to cylinder high register 52, enabling cylinder high register 52 to increment its value. This process follows blocks 26 and 28 of FIG. 2. This series of steps of updating the task file registers is necessary to give the correct physical address of the data sector being transferred.
The outputs of the sector count, sector number, drive/head, cylinder low and cylinder high registers, are connected to the host data bus/microprocessor data bus 72 through separate tri-state inverters. When the BUSY signal is logic zero, the host can access these registers. When the BUSY signal is logic one, the microprocessor has access to these registers.
This automatic updating of the AT task file reduces the command overhead in microprocessor bandwidth requirement in supporting the AT task file. If a single microprocessor is used in disk drives to support all the drive functions including the host interface (with task file updates), microprocessor bandwidth may not be available to maintain the task file register values. By performing this function without microprocessor support, the present invention assists in reducing the microprocessor's bandwidth usage and helps make single microprocessor disk drive systems more efficient.
Thus an automatic updating operation of an IBM AT task file is described. | The present invention is a network which automates the operation of the IBM AT task file registers used in hard disk drives and hard disk controller systems that are compatible with the IBM AT BIOS (Basic Input/Output System). The present invention provides registers that interface between the disk controller circuit and the IBM AT computer. The network utilizes four 8-bit digital upcounters, one 4-bit digital upcounter, an 8-bit data register and a 4-bit data register. These counters indicate the physical address of the sector of data being transferred and are incremented or reloaded as required as each sector of data is transferred. The present invention employs the 8-bit data register, the maximum sector register, to hold the number of sectors and the 4-bit register, the maximum head register, to hold the number of heads on the disk drive. The counters are then reloaded or incremented as required based upon the contents of the maximum head and maximum sector registers without microprocessor support as each sector is transferred. External circuitry (typically a microprocessor) is not required in any of these operations. Having an automatic update of the AT task file is desirable for it reduces the command overhead and microprocessor band width requirement in supporting the AT task file. | 6 |
BACKGROUND OF THE INVENTION
It is well known to utilize a slip mechanism for anchoring and/or supporting a downhole well tool in a well conduit such as a casing.
The slip mechanism of a downhole well tool such as a hanger or a packer bites into and locks into the casing. The set slip mechanism supports the weight of a tubing string attached to a hanger or a packer and any pressure differentials to which the packer may be subjected. Setting the well tool requires an axial load from a setting device which is translated into a radial force by means of a wedge which forces the exterior teeth of the slip into the casing interior wall. The weight of the tubing string may then be supported by the slip teeth. Since the magnitude of the radial force translated by the wedge is directly proportional to the magnitude of the axial force, an increased axial load will increase the radial holding force.
In some instances, using conventional slips the weight of the tubing string may be great enough so that the corresponding radial force will overstress the casing. This will not normally occur in a bottom hole packer installation where the packer is set in casing that is surrounded by cement. The support from the cement gives the casing greater load carrying capacity. However, in a hanger or shallow set packer installation, the casing may be unsupported and may be subjected to high tubing pressure due to weight and/or pressure loads. In order not to overstress the casing, hanging loads applied to shallow set hangers or packers must be limited.
The present invention is directed to a slip mechanism for a well tool which distributes the radial load transmitted to the casing wall more evenly and over a larger area thereby allowing longer and heavier tubing loads to be supported without overstressing the casing.
SUMMARY
The present invention is directed to a slip mechanism for anchoring a well tool having a cylindrical body from the inside of a well conduit. The mechanism includes a first cylindrical wedge member positioned on the outside of the well tool body. The wedge member includes in its outer surface a plurality of circumferentially extending grooves and said grooves include an outwardly tapered side. A second cylindrically shaped split slip member is positioned outside of the wedge member. The slip member includes a plurality of teeth, preferably formed by helical threads, in its outer surface and said slip member includes ridges on its inner surface mating with and coacting with the grooves on said wedge member. The ridges include a tapered side coacting with the tapered side of the wedge member for providing radial displacement of the slips when the wedge member and slip are moved relative to each other.
A further object of the present invention is wherein the circumferential grooves form a helical thread and said ridges form a helical mating thread.
Yet a still further object of the present invention is wherein the wedge member and the slip member include coacting mating stop shoulders for limiting the radial displacement of the slip member.
Still a further object of the present invention is wherein the slip member initially has an outer diameter matching the well conduit internal diameter before being split into a plurality of individual slips.
Other and further objects, features and advantages will be apparent from the following description of a presently preferred embodiment of the invention, given for the purpose of disclosure, and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-5 are elevational views, in quarter section, and are continuations of each other, of a well packer utilizing the slip mechanism of the present invention,
FIG. 6 is an exploded perspective, fragmentary sectional view illustrating the principle of operation of the present invention, and
FIG. 7 is a calculated graph comparing the hanging weight present invention with a conventional slip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present slip mechanism of the present invention will be described in conjunction with its use in a well packer, for purposes of illustration only, it is to be understood that the present slip mechanism can be used in other well tools for anchoring and/or supporting a well tool from the inside of a well conduit, such as for example only, a well hanger.
Referring now to the drawings, the numeral 10 generally indicates a Camco Mudline Hanger Packer utilizing the slip mechanism of the present invention. The packer 10 includes an inner body 12, and an outer body 14, which are normally held together and prevented from relative axial movement by shear pin 16 (FIG. 2). The Packer 10 includes means 18 (FIG. 1) for engagement by a suitable and conventional tool for moving the packer 10 into a well conduit such as a casing 20 (FIG. 6) and includes connecting means 22 at its lower end (FIG. 5) for supporting a tubing string.
Suitable sealing means, such as conventional resilient sealing elements 22 and 24 and 26 (FIG. 5) are positioned on the inner body 12 for expansion into and engagement with and sealing against the interior of a well conduit or casing 20. Conventional slips 27 (FIG. 4) are provided which ride upon cone member 29 for being set into an expanded position for holding the sealing elements 22, 24 and 26 in a set position.
In addition, most well packers have additional slip mechanisms similar to slips 27 and 29 for engagement with the interior of a well conduit or casing 20 for anchoring and/or supporting the well packer 10 and any well tubing connected to the connection 22. While such conventional slips and cone mechanisms are satisfactory in many installations, such conventional slip mechanisms may, if the weight of the tubing string is great enough, provide a radial force which will overstress a casing such as one that is not backed up or supported, such as by cement.
The present invention is directed to a slip mechanism generally indicated by the reference numeral 50 (FIGS. 3, 4 and 6) which includes a cylindrical wedge tool from the inside of a well conduit, such as for example only, a well hanger.
Referring now to the drawings, the numeral 10 generally indicates a Camco Mudline Hanger Packer utilizing the slip mechanism of the present invention. The packer 10 includes an inner body 12, and an outer body 14, which are normally held together and prevented from relative axial movement by shear pin 16 (FIG. 2). The packer 10 includes means 18 (FIG. 1) for engagement by a suitable and conventional tool for moving the packer 10 into a well conduit such as a casing 20 (FIG. 6) and includes connecting means 22 at its lower end (FIG. 5) for supporting a tubing string.
Suitable sealing means, such as conventional resilient sealing elements 22 and 24 and 26 (FIG. 5) are positioned on the inner body 12 for expansion into and engagement with and sealing against the interior of a well conduit or casing 20. Conventional slips 27 (FIG. 4) are provided which ride upon cone member 29 for being set into an expanded position for holding the sealing elements 22, 24 and 26 in a set position.
In addition, most well packers have additional slip mechanisms similar to slips 27 and 29 for engagement with the interior of a well conduit or casing 20 for anchoring and/or supporting the well packer 10 and any well tubing connected to the connection 22. While such conventional slips and cone mechanisms are satisfactory in many installations, such conventional slip mechanisms may, if the weight of the tubing string is great enough, provide a radial force which will overstress a casing such as one that is not backed up or supported, such as by cement.
The present invention is directed to a slip mechanism generally indicated by the reference numeral 50 (FIGS. 3, 4 and 6) which includes a cylindrical wedge translating and load between the wedge 30 and the slip 40. The pitch angle of the helix and the angle of the tapered sides 34 and 46 can be adjusted to provide a load necessary to engage the external teeth 42 into the casing without overstressing the casing. This design is adjustable for any load by changing slip length, thread angle and/or pitch.
The slip member 40 is preferably a plurality of separate slip segments 41. In addition, the slip member 40 is a cylinder in which the slip 40 is initially cut to match the inside diameter of the casing 20. Slip 40 is slotted at a plurality of slots 48 forming individual slips 41. The slots 48 are provided with a minimal gap when the slip member 40 is in the run position. This effectively maximizes the circumferential area to provide lower stress levels when the slips are actuated.
Coacting mating stop shoulders 52 and 54 are provided on the wedge member 30, and the slip member 40, respectively. Stop shoulders 52 and 54 limit the maximum amount of radial travel between the slip member 40 and the slips 41 and the wedge 30 thereby limiting the maximum amount of radial force exerted on the casing 20 in order to avoid overstressing the casing 20.
By the use of the helical grooves 32 and coacting helical ridges 44, the slip mechanism 50 distributes the radial and axial force components over the entire length of the slip 50 since the helix is evenly spaced over the required length. The bearing support area on the inside of the slip 50 is greater than a conventional wedge because of the helix. This design prevents the casing 20 from being overstressed, will support greater tubing weight, and will withstand greater packer pressure differentials. Furthermore, the manufacturing ease is greatly enhanced by producing controlled tolerances due to cutting a helix or thread at the wedge/slip interface.
Referring now to FIG. 4, the ends 33 and 43 of slips 27 and 41, respectively, are retained in position by a slip retaining housing 72. Retracting springs 74, 72, 76 yieldably urge the ships to a retracted position.
Referring to FIG. 7, calculated graphs 60 and 70 illustrate the advantage of the holding power of the present invention as compared with conventional slips such as slips 27 shown in FIG. 4. The calculations are made for a nonsupported (no concrete backup) casing showing hanging load versus the internal tubing pressure in the casing. It is to be particularly noted that applicant's helical slip may have a slip area of 359 square inches while the conventional slip area is only 94 square inches. This advantage is provided because the present slip mechanism provides bearing support over the entire length of the slip while in a conventional slip the bearing support is limited.
In operation, the packer 10 is lowered into the casing 20 by a conventional supporting tool engaging the notch 18 and/or face of the outer body 14 and engaging the threaded connection 19 on the inner body 12. When the packer 10 is lowered to the proper depth in the casing 20, the supporting and actuating tool moves the outer body 14 axially downward relative to the inner body 12 shearing the pin 16 (FIG. 2) and thereafter shearing pin 17 (FIG. 4). Upward movement of the inner body 12 sets the packing means 22, 24 and 26 (FIG. 5) moves the cone 29 behind the conventional slips 30 (FIG. 4) and sets the slips 30 against the interior of the casing 20. Further downward movement shears pin 31 of the outer body 14 moving the slip 40 relative to the wedge member 30 driving the slip 40 radially outwardly into the interior of the casing 20. The packer 10 is held in the set position with the sealing means and the slip means expanded and set by ratchets 21 engaging teeth 23 (FIG. 2) on the outer periphery of the inner body 12. The supporting and setting tool can then be removed. The packer 10 can be released by a pulling tool engaging the recess 18 pulling upon the outer body 14 shearing the release pin 25 raising the wedge member 30 relative to the slips 40.
The present invention, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned as well as others inherent therein. While a presently preferred embodiment of the invention has been given for the purpose of disclosure, numerous changes in the details of construction and arrangement of parts, will be readily apparent to those skilled in the art and which are encompassed within the spirit of the invention and the scope of the appended claims. | A slip mechanism for anchoring a well tool in a well conduit. A first cylindrical wedge member having on its outer surface a plurality of circumferentially extending grooves, preferably forming a helix in which the grooves include an outwardly tapered side. A second cylindrical shaped slip member having a plurality of slips is positioned outside of the first member and includes a plurality of teeth on its outer surface and includes ridges mating with and coacting with the grooves on the first member. The ridges include a tapered side coacting with the tapered sides of said first member for providing radial displacement of the slip when the wedge member and slip member are moved axially to each other. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. patent application Ser. No. 14/262,963 filed on Apr. 28, 2014 entitled METHOD FOR THE MANUFACTURE OF PRE-RIGOR SAUSAGE, the entire disclosure of which is hereby incorporated herein by reference in its entirety.
BACKGROUND
Field
This technology relates generally to the manufacture of pork sausage and, more particularly, to manufacture of pre-rigor sausage.
Background Art
Historically it is common to cut and remove meat from an animal carcass soon after slaughter. This system of processing is still practiced particularly where refrigeration resources are at a premium. However, even in the United States some animal carcasses are cut soon after slaughter. In countries like the United States where energy has been plentiful, refrigeration became so abundant that the meat industry adopted facilities that were extensively equipped with abundant refrigeration resources which were not necessarily economical or best for the meat product being cooled. A combination of these facilities having plentiful refrigeration and the practice of chilling, reheating, and re-chilling tons of product each day, created the need for an efficient processing systems became evident. There should be processing efficiency along with production efficiency to provide the consumer with the best quality at the lowest price. Hot processing helps to achieve this goal.
The pork sausage industry utilizes a short processing period from slaughter to the chilled or frozen package. The system makes raw seasoned sausage in less than 90 minutes after slaughter. This process not only takes advantage of economics in processing and chilling, but provides the consumer with a sanitary, longer shelf-life product. The majority of the raw pork sausage industry now uses pre-rigor pork. The raw pork sausage industry uses sows (a female swine that has farrowed one or more litters of pigs) with the proper ratio of fat to lean. This careful selection of the animal makes it possible to blend a product without a great amount of excess fat. Lean meat and fat are separated from the bone, chopped into uniform pieces, partially cooled, seasoned, ground, and stuffed into grease-proof casings in a matter of minutes. The chubs are then cooled using an ethylene glycol bath system or other cooling system. Pork sausage links can be extruded with or without casing. The links can then be refrigerated. The case hardened links are then packaged and tempered. Pork tissue (lean and fat) to be used for further manufacture is generally salted (2-4 percent) during the coarse chopping step and then placed in boxes or other containers to be frozen. The pre-salted meat is used in sausage manufacture because of its ability to yield actin and myosin for binding. Even though pre-rigor pork has been shown to have numerous advantages, the industry has been reluctant to process animal cuts directly from the slaughter floor without some cooling.
The pork industry has been reluctant to adopt hot processing for primal cuts for butcher hogs; barrow (a male pig that has been castrated) or gilt (female pig less than six months old that has never been pregnant), but have utilized hot boning for the manufacture of sausage using sows where the meat from entire animal carcass is utilized for the sausage. However, it would not be economically practical to use the same process for butcher hogs for processing sausage where the meat from the entire carcass is utilized because the primal cuts for the butcher hog carries a higher value than it would if it were ground into sausage. Although, hot processing of meat offers several economical advantages which result from reduction of weight loss during chilling (about 1.5%), reduction of drip loss during storage of vacuum-packaged cuts by 0.1-0.6%, reduction in cooler space by 50-55%, savings of refrigeration energy by 40-50%, quicker turnover of meat at plant, reducing capital cost for buildings, higher final yield of products manufactured from hot-boned meat, savings on labor by 20% and savings on transport costs.
Hot-boned meat offers numerous advantages in the production of comminuted meat products, attributed to higher muscle pH, higher protein solubility and increased emulsifying capacity. Due to higher pH and Residual ATP level, and better solubility of myofibrillar proteins, functional properties of hot-boned meat are superior to those of cold-boned meat. Hot-processing resulted in higher fat retention during cooking than does cold-processing of ground pork and the patties made from hot-boned pork had higher cooking yield and more desirable pink/red color which might be associated with its higher ultimate pH. Studies have shown that, not only hot-boned meat but also hot-boned fat could increase the final yield. Therefore, it is well understood that the superior functional properties of hot-boned meat are mostly due to its higher pH and protein solubility. However, hot-boning butchered hogs for the manufacture of sausage rather than using the older sows is not economically practical because the primal cuts of a butchered hog has a greater return in value than would be gained by grinding the primal cuts of a butchered hog into ground sausage. One objective of the present invention as disclosed and claimed herein is to capture the benefits of hot-boning at least a portion of a butchered hog and capture the greater return in value for the primal cut, while also retrieving a ground sausage product from the butchered hog without effecting the return on value for the primal cuts.
BRIEF SUMMARY
The invention is a method for economically retrieving pre-rigor pork sausage from a butcher hog; barrow (a male pig that has been castrated) or gilt (female pig less than six months old that has never been pregnant), (a pig approximately 285 lbs live weight, 6 months old and ready for market with no relevant abnormalities), which is a category of hog well known by those skilled in the art. Retrieving pre-rigor pork sausage from a butcher hog is not known currently in the industry because the perception is that it is not economically feasible as outlined in the background. Pork sausage, whether pre-rigor or not is retrieved from older sows because they are not typically used for the butchering of primal cuts because of the difference in the meat quality as compared to the younger and smaller butcher hogs. Whole hog sow meat is used for ground sausage, however, use of whole butcher hog meat is not believed to be economically feasible in the industry. The process technology as disclosed and claimed herein is a new method for economically retrieving and processing certain sections of a butcher hog for producing ground pork sausage while maintaining the value from the primal cuts. The ground pork sausage from this process has comparable texture, color, consistency, shelf life and other characteristics as compared to the pork sausage retrieved from the older sows, thereby meeting customer expectations. In the present technology as disclosed and claimed herein, the process harvests certain sections from butcher hogs at about approximately 1 hour to 1 hour and 45 minutes (the range can be larger for example in the Range of about approximately 30 minutes-120 minutes) post mortem. The process harvests certain sections of the butcher hog pre-rigor meat including the picnic, see FIG. 3 (subscapularis, supraspinatus, pectoralis profundi, infraspinatus, teres major, triceps brachii), jowl (pork fat), cheek (masseter), temple (head meat from the side of the head), head back (head meat from the back of the head), pate (head meat trimmed from between the ear cartilage) and trace lean (Leaf lard—Visceral fat deposit surrounding the kidneys and inside the loin). The cut for the picnic is on the picnic side of the arm bone/shoulder joint and the cut goes up through the first two ribs to include the; subscapularis, supraspinatus, pectoralis profundi, infraspinatus, teres major, triceps brachii. The following URL provides insight into the various specifics regarding the portions. http://porcine.unl.edu/pages/index.jsp?what=subprimal&hs=Ham&subprimalId=15
The foot is removed from the picnic/jowl and the picnic/jowl is skinned and deboned. In addition, the process could harvest certain sections of the butcher hog for pre-rigor meat that includes the whole pork shoulder; Picnic, Cushion and Boston Butt. The process is performed such that the shoulder is separated from the side by a straight cut that is approximately perpendicular to the length of the side. The shoulder/picnic cut shall be made posterior to the elbow, but not more than 1.0 inch from the tip of the elbow. The foot is removed and the pork shoulder is skinned and deboned. The following URL provides further insight on the specifics of the muscle complex. http://porcine.unl.edu/porcine2005/pages/index.jsp?what=subprimal&hs=Ham&subprimalId=15
Due to the possible limited real time flow of head meat raw material, it could be collected, chopped, salted and chilled the day before it is used in the ground sausage blend/formula. The picnic/jowl meat can be hot boned where the temperature of the meat is at 97° to 105° Fahrenheit (however the temperature of the meat can be within approximately the Range of 80°-110° F.). During the hot bone process, the temple meat can be removed from the head and collected for hot chopping at a temperature at about 87° to 90° Fahrenheit (however the temperature of the meat can be within approximately the Range of 80°-110° F.). The head back meat can be removed from the head and collected for hot chopping at a temperature at about 90° to 93° Fahrenheit (however the temperature of the meat can be within approximately the Range of 80°-110° F.). The cheek meat can be removed from the head and collected for hot chopping at a temperature at about 94° to 95° Fahrenheit (however the temperature of the meat be within approximately the Range of about 80°-110° F.). The hot meat can be passed on to a bowl chopper or similar device for processing the pre-rigor meat.
The temperature of the picnic jowl at chopper can be about 94-95° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the temple at the chopper can be about 83-86° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the Head Back at the chopper can be about 86-88° F.(however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the Cheek Meat at the chopper can be about 88-89° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). After chopping the hot meat can then be salted and chilled in the chopper to less than about approximately 45°. The chilled, chopped, and salted pre-rigor meat is conveyed to the blender and further chilled to 27° F. (however the temperature of the meat can be within approximately the Range of about 20°-35° F.).
The technology for the process disclosed and claimed herein
These and other advantageous features of the present invention will be in part apparent and in part pointed out herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
FIG. 1 is flow diagram for processing pre-rigor pork sausage;
FIG. 2 is an illustration for the head portions; and
FIG. 3 is an illustration of the picnic-shoulder.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
According to the embodiment(s) of the present invention, various views are illustrated in FIG. 1-3 and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the invention for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the invention should correspond to the Fig. number in which the item or part is first identified.
One embodiment of the present technology comprising method for manufacturing pork sausage teaches a novel method for manufacturing pork sausage from a butcher hog using certain portions of the butcher hog as part of a hot bone pre-rigor process.
The details of the invention and various embodiments can be better understood by referring to the figures of the drawing. Referring to FIG. 1 , FIG. 2 and FIG. 3 the picnic/jowl meat can be hot boned 102 where the temperature of the meat is at 97° to 105° Fahrenheit (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). During the hot bone process, the temple meat 206 can be removed from the head and collected for hot chopping at a temperature at about 87° to 90° Fahrenheit (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The head back meat 204 and pate meat 202 can be removed from the head and collected for hot chopping at a temperature at about 90° to 93° Fahrenheit (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The cheek meat 208 can be removed from the head and collected for hot chopping at a temperature at about 94° to 95° Fahrenheit (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The hot meat can be passed on to a bowl chopper or similar device for processing 104 the pre-rigor meat.
The temperature of the picnic jowl at chopper can be about 94-95° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the temple at the chopper can be about 83-86° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the Head Back at the chopper can be about 86-88° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). The temperature of the Cheek Meat at the chopper can be about 88-89° F. (however the temperature of the meat can be within approximately the Range of about 80°-110° F.). After chopping the hot meat can then be salted and chilled 106 in the chopper to less than 45°. The chilled, chopped, and salted pre-rigor blend is conveyed to the blender and further chilled 108 to about approximately 27° F. (however the temperature of the meat can be within approximately the Range of about 20°-35° F.).
The method for pre-rigor collection and bowl chop can generally include a lean chopper collection step and a fat chopper collection step. The output collected from these steps can be blended 108 in the desired proportions. In the Lean Chopper Collection step, lean is separated and collected from specific portions, including the Hot de-bone picnic; and the Hot de-bone cheek meat. The lean can be collected from these portions for about approximately 60-90 minutes post mortem (However, the Range can be about approximately 30-120 minutes post-mortem). The Lean Meat Block Formulation can include about approximately 50% (however the Range can be about approximately 30-70%) Picnic and 50% (however the Range can be about approximately 30-70%) Cheek lean meat. The lean can be scaled by proportion and added to the bowl chopper and the chopping process can begin. Salt can be added to the lean during this process of chopping at about approximately 1.5% (however the Range can be about approximately 0-2%) of total batch weight. The chopping process can continue until piece size of the lean is at about approximately ½″. The chopped lean can be chilled with CO 2 to about approximately 30-35° F. The chilled lean can be discharged into a combo and held for up to 72 hours prior to inputting into the final blend. The target can be in the range of about approximately 10-14% blend fat.
In the Fat Chopper Collection step, fatty portions can be collected from specific portions including the Hot de-bone pate, including trimming ear cartilage and glands, the Hot de-bone head back, the Hot de-bone temple, the Hot de-bone trace lean. The fatty portions can be separated and similarly collected for about approximately 60-90 minutes post mortem (However the Range can be about approximately 30-120 minutes post-mortem). The Fat Meat Block Formulation can include about approximately 21.2% (However can be in the Range of about 15-25%) Head Back, 24.8% (However can be in the Range of about 15-25%) Temple, 35.4% (However can be in the Range of about 25-40%) Trace Lean (which targets the natural fall). The fatty portions are scaled and added to the bowl chopper. The chopping begins and salt at 1.5% (However can be in the Range of about Range 0-2%) of total batch weight can be added during the chopping process. Chopping can continue until the piece size of the fatty portions are at about approximately ½″. The chopped fatty portions can be chilled with CO2 to 30-35° F. The chopped and chilled fatty portions can be discharged into a combo and held for up to 72 hours. The target range can be at about approximately 24-28% Ready To Use (RTU) fat. RTU denoting already chopped and salted.
Alternate method identified due to improved operational efficiency. The method for pre-rigor collection and bowl chop can generally include a natural fall chopper collection step. The output collected from this step can be blended in the desired proportions. In the natural fall Chopper Collection step, pre-rigor meat is separated and collected from specific portions, including the Hot de-bone picnic, Hot de-bone jowl, Hot de-bone cheek meat, Hot de-bone pate, Hot de-bone head back and the Hot de-bone temple. The meat can be collected from these portions for about approximately 60-90 minutes post mortem (Range 30-120 minutes post-mortem). The Meat Block Formulation can include about approximately 72.3% Picnic, 17.71% Jowl, 5.16% Cheek meat, 1.39% Pate, 1.59% Head Back and 1.85% Temple. The components can be scaled by proportion and added to the bowl chopper and the chopping process can begin. Salt can be added to the meat during this process of chopping at about approximately 1.5% (Range 0-2% salt) of total batch weight. The chopping process can continue until piece size of the lean is at about approximately ½″. The chopped pre-rigor meat can be chilled with CO 2 to about approximately 30-35° F. The chilled lean can be discharged into a combo and held for up to 72 hours prior inputting into the final blend. The target can be in the range of about approximately 21.7-25.7% RTU fat.
Various blends and percentages of the outputs from the Lean Chopper Collection and the Fat Chopper Collection or natural fall collection steps can be utilized and will vary primarily based on the type of product being produced, including producing a sausage patty product, a sausage link product, a sausage chub, a sausage grind and a dinner brat sausage link product.
For the sausage patty process, the procedure can include dumping the pre-rigor lean meat into the holding hopper, and dumping the pre-rigor fat meat into the holding hopper and measuring the fat % of the components. Pre-rigor lean and pre-rigor fat can be added to the final blender targeting about approximately 22% (or in the Range of about 5-26%) Meat Block fat. At this time various seasoning, salt and water can be added. The inputs can be blended for about approximately 1 to 5 minutes and then chilled to about approximately 27° F. (or in the Range of about 20°-35° F.). The blended and chilled product can be discharged into a stuffer having an In-line grind to about approximately 2 to 4 mm. The product can be stuffed into slicing slicks having a target of about approximately 1.5″ to 4″ diameter. The slicks can be chilled to about approximately 19-26° F. The casing can be removed and the slicks can be placed into a slicer. The product can be sliced to about approximately 1.0 oz to 4.0 oz. The slice patties can be placed on a tray and overwrapped with a label and place in the master case.
For the Breakfast Sausage Link process, the pre-rigor lean meat can be dumped into the holding hopper and the pre-rigor fat meat can be dumped into the holding hopper. The fat % of the components can be measured. Pre-rigor can be added to the blender and the blend can have a 22% (or in the Range about 18-50%) target Meat Block fat. Seasoning, salt and water can be added and the product can be blended for about approximately 1 to 5 minutes. The blended product can be chilled to about approximately 27° F. (Range 20-35). The blended and chilled product can be discharged into the stuffer having an In-line grind to 2.0 to 4.0 mm. The product can be stuffed into a 18 to 25 mm collagen casing and having a target length of about approximately 3.0″ to 4.0″ and a target weight of about approximately 0.8 oz to 2.0 oz. The links can be place on a tray and overwrap, labeled and place in the master case.
For the Sausage Chub process the pre-rigor lean meat can be dumped into the holding hopper. Frozen trace lean can be course ground at about approximately ½″, and fresh lean trim can be course ground at about approximately ½″. Pre-rigor meat, frozen fat and fresh lean can be added to the blender with a target at about approximately 34% (in the range of about approximately 20-50%) Meat Block fat and at a target of about approximately 82% (or in the Range of about approximately 60-100%) pre-rigor meat. Seasoning, salt and water can be added when blending and can blend for about approximately 1 to 5 minutes. The product can be discharged into the stuffer having an In-line grind to 2 to 4 mm and stuffed having a length at about approximately 5″ to 12″, and a diameter at about approximately 2.50-2.60″, and a weight at about approximately 16 to 32 oz. The chubs can be placed in the master case.
For the sausage grind process, the procedure can include dumping the pre-rigor lean meat into the holding hopper, and dumping the pre-rigor fat meat into the holding hopper and measuring the fat % of the components. Pre-rigor lean and pre-rigor fat can be added to the final blender targeting about approximately 22% (or in the Range of about 18-26%) Meat Block fat (Maximum blend fat of 50%). At this time various seasoning, salt and water can be added. The inputs can be blended for about approximately 3 minutes (or in the Range of about 1-5 minutes) and then chilled to about approximately 27° F. (or in the Range of about 20°-35° F.). The blended and chilled product can be discharged into a stuffer having an In-line grind to about approximately 3.5 mm (or in the Range of about 2.0-4.0 mm). The product can be extruded onto a tray, overwrapped, labeled, frozen and placed in the master case.
For the Dinner Brat process, the procedure can include dumping the pre-rigor lean meat into the holding hopper, and dumping the pre-rigor fat meat into the holding hopper and measuring the fat % of the components. Pre-rigor lean and pre-rigor fat can be added to the final blender targeting about approximately 22% (or in the Range of about approximately 18-50%) Meat Block fat. At this time various seasoning, salt and water can be added. The inputs can be blended for about approximately 1 to 5 minutes and then chilled to about approximately 27° F. (or in the Range about approximately 20°-35° F.). The blended and chilled product can be discharged into a stuffer having an In-line grind to about approximately 2.0 to 4.0 mm. The natural hog casing can be pre-soaked in water overnight. The casings can be placed into warm water prior to stuffing. The product can be stuffed into a 28-37 mm hog casing having a target length of about approximately 5.0″ to 7.0″ and having a target weight of about approximately 3 oz to 5 oz. The brats can be placed on a tray and overwrapped, labelled and placed in the master case.
Various tests were perform using the disclosed and claimed technology and various observations were noted regarding the test product including total color change over a selected period of time (Delta E), generally calculated as ΔE=[(ΔL*)2+(Δa*)2+(Δb*)2] ½, and color saturation—Chroma C. The following observations were made.
1. Initial steady pH decline beginning 0.75 hours post-mortem. Picnic was higher in pH than Cheek meat. At time 2 hours, a more rapid pH decline begins.
a. Picnic had a steady pH decline up to 1.5 hours to pH 6.51. Had a few outstanding data points before stabilizing at pH range of 6.56-6.62
b. Cheek meat had a steady pH decline up to 1 hour to pH 6.39. Rapid decline began at 2 hours from 6.42-6.19 at 4 hours post-mortem.
2. Initial rise in meat temperature at 1 hour, then steady decline until temperature equilibrium is reached.
a. Picnic temperature equilibrium at 1.5 hours and 87-93° F.
b. Cheek meat temperature equilibrium at 1.5 hours and 83-86° F.
c. Temple temperature equilibrium at 1.5 hours and 81-85° F.
d. Head Back temperature equilibrium at 1.5 hours and 81-86° F.
e. Pate temperature equilibrium at 2.5 hours and 79-80° F.
f. Trace Lean temperature equilibrium at 2.5 hours and 82-83° F.
3. Initial increase in L* values then a slow decline of values exhibited up to 4 hours post-mortem.
a. Picnic had an increase in L* value at 1 hour to 53.77 then steady decline to 46.84 at 4 hours post-mortem.
b. Cheek meat had an increase in L* value at 1.5 hours to 51.86 then a steady decline to 47.56 at 4 hours post-mortem.
4. Initial decline in a* values then a slow increase of values exhibited up to 3.5 hours post-mortem.
a. Picnic had a decrease in a* value at 1.5 hour to 16.55 then steady incline to 19.29 at 3.5 hours post-mortem.
b. Cheek meat had an increase then decrease in a* value at 1.5 hours to 15.69 then a steady incline to 19.39 at 3.5 hours post-mortem.
5. Initial increase in b* values then a rapid decline to 1.5 hours and stabilization to 4 hours post-mortem.
a. Picnic had an increase in b* value at 1 hour to 14.73 then declined to 12.37 at 4 hours post-mortem.
b. Cheek meat had an increase in b* value at 1 hour to 14.83 then declined to 13.47 at 4 hours post-mortem.
6. Initial decrease in ΔE values to 1 hour and stabilization to 4 hours post-mortem. a. Picnic had a decrease in ΔE value at 1 hour to 11.92 indicating at 1 hour post-mortem the color of picnics is closest to the target.
Following the suggested +2.3 for just noticeable difference in ΔE by the human eye, Picnic can be collected for up to 3 hours post-mortem and be within this range.
b. Cheek meat had a decrease in ΔE value at 1 hour to 13.33 indicating at 1 hour post-mortem the color of cheeks is closest to the target.
Following the suggested +2.3 for just noticeable difference in ΔE by the human eye, Cheek can be collected for up to 1.5 hours post-mortem and be within this range.
7. Chroma values indicate the intensity of the principle hue in the product. A higher number indicates more intensity.
a. Picnic had an increase in Chroma value at 1.5 hours and began a slow decline in value to 3.5 hours post mortem. Optimal hue intensity occurs at 1.5 and 4 hours.
b. Cheek meat had a decrease in Chroma value at 1 hour and began a rapid incline to a maximum value at 1.5 hours. Optimal hue intensity occurs at 1.5 hours.
8. ΔL* values are an indication of how far the sample deviates from the target color when reviewing white/black.
a. At 1.5 hours, the Picnic sample had a ΔL* score of −4.19 indicating this is the optimal time for L* value of picnics to be the closest to target.
b. At 1.5 hours, the cheek meat sample had a ΔL* score of −6.59 indicating this is the optimal time for L* value of picnics to be the closest to target.
9. Δa* values are an indication of how far the sample deviates from the target color when reviewing green/red.
a. At 3.5 hours, the Picnic sample had a Δa* score of −6.38 indicating this is the optimal time for a* value of picnics to be the closest to target. This may indicate oxygenation of the muscle.
b. At 3.5 hours, the cheek meat sample had a Δa* score of −6.28 indicating this is the optimal time for a* value of picnics to be the closest to target. This may indicate oxygenation of the muscle.
10. Δb* values are an indication of how far the sample deviates from the target color when reviewing blue/yellow.
a. At 1 hour, the Picnic sample had a Δb* score of −7.45 indicating this is the optimal time for b* value of picnics to be the closest to target.
b. At 1 hour, the cheek meat sample had a Δb* score of −8.15 indicating this is the optimal time for b* value of picnics to be the closest to target.
The various implementations of the method shown above illustrate a method for processing pork sausage from a butcher hog; barrow (a male pig that has been castrated) or gilt (female pig less than six months old that has never been pregnant), (a pig approximately 285 lbs live weight, 6 months old and ready for market with no abnormalities). A user of the present technology may choose any of the above implementation, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject process for the manufacture of pre-rigor sausage could be utilized without departing from the spirit and scope of the present invention.
As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the sprit and scope of the present invention.
Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims. | A method for economically retrieving pre-rigor lean and fat for pork sausage from a butcher hog; barrow (a male pig that has been castrated) or gilt (female pig less than six months old that has never been pregnant), (a pig approximately 285 lbs live weight, 6 months old and ready for market with no abnormalities). Retrieving pre-rigor pork sausage from a butcher hog is not known currently in the industry because the perception is that it is not economically feasible. The process technology as disclosed and claimed herein is a new method for economically retrieving and processing certain sections of a butcher hog for producing ground pork sausage while maintaining the value from the primal cuts. The ground pork sausage from this process has comparable texture, color, consistency and other characteristics as compared to the pork sausage retrieved from the older sows, which are typically utilized in industry. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 11/973,889 filed Oct. 9, 2007 and entitled “Video Coding on Parallel Processing Systems,” which claims priority from U.S. Provisional Application No. 60/849,857, filed Oct. 6, 2006 and entitled “Methods for Video Coding on Parallel Processing Systems,” both of which are herein incorporated by reference in their entireties.
TECHNICAL FIELD
[0002] This application relates generally to the field of software engineering and video coding. Specifically, it relates to software implementations of video coding on digital computer systems that operate multiple processing units in parallel, and, more specifically, to video coding for video processing, video compression, and video decompression.
BACKGROUND
[0003] A video typically comprises a number of still images (“frames”) presented in sequence, one after another. In digital videos, each frame may be digitally encoded as a series of bits (or bytes), however resource limitations (e.g. storage space and/or network bandwidth) often place a cap on the total number of bits that can be used to represent each frame, which can effectively limit the overall quality of the video. Thus, one of the main goals of video encoding has been to encode the video in a way which meets a target bitrate while maximizing video quality.
[0004] One way of accomplishing this is to encode only the “differences” between each of the frames. For example, “motion” is often isolated to certain regions of a frame at any given time. In other words, not every pixel of a given frame will be changed in the next frame. Thus, rather than re-encoding every pixel of every frame, which would require a very high bitrate, only the pixel differences between consecutive frames are encoded.
[0005] FIG. 1 illustrates a method of motion estimation. The method of FIG. 1 comprises frames 110 and 120 , a frame element 122 , and a macroblock 123 . Frame 120 corresponds to the frame currently being encoded, while frame 110 corresponds to the frame that was just previously encoded. The macroblock 123 comprises a plurality of adjacent pixels within frame 120 , on which motion estimation is currently being performed. Motion estimation is the process of finding the “best match” from frame 110 for the macroblock 123 in the frame 120 . The frame 110 is searched at several search points within a search region 111 , and the pixels at each search point are compared with the pixels in the macroblock 123 . Search points are represented with motion vectors, and a best motion vector 115 indicates the relative pixel displacement in the horizontal and vertical directions between the location of the best match block 113 in frame 110 and the relative location of the current macroblock 123 . Once the best match 113 is found, block based video compression algorithms will encode the pixel differences between the current macroblock 123 and the best match block 113 , rather than encoding the actual pixels themselves. Since a relatively good match can often be found in natural video scenes, this technique drastically reduces the amount of data that needs to be encoded into the bitstream, even after accounting for the extra bits used to encode the motion vectors themselves. The decoder then adds these differences to the best match 113 , which is extracted using the encoded motion vector. This process is known as “motion compensation”.
[0006] FIG. 2 illustrates a method of encoding a macroblock using motion estimation. Referring back the example of FIG. 1 , the macroblock 223 corresponds to the macroblock 123 of frame 120 , and the macroblock 213 corresponds to the best match block 113 of frame 110 . Block 130 represents the difference between the macroblocks 223 and 123 which, in this case, is a block of zeroes. Thus, the encoder will only need to encode this block of zeroes, and will store it into the bitstream along with a corresponding motion vector. These will then be used by the decoder to reconstruct a macroblock that corresponds to macroblock 223 . Many video compression algorithms provide very efficient ways of encoding zeroes (i.e. fewer bits are required), thus better matches produced by the motion estimation process will result in fewer number of bits encoded into the bitstream.
[0007] When looking for the best motion vector, the metric that is being minimized when finding the best match is the total number of bits produced when encoding the entire video sequence. However, the motion estimation algorithm used in encoding the current macroblock can affect the number of bits used by future macroblocks in unforeseen ways. Thus, it is extremely difficult to calculate the impact that choosing a particular motion vector for a single macroblock has on the size of the entire video sequence. One possible approach is to minimize the number of bits required to encode just the current macroblock. However, this can also be too computationally expensive, so a reasonable approximation is to use a simple distortion metric, such as the sum of absolute differences (SAD), between the pixels in the two blocks.
[0008] Further complicating the motion estimation problem is the sheer number of operations required to do an exhaustive search for the best block match, even if an approximation metric such as SAD is used. In addition, a large amount of data memory must be frequently accessed during such a search, thus a straightforward algorithm (i.e. one that searches for the best match by comparing every possible macroblock location in the previous frame to the macroblock being encoded in the current frame; also known as a “brute-force” full search) would perform poorly on an embedded processor that might not have a cache large enough to hold all of the pixels from the previous frame. Thus, there remains a need to search for a best match both efficiently and accurately. The increasing popularity and performance of parallel processors further necessitates a means for video coding which takes full advantage of such parallel processing capabilities.
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] FIG. 1 illustrates a method of motion estimation;
[0011] FIG. 2 illustrates a method of encoding a macroblock;
[0012] FIG. 3 illustrates a refinement search according to an embodiment of the invention;
[0013] FIG. 4 illustrates a determination of candidate search regions according to an embodiment of the invention;
[0014] FIG. 5 illustrates a trimming of the candidate pool according to an embodiment of the invention;
[0015] FIG. 6 illustrates a loading of candidate search regions according to an embodiment of the invention;
[0016] FIG. 7 illustrates a distortion measurement according to an embodiment of the invention;
[0017] FIG. 8 illustrates a motion vector map according to an embodiment of the invention;
[0018] FIG. 9 illustrates a distortion measurement according to another embodiment of the invention;
[0019] FIG. 10 illustrates a motion vector map according to another embodiment of the invention;
[0020] FIG. 11 illustrates a voting scheme according to an embodiment of the invention;
[0021] FIG. 12 illustrates a calculation of a predicted motion vector according to an embodiment of the invention;
[0022] FIG. 13 illustrates a total worth calculation for a macroblock according to an embodiment of the invention;
[0023] FIG. 14 is a block diagram that depicts a computer system 400 upon which an embodiment of the invention may be implemented.
DETAILED DESCRIPTION
[0024] In embodiments of the present invention, several areas of interest (“candidates”) are identified in a reference frame, and refinement searches are then performed within small windows around each candidate (“candidate search regions”). Each successive refinement search processes a finer resolution. Within a refinement stage, each macroblock is compared to the reference frame on one or more candidate search regions. For example, a candidate search region may include a motion vector. In yet other embodiments of the invention, methods are disclosed for fast and efficient video coding on parallel processing environments.
[0025] FIG. 3 illustrates a refinement stage according to an embodiment of the invention. At 310 , one or more motion vectors are identified as candidate search regions. Candidate search regions may be determined from a number of different sources. For example, candidate search regions may include: the best motion vectors from a previous frame; the best motion vectors from a previous refinement stage; the best motion vectors for previous macroblocks in the same refinement stage; and/or the current estimate of the predicted motion vector. Furthermore, candidate search regions may include any other motion estimation steps that might precede the refinement stage. For example, a brute force full search may be executed before the refinement stage to provide coverage over a large enough area, thus ensuring that the candidates comprise one or more initial motion vectors that roughly match the motion in the video sequence. In an embodiment, this search may be performed at a low resolution in order to save computation resources. Alternatively, the search may be implemented as a separate pipeline in order to ensure as large of a search range as possible.
[0026] FIG. 4 illustrates a determination of candidate search regions according to an embodiment of the invention. The embodiment of FIG. 4 comprises a reference frame 410 and candidate motion vectors 401 - 406 . In this example, candidate 401 is the best candidate resulting from a low resolution full search of the current macroblock, candidates 402 - 405 are the best candidates from a previous refinement stage for the same macroblock, and candidate 406 is the current estimate of the predicted best motion vector.
[0027] Referring back to FIG. 3 , at 320 , the total size of the candidate pool is trimmed down to isolate the search to only the “best” candidates, thus limiting the computation resources used by each macroblock. In an embodiment, redundant candidates are always trimmed (“merged”). In other embodiments, candidates that are close in proximity are also merged. For example, two candidates may be considered close in proximity if one is within the search range of the other. When merging two or more candidates, the candidate that is kept is typically the one closest to the current estimation of the predicted motion vector. Thus allows more diversity in the resulting candidates, and reduces the overall amount of computation by eliminating overlapping candidate regions. This may help achieve real-time performance constraints while allowing different macroblocks to search different numbers of candidates. If, after merging candidates, the number of remaining candidates is still more than the load-balancing constraint, then the best candidates are chosen based on their proximities to the predicted motion vector. For example, a candidate that is closer to the predicted motion vector may be preferable to one farther away. In alternative embodiments, all the candidates of a particular macroblock may be eliminated, which is known as an “early exit”. For example, this may be useful if it is known that many macroblocks will find a near perfect match with respect to a particular motion vector (i.e. any further improvements would not be significant enough to warrant the amount of computation required to do so). In an embodiment, a load-balancing algorithm is used to control the maximum number of the best candidates. The load-balancing mechanism sets a constraint on how many candidates are searched for each individual macroblock, while ensuring that the total amount of required computation does not exceed the available resources. Thus, macroblocks that are more complex can be allowed to search more candidates, while simpler macroblocks can be constrained to search fewer candidates. In an embodiment, the load-balancing mechanism tracks a running weighted average of the number of candidate vectors searched per macroblock.
[0028] FIG. 5 illustrates a trimming of the candidate pool according to an embodiment of the invention. The embodiment of FIG. 5 comprises a reference frame 510 and candidate motion vectors 501 - 506 . For the purposes of discussion, it is assumed that the reference frame 510 corresponds to the reference frame 410 , of FIG. 4 , and the candidates 501 - 506 correspond to candidates 401 - 406 , of FIG. 4 , respectively. Continuing off the example of FIG. 4 , it is assumed that there is a load-balancing constraint of three candidates. In other words, at most three of the candidate motion vectors 501 - 506 may be kept, and thus three of them must be trimmed. It should first be noted that candidate 505 is very close in proximity to candidate 504 , thus both candidates 505 and 504 may be merged into one candidate. In this case candidate 504 is kept since it is closest in proximity to the predicted best motion vector 506 . Of the remaining candidates 501 - 503 and 506 , candidates 502 and 503 are the farthest in proximity from the predicted best motion vector 506 . Thus, candidates 502 and 503 are trimmed, leaving candidates 501 , 504 , and 506 as the three remaining best candidates at the end of this step.
[0029] Referring back to FIG. 3 , at step 330 , the best candidate search regions are loaded (extracted) from the reference frame. In an embodiment, each candidate is individually loaded to an off-chip dynamic access memory (“DRAM”). However, overlapping data for various candidates of the same macroblock, and between candidates of different macroblocks, may be subsequently loaded in this manner as well. In another embodiment, a hardware cache may be used to mitigate the wasting of DRAM bandwidth on overlapping candidate loads. In an alternative embodiment, only the relevant portion of the reference frame may be kept in on-chip memory, thus reducing the required memory bandwidth. For example, this may be implemented as a software form of caching. In an embodiment, the search area is in the shape of a square or rectangle. In alternative embodiments, the search area may take any form. For example, the search area may be in the shape of a diamond. In yet another embodiment, a directional search may be performed on only one side of the candidate motion vector. In this case, the gradient of the search space is determined, based on the best vector(s) from the previous refinement stages, and computation may be saved by guiding the search in a particular direction.
[0030] FIG. 6 illustrates a loading of candidate search regions according to an embodiment of the invention. The embodiment of FIG. 6 comprises: a reference frame 620 ; candidate motion vectors 601 , 604 , and 606 ; candidate search regions 621 , 624 , and 626 ; and a storage element 630 . The search regions 621 , 624 , and 626 are rectangular in shape and centered about the candidate motion vectors 601 , 604 , and 606 , respectively. For example, if the motion vector 601 is defined by (x 1 , y 1 ), then the search region 621 may be defined as the region from (x 1 −1, y 1 −1) to (x 1 +1, y 1 +1). Along the same lines, if the motion vector 604 is defined by (x 4 , y 4 ), then the search region 624 may be defined as the region from (x 4 −1, y 4 −1) to (x 4 +1, y 4 +1). And if the motion vector 606 is defined by (x 6 , y 6 ), then the search region 626 may be defined as the region from (x 6 −1, y 6 −1) to (x 6 +1, y 6 +1). The candidate search regions 621 , 624 , and 626 are then extracted and loaded into the storage element 630 . In an embodiment, the storage element 630 is an on-chip memory. In alternative embodiments, the candidate search regions 621 , 624 , and 626 may loaded directly from an off-chip DRAM.
[0031] Referring back to FIG. 3 , at step 340 , distortions are measured at several search points around each candidate motion vector. For example, the distortion measurement may comprise: a sum of absolute differences (SAD); a sum of squared errors (SSE); or a Hadamard transform. In an embodiment, the total number of operations may be reduced by using only a subset of the pixels in the block. In another embodiment, the total number of operations may be reduced through an initial “sub-sampling” of the pixels. In alternative embodiments, the distortion measurement may include a count value which indicates the cost of encoding the motion vector for each block. For example, the count value may increase as the estimated header information required to be encoded for each block increases. In an embodiment, a shape selection algorithm is used to measure the distortion for all “block shape instances”. For example, a block shape instance may be a specific location out of all possible locations for a particular shape (grouping) of blocks. In an alternative embodiment, the shape selection algorithm may be used to measure only a subset of the block shape instances. Thus, certain block shapes may be excluded from measurement depending on their size and/or frequency. For example, the shape selection algorithm may choose to ignore all block shape instances having the smallest size, and select only the larger block shape instances on which to perform distortion measurements. Alternatively, the shape selection algorithm may choose to perform the distortion measurement on only the smallest block shapes, and then generate distortion measurements for the larger block shape instances as a sum of the distortion measurements from the smaller block shape measurements. The algorithm may then determine the number of motion vectors to store for each block shape instance. In an embodiment, the algorithm selects only the single best motion vector to be stored, in order to minimize computation and resource use. In alternative embodiments, the algorithm may store multiple “best” motion vectors, thus achieving better encoding quality. The combined list of best motion vectors for all block shape instance is known as the “motion vector map,” and may be continuously updated throughout the distortion measurement step. In an embodiment, each motion vector map is stored between refinement stages. For example, it is possible that in a subsequent refinement stage, no motion vectors in among the chosen candidates has a lower distortion measurement than the that of the best motion vector from a previous refinement stage, from a candidate in a completely different portion of the frame. Thus, storing the motion vector map intermittently guarantees that the absolute best results are always saved. In an alternative embodiment, steps 310 - 330 of a refinement stage may be skipped in order to save DRAM bandwidth. This may be done under assumption that a previous refinement stage has already loaded a sufficient amount of data around each candidate search region.
[0032] FIG. 7 illustrates a distortion measurement according to an embodiment of the invention. The embodiment of FIG. 7 comprises block shape instances 710 - 740 used for searching nine different search points (−1, −1) to (1, 1) around a first candidate (0, 0). Thus, the search points comprise a 3×3 area around the first candidate. For the purposes of discussion, it is assumed that the block shape instances are all relative to a 16×16 macroblock, and any block shape instances smaller than 8×8 are ignored. Thus, block shape 710 is 16×16 in size, block shape 720 is 16×8 in size, block shape 730 is 8×16 in size, and block shape 730 is 8×8 in size. The shaded regions of FIG. 7 correspond to the best (e.g. lowest) distortion measurements for each block shape instance. In this example, search point (0, 0) yields the best distortion measurements for every one of the block shape instances. Specifically, with regard to search point (0, 0): block shape 710 yields a distortion measurement of 80; the upper instance of block shape 720 yields a distortion measurement of 60, while the lower instance yields a distortion measurement of 20; block shape 730 yields two distortion measurements of 40; and the two upper instances of block shape 740 yield distortion measurements 30 , while the two lower instances yield distortion measurements of 10. The resulting motion vector map is illustrated in FIG. 8 ; wherein block shape instances 810 , 820 , 830 , and 840 , correspond to the block shape instances 710 , 720 , 730 , and 740 , respectively, of FIG. 7 . It is important to note here that distortion measurements for smaller block shape instances may be summed together to form distortion measurements for larger block shape instances.
[0033] FIG. 9 illustrates a distortion measurement according to another embodiment of the invention. Continuing off the example of FIG. 7 , the embodiment of FIG. 9 comprises block shape instances 910 - 940 used for subsequently searching nine different search points (X−1, Y−1) to (X+1, Y+1) around a second candidate (X, Y). The shaded regions of FIG. 9 correspond to the best (e.g. lowest) distortion measurements for each block shape instance, but only if they are better than the previous distortion measurements, for the respective block shape instance, around the first candidate. In this example, search point (X+1, Y−1) yields a better distortion measurement for block shape 920 (i.e. the size 16×8 block shape instance), as well as block shape 940 (i.e. the size 8×8 block shape instance). Furthermore, it can be seen that search points (X, Y), (X, Y+1), and (X+1, Y+1) each yield better distortion measurements for block shape 920 than was previously found with respect to the first candidate. Specifically, with regard to block shape instance 920 , the upper instance at search point (X+1, Y−1) yields a distortion measurement of 50 (<10 compared to the first candidate). With respect to block shape instance 940 , the upper-left instance at search point (X+1, Y−1) yields a distortion measurement of 25 (<5); the lower-left instance at search point (X, Y) yields a distortion measurement of 9 (<1); the lower-right instance at search point (X, Y+1) yields a distortion measurement of 8 (<2); and the upper-right instance at search point (X+1, Y+1) yields a distortion measurement of 20 (<10). The resulting motion vector map is illustrated in FIG. 10 ; wherein block shape instances 1010 , 1020 , 1030 , and 1040 , correspond to the block shape instances 910 , 920 , 930 , and 940 , respectively, of FIG. 9 . It is important to note that the motion vector map of FIG. 10 now contains motion vectors (MV), as well as distortion measurements, from different candidates.
[0034] Referring back to FIG. 3 , at step 350 , a determination is made as to whether or not the current refinement stage is the final refinement stage. For example, after the distortions are measured at step 340 , there may still be more candidates than desirable, given the hardware resource limitations. Alternatively, there may be more candidates than required for relatively high quality video encoding. Thus, further refinement may be necessary. In an embodiment, the shape selection algorithm may make this final determination. For example, a large sum of absolute differences (SAD) may be measured with respect to the particular motion vector, and the measurement may then be used as a threshold for determining whether there is sufficient activity in the macroblock to perform further motion search and refinement.
[0035] Assuming it is determined, at step 350 , that the last refinement stage had not yet been reached, candidates must now be selected for the next refinement stage, based on the measured distortions, at step 360 . In an embodiment, a voting scheme is used to select the best candidates for further refinement. According to the voting scheme, the number of times a particular motion vector appears in the motion vector map is first counted. This count value corresponds to the number of “votes” that the particular motion vector receives. Next, the best motion vectors are selected, based on their number of votes. In an embodiment, the total number of best motion vectors selected may be constant for each macroblock. In alternative embodiments, the number of best motion vectors may vary for each macroblock, depending on the load-balancing constraints. The size of the block shape instance from which a vote was received may be useful in settling a tie. For example, the motion vector with a larger block shape instance voting for it may be selected in case of a tie. In alternative embodiments, motion vector selection may be performed at random in case of ties. In an embodiment, weights may be assigned to the votes. Weight assignment may be done in a number of different ways. For example, a vote for a motion vector that had the smallest distortion measurement for a block shape instance may be assigned a greater weight than a vote for any other motion vector of the same block shape instance. Alternatively, larger block shape instances may cast more votes for their best motion vectors compared to smaller block shape instances.
[0036] FIG. 11 illustrates a voting scheme according to an embodiment of the invention. The voting scheme of FIG. 11 comprises voting grids 1110 and 1120 . Continuing off the example of FIGS. 7 , 8 , 9 and 10 , each square of a voting grid represents one of the nine different search regions around the given candidate (wherein the candidate corresponds to the square in the center). For example, the center square of grid 1110 corresponds to the candidate (0, 0) and the center square of grid 1120 corresponds to the candidate (X, Y). In reference to the motion vector map of FIG. 8 , the motion vector (0, 0) appears with each of the block shapes 810 - 840 , and it is also the only motion vector on the motion vector map. Thus, as shown on voting grid 1110 , the motion vector (0, 0) receives a total of four votes. Referring now to the motion vector map of FIG. 10 , it can be seen that the motion vector (X+1, Y−1) appears with block shapes 1020 and 1040 ; and motion vectors (X, Y), (X, Y+1), and (X+1, Y+1) each appear once with block shape 1040 . None of the remaining search regions around the candidate (X, Y) ever appear on the motion vector map. This translates to two votes for motion vector (X+1, Y−1), and one vote for each of the motion vectors (X, Y), (X, Y+1), and (X+1, Y+1), as shown on voting grid 1120 . Now assume that only four candidates are selected for further refining. The combination of voting grids 1110 and 1120 show that there are two candidates with more than one vote and a total of three candidates receiving exactly one vote. Thus, there is a three-way tie from which two candidates must be selected. Using any one of the tie-breakers discussed above (which includes simply selecting at random), it may be determined that the four best candidates are those corresponding to the shaded squares. In this case, motion vectors (0, 0), (X+1, Y−1), (X, Y), and (X, Y+1) are chosen for further refinement in the next refinement stage.
[0037] Referring back to FIG. 3 , if it is determined at step 350 that the current refinement stage is the last, the results from all the previous refinement stages will then be processed, using motion compensation, at step 370 . In an embodiment, the predicted motion vector blocks chosen by the shape selection algorithm are first extracted. For example, the motion compensation may reset the motion vector map before the distortion measurements are collected in the last refinement stage. This forces the shape selection algorithm to choose only the candidates that have already been loaded from DRAM into the on-chip memory, thus allowing for motion compensation to take place without loading any new data from DRAM. At this point there is no need to pick new candidates, and instead the shape selection algorithm picks a best final partitioning for a macroblock. In particular, it is necessary to know the predicted motion vector, since the bitstream encodes the difference between the actual motion vector and the predicted motion vector. In an embodiment, the predicted motion vector is calculated as a median of three neighboring sub blocks (e.g. block shapes). In other words, the actual motion vectors used for a median calculation depend on the block shape instances chosen by causal neighboring blocks (e.g. to the left and/or top). Thus, there is a serial dependency for an exact calculation of the predicted motion vector, since the cost of a motion vector depends on the motion vectors chosen by its neighbors. In an embodiment, an approximation is used to allow consecutive sub blocks (which would otherwise have a serial dependency) to be processed in parallel.
[0038] FIG. 12 illustrates a calculation of a predicted motion vector according to an embodiment of the invention. The embodiment comprises macroblocks 1210 , 1220 , 1230 , 1240 , 1250 , and 1260 . For purposes of discussion, it is assumed that each macroblock is 16×16 in size, and comprises multiple sub blocks (i.e. block shapes) of varying sizes (e.g. 4×8, 8×4, 8×8). The sub blocks to the bottom left and top right of each 16×16 macroblock correspond to sub blocks from neighboring macroblocks, and are therefore illustrated with a dotted outline. In this example, macroblock to the left corresponds to a respective macroblock to the right. That is to say, macroblocks 1210 and 1220 correspond to the same macroblock; macroblocks 1230 and 1240 correspond to the same macroblock; and macroblocks 1250 and 1260 correspond to the same macroblock. Referring now to macroblock 1210 , sub blocks 1212 - 124 (the lighter shaded regions) correspond to the three sub blocks from which the median 1211 (the darker shaded region) is calculated. Thus, in reference to macroblock 1220 , in order to calculate the predicted motion vector 1225 exactly, the sub block 1221 must be processed first. In other words, the predicted motion vector 1211 , of macroblock 1210 , must first be calculated. This serial dependency is further compounded if the neighboring sub blocks are smaller than 8×8 in size, as the shape of the sub blocks affects the median calculation. In an embodiment, sub blocks smaller than 8×8 are given the same predicted motion vectors as the 8×8 blocks they are part of. This approximation is further illustrated with respect to macroblocks 1230 - 1260 . For example, an 8×8 partitioning is used for the block 1231 of macroblock 1230 , thus an 8×8 partitioning is also used for the block 1245 of macroblock 1240 . Similarly, since a 4×8 partitioning is used for the (8×8) block 1251 of macroblock 1250 , a 4×8 partitioning is therefore also used for the (8×8) block 1265 of macroblock 1260 . Using this technique, the predicted motion vectors of macroblocks 1210 , 1230 , and 1250 , and the predicted motion vectors of macroblocks 1220 , 1240 , and 1260 , may be calculated in parallel, respectively.
[0039] The ability to process macroblocks in parallel is especially useful when applied to the technique of strip-mining. Within a processor, an entire strip of data is processed each time a kernel is invoked. A strip comprises a series of consecutive macroblocks, all on the same row, and the length of the strip is typically smaller than (or equal to) the number of macroblocks in a row of the frame. A pipeline comprises a series of kernels, and within each kernel there is a main loop which generally processes one macroblock per loop iteration. In this manner, each strip is processed in order, until the whole frame has been processed; and the next pipeline will then process the entire frame in the same manner. Thus, all the relevant data for the whole frame is cycled from the off-chip memory through the on-chip memory and back out to off-chip memory at least once for each pipeline. However, applying this technique to a parallel processor is more difficult, due to the serial dependency that is typically associated with adjacent macroblocks on the strip (as discussed above). The ability to process macroblocks in parallel, using the approximation described above in reference to FIG. 12 , thus allows a parallel processor to take full advantage of the strip-mining technique.
[0040] When processing a macroblock, special attention needs to be paid to transform coefficients. For example, when using a 4×4 transform on a 16×16 macroblock, there is a reasonably high chance that only a single coefficient in any 8×8 or 16×16 block will be nonzero. Such isolated coefficients can be very expensive to encode, yet may have very little impact on the quality of the final image that is reconstructed by the decoder. In an embodiment, a expensive-coefficient-detection algorithm is used to calculate the worth of each transform block. Thus, when using a 4×4 transform, the expensive-coefficient-detection algorithm calculates the worth of each 4×4 block within the macroblock. It is assumed that the first few coefficients of a block, in “zig-zag” order, represent the low frequency spectrum of the original signal. These low-frequency coefficients may have a greater impact on rate distortion than other coefficients within the block, and thus require more accurate evaluation.
[0041] In an embodiment, an expensive-coefficient-detection algorithm is used to calculate “run-levels” (i.e. the length of a run of zeroes) for only the low-frequency coefficients, and a simple sum may be used for the remainder of the coefficients, in order to detect whether a block is too costly for distortion gain. The algorithm then assigns a “worth” to each run-level, indicating how important the coefficient is to the visual integrity of the block prediction as well as how cheap the coefficient is to encode into the bitstream. Thus, the more important the coefficient is to the visual integrity the more it is worth, and conversely, the more bits that are required to encode the coefficient, the less it is worth. For example, if there is a run of zeros followed by a 1 or a −1, then the coefficient is assigned a worth based on the length of the run. For runs of zero to five the run-level may be worth 3, 2, 2, 1, 1, and 1, respectively, and the worth of any runs greater than five may be 0. The total worth of the low-frequency coefficients are then summed together. The absolute values of the remaining coefficients are then summed together and scaled by a scaling factor. This scaled sum is then added to the total worth of the low-frequency coefficients in order to obtain the total worth of the entire block. The total worth of each of the transform blocks are then combined (i.e. summed) to obtain the total worth of each larger block. During such an expansion process, certain blocks may be “zeroed” (e.g. the total worth of the block is reduced to 0) if the total worth of that block does not meet a threshold value. This process may then be expanded until the total worth of the entire macroblock is determined.
[0042] FIG. 13 illustrates a total worth calculation for a macroblock according to an embodiment of the invention. It is assumed that the thresholds for 8×8 blocks and 16×16 blocks are 5 and 6, respectively (e.g. T 8×8 =5 and T 16×16 =6). At step 1310 , the total worth of each 4×4 block within the macroblock is calculated, and the total worth of the four blocks in each corner of the macroblock are summed together and presented as the total worth for respective 8×8 blocks at step 1320 . At this point, the total worth of the bottom-right block of 1320 is less than the threshold value for 8×8 blocks (T 8×8 >3), thus the total worth of this block is subsequently zeroed, as shown at step 1330 . At step 1330 , the total worth of all four 8×8 blocks is summed up once again to obtain the total worth for the entire 16×16 macroblock, as shown at step 1340 . Now since the total worth of the 16×16 macroblock is less than the threshold value for 16×16 blocks (T 16×16 >5), the entire 16×16 macroblock is zeroed at this point as shown in step 1350 . Thus, after expansion and worth adjustment, the macroblock in this example yields a final total worth of zero.
[0043] Run-level calculation is very computationally expensive. However, this process is greatly streamlined by limiting the number of coefficients on which to perform this computation. On the other hand, the simple sum of the remaining coefficients is less accurate, but much faster. In this manner, the expensive-coefficient-detection algorithm balances performance with quality by using the more accurate but expensive processing for the important coefficients only, and the less accurate but faster processing for the less important coefficients.
[0044] Entropy coding is a technique used to minimize the number of bits required to encode a series of syntax elements (e.g. macroblocks, transform coefficients, and/or motion vectors), by using fewer bits to encode commonly occurring values of each syntax element, and more bits to encode rarely occurring values of syntax elements. For example, each syntax element is mapped to a “codeword” and each codeword has a length, in number of bits, and a value. To generate the final output bitstream, the values of all the codewords are concatenated in sequence. In order to take full advantage of a system's parallel processing capabilities it is desirable to devise a way to assemble a bitstream in parallel, which can then be decoded serially (assuming most video decoders are serial). However, the problem of parallelization is compounded, because each codeword may be a different number of bits, and the number of bits for each codeword is determined dynamically.
[0045] In an embodiment, a packing algorithm outputs (“packs”) consecutive codewords, within a group, on separate parallel processing elements (lanes). Each group produces a portion of the final bitstream, referred to herein as a “sub-stream”. For purposes of discussion, it is assumed that the bitstream comprises 32-bit data words, and the local register file (LRF) and the DRAM can only be accessed in multiples of 32 bits (note this technique may be expanded to other architectures requiring fewer or more than 32 bits). Thus, a complication arises when codewords from two different lanes need to be backed into the same 32-bit data word in the bitstream. In order to streamline the bitstream assembly process, each sub-stream is made to be an exact multiple of 32-bits. When the combined length of all the codewords in a lane is not a multiple of 32, some bits from that lane must be combined with bits from the next lane before being output. In an embodiment, each lane sums up the total number of bits among all of the codewords in its array for a given macroblock, and then counts the number of bits in the preceding lanes (the first lane counts the number of bits on the last lane, from a previous macroblock, that did not form an entire 32-bit data word), to identify if certain bits from codewords of different lanes need to be combined. The following is a pseudocode which may be used to limit the impact of the serial dependency of the packing algorithm:
[0000] #define NUM_CODES_PER_LANE_PER_MB 8 // The value 8 is just an example #define MAX_PACKED_WORDS_PER_LANE_PER_MB 8 // The value 8 is just an example for (m = 0; m < strip_size; m++) { for (n = 0, sum = 0; n < NUM_CODES_PER_LANE_PER_MB; n++) substream_length += code_array[n].length; // Sum up substream_length in all lanes with lane_id( ) less than mine my_start = get_num_bits_in_previous_lanes(substream_length) % 32; output_loc = 0; window.length = my_start; window.value = 0; for (n = 0; n < NUM_CODES_PER_LANE_PER_MB; n++) { // Add next codeword to current 32-bit window. // If the 32-bit window fills up, output the first 32 bits in out_val // and set do_output to true. pack_next_codeword(code_array[n], &window, &do_output, &out_val); if (do_output) output_array[output_loc++] = out_val; } n = 1; my_start_save = my_start; leftover = window; window.length = 0; window.value = 0; while on each lane (my_start > 0) { code = get_leftover_bits(leftover, lane_id( ) − n); if (my_start > 0) pack_next_codeword(code, &window, &dummy, &dummy); my_start −= code.length; n++; } if (my_start_save > 0) output_array[0] |= window.value; code_array += NUM_CODES_PER_LANE_PER_MB; output_array += MAX_PACKED_WORDS_PER_LANE_PER_MB; }
The operation of this kernel is further exemplified in reference to Tables 1 and 2. For purposes of discussion, it is assumed that the machine used in this example has only four parallel lanes. The input (Table 1) comprises at most eight codewords per lane and each code may be up to 32 bits in length. The codewords are ordered within each lane (and between lanes) from Lane 0 to Lane 3. The output array (Table 2) assumes that the substream produced by each lane has a maximum length of eight 32-bit data words.
[0000]
TABLE 1
Input code arrays for this macroblock in LRF
Only code lengths are shown, code values
are ignored for illustrative purposes.
Input Field
Lane 0
Lane 1
Lane 2
Lane 3
in[0]
12
—
—
18
in[1]
—
24
—
—
in[2]
13
—
5
—
in[3]
—
5
2
—
in[4]
—
—
—
14
in[5]
7
31
1
22
in[6]
—
3
—
—
in[7]
18
—
2
15
“—” indicates a NULL code (i.e., it doesn't contribute to final bitstream)
[0000] TABLE 2 Packed arrays for this macroblock Output Field Lane 0 Lane 1 Lane 2 Lane 3 out[0] Packed0 Packed1 — Packed3 out[1] — Packed2 — Packed4 out[2] — — — Packed5 out[3] — — — — out[4] — — — — out[5] — — — — out[6] — — — — out[7] — — — — “PackedX” indicates a used 32-bit value, and “—” indicates an empty value.
Assuming the lanes operate in a single instruction multiple data (SIMD) fashion, each lane must process the same number of codewords. In an embodiment, it is assumed that all codewords in the array in each lane are valid. This assumption allows for the performances for very high bitrates and very low bitrates to be the same, which may be advantageous when handling varying bitrate requirements.
[0046] In an alternative embodiment, a preprocessing kernel may be executed, for lowering performance requirements at lower bitrates. The preprocessing kernel counts the number of valid codewords and compresses them to the beginning of the codeword array in each line. The kernel then outputs the maximum number of valid codewords across the lanes (as indicated by the “used” output field), for each macroblock. The packing algorithm would then only execute this reduced number of iterations for each macroblock. The operation of the preprocessing kernel is further exemplified in reference to Tables 3 and 4.
[0000]
TABLE 3
Input code arrays for this macroblock in LRF
Only code lengths are shown, code values
are ignored for illustrative purposes.
Input Field
Lane 0
Lane 1
Lane 2
Lane 3
in[0]
12
—
—
18
in[1]
—
24
—
—
in[2]
13
—
5
—
in[3]
—
5
2
—
in[4]
—
—
—
14
in[5]
7
31
1
22
in[6]
—
3
—
—
in[7]
18
—
2
15
“—” indicates a NULL code (i.e., it doesn't contribute to final bitstream)
[0000]
TABLE 4
Output code arrays for this macroblock in LRF
Output Field
Lane 0
Lane 1
Lane 2
Lane 3
used
4
4
4
4
out[0]
12
24
5
18
out[1]
13
5
2
14
out[2]
7
31
1
22
out[3]
18
3
2
15
out[4]
—
—
—
—
out[5]
—
—
—
—
out[6]
—
—
—
—
out[7]
—
—
—
—
“—” indicates an empty value
[0047] If all of the sub-streams were the same length, assembling them into a single bitstream would be a trivial matter. However, because sub-streams vary in length, each lane will have a different number of elements to store to memory.
[0048] In an embodiment, a memory system is built for storing variable record lengths. For example, the first field of each record may contain the length of that particular record. Thus, address generators may increment the address by the particular record length specified, rather than by the stride between records on consecutive lanes. An example is herein discussed in reference to Tables 5 and 6.
[0000]
TABLE 5
Input code arrays for this macroblock in LRF
Only code lengths are shown, code values
are ignored for illustrative purposes.
Input Field
Lane 0
Lane 1
Lane 2
Lane 3
in[0]
12
24
5
18
in[1]
13
5
2
14
in[2]
7
31
1
22
in[3]
18
3
2
15
[0000] TABLE 6 Output arrays for this macroblock in LRF Output Field Lane 0 Lane 1 Lane 2 Lane 3 used 1 2 0 3 out[0] Packed0 Packed1 — Packed3 out[1] — Packed2 — Packed4 out[2] — — — Packed5 out[3] — — — — “PackedX” indicates a used 32-bit value, and “—” indicates an empty value.
For purposes of discussion, in reference to Table 5, it is assumed that the input only comprises at most four codewords per lane (as opposed to eight in the previous examples). Referring now to Table 6, each output record requires an extra “used” field in each lane to specify the number of 32-bit values in the array in the particular lane. Still referring to Table 6, the variable length memory system reads all five of the words in each lane, but writes only the values indicated in each lane as “PackedX”, where X is an integer value. The first word in each lane (the used output field) specifies, to the address generators in the memory system, which values are valid and by how much to increment the address pointer by when storing data words in each lane. For example, the two data words in Lane 1 are stored in the array in the DRAM immediately behind the word in Lane 0, and so on. The next output in the strip begins in the LRF after the fifth word in word in each lane (i.e. not necessarily directly after the last valid element in each lane).
[0049] In another embodiment, a transpose is performed, such that each consecutive 32-bit data word of the sub-stream is in a different lane. A conditional output stream may then be used to output the sub-streams, such that only the lanes with valid words output data. After all the sub-streams are output in order, a single assembled bitstream is left residing in the LRF which may then be easily written to the DRAM. Continuing off the example discussed above in reference to Tables 5 and 6, a utilization of the transpose and conditional output stream (rather than using a memory system which supports variable record lengths) is exemplified with respect to Tables 7, 8, 9, and 10. It should be noted this results in a packed array of 32-bit data words that are in order, and striped across the lanes. In an alternative embodiment, a simple sequential memory store may used to efficiently store the striped array to the bitstream buffer in memory.
[0000]
TABLE 7
Input code arrays for this macroblock in LRF
Only code lengths are shown, code values
are ignored for illustrative purposes.
Input Field
Lane 0
Lane 1
Lane 2
Lane 3
in[0]
12
24
5
18
in[1]
13
5
2
14
in[2]
7
31
1
22
in[3]
18
3
2
15
[0000]
TABLE 8
Packed arrays for this macroblock
Variable
Lane 0
Lane 1
Lane 2
Lane 3
packed[0]
Packed0
Packed1
—
Packed3
packed[1]
—
Packed2
—
Packed4
packed[2]
—
—
—
Packed5
packed[3]
—
—
—
—
“PackedX” indicates a used 32-bit value, and “—” indicates an empty value.
[0000]
TABLE 9
Transposed arrays for this macroblock
Variable
Lane 0
Lane 1
Lane 2
Lane 3
trans[0]
Packed0
—
—
—
trans[1]
Packed1
Packed2
—
—
trans[2]
—
—
—
—
trans[3]
Packed3
Packed4
Packed5
—
“PackedX” indicates a used 32-bit value, and “—” indicates an empty value.
[0000]
TABLE 10
Output for this macroblock in the LRF
LRF Index
Lane 0
Lane 1
Lane 2
Lane 3
0
Packed0
Packed1
Packed2
Packed3
1
Packed4
Packed5
—
—
2
—
—
—
—
3
—
—
—
—
“PackedX” indicates a used 32-bit value, and “—” indicates an empty value.
[0050] In yet another embodiment, conditional output streams are used to directly output the 32-bit data words in each sub-stream. However, the resulting 32-bit data words in the LRF are in no particular order. Thus, in an embodiment, an index may be written out along with each 32-bit word. Then, an indirect memory operation is performed in order to write the 32-bit data words to the DRAM. According to this embodiment, no additional hardware is necessary, and no extra cycles are spent on a inter-lane transposes. An example is herein discussed in reference to Tables 11, 12, 13, and 14.
[0000]
TABLE 11
Input code arrays for this macroblock in LRF
Only code lengths are shown, code values
are ignored for illustrative purposes.
Input Field
Lane 0
Lane 1
Lane 2
Lane 3
in[0]
12
24
5
18
in[1]
13
5
2
14
in[2]
7
31
1
22
in[3]
18
3
2
15
An underlined value will trigger a conditional output write in that lane.
[0000]
TABLE 12
Starting index in each lane
Lane 0
Lane 1
Lane 2
Lane 3
0
1
3
3
[0000]
TABLE 13
Memory index written for each conditional output
Loop Iteration
Lane 0
Lane 1
Lane 2
Lane 3
0
—
1
—
3
1
—
—
—
—
2
0
2
—
4
3
—
—
—
5
“—” indicates that no value was written to the conditional output streams
[0000] TABLE 14 Output index array in the LRF (corresponding value array not shown) LRF Index Lane 0 Lane 1 Lane 2 Lane 3 0 1 3 0 2 1 4 5 — — 2 — — — — 3 — — — — “—” indicates an empty value
For the purposes of discussion, it is assumed that there are a total of four loop iterations to process the four input codes. If a lane crosses a 32-bit boundary during any iteration, it outputs the completed (and packed) 32-bit value to a conditional stream, and then writes an index to a different conditional output stream. In an embodiment, the index is incremented locally in each lane after each conditional output write. The initial value in each lane for each macroblock may be determined easily from calculations which are already performed by the kernel. Note that the outputs to the conditional streams are not in any particular order in the LRF. Although the outputs happen to be ordered within the lane, this may not always be the case. Also note that the outputs are not necessarily in order, striped across the lanes. However, this may be remedied when the store to memory applies the indices to the values being stored.
[0051] It should be noted that although the embodiments disclosed here in are described in terms of their applicability to parallel processors, they are not so limited. A person of ordinary skill in the art may be able to apply the disclosed methods and techniques, advantageously, to a serial processor, or other form of data processing device. Furthermore, it should be noted that although the embodiments disclosed herein are described in terms of their applicability to improving video compression, they are not so limited. For example, such video coding methods may also be used to improve de-interlacing and temporal filtering quality. Moreover, they may be applicable wherever an estimation of the motion of each block in an image is required in a video sequence.
Operational Context
[0052] The embodiments described above may be implemented in a programmed general-purpose or special-purpose computer system or in a network of computer systems. Alternatively, the embodiments may be implemented in a device that includes hardwired logic for carrying out the above-described operations, or any combination of programmed processors and hardwired logic.
[0053] FIG. 14 is a block diagram that depicts a computer system 1400 upon which an embodiment of the invention may be implemented. Computer system 1400 includes a bus 1402 or other communication mechanism for communicating information, and a processing entity 1404 coupled with bus 1402 for processing information. The processing entity 1404 may include any number of general purpose and/or special purposes processors co-located within a single computing system or distributed over a network of computing systems. Computer system 1400 also includes a main memory 1406 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 1402 for storing information and instructions to be executed by processing entity 1404 , including the above described data structures (e.g., tables, variables, etc.) and instructions to be executed by processing entity 1404 to carry out the above-described operations. Main memory 1406 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processing entity 1404 . Computer system 1400 further includes a read only memory (ROM) 1408 or other static storage device coupled to bus 1402 for storing static information and instructions for processing entity 1404 . A storage device 1410 , such as a magnetic disk or optical disk, is provided and coupled to bus 1402 for storing information and instructions, such as the interval total tables described above.
[0054] Computer system 1400 may be coupled via bus 1402 to a display 1412 , such as a cathode ray tube (CRT), for displaying information to a computer user. An input device 1414 , including alphanumeric and other keys, is coupled to bus 1402 for communicating information and command selections to processing entity 1404 . Another type of user input device is cursor control 1416 , such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processing entity 1404 and for controlling cursor movement on display 1412 . This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.
[0055] The invention is related to the use of computer system 1400 for implementing the techniques described herein. According to one embodiment of the invention, those techniques are performed by computer system 1400 in response to processing entity 1404 executing one or more sequences of one or more instructions contained in main memory 1406 . Such instructions may be read into main memory 1406 from another computer-readable medium, such as storage device 1410 . Execution of the sequences of instructions contained in main memory 1406 causes processing entity 1404 to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.
[0056] The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processing entity 1404 for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device 1410 . Volatile media includes dynamic memory, such as main memory 1406 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise bus 1402 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
[0057] Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, punchcards, papertape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
[0058] Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to processing entity 1404 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer system 1400 can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on bus 1402 . Bus 402 carries the data to main memory 1406 , from which processing entity 1404 retrieves and executes the instructions. The instructions received by main memory 1406 may optionally be stored on storage device 410 either before or after execution by processing entity 1404 .
[0059] Computer system 1400 also includes a communication interface 1418 coupled to bus 1402 . Communication interface 1418 provides a two-way data communication coupling to a network link 1420 that is connected to a local network 1422 . For example, communication interface 1418 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 1418 may be a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links may also be implemented. In any such implementation, communication interface 1418 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
[0060] Network link 1420 typically provides data communication through one or more networks to other data devices. For example, network link 1420 may provide a connection through local network 1422 to a host computer 1424 or to data equipment operated by an Internet Service Provider (ISP) 1426 . ISP 1426 in turn provides data communication services through the world wide packet data communication network now commonly referred to as the “Internet” 1428 . Local network 1422 and Internet 1428 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 1420 and through communication interface 1418 , which carry the digital data to and from computer system 1400 , are exemplary forms of carrier waves transporting the information.
[0061] Computer system 1400 can send messages and receive data, including program code, through the network(s), network link 1420 and communication interface 1418 . In the Internet example, a server 1430 might transmit a requested code for an application program through Internet 1428 , ISP 1426 , local network 1422 and communication interface 1418 .
[0062] The received code may be executed by processing entity 1404 as it is received, and/or stored in storage device 1410 , or other non-volatile storage for later execution. In this manner, computer system 1400 may obtain application code in the form of a carrier wave.
[0063] The section headings in the preceding detailed description are provided for convenience of reference only, and in no way define, limit, construe or describe the scope or extent of such sections. Also, while the invention has been described with reference to specific exemplary embodiments thereof, it will be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense. | A method operates within an integrated circuit device having a plurality of processing lanes. The method determines a first number of packs among one or more first packs associated with a first processing lane of the plurality of processing lanes, associates the first number of packs with a first used field of the first processing lane, determines a second number of packs among one or more second packs associated with a second processing lane of the plurality of processing lanes, and associates the second number of packs with a second used field of the second processing lane. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to an oven for treating web stock, especially cloth stock in a tentor frame, and more particularly to such having special gaseous recycling.
In the typical treatment of textile fabric during manufacture thereof, a generally continuous web of fabric is ultimately passed through a tentor frame for stretching and drying of the textile held by tentor hooks or the equivalent along the edges of the web. Heated gases are forced over and through the stretched fabric in substantial volumes for drying. During this process, the temperature of the gases must be limited to a predetermined maximum to avoid damage to the fabric due to overheating during drying or during the post-drying heat treatment. Consequently, it is typically necessary to have several tentor frame dryer sections in series to achieve effective drying and post-drying heat treatment. Such equipment requires substantial capital outlay, space, and heat input. A great share of this generated heat is exhausted to the atmosphere and lost in the volumes of gases discharged. These gases are laden with varying amounts of liquids removed from the fabric during drying. When processing double knit fabrics, such liquids typically include oily compounds deposited on the fabric during the previous knitting operation, solvents, and carriers for the dyes. These are carried by the drying gases, in minute form and often partially combusted, into the atmosphere as smoke and fine mist. This of course is not ecologically desirable. Furthermore, some of the oily substance has a tendency to condense and coat the equipment interior and cause potential problems and fabric damage.
In sum, it is recognized in the trade that present tentor dryer equipment, though effective, is expensive and space consuming to the fabric mills. Not only the fabric mills, but also the public in general is encumbered with higher fuel costs and fabric costs due to the tremendous quantities of fuel necessary for the tentor dryers. And the public also has the ecological disadvantage of undesirable stack discharges. Though such discharges are questionable as to meeting governmental guidelines, the mills have not heretofore had available to them tentor dryers that are effective in this regard.
SUMMARY OF THE INVENTION
The present invention effectuates more efficient and rapid drying and heat treatment of web stock, particularly textile fabric, in a tentor, using less fuel and less equipment, and resulting in ecologically improved, controlled stack discharge. Using the invention, moisture and oil compounds are removed from textile fabric such as knitted polyester materials in a fashion significantly reducing fuel consumption and curbing pollution-causing stack discharge. With the special flow circuit and apparatus of the invention, the combustible volatile oil, solvent, and carrier type materials removed from the textile material during evaporation of the moisture are combusted in a special chamber, at a relatively higher temperature, the resulting gases being subsequently cooled with supplemental fresh air, with part of the gaseous stream then being returned to the oven for evaporation of moisture and oil products from additional web stock, and for preheating and/or post heating of the stock.
An advantageous feature of the invention is its adaptability to existing equipment, particularly tentor frames presently used for drying and heat treating of cloth. The invention renders available to textile mills the capacity to control stack discharge for curbing air pollution of combustible materials to meet pollution control standards. Yet, the amount of actual equipment is considerably lessened over that previously required, rather than increased as might be expected. And, furthermore, fuel requirements are markedly lowered from previous requirements. Experimental operation on a trial basis under actual textile mill conditions shows that the invention enables substantial fuel conservation, increased production rates and/or less equipment for present production rates, and curbed stack output for pollution control.
Conversion of even existing tentor apparatus is accomplished without great difficulty and with immediate benefits.
Because the invention was conceived and developed for drying and heat treating of textile stock, and is particularly useful for such, it will be described herein chiefly in this context. However, it is believed that the concept in its broader aspects could be adapted to heat treatment of other web stock also where combustible pollutants are driven off the stock, e.g. paper, wood, polymer stock and the like.
These and several other advantages, features and objects of the invention will be apparent upon reviewing the following detailed disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a five zone tentor apparatus employing the invention;
FIG. 2 is an end elevational view of the input end into zone 1 of the apparatus in FIG. 1;
FIG. 3 is a sectional, end, partially schematic view of one of the zones in FIG. 1;
FIG. 4 is a fragmentary, side elevational view of the zone in FIG. 3;
FIG. 5 is an elevational view of a conventional eight zone tentor which was replaced by the apparatus in FIG. 1; and
FIG. 6 is a schematic diagram of a second embodiment of the concept.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The manufacture of cloth fabric at textile mills typically involves use of a tentor or tentor frame by which the fabric is stretched and heated to dry the fabric, and usually to heat treat the fabric. Treatment of double knit polyester fabric, for example, typically involves removal of moisture quantities of 15 to 40% by weight and heat treating the fabric, both while the fabric is in a stretched condition. In this type of operation, temperatures of 350° to 375° F. should not be exceeded, to avoid damage to the fabric by fusion or the like.
It is significant that, during the formation of the fabric as by knitting, oils and solvents such as needle oil, sludge solvents, metallic cleaners and other organic compounds, are typically employed. As the polyester knit cloth is dried in the conventional tentor, smoke is emitted as a result of the oils and solvents present in the cloth and volatilized therefrom by the heated drying gases. Some of this oily material recondenses inside the tentor housing, some of it recondenses on the roof areas of the building at the stacks, and some is ejected into the atmosphere as smoke to the disadvantage of personnel, plants, and structures in the area.
The degree of effectiveness of conventional tentors in drying and heat treating cloth is dependent upon flow of vast quantities of hot gases. The gases are heated to approximately 350° to 375° F., passed over the stock, and exhausted at temperatures of approximately 250° F. These tentor units are typically formed of ten foot length sections, each several feet wide. The fabric is stretched, for example, from a width of about 48 inches to about 63 inches or so, during which and subsequent to which several pounds of water per minute are evaporated for lowering the moisture content from about 15 to 40% by weight to a few percent. This also results in evaporation of substantial quantities of knitting oil (light machine oil), solvents, dye carriers and other chemicals from the fabric. The discharge from these tentor units results in tremendous heat loss up the stack. Increased fuel costs in recent years has rendered these heat losses very serious. Further, meeting recent pollution control standards has been all but impossible with equipment heretofore available to the textile mills.
Experimentation employing the present inventive concept was conducted in an actual operating textile mill. One experiment involved conversion of two specific zones of a conventional seven zone tentor. The converted system was operated for several months to determine and solve problem areas, and to reduce the invention to practice. The results were exciting and encouraging, both to the inventor hereof and the managing personnel of the mill.
Referring now specifically to the drawings, the prior art apparatus depicted in FIG. 5 constitutes a typical eight zone tentor through which the cloth stock in web form would flow for removal of moisture from the cloth as the cloth is held stretched on a tentor frame. Hot gases are normally used for drying and also to heat treat the fabric. The temperature of the inflowing gases is usually between about 350° and 375° F.
Typically, each zone of a conventional tentor of the type employed, such as an "Artos" brand unit, will exhaust from about 6,000 to about 8,500 cubic feet per minute of hot gases at a temperature of about 300° F. to 360° F. If the flow rates are allowed to drop to less than about 4,000 cubic feet per minute, the oil evaporated from the cloth will tend to recondense in the equipment, to cause problems within the equipment and on the fabric itself. To attempt to incinerate the vaporized products in this volume of air would require more heat input than for the drying process itself. This necessity for such tremendous amounts of air limits the production from the apparatus and causes substantial heat losses. The hot exhaust gases are vented from multiple zones of the conventional tentor 100 through a series of exhaust stacks 102, each typically including an exhaust fan 104 and motor 106 therefor.
Experimentation with this multiple zone tentor showed that by conversion of two of the zones in the central portion of a conventional seven zone tentor in accordance with the present invention, only five zones total were needed in the tentor 10 (FIG. 1) to obtain equal or superior production output to a conventional eight zone tentor (as in FIG. 5), at greatly reduced heat consumption, as well as simultaneously achieving pollution control. Since the first and last zones were not employed, FIG. 1 is shown with the remaining five zones only, numbered consecutively as 1-5. Zones 2 and zone 3 of the apparatus (as depicted in FIG. 1) employ the novel concept, zone 3 being shown in FIG. 3 in cross section for illustration purposes, with zone 2 being basically identical therewith.
Each of the five zones, e.g. zone 3 shown at 10' in FIG. 3, includes a housing 12 of generally rectangular cross section, lined with insulation 14 and defining an internal chamber 16 having an opening on both the inlet and outlet ends comparable to the inlet opening 18 for zone 1 shown in the end view of FIG. 2. The web stock that passes through these chambers successively, (indicated by phantom line W in FIG. 3), is straddled above and below by a series of hot gas manifolds or pipes 20 and 22 respectively which project laterally, i.e., transversely of the stock direction of travel. From orifices in these manifolds, hot gases are ejected downwardly and upwardly respectively, onto and through the fabric stock as the advancing stock is held in a stretched condition in conventional fashion by typical tentor hooks or the equivalent. The tentor hooks are on supports 24 at the opposite edges of the web stock. Manifolds 20 and 22 are mounted to and in flow communication with conduits 30 and 32 respectively, both connected to and receiving hot gases from a common supply conduit 34. These components 20, 22, 30, 32 and 34 are conventional, as are the tentor hooks and supports 24. However, instead of the hot gases being vented directly to the atmosphere through exhaust stacks as is conventionally done, such gases, containing substantial quantities of evaporated water and vaporized oil and related solvent products, are specially processed, resulting in significant advantages.
Specifically, the hot gases emitted from manifold pipes 20 and 22 engage and pass through and over the moving stretched fabric, and then, laden with vaporized material, flow out return duct 40 and preferably through a filter 42 across which an indicating manometer 44 may be mounted to measure the pressure drop at the filter. The hot gases in the 300° F. plus range contain substantial quantities of combustible vapor, largely oil and solvents, as well as moisture. The oil, solvent, and carrier substances are combustible at temperatures above about 600° F., and often temperatures in the range of about 1400° F. The oils actually have kindling temperatures below 600° F. but the organic carriers usually have kindling temperatures above 600° F. But, temperatures this high cannot be tolerated in the oven since such would seriously damage the cloth being treated. According to the present concept, these gases are passed in front of an elongated high velocity burner assembly 48, as of the type set forth at FIG. 3 and described in column 6, Second Form, of U.S. Pat. No. 3,436,065, and also at 38 in U.S. Pat. No. 3,744,963, specifically incorporated by reference herein. Burner assembly 48 is supplied with a mixture of gaseous fuel and air from mixer 47 to which air line 45 and gas line 43 connect. The burner causes the combustion of the vaporized combustible oils and solvents, the temperature thereof being raised to the incineration range, i.e., above 600° F. in plenum 50. A grid 52 adjacent the burner may be used to assist in effective dispersal for efficient combustion. Adjacent the grid and burner assembly 48 is an elongated air supply manifold 54 having a series of orifices for directing air jets into the gaseous flow from the burner. This accomplishes two things, namely, supplying oxygen for combustion of the oil and solvent substances in the event the circulated air becomes saturated with moisture and lacks oxygen, and secondly creating turbulence to thoroughly mix the hot gases from the burner with the recirculated gases from the oven and fresh air from manifold 54. This mixture of gases at combustion range temperatures is directed through plenum 50 which has, downstream from the burner, fresh cooler air inlet means 58 controlled by dampers 60. The introduced cool air controllably lowers the temperature of the gases back down to drying range temperatures, i.e., the range of about 350° to 375° F. The temperature is controlled to the highest that is tolerable in the oven for the particular fabric. The gas temperature is sensed for control by a suitable high limit temperature sensor 62 such as a thermocouple projecting into the plenum to prevent the temperature from exceeding the maximum allowed for the cloth. Part of these gases are then drawn by blower 64 into duct 34, which may also include an added temperature sensor 66. Sensor 66 operates a temperature controller to control temperature in the tentor frame. Sensor 66 could also be used to govern the amount of fresh air allowed through inlets 58 for regulating the temperature of the gases re-entering the oven. The less air that is allowed to enter through inlet 58, the higher the temperature is created in plenum 50 to maintain the temperature required at sensor 66.
As noted, part of the gases from plenum 50 are advanced by blower 64 back into the oven. The other part passes into duct 70, drawn by blower 72, for advancement either into a succeeding zone or a preceding zone of the assembly. More specifically, as depicted in FIGS. 1 and 3, this other part of the gases from plenum 50 of zone 3 passes through blower 72 and duct 73 into the succeeding zone 4 downstream, for heat treatment of the cloth passing through the tentor. In contrast, the like apparatus to that depicted in FIG. 3, as applied to zone 2 (FIG. 1), has part of the gases from plenum 50A returned back to zone 2 through conduit 34A and blower 64A, and part propelled into any one or more of the other zones, e.g. zone 1 through blower 72A and duct 73A for preheating the cloth stock as it passes through zone 1 to zone 2. Each of zones 1 and 4 includes a plurality of manifold elements (such as 20 and 22 in FIG. 3) for vertically straddling the cloth stock. The gases exhausted from zone 1 are passed up through an exhaust stack 102 (FIG. 1) containing a conventional exhaust fan 104 and motor 106 therefor. The gases exhausted from zone 4 are shown transferred by blower 78 through conduit 80 to zone 5. The exhaust from zone 5 is conducted out through an exhaust stack 102. The number of gaseous recycle subassemblies as in FIG. 3, the particular location of the stacks, and arrangement of the conduits for flow from one zone to another can be varied to suit the circumstances, equipment, components and fabric conditions at the mill involved.
The embodiment set forth in FIGS. 1 and 3 involves recirculation of all of the gases from the selected oven zones to the combustion chamber and back to the oven. However, in some instances it may be desirable to recirculate only a fraction of the gases from the particular zone to the combustion chamber as explained relative to the embodiment in FIG. 6.
Preferably, air curtain units 86 and 88 are employed at the entrance to the first zone and at the exit to the last zone, these being for example of the type disclosed in more detail in U.S. Pat. No. 3,744,963 at 22 and 24. This helps to lessen hot gas flow out the inlet and exit for the stock.
Extensive experimentation with this apparatus has shown that, by converting two of the conventional tentor zones of a conventional eight zone assembly, to employ the invention herein, the same production output can be achieved using only five zones in lieu of the previously required eight zones. Further, as close as can be determined, fuel savings over 30% have been achieved. It is expected that savings as high as 60% can be achieved in some installations. The amount of hot gases exhausted to the atmosphere is drastically cut to a small fraction of that previously exhausted, i.e., in the range of about 25 to 30%. For example, in the experimental apparatus, 1500 cubic feet per minute of gases were handled, per zone, instead of the previous 8000 cfm per zone. In fact, the exhaust rate is considerably less than that even tolerable in previous units because such a low exhaust rate would have dictated low gas flow rates that would have resulted in the vaporized oil and solvent products recondensing in the equipment and on the textile material. With the novel apparatus, these undesirable solvent and oil materials are actually taken advantage of, by combusting them using the burner assembly at the added plenum of the recycle system, to clean up the gases as well as achieving significant heat conservation therefrom. Thus, the significantly smaller fraction of gases that are actually exhausted are basically free of the oil and solvent substances. If it were attempted to combust the volatiles carried in the gaseous flow mass of the prior art, the amount of heat necessary to simply heat up the tremendous amount of gases, e.g. 6000 to 8500 cfm, would be greater than the entire amount of heat otherwise needed for the process of drying and heat treating.
The results of the invention therefor are increased production and/or lower capital equipment costs and requirements, significantly greater heat conservation, with concomitant less fuel consumption and pollution control.
Another operating criterion for tentor frames is that the faster the textile fabric can effectively advance through it, the greater the efficiency thereof. Using the invention, rates of fabric feed can be increased by over 30% and often considerably more, yet with effective drying and heat treating, thereby increasing efficiency per pound of fabric processed as well as production output. Tentors presently in use can be converted to employ the invention without significant difficulty or great expense, resulting in significantly improved operation and savings.
Referring to FIG. 6, a second embodiment of the invention there shown as assembly 200 has a plurality of six oven zones with an elongated passage through which web stock entering one end of the oven passes before exiting at the other end of the oven. Each zone includes a chamber in which volatilizable material is removed from the stock and/or the stock is heat treated by flow of hot gases. Burner 248 and plenum 250 into which it fires has a combination effect with a plurality of zones, specifically all six in the depicted version. As shown, a portion of the hot gases in each of zones 1-6 is recirculated while the other portion is conducted to the burner (zones 2-5) or to a stack (zones 1 and 6). The gaseous portion that is recirculated is mixed with the incinerated gases from the burner plenum at re-entry into the oven. The incinerated gases may be conducted back to the oven zones through a manifold arrangement. And, the gaseous portion removed may be conducted through a manifold arrangement to the burner.
More specifically, hot incinerated gases at a controlled temperature from plenum 250 are conducted through duct 234, which leads into manifold 234' and into branch ducts 234a to respective blowers 264. The blowers also receive a portion of the gases and vapors from the oven zones through ducts 234b. The mixture of gases is forced into the individual oven zones to the web stock. As to the intermediate zones 2-5, the other portion of the gases and vapors are ducted through exit ducts 265 into manifold 267 to exhaust duct 269 in which a supplemental blower 271 operates to propel these gases and vapors to burner 148 for incineration of the combustible volatilized vapors at temperatures in the range of about 450° F. to about 1400° F. Supplemental air is ejected through outlets 254 adjacent burner 248 for oxygen supply and turbulence generation. A controlled amount of ambient temperature air is allowed to enter the plenum past the valve at inlet 258 to lower the temperature of the mixture of gases flowing therepast to that tolerable for the material treated in the oven prior to re-entry of the gases into selected oven zones. The lowered temperature of the hot gases will vary, depending upon the material, but for cloth will typically be about 350° F. to 375° F.
A portion of the gases in the end zones 1 and 6 is ejected out the respective stacks 202 under the influence of blowers 204 operated by motors 206, rather than recirculated. Thus, there is constant incineration of the combustible material in a portion of the gases and constant venting of a graduated amount. The blowers 264 recirculate the hot gases in the zones while pulling sufficient incinerated gaseous products from the plenum 250 to maintain temperature and replace gases being drawn out of the oven, mainly up the stacks. If desired, an additional stack can connect to one of the intermediate zones.
For example, if 1500 cubic feet per minute (cfm) is circulated in each zone, about 300 cfm or so could be withdrawn to the incineration burner, incinerated, cooled to a lower elevated temperature and returned. Surplus from the intermediate zones could be supplied to the zones from wherein the gases contain no pollutants such as the first zone and the last zone.
To be certain the ratio of organic carriers commonly employed for cloth dyes to air is kept well below the explosive range, sufficient dilution of noncombusted carriers is practiced by controlled entry of air. Specifically, the dilution factor is kept in the range of 3 to 1 up to 20 to 1 of air to carrier.
Although the specific illustrative embodiments depicted employ gaseous fuel for direct heating in the chamber, other fuels such as coal, coke or heavy oils could conceivably be employed as for indirect heating of the chamber to an incineration temperature. Or, electrical heat could be utilized in some instances or as an emergency standby.
Once the inventive concept is understood, it will be realized by those in the art that details of the illustrative arrangement can be modified to suit a particular installation, type of textile, size of mill, and other factors, the illustrative version depicted being exemplary of the concept. | An oven for treating web stock, especially a tentor for treating textile fabric, to remove volatile combustible substances therefrom in a manner that results in more rapid operation with less capital outlay for equipment, less fuel consumption, and controlled stack discharge. The oven employs a recycle circuit in which the temperature of the oven discharge gaseous stream is first raised by combustion of the volatilized substances therein, and then lowered by entry of cooler, supplemental air, after which part of the gaseous stream is returned to the oven and part used for stock preheating or post heating in other oven sections. | 5 |
BACKGROUND OF THE INVENTION
The present invention is directed to a package, and in particular to a flexible package for holding food items.
Certain food items, such as dry cereals, are presently packaged for distribution to consumers in chipboard (i.e,. non-corrugated cardboard) boxes with an interior paper bag-like package within which the dry cereal is contained. The interior paper package has a one-time peelable seal near its top so that a consumer may peelably open the top of the interior paper package to gain access to the enclosed cereal. The chipboard box is generally provided with four flaps which, when folded in the correct configuration, accommodate insertion of a tab on one of the four flaps within a slot in an opposing of the four flaps to maintain the top of the box in a closed position. Slipping the tab of the one flap from engagement with the slot presented in the opposing flap allows easy opening of the top of the box to gain access to the interior paper package and, thence, to the cereal contained within that paper package.
Packaging of such foodstuffs as dry cereals in a flexible, generally pouch-like, package without an exterior chipboard box would reduce the cost of packaging of such foodstuffs. Savings would be realized by eliminating the materials employed in constructing the chipboard box, as well as by eliminating the need for printing of the exterior chipboard box to identify the products contained within. Printing costs associated with applying labeling to flexible packaging are significantly less than such costs associated with chipboard boxes.
If such a flexible package is used for delivering foodstuffs to consumers, a method of temporarily maintaining the package in a closed position after it has initially been opened to gain access to its contents is a necessity.
Accordingly, the present invention provides a package having a closure structure appropriate for temporarily maintaining the package in a closed position while affording easy access to and reclosing of the package for its normal employment. Thus, the package of the present invention allows a user to repeatedly gain access to the contents of the package while preventing spilling of the package when it is stored.
SUMMARY OF THE INVENTION
The invention is a package comprising at least one wall which defines a well having an openable end, and a closure structure for closing the openable end. The openable end is bounded by at least one generally flexible sheet which is extendable across the openable end to a covered position, which covered position presents at least two sheet segments of the at least one sheet in substantially adjacent facing relationship across a generally planar expanse. The closure structure comprises at least one interference-fit structure within the expanse established by the at least two sheet segments in the covered position. Each interference-fit structure comprises an aperture-set which includes a respective aperture in each of the at least two sheet segments.
Each aperture has a tab structure for effecting an interference fit in the closed position, which tab structure presents a free distal end depending within its respective aperture from a flex line. The flex line partially bounds the respective aperture, and respective apertures in each aperture-set are generally adjacently registrable in the covered position.
Each interference-fit structure is configured to hold the at least two sheet segments in the covered position by displacing the distal end of the tab structure associated with each respective aperture of an aperture-set in a first direction generally laterally to the sheets in the covered position through at least the next adjacent respective aperture of the aperture-set.
In its preferred embodiment, the package is integrally formed as a generally flexible pouch which, in the covered position, presents two facing sheet segments in substantially adjacent facing relationship. In an alternate embodiment, the pouch may be formed as a gusseted pouch, in which case the covered position presents folded gussets, each presenting two gusset-panels sandwiched between the two sheet segments for an expanse at the edges of the two sheet segments in the covered position. In this alternate embodiment, there may be provided a plurality of apertures in register through the two sheet segments and a plurality of apertures in register through the sandwiched gusset panels at the edges of the two sheet segments in the covered position.
In order to provide an enhanced interference fit for maintaining the package in its covered position, other embodiments of the present invention provide that the flex line from which the respective tab structure of a first aperture depends in a first sheet segment is offset from the flex line from which the tab structure of a second aperture in a second sheet segment depends so that displacement of a first tab structure through a second aperture presents an extension of the first tab beyond the edge of the second aperture, thereby enhancing the interference fit provided by the first tab in its extending through the second aperture. A similar effect may be realized by maintaining the flex line of a first aperture substantially in register with the flex line of a second aperture while providing that the tab of the first aperture be of greater length from its respective flex line than such length of the tab of the second aperture, thereby also providing that the first tab extends beyond the edge of the second aperture when inserted therethrough to enhance the interference fit thus established.
Of course, a combination of displacing the flex line and providing a longer tab in the first aperture will also establish the same enhanced interference-fit effect.
In yet another alternate embodiment of the present invention, a crease line is provided at the top of the package to facilitate folding of the sheet segments in an enhanced covered position. In this alternate embodiment, a plurality of first apertures and their respective depending first tabs is provided in the original meeting of the two sheet segments, and a plurality of second apertures and their respective depending second tabs is provided in the folded portion of the two sheet segments, thereby providing four apertures and their respective depending tabs for cooperating to establish an interference fit to maintain the enhanced closed position.
In a gusseted version of this alternate embodiment having a crease line, a total of eight apertures and their respective depending tabs will be presented in the area where the gusset panels are sandwiched between the two sheet segments to provide an enhanced covered position when the sheets and their sandwiched gusset panels are folded over at the crease line.
It is, therefore, an object of the present invention to provide a package which is economical to produce and provides an effective closure structure for maintaining the package in a temporarily closed orientation which enables easy access to the package contents and facilitates repeated reclosing.
Further objects and features of the present invention will be apparent from the following specification and claims when considered in connection with the accompanying drawings illustrating the preferred embodiments of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the present invention.
FIG. 2 is a perspective view of a second embodiment of the present invention.
FIG. 3 is a perspective view of a third embodiment of the present invention.
FIG. 4 is a perspective view of the preferred embodiment of the present invention.
FIG. 5 is a detailed partial perspective illustration of the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a perspective view of a package 10 is presented. Package 10 is comprised of a first wall 12 having a top edge 14, a first side edge 16, a second side edge 18, a bottom edge 20, an inner face 22, and an outer face 24. A second wall 30 has a top edge 32, a first side edge 34, a second side edge 36, a bottom edge 38, an inner face 40 and an outer face 42.
First wall 12 and second wall 30 are joined at their respective first side edges 16, 34 and their respective second side edges 18, 36.
Package 10 has a bottom 60 which is preferably integrally formed with first wall 12 and second wall 30 to present a well 62 for receiving contents.
FIGS. 1-4 illustrate various embodiments of package 10 in a discontinuous manner, indicating that the height of the illustrated packages is not limited and that the proportions illustrated in FIGS. 1-4 are not intended to restrict the scope of the present invention in any way.
For example, the portion of FIG. 1 above the discontinuity could represent an attachment to the top of a chipboard box (not shown in FIG. 1) to provide a closure structure for such a box.
Package 10 is preferably flexible and constructed of a unitary multi-layer construction. Such unitary multilayer construction could, for example, comprise a polypropylene outer layer, a plastic or paper intermediate layer, and a peelable polyethylene inner layer. In such a configuration, a sealing line 64 may be provided to seal first wall 12 with second wall 30 for shipment of goods within well 62 to a consumer. The peelable polyethylene interior layer of the unitary multi-layer construction would facilitate a peeling open of package 10 along sealing line 64. Subsequent reclosing of package 10 would be effected by the closure structure of package 10.
Still referring to FIG. 1, a closure structure comprising interference-fit structure 66 is illustrated. Interference-fit structure 66 is comprised of a first aperture 72 in first wall 12 and an associated depending tab 74 disposed within first aperture 72 from a flex line 76. Interference-fit structure 66 further includes a second aperture 78 in second wall 30. Disposed within second aperture 78 is a depending tab 80 which depends from a flex line 82.
Package 10 preferably includes as its closure means at least one interference-fit structure 66. Any additional interference-fit structures 66 would be arrayed (if employed) along a line generally parallel with sealing line 64. When package 10 is in a closed position, first wall 12 is in substantial adjacent facing relation with second wall 30, and inner face 22 substantially abuts inner face 40.
An interference fit may be established between apertures 72, 78 in the closed position with inner faces 22, 40 in facing relation. The interference fit is effected by displacing tab 74 obliquely to first wall 12 toward second wall 30 sufficiently to urge tab 74 through aperture 78, displacing tab 80 in the process. Release of the interference-fit is easily effected by urging tabs 74, 80 in the opposite direction, from second wall 30 toward first wall 12, while spreading walls 12, 30 to open package 10.
In the interest of facilitating understanding of the present invention, like elements will be identified by the same reference numerals in the various drawings.
FIG. 2 is a perspective view of a second embodiment of the present invention.
In FIG. 2, a package 11 is comprised of a first wall 12 having a top edge 14, a first side edge 16, a second side edge 18, a bottom edge 20, an inner face 22, and an outer face 24. A second wall 30 has a top edge 32, a first side edge 34, a second side edge 36, a bottom edge 38, an inner face 40 and an outer face 42.
First wall 12 and second wall 30 are joined by a gusset 44 joining first side edges 16, 34 and a gusset 46 joining second side edges 18, 36. Gusset 44 is a unitary structure presenting a first gusset panel 48 extending from first side edge 16 to a fold line 50 and a second gusset panel 52 extending from fold line 50 to second side edge 34. Similarly, gusset 46 is a unitary structure presenting a first gusset panel 54 extending from second side edge 18 to a fold line 56 and a second gusset panel 58 extending from fold line 56 to second side edge 36.
First wall 12, second wall 30, and gussets 44, 46 are preferably flexible and constructed of a unitary multi-layer construction, as previously described in connection with FIG. 1.
As in the above-described first embodiment, interference-fit structure 66 is comprised of a first aperture 72 in first wall 12 having an associated depending tab 74 disposed from a flex line 76. Interference-fit structure 66 further includes a second aperture 78 in second wall 30. Disposed within second aperture 78 is a depending tab 80 which depends from a flex line 82.
In this second embodiment of the present invention, package 11 includes as its closure means at least one interference-fit structure 66 intermediate the reaches of gussets 44, 46 inward from first edges 16, 34 and second edges 18, 36 when package 11 is in a closed position with first wall 12 in substantial adjacent facing relation with second wall 30 having inner face 22 substantially abutting inner face 40. In the closed position, gusset panels 48, 52 and gusset panels 54, 58 are sandwiched between first wall 12 and second wall 30.
FIG. 3 is a perspective view of a third embodiment of the present invention.
In FIG. 3, a package 13 has a first wall 12 and second wall 30 joined by a gusset 44 joining first side edges 16, 34 and gusset 46 joining second side edges 18, 36. Gusset 44 presents a gusset panel 48 extending from first side edge 16 to a fold line 50 and a second gusset panel 52 extending from fold line 50 to second side edge 34. Similarly, gusset 46 presents a first gusset panel 54 extending from second side edge 18 to a fold line 56 and a second gusset panel 58 extending from fold line 56 to second side edge 36.
Interference-fit structures 66 and 70 are illustrated. Interference-fit structure 66 is constructed as previously described in connection with the first and second embodiments of the present invention.
Interference-fit structure 70 is associated with gusset 44 and includes an aperture and tab structure in first wall 12 (not shown) substantially of the same construction as other aperture-and-tab structures of interference-fit structure 70, and an aperture 102 in first gusset panel 48 with a depending tab 104 disposed within aperture 102 depending from a flex line 106. Interference-fit structure 70 further includes a similar aperture and depending tab situated in second gusset panel 52 (not shown) and an aperture 108 with a depending tab 110 disposed therein from a flex line 112.
When package 13 is closed with gusset panels 48, 52 compressively sandwiched between first wall 12 and second wall 30, the various apertures of interference-fit structure 70 are generally in register to facilitate a displacement of tabs obliquely to the walls 12, 30 and through adjacent apertures of interference-fit structure 70 to effect an interference-fit among first wall 12, gusset panels 48, 52, and second wall 30 in a manner substantially the same as previously described in connection with interference-fit structure 66. Thus, in the case of interference-fit structures associated in register with gusset panels, of which interference-fit structure 70 is an example, four apertures are involved rather than the two apertures required intermediate the reach of gusset panels in the closed position.
FIG. 4 is a perspective view of the preferred embodiment of the present invention.
In FIG. 4, a package 15 has a first wall 12 and second wall 30 connected by a gusset 44 joining first side edges 16, 34 and a gusset 46 joining second side edges 18, 36. Gusset 44 presents a gusset panel 48 extending from first side edge 16 to a fold line 50 and a second gusset panel 52 extending from fold line 50 to second side edge 34. Similarly, gusset 46 presents a first gusset panel 54 extending from second side edge 18 to a fold line 56 and a second gusset panel 58 extending from fold line 56 to second side edge 36.
First wall 12, second wall 30, and gussets 44, 46 are preferably flexible and constructed of a unitary multi-layer construction as previously described in connection with FIG. 1 in describing the first embodiment of the present invention. A sealing line 64 is provided to seal all of first wall 12, second wall 30, and gussets 44, 46 for shipment of goods within well 62 to a consumer. The peelable polyethylene interior layer of the unitary multi-layer construction facilitates a peeling open of package 15 along sealing line 64. Subsequent reclosing of package 15 would be effected by the closure structure of package 15.
A closure structure comprising interference-fit structures 66, 68, and 70 is illustrated. Interference-fit structure 66 is comprised of a first aperture 72 in first wall 12 and an associated depending tab 74 disposed within first aperture 72 from a flex line 76. Interference-fit structure 66 further includes a second aperture 78 in second wall 30. Disposed within second aperture 78 is a depending tab 80 which depends from a flex line 82.
Package 15 includes a crease line 84 for facilitating folding to an enhanced closed position in which inner face 22 remains in adjacent facing relation with inner face 40 while outer face 42 is folded to an adjacent facing relation with itself. In such an enhanced closed position, interference-fit structure 66 is in register with interference-fit structure 68 to facilitate establishing an interference fit. Interference-fit structure 68 includes an aperture 90 having depending therein a tab 92 depending from a flex line 94 which partially borders aperture 90 and an aperture 96 having depending therein a tab 98 depending from a flex line 100 which partially borders aperture 96.
An interference fit may be established in the enhanced closed position among the various apertures 72, 78, 90, 96, by displacing tab 92 toward second wall 30 sufficiently to urge tab 92 through apertures 96, 78, and 72. Tab 92 displaces succeeding tab 98 to extend through apertures 78, 72, displaces tab 80 to extend through aperture 72, and displaces tab 74 in the process of such urging.
Release of the interference fit is easily effected by urging the various tab structure in the opposite direction, from second wall 30 toward first wall 12, while spreading walls 12, 30 to open package 15.
Package 15 includes as its closure means an array of at least one interference-fit structure 66 and a corresponding array of at least one interference-fit structure 68, additional interference-fit structures 66, 68 being arrayed (if employed) intermediate the reaches of gussets 44, 46 inward from first edges 16, 34 and second edges 18, 36 when package 15 is in a closed position.
To further enhance the interference-fit established by interference-fit structures 66, 68, flex line 94 may be displaced from flex line 76 a distance D 1 , and flex line 100 may be displaced from flex line 82 a substantially equal distance D 2 . In such a configuration, when an interference fit is established by displacing each respective tab through its next adjacent aperture, as described above, tabs 92, 98 will extend beyond apertures 78, 72. Alternatively, an enhanced interference fit may be established if flex lines 76, 94 and flex lines 82, 100 are generally in register, and the length of displacement of tabs 92, 98 from their respective flex lines 94, 100 being greater than the length of displacement of respective tabs 74, 80 from their respective flex lines 76, 82. With such structure, an enhanced interference fit will present tabs 92, 98 extending beyond apertures 72, 78. Of course, a combination of displacing flex lines and varying lengths of tabs may also be employed to yield such an enhanced interference fit.
Interference-fit structures 70, 102 are associated with gusset 44. Thus, interference-fit structure 70 includes an aperture and an associated tab in first wall 12 (not shown), and an aperture 102 in first gusset panel 48 with a depending tab 104 disposed within aperture 102 depending from a flex line 106. Interference-fit structure 102 also includes a similar aperture and depending tab situated in second gusset panel 52 (not shown) and an aperture 108 with a depending tab 110 disposed therein from a flex line 112.
When package 15 is closed with gusset panels 48, 52 sandwiched between first wall 12 and second wall 30, the various apertures of interference-fit structure 70 are generally in register to facilitate a displacement of tabs obliquely to walls 12, 30 and through adjacent apertures of interference-fit structure 70 to effect an interference fit among first wall 12, gusset panels 48, 52, and second wall 30 in a manner substantially as previously described in connection with interference-fit structures 66, 68. Thus, in the case of interference-fit structures associated with gusset panels, four apertures are involved, rather than two apertures as is the case in areas of package 15 not involving gusset panels. If the enhanced closed position involving crease line 84 is contemplated with regard to a gusset panel area in the closed position of package 15, then eight apertures are involved in effecting an interference-fit involving gusset panels. In such case, interference-fit structure 115, having four apertures, including apertures 116, 122, and four associated respective tabs, including tabs 118, 124, depending from four respective flex lines, including flex lines 120, 126, would participate in establishing the interference fit.
Of course, enhancement of the interference fit by displacing flex lines by varying lengths of tabs, or by both such structural variations, is possible with the preferred embodiment of FIG. 4.
FIG. 5 is a detailed partial perspective illustration of the preferred embodiment of the present invention.
In FIG. 5, first wall 12 is illustrated in generally adjacent facing relation with second wall 30 with inner face 22 generally abutting inner face 40 across an expanse 26. First wall 12 and second wall 30 are folded at crease line 84 to present inner face 42 in general adjacent abutting relation with itself. Tabs 92, 98, 80, 74 are illustrated as having been displaced obliquely to walls 12, 30 from first wall 12 toward second wall 30 sufficiently to extend tabs 92, 98, 80 through aperture 72, and thereby also displacing tab 74 outwardly of outer face 24 along its flex line 76. Tabs 92, 98 extend beyond aperture 72 to establish an enhanced interference fit. Such extension of tabs 92, 98 beyond aperture 72 may be effected by providing a longer length of displacement of tabs 92, 98 from their respective flex lines 94, 100 (not shown in FIG. 5), or by displacing flex lines 94, 100 from flex lines 76, 82, or by a combination of a longer length for respective tabs 92, 98 and appropriate displacement of flex lines.
It is to be understood that, while the detailed drawings and specific examples given describe preferred embodiments of the invention, they are for the purpose of illustration only, that the apparatus of the invention is not limited to the precise details and conditions disclosed and that various changes may be made therein without departing from the spirit of the invention which is defined by the following claims: | A package having an openable end, and a closure structure for closing the openable end. The closure structure comprises at least one aperture-set which includes a respective aperture in each of at least two sheet segments of the package. Each aperture has a tab which presents a free end depending within its respective aperture from a flex line. The flex line partially bounds the respective aperture, and respective apertures in each aperture-set are generally adjacently registrable in a covered position. The at least two sheet segments are held in the covered position by displacing the distal end of the tab associated with each respective aperture of an aperture-set through at least the next adjacent respective aperture of the aperture-set. | 1 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention pertains to the field of art encompassing earth-moving machines and more particularly to excavation tool assemblies, for example, of the kind comprising excavation buckets and excavation thumbs to which working implements are mounted thereon. The present invention relates to a detachable implement adapter that is initially coupled to a excavation bucket or an excavation thumb of an excavation tool assembly without the need for manual assistance. Additionally, the implement adapter provides improved excavation versatility by mounting upon various sizes of excavation tools and articulating attached working implements in multiple ranges of motion.
2. General Background and Discussion of Prior Art
In the past, implements themselves have been mounted directly on excavation buckets utilizing a unitary constructed implement fastened directly to a bucket with a plurality of manually connected fasteners. This attachment method creates a labor and time intensive process of installation or detachment of the heavy working implements designed to withstand the bending influence during operation. As a result of the implements' heavy weight, the manual labor of several persons is required to position and fasten the implement on the excavation tool. The unitary construction of such implements also results in costly replacement or repairing after appreciable wear of the cutting edge has taken place.
Examples of what is known in the prior art showing a blade implement for attachment directly to an excavation bucket, are as follows: Smith, U.S. Pat. No. 2,644,251, Discenza, U.S. Pat. Nos. 3,043,032 & 3,181,256; Slaughter, U.S. Pat. No. 3,039,210; Hood et al., U.S. Pat. No. 3,469,330; Bolyard et al., U.S. Pat. No. 3,523,380; Johnson, U.S. Pat. No. 4,009,529; Jarvis, U.S. Pat. No. 4,360,980; Webb et al., U.S. Pat. No. 5,253,449; Cote, U.S. Pat. No. 5,297,351; and Von Schalscha, U.S. Pat. No. 5,596,825. Felstet, U.S. Pat. No. 4,550,512 teaches an excavator bucket with interchangeably detachable implements connecting directly to the excavator bucket. Jennings, U.S. Pat. No. 4,125,952 teaches a fork type implement for attachment to an excavator bucket. Timmons, U.S. Pat. No. 4,974,349 teaches a compactor attached to the back of an excavator bucket. Stormon, U.S. Pat. No. 4,087,010 teaches an apparatus for mounted hand held tools to an excavator bucket.
Implements have also been directly mounted on excavation thumbs of excavation tool assemblies. Cobb et al., U.S. Pat. No. 3,915,501 teaches an impact rock breaker integral with a thumb-like structure. Somero, U.S. Pat. No. 5,544,435 teaches a brush rake directly attached to a thumb portion of an excavation tool assembly. Hawkins, U.S. Pat. No. 5,678,332 teaches a changeable and retractable implement for use on a thumb portion of an excavation tool assembly. However, the prior art fails to teach an adjustable adapter for mounting to excavation tool assembly thumbs of different sizes and the ability to mount interchangeable working implements.
Implements have also been attached to cumbersome mounting devices designed for a single excavation bucket. Lamb, U.S. Pat. No. 3,665,622 teaches a device for mounting to a lift bucket upon which a working implement is attached. However, Lamb's mounting bracket fails to have any adjustable feature allowing for adaptation on excavation buckets of different sizes. Additionally, the mounting arrangement of the working implement on this mounting device fails to allow for any type of articulation of the implement relative to the mounting device.
Finally, none of the prior art teaches an implement adapter for mounting on an excavation tool assembly where the adapter's geometry automatically holds the adapter at in a position to be engaged by the excavation tool assembly without any need of manual assistance. Kaczmarczyk et al., U.S. Pat. No. 5,639,205 teaches a parkable grapple for attachment to a front-end loader holder, having a parking foot (ref. no. 102) for holding the detached grapple at a certain height for engagement with the front-end loader holder.
OBJECTS AND ADVANTAGES
It is the principle object of the present invention to provide an implement adapter for having a coupling attachment and method of attachment to an excavation tool assembly wherein there is no need for manual assistance.
It is a further object of the present invention to provide an implement adapter that accommodates the rotatable articulation of mounted implements.
It is a further object of the present invention to provide a multipoint progressive loading connection between the implement adapter and the excavation tool assembly to eliminate excessive wear at high stress engagement points, thereby increasing the useful field life of the excavation tool assembly and the implement adapter.
It is a further object of the present invention to provide a multipoint progressive loading connection between the implement adapter and the excavation tool assembly to eliminate vibratory generated squeaks and rattles caused by the engagement points.
It is a further object of the present invention to provide a smaller overall dimension of the implement adapter relative to the prior art for improved maneuverability of the implement when in operation.
It is a further object of the present invention to provide a more closely aligned transmitted lateral force from the implement to the forward cutting edge of the excavation tool thereby lessening the torsional stress on the implement adapter under load.
It is a further object of the present invention to provide a manner of attachment of the implement adapter to the excavation tool assembly which provides for a quick and simple means for moving the implement adapter without manual assistance, e.g., from a transportable storage position to a temporary accessible position in the work field.
It is a further object of the present invention to provide for fully automatic engagement of the implement adapter to the excavation tool assembly with no need for manual assistance.
It is a further object of the present invention to provide an adjustable implement adapter that can be used on more than one differently dimensioned excavation tool, e.g., on excavation buckets and excavation thumbs.
It is a further object of the present invention to provide an adjustable implement adapter which enables the manufacture of a universal implement adapter for adjustment to fit a wide range of sizes of excavation tools with the option of permanently affixing the adjustable frame once it has been sized for a particular excavation tool.
It is a further object of the present invention to provide for improved load distribution upon the implement adapter during earth moving operations to reduce high concentrations of stress where the implement and implement adapter are connected.
It is a further object of the present invention to provide an excavation thumb mounted implement adapter which eliminates the need to remove the implement adapter from the excavation tool assembly when the bucket is desired be used.
It is a further object of the present invention to provide an excavation thumb mounted implement adapter to accommodate various excavation thumb configurations.
It is a further object of the present invention to provide an excavation thumb mounted implement adapter that enables the unhindered operation of the excavation thumb without interference of the mounted implement.
SUMMARY OF THE PRESENT INVENTION
The herein disclosed and claimed implement adapter for an excavation tool assembly of universal applicability readily accommodating mounting to a wide variety of excavation buckets (the like of which includes, but is not limited to, track loaders, backhoes, excavators, wheel loaders and skid steer loaders), and accommodating a wide variety of working implements mounted thereon. The implement adapter comprises a frame means adapted to hold a desired working implement, coupling and attachment means integral with the frame means for affixing to an excavation tool assembly, and parking means for holding the coupling means at a sufficient height above a surface when the implement adapter is detached from the excavation tool assembly and supported on the surface by the parking means and said lowermost portion of either the frame means or the implement. The height at which the coupling means is held by the parking means enables engagement of the coupling means with a cooperative coupling means on the excavation tool assembly without the need for any manual assistance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Perspective exploded view of the fixed frame implement adapter for attachment to the bucket pivot pin with a hydraulically tilting blade.
FIG. 2 Side view of the fixed frame implement adapter attached to the bucket pivot pin with a hydraulically tilting blade.
FIG. 3 Front view of the fixed frame implement adapter attached to the bucket pivot pin with a hydraulically tilting blade.
FIG. 4 Side view of an alternative embodiment fixed frame implement adapter attached to bucket brackets with a hydraulically tilting blade.
FIG. 5 Front view of an alternative embodiment fixed frame implement adapter attached to bucket brackets with a hydraulically tilting blade.
FIG. 6 Side view of an alternative embodiment fixed frame implement adapter attached to bucket brackets with a manually indexed tilting blade.
FIG. 7 Front view of an alternative embodiment fixed frame implement adapter attached to bucket brackets with a manually indexed tilting blade.
FIG. 8A Side view of the first attachment sequence step wherein the adapter is resting on ground.
FIG. 8B Side view of the second attachment sequence step wherein the bucket coupling mechanism is engaged with the upper coupling portion of the implement adapter.
FIG. 8C Side view of the third attachment sequence step wherein the implement adapter is lifted off the ground while pivotally coupled to the bucket.
FIG. 8D Side view of the fourth and final sequence step where the lower portion of the implement adapter is positioned to be securely attached to the excavation bucket.
FIG. 9 Perspective exploded view of an adjustable frame implement adapter for attachment to a bucket wrist pin with a hydraulically tilting blade.
FIG. 10 Rear perspective view of an adjustable frame implement adapter with a hydraulically tilting blade.
FIG. 11 Rear perspective view of an adjustable frame implement adapter with a hydraulically tilting blade with an alternative upper coupling embodiment for attachment to bucket brackets.
FIG. 12 Rear perspective view of an adjustable frame implement adapter with a hydraulically tiling and skewing blade.
FIG. 13 Side view of an adjustable frame implement adapter with a hydraulically tiling and skewing blade.
FIG. 14 Side view of an adjustable frame implement adapter attached to excavation tool brackets with a hydraulically tilting scarifying rake.
FIG. 15 Front view of adjustable frame implement adapter attached to excavation tool brackets with a hydraulically tilting scarifying rake.
FIG. 16 Perspective view of an alternative embodiment of a frame for an adjustable implement adapter for connection to a lower portion of the excavation tool cutting edge.
FIG. 17 Side view of an alternative embodiment of a frame for an adjustable implement adapter for connection to the excavation tool's cutting edge.
FIG. 18 Side view of adjustable frame implement adapter attached to an excavation thumb with a hydraulically tilting blade.
FIG. 19 Front view of adjustable frame implement adapter attached to an excavation thumb with a hydraulically tilting blade.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3. Description of a Fixed Frame Implement Adapter for Attachment to an Excavation Tool Wrist Pin
An excavation bucket 10 has an open front defined by two opposed side edges 11, a lower cutting edge 12 with a plurality of teeth 13, and an upper edge opposite the lower cutting edge 12 where bucket attachment flanges 14 are integrally mounted. An exemplary embodiment of the invention comprises an excavation machine boom arm (not shown) attached to the excavation bucket 10 at wrist pin 15 mounted through a forward a set of attachment holes (similar to the rearward set of attachment holes 16) on the attachment flanges 14. The wrist pin 15 is retained on the attachment flanges 14 by pin retainers 17 which are fixedly attached to wrist pin 15 on both inwardly and outwardly facing sides of the bucket attachment flanges 14 to prevent pin 15 from moving laterally out of connection within the forward set of attachment holes of the attachment flanges 14. Located on both distil ends of the wrist pin 15 are pin end stops 18 which are fixedly attached to the wrist pin 15 and project radially therefrom. The excavation bucket 10 described in this disclosure is similar to many other excavation buckets for use on excavation machines, which includes, but is not limited to, track loaders, backhoes, excavators, wheel loaders and skid steer loaders.
A fixed frame implement adapter 20 is provided with a frame comprising two parallel frame arms 21, an implement mounting plate 22 connected to a forward lower portion of the frame arms 21, and a lower connecting assembly 23 connected to a rearward lower portion of the frame arms 21 as indicated by path lines 36.
The lower connecting assembly 23 comprises parallel lower connecting assembly arms 24 each attached to and rearwardly projecting from the lower portion of the frame arms 21. Midway on the outside of each of the lower connecting assembly arms 24 are outwardly projecting abutment tabs 25. Between each of the abutment tabs 25 and the distil ends of lower connecting assembly arms 24 are connecting holes 26. Between each distil end of the lower connecting assembly arms 24 is a spanner 27.
The fixed frame implement adapter 20 is first attached to the excavation bucket 10 at the wrist pin 15 by means of coupling yokes 28 at upper rearward portions of each frame arm 21, as indicated by path lines 34. The open portions of the coupling yokes 28 are rotatably coupled with the wrist pin 15, wherein with each coupling yoke 28 engages opposite ends of wrist pin 15 between the pin retainer 17 and the pin end stop 18.
Excavation machines that fail to have a wrist pin in a position proximate the upper edge of an excavation bucket opening can be adapted to mount a rod structure on the upper edge of an excavation bucket to functionally replace the wrist pin 15 described above. Thus, after mounted a coupling rod structure at an appropriate position, excavation tools having different articulation geometries can be easily adapted to receive the coupling yokes 28.
Implement adapter 20 is finally attached to excavation bucket 10 by means of the lower connection assembly 23 moving along an angular path, defined by coupling yokes 28 rotatably engaging wrist pin 15, wherein the lower connecting assembly arms 24 move into the excavation bucket 10 front opening until the abutment tabs 25 contact the front edge of the bucket side edges 11. In this contacted position, connecting holes 26 of the lower connecting assembly 23 are aligned with the excavation bucket side edge attachment holes 19. Fasteners 29 are then inserted into bucket attachment holes 19 and lower connecting assembly connecting holes 26 and are fixedly retained with nuts 30, as illustrated by path lines 35.
An alternative means for affixing the lower connection assembly 23 to the lower front edge portion of the bucket replaces the manually positioned fasteners 29 with a hydraulic actuation assembly mounted on the implement adapter that automatically engages the connecting holes 19 of the excavation bucket 10. This enables the final connection step of the implement adapter to be made completely automatic, thus eliminating the need for manual assistance for attachment and removal of the implement adapter from the excavation tool.
A blade-type implement 40 is rotationally attached to a lower central portion of the implement mounting plate 22 by means of a stud 41 fixedly attached to the back of the implement 40, for passage through a hole 31 in a center lower portion of the implement mounting plate 22 and into a collar 42 fixedly attached to the rearwardly facing surface of the implement mounting plate 22. A threaded distal end portion of stud 41 projects rearwardly past collar 42 for engagement with a washer 43 and nut 44 (FIG. 2) for rotationally securing implement 40 relative to the forward surface of implement mounting plate 22.
Implement 40 is able to be rotated with a hydraulic actuating component 45 coupled to a hydraulic implement connection 46 mounted a longitudinal distance on the implement 40 away from the stud 41, and to a hydraulic frame connection 32. Through standard means of hydraulic actuation, implement 40 is able to be rotated around the longitudinal axis of stud 41 while mounted on the implement mounting plate 22 of the fixed frame implement adapter 20.
Connecting holes 26 of the lower connecting assembly 23 are designed to loosely receive fastener 29 such that the lower connecting assembly 23 is able to move a small incremental amount while connected to and with respect to bucket 10. This loose fitting allows for movement of the lower connecting assembly 23, and thus the implement adapter 20, relative to the forward edge of the bucket side edges 11. Upon loading of the implement 40, abutment tabs 25 move into engagement with the forward edge of bucket side edges 11. Upon a further increase in the transferred loading force generated by the implement 40, a pressure plate 33 fixedly attached (as illustrated by path line 37) to a lower rearward portion of the frame arms 21 (see FIG. 2) engages teeth 13 along the lower cutting edge 12 of the excavation bucket 10. In this loading situation, the implement adapter 20 is restrained from moving in a forward direction at the coupling of the bucket wrist pin 15 and the coupling yokes 28 due to the contacting fulcrum point of the abutment tabs 25 on the front edge of the bucket side edges 11, while a majority of the force generated by the implement 40 is transferred via the pressure plate 33 through teeth 13 to the lower cutting edge 12.
This multipoint progressive loading design better distributes the implement generated force across the bucket geometry eliminating excessive wear at high stress engagement points on the implement adapter and excavation tool, thereby increasing their useful field life, and eliminating vibratory generated squeaks and rattles during operation at engagement points throughout all stages of loading the implement adapter.
FIGS. 4-5. Description of Fixed Frame Implement Adapter for Attachment to Bucket Mounted Brackets
A second embodiment of the fixed frame implement adapter connected to excavation bucket 10 depicted generally by reference number 50 as illustrated in FIGS. 4 & 5. Implement adapter 50 is provided with a frame comprising two parallel frame arms 51, an implement mounting plate 52, and a lower connecting assembly 53 identical in geometry to lower connecting assembly 23 of FIGS. 1-3. The lower connected assembly 53 comprises lower connecting arms 54 connected to the outside of the frame arms 51, outwardly projecting abutment tabs 55, bucket connecting holes 56, and a spanner 57 traversing between each distil end of the lower connecting arms 54.
Fixed frame implement adapter 50 further comprises a reinforcing plate 58 which functions in a first capacity as a mounting bracket for a hydraulic actuator 59. Hydraulic actuator 59 is connected to a hydraulic mounting connection 60 on an implement 61 rotatably connected to the implement mounting plate 52 in like manner to the implement adapter 20 in FIGS. 1-3 via an implement mounting hole 62 (FIG. 5) and a fastener assembly 63 (FIG. 4). Reinforcing plate 58 additionally operates in a second capacity to limit any relative movement of the frame arms 51 with respect to each other due to any torsional stress on the implement adapter 50 generated by implement 61 under normal working conditions.
Each frame arm 51 further comprises a quick assembly feature of an upper alignment stops 64 and a lower alignment stops 65. These stops provide a self-aligning feature to save time and improve dimensional accuracy during assembly by implement mounting plate 52 abutting against the lower alignment stops 65, and reinforcing plate 58 abutting against upper alignment stops 64. These features allow for pre-fabricated parts to be quickly and easily aligned and fastened together during assembly.
Fixed frame implement adapter 50 further comprises a coupling rod 66 fixably connected between the upper ends of frame arms 51. Each distal end of coupling rod 66 projects a distance beyond the outer surface of each frame arm 51 as shown in FIG. 5. implement adapter 50 is coupled to bucket 10 with the coupling rod 66 engaging bucket brackets 67 mounted on the inside edges of the excavation bucket 10. Bucket brackets 67 are removeably fastened by bucket mounting holes 68 through which appropriate fasteners (not shown) are applied to secure the bucket brackets 67 to bucket 10.
The attachment of implement adapter 50 to the excavation bucket 10 differs from FIGS. 1-3 in that the first step of attachment is with the distil ends of the coupling rod 66 engaging the open portions of the bucket brackets 67. Once the coupling rod 66 is rotatably engaged with the bucket brackets 67, the lower portion of the implement adapter 50 swings angularly toward the lower edge of bucket such that the lower connecting assembly 53 contacts the forward edge of the bucket sides 11 with abutment tabs 54. Appropriate fasteners are then inserted through bucket connecting holes 56 into aligned and slightly oversized holes in the lower connecting assembly arms 54 in like manner to the invention of FIGS. 1-3.
Implement adapter 50 additionally has an attached pressure plate 69 mounted to each lowermost portion of the implement adapter frame arms 51. In a similar manner to implement adapter 20 of FIGS. 1-3, upon loading of implement 61, abutment tabs 55 move into engagement with the forward edge of bucket side edges 11. Upon a further increase in the transferred loading force generated by the implement 61, the pressure plate 69 engages the lower cutting edge 12 of the excavation bucket 10 at teeth 13. In this loading situation, the implement adapter 50 is restrained from moving in a forward direction from the coupling rod 66 and the bucket brackets 67 due to the fulcrum point of the abutment tabs 55 on the front edge of the bucket side edges 11, while a majority of the force generated by the implement 61 is transferred via the pressure plate 69 through teeth 13 to the lower cutting edge 12.
Implement adapter 50 additionally differs from the invention of FIGS. 1-3 in that the center line of implement 61, aligned with the longitudinal axis of fastener assembly 63, is above the lowermost portion of teeth 13 and intersects the lowermost cutting edge 12. This provides a smaller overall dimension of the implement adapter for ease of use and maneuverability of the implement when in operation, and directly aligns the lateral force generated by the operating implement 61 through pressure plate 69 to the lower cutting edge 12, thus lessening the torsional stress acting upon the implement mounting plate 52.
FIGS. 6-7. Description of a Fixed Frame Implement Adapter with Manually Indexed Tilting Blade
FIGS. 6 & 7 illustrate an alternative embodiment for an implement adapter 70 connected to an excavation bucket 10 with similar frame geometry to implement adapter 20 of FIGS. 1-3, but with a bucket bracket mounting configuration similar to implement adapter 50 of FIGS. 4 & 5. Implement adapter 70 replaces the hydraulic tilting system of FIGS. 1-5 with a manual-indexing configuration.
The frame of implement adapter 70 comprises frame arms 71 to which is attached an implement mounted plate 72. An implement 73 is rotationally attached to a lower central portion of implement mounting plate 72 in a manner similar to the implement adapters 20 & 50 of FIGS. 1-5. Implement mounting plate 72 has a plurality of angularly spaced detents 74 a distance from the rotational axis of the implement 73 for engagement with a rearward projecting tab 75 (FIG. 7) on an index arm 76 mounted to the rear of implement 73.
Thus, if an excavation tool fails to have means for auxiliary hydraulic actuation, an operator is able to manually rotate implement 73 by disengaging projecting tab 75 of index arm 76 out of a first detent 74 position, and rotate the implement 73 and the index arm 76 such that projecting tab 75 engages another angularly displaced detent 74 position.
FIGS. 8A-8D. Description of Attachment Sequence of an Implement Adapter to an Excavation Tool Assembly Without Manual Assistance
FIGS. 8A-D illustrate the attachment sequence of fixed frame implement adapter 50 of FIGS. 4 & 5 to the excavation bucket 10. FIG. 8A illustrates implement adapter 50 resting on a horizontal surface 80 supported generally by the lower connection assembly 53, pressure plate 69 and the lowermost rearward portion of implement 61. Spanner 57 extends between the distal end of both sides of the lower connection assembly 53 in the form of a bar (in the same configuration as spanner 27 in FIGS. 1-3) and supports the frame of implement adapter 50 at a predetermined angle with respect to surface 80. This enables the coupling rod 66 to be parked at a certain height D above the surface 80 when the implement adapter 50 rests on the surface 80. Excavation bucket 10 is prepared for engagement to the implement adapter 50 with the coupling bucket brackets 67 mounted to the front side edges of the bucket 10. Once the excavation bucket 10 is pivotally connected to the excavation boom arm 81, the excavation bucket brackets 67 can be aligned with respect to the coupling rod 66 of the implement adapter 50.
FIG. 8B illustrates the rearwardly tilting position of the excavation bucket 10 as lowered by the boom arm 81 at the moment of coupling engagement between the bucket brackets 67 and the coupling rod 66. The height D, which coupling rod 66 is parked above the surface 80, allows the boom arm 81 to manipulate the excavation bucket 10 and its attached bucked brackets 67 into engagement with coupling rod 66 without the teeth 13 or any other portion of the forward lowermost portion of the excavation bucket 10 interfering with the surface 80.
Once coupling rod 66 is rotatably secured within the corresponding bucket brackets 67, excavator boom arm 81 is raised upward causing implement adapter 50 to rotate simultaneously about the axis of coupling rod 66 and about a longitudinal axis created by the lowermost portion of implement adapter 50 bearing along the surface 80. After excavator boom arm 81 has raised implement adapter 50 completely off the surface 80, (FIG. 8C), the hydraulic actuators of the boom arm 81 rotate the excavation bucket 10 around the wrist pin 82 to move the forward open edge of excavation bucket 10 toward the implement adapter 50.
In this manner, the implement adapter 50 is initially coupled to the excavation bucket 10 without the need for any manual assistance. Additionally, this manner of attachment provides for a quick and simple means for moving the implement adapter 50 without manual assistance, e.g., from a transportable storage position to a temporary accessible position in the work field.
For fully secured attachment of the implement adapter 50 to excavation bucket 10, the excavation bucket 10 is rotated about wrist pin 82 to such a position where the lower connection assembly 53 engages the front side edge surface of excavation bucket 10, (FIG. 8D). At this position, fasteners can be manually or automatically engaged through side connecting holes 19 of the excavation bucket 10 for releaseable attachment to the bucket connecting holes 56 of lower connection assembly 53 of the implement adapter 50, thus fully securing implement adapter 50 to the excavation bucket 10.
FIGS. 9-10. Description of an Adjustable Frame Implement Adapter for Attachment to a Bucket Wrist Pin
The remaining figures illustrate an adjustable frame adapter which allows a single implement adapter to be used on more than one differently dimensioned excavation tool, and enables the manufacture of a single universal adjustable implement adapter that can be adjusted to fix a wide range of sizes of excavation tools with the option of permanently affixing the adjustable frame once it has been sized for a particular excavation tool.
The adjustable implement adapter 100 of FIGS. 9 & 10 comprises an adjustable frame 101 having a horizontal frame member 102 spanning a longitudinal distance in an axis parallel to the axis of the excavation bucket 10 lower cutting edge 12. A vertical frame member 103 is connected to an upper midpoint of horizontal frame member 102 and extends upward in a longitudinal direction. Attached to the lower surface of horizontal frame member 102 are end brackets 104 mounted at both distal ends of the horizontal frame member 102, and a center bracket 105 mounted at the center of the horizontal frame member 102. Both end brackets 104 and center bracket 105 have rearwardly and downwardly angled mounting edges planarly aligned to receive and fixedly mount a planar surface of a pressure plate 106 thereto. Additionally, end brackets 104 and center bracket 105 have forwardly facing vertical edges and coplanarly aligned surfaces to receive and fixedly mount the planar surface of an implement mounting plate 107 thereto.
A blade-type implement 108 is rotationally attached to the central portion of the implement mounting plate 107 by means of a stud 109 fixedly attached to the back of implement 108 for passage through an implement mounting plate hole 110 in the center portion of the implement mounting plate 107 and a center bracket hole 111 into a collar 112 fixedly attached to a rearwardly facing surface of the center bracket 105. A threaded end portion of stud 109 projects rearwardly past collar 112 for engagement with a washer 113 and nut 114 for rotationally securing implement 108 relative to the forward surface of implement mounting plate 107.
Implement 108 is able to be rotated with a hydraulic actuating component 115 coupled to a hydraulic implement connection 116 mounted on the implement 108 a longitudinal distance away from the rotational axis of the stud 109, and to a hydraulic frame connection 117. Through standard means of hydraulic actuation, implement 108 is able to be rotated around the rotational axis of the stud 109 while mounted on the implement mounting plate 107 of the fixed frame implement adapter 100.
The implement 108 additionally has two wear plate assemblies 118 attached to the rearward surface of the implement 108 for engagement with longitudinal distil end portions of the implement mounting plate 107. The wear plate assemblies 118 comprises a front wear plate 119 having a forward edge contacting the rearward surface of implement 108, a series of wear plate shims 120 contacting the rearward surface of the front wear plate 119, and a rear wear plate 121 contacting the rearward surface of the rearmost wear plate shim 120. When the wear plate assembly is fastened together and fixed to the rear of implement 108, the inside forward surface of the rear wear plate 121 contacts the rearward facing longitudinally distal end surface of the implement mounting plate 107.
There are two instances when operation of the implement 108 would generated a forward force on the implement causing the implement to separate from the implement mounting plate 107. The first is when the implement 108 is moved against material in a rearward direction, commonly called back-blading, where the implement is dragged rearwardly against working material. The second occurs while the implement 108 moves in a forward direction and only one of the longitudinal edges of the implement 108 catches on working material creating a torsional stress on the opposite edge of implement 108 causing it to move away from the implement mounting plate 107. The wear plate assemblies 118 contacting the implement mounting plate 107 retain the implement from movement in a forward direction thus providing reduced stress upon the stud 109 connection of the implement mounting plate 107 and the implement 108.
An upper vertical frame member 122 is slidingly received by the uppermost portion of vertical frame member 103. A hole in vertical frame member 103 allows for a semi-fixed attachment to the upper vertical frame member 122 with a vertical frame member pin 123 attached at one of a plurality of lengths determined by a plurality of spaced holes on the upper vertical frame member 122. At the uppermost longitudinal end of upper vertical frame member 122 is a coupling frame member 124 which projects in two directions outwardly and orthogonal to the upper vertical frame member 122. Outer coupling frame members 125 are slidingly received by the coupling frame member 124. A hole at each distal end of the coupling frame member 124 allows for semi-fixed attachment to the outer coupling frame members 125 with coupling frame pins 126 attached at one of a plurality of lengths determined by a plurality of spaced holes on the outer coupling frame members 125. At each distil end of the outer coupling frame members is a coupling yoke 127 with a semi-circular opening sized to be rotationally coupled with the excavation bucket wrist pin 15.
Outer horizontal frame members 128 are slidingly received by the outer portions of the horizontal frame member 102. A hole in the horizontal frame member 102 allows for the semi-fixed attachment to the outer horizontal frame member 128 with horizontal frame member pins 129 attached at one of a plurality of lengths determined by a plurality of spaced holes on the outer horizontal frame members 128. At each distil end of the outer horizontal frame member is an outer guide plate 130 and a parallel inward spaced inner guide plate 131. The forward edge of the outer guide plate 130 fixedly attaches to implement mounting plate 107 to improve the rigidity of the implement adapter 100 during operation of the implement. Each guide plate has openings to receive a guide plate fastener 132 therethrough. When each respective forward side edge 11 of the excavation bucket 10 is brought between the outer guide plate 130 and the inner guide plate 131, whereby the attachment holes 19 align with the guide plate openings, the guide plate fasteners 132 can then be inserted manually or automatically, as previously disclosed, through the holes in the outer guide plate 130, the excavation bucket attachment holes 19, and finally the inner guide plate 131.
Parking foot assembly 133 is mounted midway on the vertical frame member 103 by means of a parking frame 134 extending rearwardly and fastened to the vertical frame member 103 with U-bolts 135 and fastening hardware 136. A parking foot 137 slidingly receives the rearmost distal end of the parking frame 134. A hole in parking foot 137 allows for semi-fixed attachment to the parking frame 134 with a parking foot pin 138 attached at one of a plurality of lengths determined by a plurality of spaced holes on parking frame 134. Parking foot assembly 133 is adjusted such that when the adjustable implement adapter 100 is separated from the excavation bucket and rests on a horizontal surface contacting the end portion of the parking foot 137 and either the pressure plate 106 or the implement 108, the coupling yoke 127 will be a sufficient distance from the surface for the coupling wrist pin 15 of an excavation bucket 10 to engage the coupling yoke 127 of the adjustable implement adapter without the need for manual assistance.
An alternative embodiment achieving the same parking function of the parking foot assembly 133, provides a rigid spanner bar between the inside portions of the inner guide plates 131 in a manner similar to spanner 27 of FIG. 1.
To attach the adjustable implement adapter 100 to the excavation bucket 10, the outer coupling frame members 125 are adjusted and fastened with respect to coupling frame member 124 such that the distance between the coupling yokes 127 is the same distance between the coupling surface portions on wrist pin 15. The upper vertical member 122 is adjusted and fastened with respect to the vertical frame member 103 such that fastening holes of the inner 131 and outer guide plates 130 are on the same horizontal plane upon alignment when the coupling yokes 127 are attached to the wrist pin 15. Next, the outer horizontal frame members 128 are adjusted and fastened with respect to the horizontal frame member 102 such that the inner 131 and outer guide plates 130 will receive the forward side edges 11 of the excavation bucket 10 when the adjustable implement adapter is pivotally swung into contact with the excavation bucket 10.
A rearward facing surface of the outer horizontal frame member between each inner 131 and outer guide plates 130 acts as an abutment stop to properly align the slightly oversized openings of the inner 131 and outer guide plates 130 with the attachment holes 19 of the excavation bucket 10, and to be the first load bearing contact with the bucket when the implement 108 generates loading during operation. As additional force is transferred by the implement 108 to the excavation bucket 10, the adjustable implement adapter 100 is restrained from moving in a forward direction at the coupling of the bucket wrist pin 15 and the coupling yokes 127 due to the fulcrum point of the rearward surface of the outer horizontal frame member 128 on the front edge of the bucket side edges 11. A majority of the force generated by the implement 108 is then transferred via the pressure plate 106 through teeth 13 to the lower cutting edge 12.
FIG. 11. Description of an Alternative Embodiment of the Adjustable Frame Adapter for Attachment to Bucket Brackets
Adjustable implement adapter 200 and implement 201 of FIG. 11 is identical in structure to the adjustable implement adapter 100 of FIGS. 9 & 10, except the coupling frame member 124 and corresponding outer coupling frame 125 and coupling yoke 127 (see, FIGS. 9 & 10) have been replaced with an adjustable length T-rod assembly 202 comprising a rod mount 203 and a coupling T-rod 204 projected outwardly and away from the rod mount 203. At each distal end portion of the coupling T-rod 204 is a rod stop 205. T-rod assembly 202 mounts to the excavation bucket 10 in the same manner as illustrated by FIGS. 4-7, i.e., by coupling the T-rod 204 to the bucket brackets fixedly mounted on the inside forward edges the bucket side edges.
Depending on the length of the coupling T-rod 204, the adjustable implement adapter 200 can be used in conjunction with the bucked mounted brackets on any excavation tool where the width between the side edges of the bucket is less than or equal to the length of the coupling T-rod 204. Coupling T-rod 204 provides for a continuously adjustable bearing surface along the longitudinal axis of the rod to receive the corresponding journal surfaces of the bucket brackets.
FIGS. 12 & 13. Description of an Adjustable Frame Implement Adapter with a Hydraulically Rotating and Skewing Blade Implement
Implement adapter 300 of FIGS. 12 & 13 illustrate an alternative embodiment to that of implement adapter 200 of FIG. 11 which allows the implement to be skewed, or rotated about a vertical axis while mounted to the implement adapter. The lower portion of the adjustable frame 301 has centrally located frame hinge fittings 302 rotatably coupled by a hinge pin 303 to corresponding hinge fittings 305 on the implement mounting plate 304. The implement 306 is positioned in a forward direction away from the forward surface of the adjustable frame 301 which allows the implement 306 to be rotated around the hinge pine 303 during operation.
Skewing hydraulic actuators 307 are attached to skewing tabs 308 mounted on a top outward portion of each longitudinal end of the implement mounting plate 304. The opposite end of the skewing hydraulic actuators 307 are affixed to a parking spanner 309. Each distil end of the parking spanner 309 is attached to a rearmost upper portion of an extended inner guide plate 310. Hydraulic skewing of the implement about the vertical axis of the hinge pin 303 takes place when each hydraulic actuator 307 extends or retracts in a direction opposite the other to induce a rotational moment of the implement 306 around the axis of the hinge pin 303. Additionally, as described previously in the invention of FIGS. 1-5 & 9-11, implement 306 can be rotated around a horizontal axis in the forward direction by means of another hydraulic actuator 311 mounted between an implement mounted bracket and an implement mounting plate bracket 312. Thus, implement adapter 300 is enabled to rotatably articulate the implement 306 along two axes orthogonal to each other giving the operator control over an additional range of motion for the implement.
The extended inner guide plate 310 in combination with the parking spanner 309 functionally serves a rigid attachment point for the skewing hydraulic actuators 307, and additionally serves as a parking support for the adjustable implement adapter 300. This parking support allows a top coupling portion of the frame 301 to remain a distance above a surface the implement adapter rests upon when detached from an excavation tool. The distance the top coupling portion of the frame 301 maintains with the resting surface of the implement adapter 300 allows for an excavation tool to engage and disengage the implement adapter 300 without the need for any manual assistance.
Parking spanner 309 can also be configured to adjust in length relative to the adjustable width feature of the horizontal frame member of frame 301. In this configuration, parking spanner 309 comprises a central fixed length member that mount each of the rearward ends of the skewing hydraulic actuators 307 and separate members having a plurality of attachment points fastened to each end of the central fixed length member and the upper distal ends of the extended inner guide plates 310. This adjustable configuration provides for fixed points of attachment for the skewing hydraulic actuators 307 while still allowing the implement adapter 300 to mount on excavation tools of various widths.
In summary, the configuration of the sparking spanner 309 in combination with the inner guide plate extension 310 provides a three-fold purpose for implement adapter 300: a locating guide for attachment of the implement adapter 300 to an excavation tool; a parking foot that orients the geometry of the implement adapter 300 for non-assisted attachment to an excavation tool; and a fixed point of attachment for actuators 307 that enable an implement 306 to be rotated about a vertical axis.
Where hydraulic actuation is unavailable to skew implement 108, an alternative embodiment of implement adapter 300 would replace hydraulic actuators 307 with a rigid fastening element able to be manually fastened to skewing tabs 308 and the parking spanner 309 along a plurality of fastening positions. Thus, an operator is able to manually skew and angularly affix the implement 108 by changing the fastening positions of the rigid element while connected to the skewing tabs 308 and the parking spanner 309.
FIGS. 14 & 15. Description of an Adjustable Frame Implement Adapter with a Hydraulically Tilting Scarifying Rake Implement
FIGS. 14 & 15 illustrate an adjustable frame implement adapter 400 similar to the bucket bracket mounted adjustable implement adapter 200 of FIG. 11, except that the blade-type implement has been replaced with a hydraulically tilting scarifying rake assembly 401. Adjustable frame implement adapter 400 is coupled via the coupling T-rod 204 to the excavation bucket 10 with the bucket brackets 67 attached at the bucket mounting holes 68. Vertical frame member 402 connects the T-rod 204 to the adjustable horizontal frame member 403 whose outer horizontal frame members 404 connect to a lower forward portion of the excavation bucket 10 at the attachment holes 19. Parking foot assembly 133 is connected to and extends rearwardly into the excavation bucket 10 opening from a middle portion of the vertical frame member 402.
The scarifying rake assembly 401 is attached to the lower portion of the vertical frame member 402 that extends below the horizontal frame member 403. A first portion of an implement mounting bracket 405 is attached to a forward surface of the vertical frame member 402 and a second portion extends in a forward direction a distance sufficient to hold an implement between the first and second portion. A scarifying rake implement 406 having a plurality of teeth 407 is rotatably coupled at its midpoint between the first and second portions of the implement mounting bracket 405 by a pivot pin 408. This allows for the scarifying rake implement to be rotated around the pivot pin 408 relative to the adjustable frame implement adapter 400. A hydraulic actuating mechanism 409 controls the rotational movement of the scarifying rake implement 406 by attachment to a frame bracket 410 on the vertical frame member 402 and to an implement bracket 411 located on a portion of the scarifying rake implement 406 between its distil longitudinal end and the pivot pin 408.
FIGS. 16 & 17. Description of an Alternative Embodiment of an Adjustable Frame Implement Adapter for Connection to a Lower Portion of an Excavation Bucket Cutting Edge
An alternative embodiment of the adjustable frame implement adapter of FIGS. 9-15 is an adjustable frame implement adapter 500 mounted on a lower cutting edge of an excavation bucket. FIGS. 16 & 17 show an upper coupling assembly 501 coupled to an excavation bucket 502 wrist pin 503 (similar to the invention of FIGS. 9 & 10), an adjustable vertical frame member 504 (similar to the invention of FIGS. 9-15), and an adjustable horizontal frame member 505 (similar to the invention of FIGS. 9-15). The adjustable frame implement adapter 500 receives an implement mounted plate for mounting a working implement (not shown) on the forward lower surface of the adjustable vertical frame member 504 and the forward surface of the adjustable horizontal frame member 505 in a similar manner to the invention disclosed in FIGS. 9-11.
A rearwardly projecting mounting foot 506 is attached at a first portion 507 to the lower surfaces of each outer adjustable horizontal frame member 508. The mounting foot 506 has a second portion 509 projecting rearwardly from the first portion 507 at an angle relative to the first portion 507 which allows the second portion 509 to lie flush upon the inner lower surface 510 of the excavation bucket 502. The adjustable frame implement adapter 500 is connected to the excavation bucket by each second portion 509 of the mounting foot 506 having an slightly oversized attachment hole through which a fastener 511 is inserted for receipt in an aligned hole in the lower cutting surface 510 of the excavation bucket 502.
A third portion 512 of the mounting foot 506 projects rearwardly from the second portion 509 at an angle of approximately fifteen degrees relative to the second portion 509 and the inner lower surface 510 of the excavation bucket 502. Additionally, the third portion 512 spans continuously between each of the second portions 509. The third portion 512 of the mounting foot 506 enables the adjustable frame implement adapter 500 to be held in a parked position for maintaining the upper coupling assembly 501 at a sufficient height above a surface when the implement adapter 500 is detached from the excavation bucket 502 and supported on the surface by the third portion 512 of the mounting foot and a lowermost portion of either the frame or the working implement. The height at which the upper coupling assembly 501 is held by the third portion 512 of the mounting foot 506 enables engagement of the upper coupling assembly 501 with the wrist pin 503 on the excavation bucket 502 without the need for any manual assistance.
An alternative embodiment of the third portion's 512 connection to the second portion 509 is by use of removable fasteners. This allows the third portion 512 to have a plurality of fastener positions with respect to a single mating fastener element on the second portion 509 thereby operating in a complementary fashion with the adjustable horizontal frame member 505.
Integrally attached to each of the lower surfaces of the first portions 507 of the mounting foot 506 are abutment tabs 513 (FIG. 19), having a vertical rearwardly facing surface for engagement with the lower forward cutting edge 514 of the excavation bucket 502. The abutment tabs 513 coupled with the oversized attachment holes in the second portions 509 of the mounting foot allow for movement of the lowermost portion of the adjustable frame implement adapter 500 relative to the forward cutting edge 514 of the bucket 502. While operating an implement mounted on the vertical 504 and horizontal 505 frame member, the implement transmitted loading moves the abutment tabs 513 into engagement with the forward cutting edge 514 of the bucket 502. This engagement arrangement transfers the load to the forward cutting edge 514 to prevent shear loading of the fasteners 511 while connecting the adjustable frame implement adapter 500 to the bucket 502.
FIGS. 18 & 19. Description of an Excavation Thumb Mounted Adjustable Frame Implement Adapter
The excavation tool assembly in FIGS. 18 & 19 include an excavation thumb mounted adjustable frame implement adapter 600 attached to an excavation thumb 601. Excavation thumb 601 comprises multiple parallel arms (see FIG. 17) each pivotally joined at a longitudinal end to distal ends of the excavation bucket wrist pin 15. Near a middle portion of each excavation thumb 601 is a flange 602 for attachment to one end of a hydraulic actuator 603. The second end of the hydraulic actuator 603 is attached (not shown) to the boom arm 604 for rotationally displacing the excavation thumb 601 into and out of engagement with the teeth 13 at the lower forward cutting edge 12 of the excavation bucket 10.
A connection rod 605 is attached by fasteners 606 at an inside middle portion of each excavation thumb 601. The connection rod 605 is coupled to a pair of coupling yokes 607 of the excavation thumb mounted adjustable frame implement adapter 600. Coupling yokes 607 are connected to an adjustable coupling frame member 608 which allows the distance between the coupling yokes 607 to be adjusted for different sized connection rods 605, as similarly described in the invention of FIGS. 9 & 10. The adjustable coupling frame member 608 is connected to an adjustable frame member 609 having a lower adjustable horizontal frame members (not shown) similar to the invention disclosed in FIGS. 9-15 each having a guide plate assembly 610 connected to the outer distal ends of the lower adjustable horizontal frame member (in a similar manner to FIGS. 9-15). Each guide plate assembly 610 is connected to a lower portion of the excavation thumb via a fastener coupled through a connection hole 611 in the guide plate assembly 610 into a corresponding receptacle in the lower portion of the excavation thumb 601.
An implement mounting plate 612 is attached to a lower portion of the vertical frame member 609 and the lower adjustable horizontal frame member for rotatably mounting an implement 613. One end of a hydraulic actuator 615 is attached to a frame connection plate 614 fixed to both the horizontal and the vertical frame member 609, and the other end to an implement mounting bracket 616 on the implement 613. Hydraulic actuator 615 enables rotational displacement of the implement 613 around a centrally located rotational attachment to the excavation thumb mounted adjustable frame implement adapter 600 similar to the invention disclosed in FIGS. 1-5 & 8-11.
The advantages of an excavation thumb mounted implement adapter on a excavation tool assembly enables the initial coupling of the implement adapter 600 to the excavation thumb without manual assistance when the implement adapter rests on a surface supported by the guide plate assembly 610 and the lower portion of either the adapter frame or the implement. The mounting arrangement of the implement adapter on the opposite side of the excavation thumb's engaging surface allows for the unhindered operation of the excavation thumb without interference from the mounted implement adapter and the implement. Since the implement can be quickly swung into and out of a working position with the movement of the excavation thumb, the bucket or another excavation tool can be used while the excavation thumb and implement are in a retracted position 617. This eliminates the need to remove the implement adapter from the excavation tool, in this case the excavation bucket, when the excavation tool is desired be used alone.
Additionally, alternative attachment means would replace the coupling yokes 607 of the excavation thumb mounted adjustable frame implement adapter 600 with a T-rod similar to the T-rod 204 of FIG. 11, for reception by bearing surfaces in the excavation thumb mounted brackets.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | An implement adapter for providing improved excavation versatility that couples with and attaches to an excavation tool assembly for mounting a working implement thereon. The implement adapter comprises a frame for holding a working implement, wherein the frame is coupled and semi-fixedly attached to an excavation tool assembly. A parking projection holds the coupling element of the frame at a sufficient height above a surface when the implement adapter is detached from the excavation tool assembly and supported on the surface by the parking projection and a lowermost portion of either the frame or the working implement. The height at which the coupling portion is held by the parking projection enables engagement of the coupling portion with a cooperative coupling element on the excavation tool assembly without the need for any manual assistance. Additionally, the implement adapter is capable of mounting upon various sizes of excavation tools and articulating attached working implements in multiple ranges of motion. | 4 |
This is a continuation of application Ser. No. 08/070,941 filed on Jun. 4, 1993, now abandoned.
FIELD OF THE INVENTION
The invention concerns an osteosynthetic fastening device, specifically a pedicle screw or a spinal column hook designed to be attached to a support rod.
BACKGROUND OF THE INVENTION
A fastener of this type, of particular application in spinal column surgery, is described in DE-U1 89.15,443.6. In essence that device consists of a lower part having the shape of a screw or a blade for attachment to a bone; and, adjoining the lower part, an upper part for fastening onto a rod. A channel that is open toward the top is formed in the upper part; this channel is bordered by two side walls between which the rod can be contained. Attachment of the rod within the channel is achieved by a threaded stud that can be screwed in. The lower end of this stud, which is meant to be engaged with the rod, is provided with attachment devices in the form of one or more sharp points.
The sharp points that are engaged during screwing in of the threaded stud between the two side walls of the body into the rod positioned there, dig at several locations into the surface of the rod and effect a stable attachment of the rod relative to the body. A disadvantage of this design, however, is that contact between the rod and the threaded stopper is at several separate locations, which can easily loosen if forces are exerted between the rod and the fastening device, as is common in the spinal column area. Forces which affect the rod act through long lever arms on the points which are engaged at separate locations. These lever arms can cause a sudden and irreversible loosening of fixation when very small increments of force are applied.
The invention provides a remedy for this problem by providing an osteosynthetic bone fastener of the type described, which will retain a tight clamping action when forces are applied, or else create a self-clamping effect so that loosening of the parts attached to each other is prevented.
SUMMARY OF THE INVENTION
In accordance with the invention, an osteosynthetic fastening device, useful as a pedicle screw or hook, is provided having a longitudinal axis, a lower portion for attachment to a bone and an upper portion adjoining the lower portion along the longitudinal axis, said upper portion having a transverse channel for receiving a longitudinal support rod, a cylindrical socket with an axis coaxial with said longitudinal axis and a fixation element in said socket, said fixation element having a cavity and a spherical contact element in said cavity, protruding from the bottom of said cavity, thereby to contact a support rod in said transverse channel.
As noted, the fastening element according to the invention has on the lower end of its fixation part a spherical element, located in a cavity and partially protruding from it. The spherical element is preferably movable. As compared to conventional fixation hardware, this design has the advantage of adapting itself automatically to the direction of the rod. Thanks to the geometry of the sphere, which permits compensation by rolling motion, a lasting, continuous clamping effect can be maintained.
The spherical element may be in the form of a segment of a sphere, or a spherical layer, so that support and clamping are linear instead of at discrete points.
If the sphere or partial sphere is movable, then when translational motion between the spherical element and the longitudinal support occurs, because of friction, the sphere seeks to turn, which leads to a skewness and thus even to an increase in the clamping.
In another embodiment of the invention, the spherical element is provided with a concave circular or cylindrical countersink, perpendicular to a radius of the spherical element, to allow an interlocking fit onto the longitudinal support rod. This permits a durable surface contact to be achieved.
In yet another embodiment of the invention, the spherical element is provided with a concave spherical countersink, perpendicular to a radius of the spherical element, for the purpose of allowing an interlocking fit onto a slip-on spherical collar on the longitudinal support rod. If, owing to application of a force to the longitudinal support, the spherical collar tends to turn in any direction, the spherical element with the spherical countersink tends to move in the opposite direction due to friction, which again leads to an increase in the clamping action.
In yet a further embodiment of the invention, an improvement can be achieved by having between the lower section of the longitudinal support rod and the floor of the transverse channel an additional element. For this purpose the floor of the socket is formed with a concave surface in the shape of a circular cylinder, whose cylindrical axis is perpendicular to the longitudinal axis and goes through the center of the sphere (when the sphere is seated on the longitudinal support rod). Between the floor and the longitudinal support rod a tipping piece or part can be placed, whose one convex side corresponds to the surface of the socket, and whose other side, being concave with the shape of a circular cylinder, matches the surface of the longitudinal support rod. The cylindrical axis of the convex side runs perpendicular to the longitudinal support rod. By means of this additional tipping piece, which rotates about the same axis as the sphere, a complete adaptation is possible within a considerable angular range to any changes in angle between the longitudinal support rod and the fastener, without loosening the clamping action between the individual parts.
Preferably in this configuration the floor of the socket is formed either with toothed surface or a wedge geometry. The convex surface of the tipping piece can be shaped in an analogous way. The preferred combinations of surfaces coming into contact with each other are as follows:
______________________________________Tipping Piece Socket______________________________________toothed/hard material smooth/soft materialsmooth/soft material toothed/hard materialtoothed toothedwedge-shaped geometry wedge-shaped geometry of theof the longitudinal sides longitudinal sides______________________________________
Preferably the transverse channel is made to be open at the top, in such a way that the upper cutout forms a U-shaped accommodation with two side walls for the longitudinal supports. In this configuration both of the flanks may be secured by a stabilizer cap, since the flanks have a tendency to open up when the fixation hardware is screwed in. For special applications, however, the passageway channel can remain closed at the top, so that no stabilizer socket is necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described further with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a fastener according to the invention with a sphere as the essential fastening part.
FIG. 2 is a perspective view of another embodiment of the invention with a spherical part as the essential fastening part.
FIG. 2A is an elevational view of a contact element which has a flat contact surface.
FIG. 3 is a perspective view of an embodiment of the invention with an additional tipping piece.
FIG. 4 is a partial longitudinal section through a closed fastener according to FIG. 3.
FIG. 5 is a perspective view of the tipping piece of FIG. 3.
FIG. 6 is a cross section through another embodiment of the invention having a supplementary stabilizer socket.
FIG. 7 is a partial longitudinal section through yet another embodiment of the invention with a supplementary collar for a longitudinal support rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a fastener according to the invention has a bottom portion 2 that can be anchored in bone and an adjoining top portion 3 which is aligned with the longitudinal axis 1 of the fastener. The end of lower portion 2 can be shaped as a screw (e.g. as a pedicle screw) or a curved blade (e.g. a spinal column hook).
The upper portion 3 contains a channel 4 that is open toward the top and is transverse to the longitudinal axis 1. The channel 4 of the upper portion 3 is U-shaped with two side walls 26 facing each other, and a rounded floor in which a longitudinal support rod 5 may be easily inserted. The upper portion of the channel 4 in addition forms a socket 6, shaped like a cylinder parallel to the longitudinal axis 1. On the inside of the socket 6, i.e. on the inner sides of each of the walls 26, an interior thread 11 is provided. For closing the socket 6 and clamping the longitudinal support 5 between the two side walls 26, a fixation element 7 in the form of a circular cylinder is provided. The element 7 has exterior threading 12 which engages the interior threading 11.
On its bottom 8, which is intended to adjoin the longitudinal support rod 5, the fixation element 7 has a cavity 9 which is a segment of a sphere. Into this cavity a sphere 10 is fitted so as to be able to turn. It protrudes partially from the cavity 9.
On its top end 16 the fixation element 7 has a polygonal socket 17 running in the direction of the longitudinal axis 1. Into this socket a suitable instrument such as a hex wrench can be inserted to screw the fixation part 7 into the interior threading 11 between the two side walls 26 and clamp it securely against the longitudinal support 5.
Referring to FIG. 2, in another configuration of the fastener according to the invention, in which instead of a full sphere only a spherical part 25 (actually a spherical layer) is provided. The spherical part 25 is either flat on one side shown as 25a in FIG. 2A or has a concave circular-cylindrical countersink 13, perpendicular to its radius, for an interlocking fit with the longitudinal support rod 5. The concave surface 13 is naturally fitted to the surface geometry of the longitudinal support rod 5 that is employed, i.e. it must have the same curvature to achieve the optimum effect, which is to create a durable surface contact between the surface 13 of the spherical part 25 and the longitudinal support rod 5.
Referring to FIGS. 3-5, in another embodiment of the invention, the floor 18 of the channel 4 has a concave, cylindrical surface, whose cylindrical axis 19 is perpendicular to the longitudinal axis 1 and through the center 20 of the spherical element 25 (when the element 25 is seated on the support rod 5). An additional tipping part 21 that can be placed between the floor 18 and the longitudinal support rod 5, permits a coaxial rotation synchronized with the spherical part 25. The tipping part 21, which is depicted in detail in FIG. 4, has a convex surface 22 that matches the surface 18 of the channel 4 on one side, and a concave cylindrical surface 23 which matches the surface of the longitudinal support 5. The cylindrical axis of the surface 23 runs perpendicular to cylindrical axis 19. The center of rotation of the tipping piece 21 is identical with the center 20 of the spherical cavity 9 in the fixation part 7, when the fixation part 7 is tightened.
Referring to FIG. 6, yet another embodiment of the invention has the floor 18 of the channel 4 of the upper portion 3 provided with wedge-shaped walls 27 parallel to the channel 4; matching them are wedge shapes in the outer longitudinal sides 28 of the tipping part 21.
In FIG. 6, the concave surface 23 of the tipping part 21 is provided with longitudinal toothing 29, which corresponds to matching longitudinal toothing 30 of the longitudinal support rod 5, so that after tightening of the fixation part 7, the longitudinal support 5 is protected against torsion.
Lastly, the upper portion 3 has a stabilizer cap 31 that can cover over the two sides 26. It has a central borehole 34, and it protects the two sides 26 from spreading, as can occur when the fixation part 7 is screwed in and tightened.
Instead of having a polygonal slot 17 (FIGS. 1-3), in the configuration of FIG. 6 the fixation element 7 is provided with a threaded bore 32 and a transverse slot 33 for a screwdriver-like instrument. Such a configuration facilitates putting the fixation part 7 in as well as manipulating it and tightening it.
Lastly, referring to FIG. 7, another embodiment of the fastener according to the invention has a spherical part 25 (here in the form of a spherical segment) equipped with a spherical countersink 14, perpendicular to the radius of the spherical part 25. This countersinking 14 permits an interlocking fit onto a slip-on spherical collar 15 on the longitudinal support rod 5. The collar 15 has a central borehole with a slot 29, to permit a spring-mounted attachment on the longitudinal support rod 5. Also in this configuration the spherical surfaces of the collar 15 and the countersink 14 must be adjusted to each other, i.e., must have the same curvature. | An osteosynthetic fastening device, preferably in the form of a pedicle screw or a spinal column hook, has a channel in its upper section for receiving a support rod and a retaining element which clamps the rod in the socket through a spherical contact element. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority under 35 USC §119 to U.S. Provisional Patent Application No. 61/397,228 filed on Jun. 7, 2010.
TECHNICAL FIELD
The present invention is in the technical field of weight/strength training devices. More particularly, the present invention is in the technical field of dumbbell training systems, including an adjustable dumbbell training device/system.
BACKGROUND OF THE INVENTION
Various prior art publications relate to fee weight devices. For example:
Prior art reveals a weight adjustable dumbbell for performing a push up (US20100022365) Steve Ngu (Jan. 28, 2010); Prior art reveals a dual purpose dumbbell (US20090156375) Pang-Ching Chiang (Jun. 18, 2009); Prior art reveals a dumbbell weight training device with detachable weight plates (US20090048079) Mark Nalley (Feb. 19, 2009); Prior art reveals a dumbbell weight training device with detachable weight plates (U.S. Pat. No. 7,588,520) Mark Nalley (Sep. 15, 2009); Prior art reveals a fitness dumbbell with an ornamental design of a circle with a handle through the middle. (USD575,361) Charles P. Davis (Aug. 19, 2008) and (USD274,283) Forrest S. Wright (Jun. 12, 1984); Prior art reveals a fitness dumbbell with an ornamental design of an oblong circle with a handle through the middle. (USD244,628) Forrest S. Wright (Jun. 7, 1977); Prior art reveals a fitness dumbbell with an ornamental design of a three layered circle with a handle through the middle (USD438,265) Paul J. Fenelon (Feb. 27, 2001); Prior art reveals a pushup exercise device that allows the user to perform pushups with the wrists in a neutral position with a rotating handle however it does not provide any significant external weight that would allow the user to perform more than just pushups with the device (D597,153) Mark B. Friedman (Jul. 28, 2009).
As is known in the art, a dumbbell is a conventional weight training device that has long been used by body builders and others to improve their physical strength and appearance as part of a weight training or exercise program. Such a dumbbell typically includes a cylindrical gripping handle that carries a pair of weight plates at opposite ends thereof. In this regard, the weight plates are typically fixedly and connected to the ends of the gripping handle. Should the user wish to increase the weight to be lifted, he/she must find an altogether different dumbbell. In such devices, there is no way for the user to selectively adjust or progressively change the weight of a dumbbell to be used during a workout, such that the gross weight of each dumbbell remains the same at all times.
As a consequence of the foregoing, the fitness center or the user (should the person elect to exercise at their home or office) must maintain many different dumbbells having characteristically different gross weights. Accordingly, the cost to acquire a variety of dumbbells and the space consumed as a result thereof are undesirably increased. Moreover, the user's ability to easily and quickly expand his/her personal weight training program is hampered by the requirement to have ready access to such different dumbbells.
Nevertheless, a number of commercially available adjustable weight dumbbell system are available, such as shown in U.S. Pat. No. 5,839,997 and others. These dumbbell systems are typically mechanically complicated and potentially unstable as they rely on locking mechanisms that can become faulty with progressive use. Therefore, users may experience either confusion which may lead to mistakes when attempting to vary the gross weight of the dumbbell during a workout, or training accidents which can be potentially dangerous.
Likewise a commercially available rotating pushup device is available (e.g., U.S. Pat. No. 7,468,025) that allows the user to perform a pushup exercise while freely rotating the wrists through supination and pronation which allows for increased chest, shoulder, forearm and triceps muscle recruitment without compromising wrist joint integrity. This system however is significantly limited in its strength building applications beyond just this one exercise as it does not allow the user to utilize the device for any other form of overloaded exercise. The muscle overload that is lacking from this device prevents it from being used for any other strength building purpose (as a traditional dumbbell would) than the push up exercise that it is used for. The limitation to the user to just performing pushups with this device will compromise their potential total body strength gains by not allowing them to use the device to train their legs, back, abs, and the aforementioned muscles (chest, shoulders, forearms, triceps) in more direct, diverse and multiple ways.
SUMMARY OF THE INVENTION
Hence, what is desirable is a mechanically simple and easy-to-use dumbbell weight training device having a series of interchangeable weighted arms with correspondingly different weights that are configured to be detachably connected to one another or to the base device in many different combinations so that the gross weight of a single dumbbell may be selectively and progressively varied to conform to the weight training program of the user. Additionally, the asymmetrical loading made possible through the present invention enables off balance loading which can increase muscle fiber recruitment and/or vary the recruitment pattern of muscle fibers in the working muscles so as to produce a stimulus needed for adaptations in strength and muscle growth. Finally, a rotating pushup device that can alternatively or additionally be used as a dumbbell strength training device either from within the position assumed during the pushup exercise or any other body position that can increase the number of exercises and muscle groups targeted by the training tool to make it a much more versatile and complete tool for the user, is needed. The versatility of the present invention allows the user to complete virtually every exercise without needing multiple training devices or dumbbells to accomplish the task.
The present invention provides a different configuration and appearance as compared to a traditional dumbbell, as well as an entirely new device for challenging the muscles worked with traditional dumbbells in a new way due to the change in weight distribution to an “X” shape that the dumbbell training device assumes. Furthermore, the ability to train while holding individual arms of the device creates an additional asymmetrical loading pattern that places an additional productive stress on the muscle being worked (when compared to a traditional dumbbell) and therefore makes it a more functional training device when being used to strengthen muscles for the asymmetrical force loads that they will be subject to during the course of sport activities. Next, the ability of the current invention to rotate freely while performing closed chain exercises (with the dumbbell resting on the ground), provides both the biomechanical comfort to normal wrist mechanics that is not afforded by traditional fixed arm dumbbells, as well as the opportunity to at any point in time revert to traditional technology and assume this fixed position once the device is lifted off the ground. Finally, the current invention provides the user with the opportunity to alter the force load (either symmetrically or asymmetrically) by attaching, detaching, or reattaching, various weighted “arms of the X”, classifying this invention in the category of an adjustable dumbbell system as well, without the need for complicated locking mechanisms, pin mechanisms, etc that are susceptible to mechanical breakdown and confusion on behalf of the novice user, since the present invention provides a simple threaded screw attachment for applying and undoing of the arms.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the present invention, reference is made to the following figures, in which:
FIG. 1 is a side perspective view of an adjustable weight (dumbbell) training system according to the present invention;
FIG. 2 is a top view of an adjustable weight (dumbbell) training system according to the present invention;
FIG. 3 is a ground side perspective view of a core unit of an adjustable weight (dumbbell) training system according to the present invention with the arms detached from the core unit as shown in FIGS. 3A and 3B .
FIG. 3A is a perspective view of an arm of the adjustable weight (dumbbell) training system according to the present invention showing a threaded extension for threaded engagement with threads of a threaded recess in the core unit or in a threaded recess of another arm.
FIG. 3B is a perspective view of an arm of the adjustable weight (dumbbell) training system according to the present invention showing a threaded recess for threaded engagement with the threaded extension of another arm.
FIGS. 4-6 are diagrammatic views of the adjustable weight training system showing some of the various configurations of the arms with respect to the core unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As best seen in FIGS. 1-3 , an embodiment of an adjustable dumbbell weight training device 20 according to the present invention comprises a core unit 1 having a contoured plate 22 with elevated end points that act as a supporting platform for an attached handle 2 . The plate may be fabricated from aluminum. The core unit can be made of steel, cold roll, stainless steel, high strength plastic or polyvinyl chloride (PVC) depending on the desired total weight. The core unit may have a smaller diameter than shown in FIG. 1 if it is desired to have the overall size of the device more compact (such as for a travel-friendly version of the invention). The areas of the plate that elevate, form sides 3 which are located approximately 180 degrees opposite each other and are shaped to have a height so as to create enough of an elevation of the handle to allow for the user to grip the device without having their knuckles uncomfortably in contact with platform 4 (see FIG. 2 ) of the core unit below it. The handle is typically 1.5″ in diameter and 7″ in length and is covered by a durable rubber sleeve 5 that is typically 5″ in length. The sleeve 5 is used to increase traction of the user's hand on the device to provide support stability and support during use. The handle is held in place by, for example, one hex-wrench compatible screw 6 on each end (see FIG. 2 ).
As seen in FIG. 1 , the core unit may be attached to a base 7 that has a thin platform that can be made of either high strength plastic, PVC, aluminum, steel, stainless steel or cold rolled steel. To make the surface of the device non-slip in nature, the bottom of the base can be covered in a 7.5″ diameter piece of rubber or equivalent non-slip material 28 that is affixed thereto, such as with glue, press fit, or adhesive. The base has a 3.25″ square lazy susan type ball bearing device 8 (shown in phantom) that is centered on the base and allows for the core unit and its fixed handle to rotate freely in either direction as shown by arrows 24 relative to base 7 when the user applies an appropriate force to either the handle or the arms 9 as described below.
Connected to the core unit at an arm cradle region 10 on the sides 3 of the unit are either zero, one, two, three, or four cylindrical arms 9 that are attached or detached via a simple 0.5″ threaded extension 11 . A threaded recess 26 is formed in each arm cradle region 10 for mating with a threaded extension 11 of an arm 9 . The arms can be 5″ in length or longer depending upon the desired total weight of the arm as it relates to altering the weight of the device for a desired training effect. The arms can be made, for example, of steel, cold roll, stainless steel, aluminum, or lead capped depending upon the total desired weight of the device for a desired training effect. The arms can be of thinner diameter to accommodate a smaller hand or thicker to accommodate a larger hand. The arms can assume alternate shapes and do not have to be cylindrical in shape. They can have an octagonal, square, or hexagonal shape, for example. The arms can have a knurled texture across its entire longitudinal periphery to increase the traction and ease of grip for the user. Alternatively, the arms can be covered in a similar rubber sleeve as appears on the handle for the same purpose. The arms are connected at such a height (such as 1.75″) to allow the user to assume a prone plank position (standard pushup position) gripping polar opposite arms, one with each hand, and having enough clearance between the floor or exercising surface without making uncomfortable contact between the user's knuckles and said floor or surface. Finally, the arms each can have a 0.5″ threaded hole 12 centrally located on one end that allows for other arms or potential future attachments to be connected to each other (via threaded extension 11 ) to significantly alter the training effect of the device by changing its weight distribution and potential function greatly. One, two, three or four of the arms may be connected to each other in series to create various configurations of the present invention for different strength training purposes or exercises.
The weight training device can be configured in various configurations. The user may then use the present invention in these different combinations (utilizing the arms and the core as described above) to elicit various training effects and to target different muscles. In its primary configuration, as shown in FIGS. 1 and 2 , the user can attach each of the four arms 9 to the core unit 1 by screwing in the either four equally weighted arms or four unequally weighted arms. The user can then perform exercises while either gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.) one arm with two hands, one arm with one hand, any combination of two arms with two hands, or one arm and the handle with two hands. The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle or arms for the desired training effect.
As shown in FIG. 4 , the user may use the present invention in an alternative configuration whereby the user can attach three arms to the core unit by screwing in either three equally weighted arms or three unequally weighted arms. The user can then perform exercises while either gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.) one arm with two hands, one arm with one hand, any combination of two arms with two hands, or one arm and the handle with two hands. The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle or arms for the desired training effect.
As seen in FIG. 5 , the user may also use the present invention in an alternative configuration whereby the user can attach two arms to the core unit by screwing in either two equally weighted arms or two unequally weighted arms. The arms can be connected either adjacent to each other in the 30 degree apart configuration (arms 9 ′ and 9 ″), adjacent to each other in the 150 degree apart configuration ( 9 ′ and 9 ″), or opposite each other in the 180 degree apart configuration ( 9 ′ and 9 ). The user can then perform exercises while either gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.) one arm with two hands, one arm with one hand, two arms with two hands, or one arm and the handle with two hands. The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle or arms for the desired training effect.
As seen in FIG. 6 , the user may use the present invention in an alternative configuration whereby the user can have multiple arms 9 attached to each other (threaded section 11 screwed into threaded recess 12 of the adjacent arm) and secured to one threaded section 26 of core unit 1 . The user can then perform exercises while either gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.) one arm with two hands, one arm with one hand, or one arm and the handle with two hands. The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle for the desired training effect. FIG. 6 shows four arms connected to each other and connected to the core at one threaded recess thereof.
The user may further use the present invention in an alternative configuration whereby the user can use just the core unit 1 (as shown in FIG. 3 ) without any arm attachments. The user can then perform exercises while gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.). The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle for the desired training effect.
As shown in FIG. 5 , the user may also use the present invention in an alternative configuration whereby the user can attach four total arms (e.g., 9 ′, 9 *; 9 , 9 **) with two arms attached to the core unit by screwing in either two equally weighted arms or two unequally weighted arms. The arms connected to the core can be either adjacent to each other in the 30 degree apart configuration, adjacent to each other in the 150 degree apart configuration, or opposite each other in the 180 degree apart configuration. The remaining two arms can be attached one each to the ends of each of the already attached arms via the threaded opening at the end of the arm. This will effectively lengthen the total individual arm length to 10″ in the present configuration (or shorter/longer depending upon the weight of the arms selected). Alternately, the user can attach all four arms on end to each other and then connect this to the core via one of the threaded openings. The user can then perform exercises while either gripping the handle with one or two hands (on the floor, seated, standing, reclined, prone, supine, lying on a bench, lying on a physioball, lying on the floor, kneeling, etc.) one arm with two hands, one arm with one hand, two arms with two hands, or one arm and the handle with two hands. The user may decide to rotate the core upon the base by directing a pronation or supination force through the handle or arms for the desired training effect.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. | An adjustable weight training device includes a core unit which has a substantially flat, rotatable, base with a pair of sides extending away from the base, the sides separated from each other so as to provide for attachment of a handle across the sides, wherein the handle is positioned above the base and dimensioned for gripping by a user's hand. The sides of the core unit include arm cradle regions which are dimensioned for removable receipt of an arm, wherein the arms are dimensioned for removable attachment to the arm cradle regions in the sides of the core unit and extend away from the sides so as to provide for gripping by a user's hand. The arms can be selectively attached to the arm cradle areas and to each other so as to create different configurations of the weight training device. | 0 |
[0001] The present invention relates to novel compounds selected from 2-(3-aminoaryl)amino-4-aryl-thiazoles that selectively modulate, regulate, and/or inhibit signal transduction mediated by certain native and/or mutant tyrosine kinases implicated in a variety of human and animal diseases such as cell proliferative, metabolic, allergic, and degenerative disorders. More particularly, these compounds are potent and selective c-kit inhibitors.
[0002] Tyrosine kinases are receptor type or non-receptor type proteins, which transfer the terminal phosphate of ATP to tyrosine residues of proteins thereby activating or inactivating signal transduction pathways. These proteins are known to be involved in many cellular mechanisms, which in case of disruption, lead to disorders such as abnormal cell proliferation and migration as well as inflammation.
[0003] As of today, there are about 58 known receptor tyrosine kinases. Other tyrosine kinases are the well-known VEGF receptors et al., Nature 362, pp. 841-844, 1993), PDGF receptors, c-kit and the FLK family. These receptors can transmit signals to other tyrosine kinases including Src, Raf, Frk, Btk, Csk, Abl, Fes/Fps, Fak, Jak, Ack. etc.
[0004] Among tyrosine kinase receptors, c-kit is of special interest. Indeed, c-kit is a key receptor activating mast cells, which have proved to be directly or indirectly implicated in numerous pathologies for which the Applicant filed WO 03/004007, WO 03/004006, WO 03/003006, WO 03/003004, WO 03/002114, WO 03/002109, WO 03/002108, WO 03/002107, WO 03/002106, WO 03/002105, WO 03/039550, WO 03/035050, WO 03/035049, U.S. 60/359,652 and U.S. 60/359651.
[0005] It was found that mast cells present in tissues of patients are implicated in or contribute to the genesis of diseases such as autoimmune diseases (rheumatoid arthritis, inflammatory bowel diseases (IBD)) allergic diseases, tumor angiogenesis, inflammatory diseases, and interstitial cystitis. In these diseases, it has been shown that mast cells participate in the destruction of tissues by releasing a cocktail of different proteases and mediators such as histamine, neutral proteases, lipid-derived mediators (prostaglandins, thromboxanes and leucotrienes), and various cytokines (IL-1, IL-2, IL-3, IL-4, IL-5, IL-6, IL-8, TNF-α, GM-CSF, MIP-1a, MIP-1b, MIP-2 and IFN-γ).
[0006] The c-kit receptor also can be constitutively activated by mutations leading to abnormal cell proliferation and development of diseases such as mastocytosis and various cancers.
[0007] For this reason, it has been proposed to target c-kit to deplete the mast cells responsible for these disorders.
[0008] The main objective underlying the present invention is therefore to find potent and selective compounds capable of inhibiting wild type and/or mutated c-kit.
[0009] Many different compounds have been described as tyrosine kinase inhibitors, for example, bis monocyclic, bicyclic or heterocyclic aryl compounds (WO 92/20642), vinylene-azaindole derivatives (WO 94/14808) and 1-cycloproppyl-4-pyridyl-quinolones (U.S. Pat. No. 5,330,992), styryl compounds (U.S. Pat. No. 5,217,999), styryl-substituted pyridyl compounds (U.S. Pat. No. 5,302,606), selenoindoles and selenides (WO 94/03427), tricyclic polyhydroxylic compounds (WO 92/21660) and benzylphosphonic acid compounds (WO 91/15495), pyrimidine derivatives (U.S. Pat. No. 5,521,184 and WO 99/03854), indolinone derivatives and pyrrole-substituted indolinones (U.S. Pat. No. 5,792,783, EP 934 931, U.S. Pat. No. 5,834,504, U.S. Pat. No. 5,883,116, U.S. Pat. No. 5,883,113, U.S. Pat. No. 5,886,020, WO 96/40116 and WO 00/38519), as well as bis monocyclic, bicyclic aryl and heteroaryl compounds (EP 584 222, U.S. Pat. No. 5,656,643 and WO 92/20642), quinazoline derivatives (EP 602 851, EP 520 722, U.S. Pat. No. 3,772,295 and U.S. Pat. No. 4,343,940) and aryl and heteroaryl quinazoline (U.S. Pat. No. 5,721,237, U.S. Pat. No. 5,714,493, U.S. Pat. No. 5,710,158 and WO 95/15758).
[0010] However, none of these compounds have been described as potent and selective inhibitors of c-kit or of the c-kit pathway.
[0011] In connection with the present invention, we have found that compounds corresponding to the 2-(3-aminoaryl)amino-4-aryl-thiazoles are potent and selective inhibitors of c-kit or c-kit pathway. These compounds are good candidates for treating diseases such as autoimmunes diseases, inflammatory diseases, cancer and mastocytosis.
DESCRIPTION
[0012] Therefore, the present invention relates to compounds belonging to the 2-(3-amino)arylamino-4-aryl-thiazoles. These compounds are capable of selectively inhibiting signal transduction involving the tyrosine phosphokinase c-kit and mutant forms thereof. In a first embodiment, the invention is aimed at compounds of formula I, which may represent either free base forms of the substances or pharmaceutically acceptable salts thereof:
and wherein R 1 is:
[0013] a) a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0014] b) an aryl or heteroaryl group optionally substituted by an alkyl or aryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0015] c) a —CO—NH—R, —CO—R, —CO—OR or a —CO—NRR′ group, wherein R an d R′ are independently chosen from H or an aryl, heteroaryl, alkyl and cycloalkyl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0016] R 2 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0017] R 3 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0018] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0019] R 5 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0020] R 6 is one of the following:
[0021] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0022] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0023] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy,
[0024] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0000] and R 7 is one of the following:
[0025] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0026] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0027] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0028] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2—R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0029] In another preferred embodiment, when R 1 has the meaning depicted in c) above, the invention is directed to compounds of the following formula:
wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality.
[0030] Among the particular compounds in which R1 has the meaning as depicted in c) above, the invention is directed to amide-aniline compounds of the following formula:
wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and I or bearing a pendant basic nitrogen functionality;
[0031] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality
[0032] Among the particular compounds in which R1 has the meaning as depicted in c) above, the invention is directed to amide-benzylamine compounds of the following formula:
wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or an alkyl, cycloalkyl, aryl or heteroaryl group substituted by a alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0033] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H or an aryl heteroaryl, alkyl and cycloalkyl group optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality.
[0034] Among the particular compounds in which R1 has the meaning as depicted in c) above, the invention is directed to amide-phenol compounds of the following formula:
wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0035] a cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or an alkyl, cycloalkyl, aryl or heteroaryl group substituted by a alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality;
[0036] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H or an aryl, heteroaryl, alkyl and cycloalkyl group optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality.
[0037] Among the particular compounds in which R1 has the meaning as depicted in c) above, the invention is directed to urea compounds of the following formula:
wherein R is H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen is functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0038] Among the particular compounds in which R1 has the meaning as depicted in a) and b) above, the invention is directed to N-Aminoalkyl-N′-thiazol-2yl-benzene-1,3-diamine compounds of the following formula:
wherein Y is a linear or branched alkyl group containing from 1 to 10 carbon atoms;
[0039] wherein Z represents an aryl or heteroaryl group, optionally substituted at one or more ring position with any permutation of the following groups:
a halogen such as F, Cl, Br, I; a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an alkyl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an O—R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NRaRb, where Ra and Rb represents a hydrogen, or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality or a cycle; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group: substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and I or bearing a pendant basic nitrogen functionality, a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NHCOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality, or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NHCONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0051] R 2 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0052] R 3 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0053] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0054] R 5 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0055] R 6 is one of the following:
[0056] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0057] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0058] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0059] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl group containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality;
[0000] and R 7 is one of the following:
[0060] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0061] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0062] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0063] iv) H, an halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0064] An example of preferred compounds of the above formula is depicted below:
001: 4-{[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylamino]-methyl}-benzoic acid methyl ester
[0065] Among the compounds of formula I, the invention is particularly embodied by the compounds of the following formula II:
wherein X is R or NRR′ and wherein R and R′ are independently chosen from H, an aryl, a heteroaryl, an alkyl, or a cycloalkyl group optionally substituted with at least one heteroatom, such as for example a halogen chosen from F, I, Cl and Br and optionally bearing a pendant basic nitrogen functionality, or an aryl, a heteroaryl, an alkyl or a cycloalkyl group substituted with an aryl, a heteroaryl, an alklyl or a cycloalkyl group optionally substituted with at least one heteroatom, such as for example a halogen chosen from F, I, Cl and Br and optionally bearing a pendant basic nitrogen functionality,
[0066] R 2 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0067] R 3 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0068] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0069] R 5 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0070] R 6 is one of the following:
[0071] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0072] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0073] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0074] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0075] In another alternative, substituent R6, which in the formula II is connected to position 4 of the thiazole ring, may instead occupy position 5 of the thiazole ring.
[0076] Among the preferred compounds corresponding formula II, the invention is directed to compounds in which X is a substituted alkyl, aryl or heteroaryl group bearing a pendant basic nitrogen functionality represented for example by the structures a to f shown below, wherein the wavy line corresponds to the point of attachment to core structure of formula II:
[0077] Among group a to f, X (see formula II) is preferentially group d.
[0078] Furthermore, among the preferred compounds of formula I or II, the invention concerns the compounds in which R 2 and R 3 are hydrogen. Preferentially, R 4 is a methyl group and R 5 is H. In addition, R 6 is preferentially a 3-pyridyl group (cf. structure g below), or a 4-pyridyl group (cf structure h below). The wavy line in structure g and h correspond to the point of attachment to the core structure of formula I or II.
[0079] Thus, the invention contemplates:
1—A compound of formula II as depicted above, wherein X is group d and R 6 is a 3-pyridyl group. 2—A compound of formula II as depicted above, wherein X is group d and R 4 is a methyl group. 3—A compound of formula I or II as depicted above, wherein R 1 is group d and R 2 is H. 4—A compound of formula I or II as depicted above, wherein R 1 is group d and R 3 is H. 5—A compound of formula I or II as depicted above, wherein R 1 is group d and R 2 and/or R 3 and/or R 5 is H. 6—A compound of formula I or II as depicted above, wherein R 6 is a 3-pyridyl group and R 3 is a methyl group. 7—A compound of formula I or II as depicted above, wherein R 6 is a 3-pyridyl group and R 2 is H. 8—A compound of formula I or II as depicted above, wherein R 2 and/or R 3 and/or R 5 is H and R 4 is a methyl group. 9—A compound of formula I or II as depicted above wherein R 2 and/or R 3 and/or R 5 is H, R 4 is a methyl group and R 6 is a 3-pyridyl group.
[0089] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein R2, R3, R5 are hydrogen, corresponding to the following formula II-1:
wherein X is R or NRR′ and wherein R and R′ are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0090] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0091] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0092] R 6 is one of the following:
[0093] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0094] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, allyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0095] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0096] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0097] In another alternative, substituent R6, which in the formula II is connected to position 4 of the thiazole ring, may instead occupy position 5 of the thiazole ring.
EXAMPLES
[0098] 002: 2-(2-methyl-5-amino)phenyl-4-(3-pyridyl)-thiazole
003: 4-(4-Methyl-piperazin-1-ylmethyl)-N-[3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
004: N-[4-Methyl-3-(4-phenyl-thiazol-2-ylamino)-phenyl]-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
005: N-[3-([2,4′]Bithiazolyl-2′-ylamino)-4-methyl-phenyl]-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
006: 4-(4-Methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyrazin-2-yl-thiazol-2-ylamino)-phenyl]-benzamide
007: 2-[5-(3-Iodo-benzoylamino)-2-methyl-phenylamino]-thiazole-4-carboxylic acid ethyl ester
008: 2-{2-Methyl-5-[4-(4-methyl-piperazin-1-ylmethyl)-benzoylamino]-phenylamino}-thiazole-4-carboxylic acid ethyl ester
027: 2-2-chloro-5-amino)phenyl-4-(3-pyridyl)-thiazole
128: 3-Bromo-N-{3-[4-(4-chloro-phenyl)-5-methyl-thiazol-2-ylamino]-4-methyl-phenyl}-benzainide
129: {3-[4-(4-Chloro-phenyl)-5-methyl-thiazol-2-ylamino]4-methyl-phenyl-}-carbamic acid isobutyl ester
130: 2-[5-3-Bromo-benzoylamino)-2-methyl-phenylamino]-5-(4-chloro-phenyl)-thiazole-4-carboxylic acid ethyl ester
131: 2-[5-(3-Bromo-benzoylamino)-2-methyl-phenylamino]-5-(4-chloro-phenyl)-thiazole-4-carboxylic acid (2-dimethylamino-ethyl)-amide
110: N-{3-[4-(4-Methoxy-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
116: 4-(4-Methyl-piperazin-1-ylmethyl)-N-{4-methyl-3-[4-(3-trifluoromethyl-phenyl)-thiazol-2-ylamino]-phenyl}-benzamide
117: N-{4-Methyl-3-[4-(3-nitro-phenyl)-thiazol-2-ylamino]-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
124: N-{3-[4-(2,5-Dimethyl-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
108: N-{3-[4-(4-Chloro-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzainide
113: N-{3-[4-(3-Methoxy-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
063: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-isonicoitiamide
064: 2,6-Dichloro-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-isonicotinamide
091: 3-Phenyl-propynoic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-amide
092: Cyclohexanecarboxylic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-amide
093: 5-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-pentanoic acid ethyl ester
094: 1-Methyl-cyclohexanecarboxylic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-amide
095: 4-tert-Butyl-cyclohexanecarboxylic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-amide
096: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-morpholin-4-yl-butyramide
beige powder mp: 116-120° C.
[0099] 1 H RMN (DMSO-d 6 )δ=1.80-2.00 (m, 2H); 2.29 (s, 3H); 2.30-2.45 (m, 6H); 3.55-3.65 (m, 6H); 7.15-7.25 (m, 2H); 7.46-7.50 (m, 2H); 7.52 (s, 1H); 8.35 (d, J=6.2 Hz, 1H); 8.55 (dd, J=1.5 Hz, J=4.7 Hz, 2H); 9.22 (s, 1H); 9.45 (s, 1H); 9.93 (s, 1H)
[0100] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein X is a urea group, a —CO—NRR′ group, corresponding to the [3-(thiazol-2-ylamino)-phenyl]-urea family and the following formula II-2:
wherein Ra, Rb are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0101] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, or bearing a pendant basic nitrogen functionality.
[0102] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0103] R6 is one of the following:
[0104] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0105] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0106] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy.
[0107] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2—R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
[0108] 009: 1-(4-Methoxy-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2ylamino)-phenyl]-urea
010: 1-(4-Bromo-phenyl)-3-[4meethyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
011: 1-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-(4-trifluoromethyl-phenyl)-urea
012: 1-(4-Fluoro-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
013: 1-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-(3,4,5-trimethoxy-phenyl)-urea
014: 4-{3-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-ureido}-benzoic acid ethyl ester
015: 1-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-thiophen-2-yl-urea
016: 1-Cyclohexyl-1-(N-Cyclohexyl-formamide)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
017: 1-2,4-Dimethoxy-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
018: 1-(2-Iodo-phenyl)-1-(N-(2-Iodo-phenyl)-formamide)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
019: 1-(3,5-Dimethyl-isoxazol-4-yl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
020: 1-(2-Iodo-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
021: 1-(4-Difluoromethoxy-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
022: 1-(4-Dimethylamino-phenyl)-3-[4-methyl-3-(4pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
023: 1-(2-Fluoro-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
light brown powder mp : 203-206° C.
[0109] 1 H NMR (DMSO-d 6 ): δ=2.24 (s, 3H); 6.98-7.00 (m, 2H); 7.10-7.23 (m, 3H); 7.40 (m, 1H); 7.48 (s, 1H); 8.25 (m, 1H); 8.37 (d, J=7.8 Hz, 1H); 8.51 (m, 3H); 9.03 (s, 1H); 9.19(s, 1H); 9.39(s, 1H)
024: 1-(2-Chloro-phenyl)-3-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
025: 1-(3-Fluoro-phenyl)-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-urea
white powder mp: 210-215° C.
[0110] 1 H NMR (DMSO-d 6 ): δ 2.24 (s, 3H); 6.79 (t, J=6.3 Hz, 1H); 6.99 (m, 1H); 7.09-7.14 (m, 2H); 7.30 (m, 1H); 7.41 (t, J=4.7 Hz, 1H); 7.48 (s, 1H); 7.56 (d,J=1.2 Hz, 1H); 8.39 (d, J=8.0 Hz, 1H), 8.49-8.52 (m, 2H); 8.71 (s, 1H); 8.87 (s, 1H); 9.18 (s, 1H); 9.38 (s, 1H)
026: 1-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino-phenyl]-3-p-tolyl-urea
white powder mp: 238-240° C.
[0111] 1 H RMN (DMSO-d 6 ) δ=2.29 (s, 3H); 2.31 (s, 3H); 7.05 (d, J=6.2 Hz, 1H); 7.10-1.16 (m,3H); 7.42-1.49(m, 3H); 7.53(s, 1H);8.35-8.62(m,5H); 9.22 (d, J=1.6 Hz, 1H); 9.43 (s, 1H)
[0112] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein X is a substituted Aryl group, corresponding to the N-[3-(Thiazol-2-ylamino)-phenyl]-amide family and the following formula II-3:
wherein Ra, Rb, Rc, Rd, Re are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
[0113] a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and or bearing a pendant basic nitrogen functionality;
[0114] Ra, Rb, Rc, Rd, Re may also be
a halogen such as I, Cl, Br and F a NRR′ group where R and R′ are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatoms, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon, atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F; and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with, at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; a CN group a trifluoromethyl group
[0127] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0128] R 6 is one of the following:
[0129] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0130] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0131] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0132] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
[0133] 028: 3-Bromo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
029: 3-Iodo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
030: 4-Hydroxymethyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
031: 4-Amino-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
032: 2-Iodo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
033: 4-Iodo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylarnino)-phenyl]-benzamide
034: 4-(3-{4-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-phenyl}-ureido)-benzoic acid ethyl ester
035: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-[3-(4-trifluoromethyl-phenyl)-ureido]-benzamide
036:, 4-[3-(4-Bromo-phenyl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide.
037: 4-Hydroxy-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
038: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-(3-thiophen-2-yl-ureido)-benzamide
039: 4-[3-(3,5-Dimethyl-isoxazol-4-yl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
040: 4-[3-(4-Methoxy-phenyl)-ureido]-N-[4-methyl-3-(pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
041: 4-[3-(4-Difluoromethoxy-phenyl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
042: Thiophene-2-sulfonic acid 4-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)- phenylcarbamoyl]-phenyl ester
043: 4-Iodo-benzenesulfonic acid 4-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-phenyl ester
044: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-(thiophene-2-sulfonylamino)-benzamide
brown powder mp: 230-233° C.
[0134] 1 H NMR (DMSO-d 6 ) δ=2.29 (s, 3H); 7.15-7.18 (m, 2H); 7.22-7.32 (m, 3H); 7.48 (m, 2H); 7.67 (dd, J=1.3 Hz, J=3.7 Hz, 1H); 7.90-7.96 (m, 3H); 8.38-8.42 (m, 1H); 8.51 (m, 1H); 8.57 (d, J=1.9 Hz, 1H); 9.17 (d, J=1.7 Hz, 1H); 9.44 (s, 1H); 10.12 (s, 1H); 10.82 (s, 1H)
045: 3-Fluoro-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
off-white foam mp: 184-186° C.
[0135] 1 H NMR (CD 3 OD-d 4 ): δ=2.23 (s, 3H); 7.12-7.14 (m, 2H); 7.20-7.23 (m, 2H); 7.30 (m, 1H); 7.43 (m, 1H); 7.50 (m, 1H); 7.66 (d, J=1.0 Hz, 1H); 8.23 (m, 1H); 8.33 (m, 1H); 8.38 (s, 1H); 8.98 (s, 1H)
046: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-pyridin-4-yl-benzamide
yellow powder mp: 254-256° C.
[0136] 1 H NMR (DMSO-d 6 ): δ 2.34 (s, 3H); 7.28 (d, J=8.0 Hz, 1H); 7.45-7.49 (m, 2H); 7.54 (s, 1H) ; 7.78 (t, J=7.6 Hz, 1H); 7.89-7.91 (m, 2H) ; 8.10 (t, J=7.8 Hz, 2H); 8.37-8.42 (m, 2H); 8.55 (d, J=4.7 Hz, 1H); 8.73-8.77 (m, 3H); 9.24 (s, 1H); 9.52 (s, 1H); 10.43 (s, 1H)
047: 4-Dimethylamino-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
beige powder mp: 147-150° C.
[0137] 1 H NMR (DMSO-d 6 ): δ 2.25 (s, 3H); 2.99 (s, 6H); 6.76 (d, J=8.9 Hz, 2H); 7.16 (d, J=8.3 Hz, 1H); 7.35 (d, J=2.0 Hz, 1H); 7.44-7.47 (m, 2H); 7.86-7.89 (m, 2H); 8.34-8.36 (m, 1H); 8.48-8.50 (m, 1H); 8.56-8.57 (m, 1H); 9.16 (s, 1H), 9.44 (s, 1H); 9.85 (s, 1H)
048: 2-Fluoro-5-methyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
brown orange powder mp: 103-106° C.
[0138] 1 H RMN (DMSO-d 6 ) δ=2.26 (s, 3H, ); 7.17-7.47 (m, 7H); 8.29 (dd, J=1.6 Hz, J=7.9 Hz, 1H); 8.47 (d, J=3.5 Hz, 1H); 8.57 (s, 1H); 9.15 (d, J=2.0 Hz, 1H) 9.44 (s, 1H); 10.33 (s, 1H)
049: 4-tert-Butyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
brown powder mp: 145-150° C.
[0139] 1 H RMN (DMSO-d 6 ) δ=1.32 (s, 9H); 2.04 (s, 3H); 7.18 (d, J=8.4 Hz, 1H); 7.35-7.44 (m, 2H) ; 7.46 (s, 1H) 7.55 (d, J=8.5 Hz, 1H); 7.90 (d, J=8.5 Hz, 1H); 8.32 (d, J=7.9 Hz, 1H); 8.47 (dd, J=1.5 Hz, 4.7 Hz, 1H); 8.60 (d, J=2.0 Hz, 1H) 9.15 (d, J=1.7Hz,1H);9.43(s, 1H); 10.15(s, 1H)
050: 4-Isopropoxy-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
brown powder mp:.154-155° C.
[0140] 1 H RMN (DMSO-d 6 ) δ=1.34 (d, J=5.9 Hz, 6H); 4.72 ept, J=5.9 Hz, 1H); 7.01 (d, J=7.0 Hz, 2H); 7.18 (d, J=8.5 Hz, 1H); 7.35-7.44 (m, 2);7.46 (s, 1H); 7.94 (dd, J=2.0 Hz, J=6.7 Hz, 2H); 8.32 (d, J=8.3 Hz, 1H); 8.48 (dd, J=3.3 Hz, J=4.8 Hz, 1H); 8.58 (d, J=2.0 Hz, 1H); 9.15 (d, J=1.8 Hz, 1H); 9.43 (s, 1H); 10.4 (s, 1H)
051: Benzo[1,3]dioxole-5-carboxylic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-amide
brown orange powder mp: 130-132° C.
[0141] 1 H RMN (DMSO-d 6 ) δ=2.23 (s, 3H); 6.10 (s, 2H) ; 7.03 (d, J=8.1 Hz, 1H); 7.15 (d, J=8.3 Hz, 1H); 7.25-7.55 (m, 6H); 8.26 (s, 1H); 8.45 (dd, J=1.5 Hz, J=4.7, 1H) ; 8.55 (d, J=2.0 Hz, 1H); 9.12 (d, J=1.7 Hz, 1H); 9.40 (s, 1H); 10.01 (s, 1H)
052: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-(2-morpholin-4-yl-ethoxy)-benzamide
beige yellow powder mp: 75-80° C.
[0142] 1 H RMN (DMSO-d 6 ) δ=2.10-2.25 (m, 4H); 2.50-2.60 (m, 2H); 3.19 (s, 3H); 3.41-3.48 (m, 4H); 4.00-4.06 (m, 2H); 7.00-7.11 (m, 2H); 7.22-7.35 (m, 6H), 8.18 (d, J=8.0 Hz, 1H); 8.33 (d, J=0.9 Hz, 1H); 8.49 (d, J=1.7 Hz, 1H); 9.03 (s, 1H); 9.31 (s, 1H); 10.05 (s, 1H)
053: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-4-pyridin-4-yl-benzamide
brown powder mp: dec. 250° C.
[0143] 1 H RMN (DMSO-d 6 ) δ=2.28 (s, 3H); 7.21 (d, J=7.9 Hz, 1H); 7.30-7.50 (m, 3H); 7.81 (d, J=4.7 Hz, 1H); 7.98 (d, J=7.5 Hz, 2H); 8.13 (d, J=7.9 Hz, 2H); 8.32 (d, J=7.7 Hz, 1H); 8.48 (d, J=4.9 Hz, 1H); 8.62-8.69 (m, 3H); 9.16 (s, 1H); 9.45 (s, 1H); 10.34(s, 1H)
054: 3-Cyano-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
055: 2-Fluoro-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-trifluoromethyl-benzamide
056: 3-Fluoro-benzenesulfonic acid 4-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-phenyl ester
057: 4-Aminomethyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
058: 2-Fluoro-benzenesulfonic acid 4-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-phenyl ester
059: 3-Methoxy-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
white powder, mp: 76-79° C.
[0144] 1 H RMN (DMSO-d 6 ) δ=2.32 (s, 3H); 3.89 (s, 3H) ;7.22-7.25 (m, 2H), 7.44-7.58 (m, 4H), 8.28-8.35 (m, 1H); 8.52 (dd, J=1.6 Hz, J=4.7 Hz, 1H); 8.66 (d, J=2.0 Hz, 1H); 9.20(d, J=1.4Hz, 1H); 9.50(s, 1H); 10.25 (s, 1H)
060: 4-(4-Methyl-piperazin-1-yl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
beige brown powder mp: 128-130° C.
[0145] 1 H RMN (DMSO-d 6 ) δ=2.15 (s, 3H); 2.18 (s, 3H); 2.35-2.41 (m, 4H); 3.18-3.3.24 (m, 4H); 6.94 (d, J=8.9 Hz, 2H); 7.09 (d, J=8.4 Hz, 1H) ; 7.28-7.38 (m, 3H); 7.81 (d, J=8.9 Hz, 2H); 8.20-8.25 (m, 1H); 8.40 (dd, J=1.6 Hz, J=4.7, 1H); 8.48 (d, J=1.9 Hz, 1H); 9.07 (d, J=1.5 Hz, 1H); 9.35 (s, 1H); 9.84 (s, 1H)
061: 3-Methyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
062: Biphenyl-3-carboxylic acid [4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-amide
065: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-trifluoromethyl-benzamide
099: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-pyrrolidin-1-ylmethyl-benzamide
100: 4-[3-(2,4-Dimethoxy-phenyl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
101: 4-[3-(2-Iodo phenyl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
102: 4-[3-(4-Fluoro-phenyl)-ureido]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
105: 3-Bromo-4methyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
106: 4-Fluoro-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
103: 4-Cyano-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
104: 4-Fluoro-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
[0146] Among compounds of formula II, the invention is particularly embodied by the compounds wherein X is a -substituted-aryl group, corresponding to the 4-(4-substituted-1-ylmethyl)-N-[3-(thiazol-2-ylamino)-phenyl]-benzamide family and the following formula II-4:
wherein X is a heteroatom, such as O or N
[0147] wherein Ra, Rb, Rd; Re, Rf, Rg, Rh are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
or a NRR′ group where R and R′ are H or a linear or branched allyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl; an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted wit a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality, or a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality, or a cycloalkyl an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or, bearing a pendant basic nitrogen functionality, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and I or bearing a pendant basic nitrogen functionality; or an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality, Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl: an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0158] Ra, Rb, Rd, Re can also be halogen such as Cl, F, Br, I or trifluoromethyl;
[0159] R 4 is hydrogen, halogen-or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0160] R 6 is one of the following:
[0161] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0162] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0163] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-5 thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0164] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
[0165] 066: 4-(4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
067: 3,5-Dibromo-4-(4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
068: 4-Diethylaminomethyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
069: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-morpholin-4- ylmethyl-benzamide
070: 4-Dipropylaminomothyl-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
071: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-piperidin-1-ylmethyl-benzamide
072: 4-[(Diisopropylamino)-methyl]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
073: {4-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenylcarbamoyl]-benzyl}-carbamic acid tert-butyl ester
074: 3-Fluoro-4-(4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
075: 4-(4-Methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-3-trifluoromethyl-benzamide
yellow crystals mp: 118-120° C.
[0166] 1 H RMN (DMSO-d 6 ) δ=2.22 (s, 3H); 2.33 (s, 3H); 2.34-2.50 (m, 8H); 3.74 (s, 2H); 7.26 (d, J=8.3Hz, 1H); 7.41-7.49 (m, 2H); 7.53 (s, 1H) ; 7.99 (d, J=8.0 Hz, 1H); 8.28-8.31 (m, 2H); 8.38 (d, J=7.9 Hz, 1H); 8.53 (dd, J=1.3 Hz, J=4.7 Hz, 1H); 8.68 (d, J=1.9 Hz, 1H); 9.21 (d, J=2.0 Hz, 1H); 9.53 (s, 1H); 10.49 (s, 1H)
076: 2,3,5,6-Tetrafluoro-4-(4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
077: N-{3-[4-(4-Fluoro-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
078: 3-Bromo-4-(4methyl-piperazin-1-ylmethyl)-N-[4-methyl -3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
079: 3-Chloro-4-4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-phenyl]-benzamide
080: 4-(4-Methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-4-yl-thiazol-2-ylamino)-phenyl]-benzamide
081: N-{3-[4-(4-Cyano-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
082: 4-[1-(4-Methyl-piperazin-1-yl)-ethyl]-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
beige powder mp: 153-155° C.
[0167] 1 H RMN (DMSO-d 6 ) δ=1.29 (d, J=6.6 Hz, 3H); 2.15 (s, 3H); 2.26 (s, 3H); 3.15-3.25 (m, 9H); 7.18 (d, J=8.4 Hz, 1H); 7.35-7.47 (m, 5H); 7.91 (d, J=8.2 Hz, 2H); 8.31 (d, J=8.0 Hz, 1H); 8.47 (dd, J=1.6 Hz, J=4.7 Hz, 1H); 8.60 (d, J=2.0, 1H); 9.15 (d, J=0.6, 1H); 9.45 (s, 1H); 10.18 (s, 1H)
083: 4-(1-Methoxy-ethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
084: N-{4-Methyl-3-[4-(5-methyl-pyridin-3-yl)-thiazol-2-ylamino]-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
085: 3-Iodo-4(4-methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylmethyl)-phenyl]-benzamide
086: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-[3-(4-trifluoromethyl-phenyl)-ureidomethyl]-benzamide
087: 3,5-Dibromo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-[(3-morpholin-4-propylamino)-methyl]-benzamide
107: 3,5-Dibromo-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-4-piperidin-1-ylmethyl-benzamide
122: 4-(4-Methyl-piperazin-1-ylmethyl)-N-[4-methyl-3-(4-pyridin-2-yl-thiazol-2-ylamino)-phenyl]-benzamide
111: N-{3-[4-(3-Fluoro-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamide
118: N-{3-[4-(2-Fluoro-phenyl)-thiazol-2-ylamino]-4-methyl-phenyl}-4-(4-methyl-piperazin-1-ylmethyl)-benzamides
[0168] Among compounds of formula II, the invention is particularly embodied by the compounds wherein X is a -aryl-substituted group, corresponding to the 3-Disubstituted-amino-N-[3-(thiazol-2-ylamino)-phenyl]-benzamide family and the following formula II-5:
wherein Ra, Rb, Rc, Re, Rf, Rg are independently chosen from H or an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality;
or a NRR′ group where R and R′ are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality, or an OR group where R is H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with, at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; a —SO2-R′ group wherein R′ is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCORb group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a NRaCONRbRc group where Ra and Rb are H or a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a COOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a CONRaRb, where Ra and Rb are a hydrogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NHCOOR, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; an OSO 2 R, where R is a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or an NRaOSO 2 Rb, where Ra and Rb are a linear or branched alkyl group containing from 1 to 10 carbon atoms atoms optionally substituted with at least one heteroatom (for example a halogen) and/or bearing a pendant basic nitrogen functionality; Ra can also be a hydrogen; a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group substituted by an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality; or a —SO2-R group wherein R is an alkyl, cycloalkyl, aryl or heteroaryl optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F or bearing a pendant basic nitrogen functionality; or a —CO—R or a —CO—NRR′ group, wherein R and R′ are independently chosen from H, an alkyl, a cycloalkyl, an aryl or heteroaryl group optionally substituted with at least one heteroatom, notably selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
[0179] Ra, Rb, Rc, Re can also be halogen such as Cl, F, Br, I or trifluoromethyl;
[0180] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0181] R 6 is one of the following:
[0182] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0183] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0184] (iii) a five-membered ring aromatic-heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0185] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO02 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and/or bearing a pendant basic nitrogen functionality.
EXAMPLES
[0186] 088: 3-Dimethylamino-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
beige powder mp: 197-198° C.
[0187] 1 H NMR (DMSO-d 6 ): δ=2.32 (s, 3H); 3.03 (s, 6H); 6.97 (d, J=6.4 Hz, 1H); 7.23-7.56 (m, 7H); 8.37 (d, J=7.3 Hz, 1H); 8.53 (d, J=4.7 Hz, 1H); 8.63 (s, 1H); 9.20 (s, 1H); 9.48 (s, 1H); 10.15 (s, 1H)
089: 3-(4-Methyl-piperazin-1-yl)-N-[4-methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-benzamide
beige powder mp: 274-246° C.
[0188] 1 H RMN (DMSO-d 6 ) δ=2.23 (s, 3H); 2.24-2.30 (m, 4H); 3.22-3.27 (m, 4H); 7.07-7.20 (m, 2H); 7.36-7.53 (m, 6H); 8.31 (d, J =7.5 Hz, 1H); 8.47 (d, J=3.7 Hz, 1H); 8.58 (s, 1H); 9.12 (d, J=7.8 Hz, 1H); 9.44 (s, 1H); 10.12 (s, 1H)
090: N-[4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-3-morpholin-4-yl-benzamide
beige powder mp 247-248° C.
[0189] 1 H RMN (CDCl 3 ) δ=1.50 (s, 3H); 3.15-3.18 (m, 4H) 3.79-3.82 (m, 3H); 6.85 (s, 1H); 7.00-7.30 (m, 7H); 7.41 (s, 1H); 7.75 (s, 1H) ; 8.08 (d, J=7.9 Hz, 1H); 8.22 (d, J=1.7 Hz, 1H); 8.46 (dd, J=1.3Hz, J=4.7Hz, 1H); 9.01 (d, J=1.6 Hz, 1H)
[0190] Among the compounds of formula II, the invention is particularly embodied by the compounds wherein X is a —OR group, corresponding to the family [3-(Thiazol-2-ylamino)-phenyl]-carbamate and the following formula II-6
wherein R is independently chosen from an organic group that can be selected for example from a linear or branched alkyl group containing from 1 to 10 carbon atoms optionally substituted with at least one heteroatom and/or bearing a pendant basic nitrogen functionality; a cycloalkyl, an aryl or heteroaryl group optionally substituted with an heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality; or a cycloalkyl, an aryl or heteroaryl group optionally substituted with a cycloalkyl, an aryl or heteroaryl group optionally substituted with a heteroatom, notably a halogen selected from I, Cl, Br and F and/or bearing a pendant basic nitrogen functionality;
[0191] R 4 is hydrogen, halogen or a linear or branched alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl or alkoxy;
[0192] R 6 is one of the following:
[0193] (i) an aryl group such as phenyl or a substituted variant thereof bearing any combination, at any one ring position, of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;
[0194] (ii) a heteroaryl group such as a 2, 3, or 4-pyridyl group, which may additionally bear any combination of one or more substituents such as halogen, alkyl groups containing from 1 to 10 carbon atoms, trifluoromethyl and alkoxy;
[0195] (iii) a five-membered ring aromatic heterocyclic group such as for example 2-thienyl, 3-thienyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, which may additionally bear any combination of one or more substituents such as halogen, an alkyl group containing from 1 to 10 carbon atoms, trifluoromethyl, and alkoxy;s
[0196] iv) H, a halogen selected from I, F, Cl or Br; NH2, NO2 or SO2-R, wherein R is a linear or branched alkyl goup containing one or more group such as 1 to 10 carbon atoms, and optionally substituted with at least one heteroatom, notably a halogen selected from I, Cl, Br and F, and o or bearing a pendant basic nitrogen functionality.
EXAMPLES
[0197] 097: [4-Methyl-3-(4-pyridin-3-yl-thiazol-2-ylamino)-phenyl]-carbamic acid isobutyl ester
098: 2-(2-methyl-5-tert-butoxycarbonylamino)phenyl-4-(3-pyridyl)-thiazole
[0198] In a second embodiment, the invention is directed to a process for manufacturing a compound of formula I depicted above. This entails the condensation of a substrate of general formula 10 with a thiourea of the type 11.
[0199] Substituent “L” in formula 10 is a nucleofugal leaving group in nucleophilic substitution reactions (for example, L can be selected from chloro, bromo, iodo, toluenesulfonyloxy, methanesulfonyloxy, trifluoromethanesulfonyloxy, etc., with L being preferentially a bromo group).
[0200] Group R1 in formula 11a corresponds to group R1 as described in formula I.
[0201] Group “PG” in formula 11c is a suitable protecting group of a type commonly utilized by the person skilled in the art.
[0202] The reaction of 10 with 1a-d leads to a thiozole-type product of formula 12a-d.
[0203] Formula 12a is the same as formula I. Therefore, R1 in 12a corresponds to R1 in formula I.
[0204] Formula 12b describes a precursor to compounds of formula I which lack substituent R1.
[0205] Therefore, in a second phase of the synthesis, substituent R1 is connected to the free amine group in 12b, leading to the complete structure embodied by formula I:
12 b +“R1”→I
[0206] The introduction of R1, the nature of which is as described on page 3 for the general formula I, is achieved by the use of standard reactions that are well known to the person skilled in the art, such as alkylation, acylation, sulfonylation, formation of ureas, etc.
[0207] Formula 12c describes an N-protected variant of compound 12b. Group “PG” in formula 12c represents a protecting group of the type commonly utilized by the person skilled in the art. Therefore, in a second phase of the synthesis, group PG is cleaved to transform compound 12c into compound 12b. Compound 12b is subsequently advanced to structures of formula I as detailed above.
[0208] Formula 12d describes a nitro analogue of compound 12b. In a second phase of the synthesis, the nitro group of compound 12d is reduced by any of the several methods utilized by the person skilled in the art to produce the corresponding amino group, namely compound 12b. Compound 12b thus obtained is subsequently advanced to structures of formula I as detailed above.
EXAMPLES OF COMPOUND SYNTHESIS
[0209] General: All chemicals used were commercial reagent grade products. Dimethylformamide (DMF), methanol (MeOH) were of anhydrous commercial grade and were used without further purification. Dichloromethane and tetrahydrofuran (THF) were freshly distilled under a stream of argon before use. The progress of the reactions was monitored by thin layer chromatography using precoated silica gel 60F 254, Fluka TLC plates, which were visualized under UV light. Multiplicities in 1 H NMR spectra are indicated as singlet (s), broad singlet (br s), doublet (d), triplet (t), quadruplet (q), and multiplet (m) and the NMR spectrum were realized on a 300 MHz Bruker spectrometer.
3-Bromoacetyl-pyridine, HBr salt
[0210] Dibromine (17.2g, 108 mmol) was added dropwise to a cold (0° C.) solution of 3-acetyl-pyridine (12 g, 99 mmol) in acetic acid containing 33% of HBr (165 mL) under vigourous stirring. The vigorously stirred mixture was warmed to 40° C. for 2h and then to 75° C. After 2h at 75° C., the mixture was cooled and diluted with ether (400 mL) to precipitate the product which was recovered by filtration and washed with ether and acetone to give white crystals (100%). This material may be recrystallised from methanol and ether.
[0211] IR (neat): 3108, 2047,2982, 2559, 1709, 1603, 1221, 1035, 798 cm −1 - 1 H NMR (DMSO-d 6 ) δ=5.09 (s, 2H, CH 2 Br); 7.88 (m, 1H, pyridy-1H); 8.63 (m, 1H, pyridyl-H); 8.96 (m, 1H, pyridyl-H); 9.29 (m, 1H, pyridyl-H).
Methyl -[4-(1-N-methyl-piperazino)-methyl]-benzoate
[0212] To methyl-4-formyl benzoate (4.92 g, 30 mmol) and N-methyl-piperazine (3.6 mL, 32 mmol) in acetonitrile (100 mL) was added dropwise 2.5 mL of trifluoroacetic acid. The reaction mixture was stirred at room temperature for 1 h. After slow addition of sodium is cyanoborohydride (2 g, 32 mmol), the solution was left stirring overnight at room temperature. Water (10 mL) was then added to the mixture, which was further acidified with 1N HCl to pH=6-7. The acetonitrile was removed under reduced pressure and the residual aqueous solution was extracted With diethyl ether (4×30 mL). These extracts were discarded. The aqueous phase was then basified (pH>12) by addition of 2.5 N aqueous sodium hydroxyde solution. The crude product was extracted with ethyl acetate (4×30 mL). The combined organic layers were dried over MgSO 4 and concentrated under reduced pressure to afford a slightly yellow oil which became colorless after purification by Kugelrohr distillation (190° C.) in 68% yield.
[0213] IR(neat): 3322, 2944, 2802, 1721, 1612, 1457, 1281, 1122, 1012- 1 H NMR (CDCl 3 ) δ=2.27 (s, 3H, NCH 3 ); 2.44 (m, 8H, 2×NCH 2 CH 2 N); 3.53 (s, 2H, ArCH 2 N); 3.88 (s, 3H, OCH 3 ); 7.40 (d, 2H, J=8.3 Hz,2×ArH); 7.91 (d, 2H, J=8.3 Hz, 2×ArH)- 13 C NMR (CDCl 3 ) δ=45.8 (NCH 3 ); 51.8 (OCH 3 ); 52.9 (2×CH 2 N); 54.9 (2×CH 2 N); 62.4 (ArCH 2 N); 128.7 (2×ArC); 129.3 (2×ArC); 143.7(ArC); 166.7 (ArCO 2 CH 3 )-MS CI (m/z)(%): 249 (M+1, 100%).
2-Methyl-5-tert-butoxycarbonylamino-aniline
[0214] A solution of di-tert-butyldicarbonate (70 g, 320 mmol) in methanol (200 mL) was added over 2 h) to a cold (−10° C.) solution of 2,4-diaminotoluene (30 g, 245 mmol) and triethylamino (30 mL) in methanol (15 mL). The reaction was followed by thin layer chromatography (hexane/ethyl acetate, 3:1) and stopped after 4 h by adding 50 mL of water. The mixture was concentrated in vacuo and the residue was dissolved in 500 mL of ethyl acetate. This organic phase was washed with water (1×150 mL) and brine (2×150 mL), dried over MgSO 4 , and concentrated under reduced pressure. The resulting light brown solid was washed with small amounts of diethyl ether to give off-white crystals of 2-methyl-5-tert-butoxycarbonylamino-aniline in 67% yield.
[0215] IR (neat): 3359; 3246; 2970; 1719; 1609; 1557; 1173; 1050 cm −1 - 1 H NMR (CDCl 3 ): δ=1.50 (s, 9H, tBu); 2.10 (s, 3H, ArCH 3 ); 3.61 (br s, 2H, NH 2 ); 6.36 (br s, 1H, NH); 6.51 (dd, 1H, J=7.9 Hz, 2.3 Hz, ArH); 6.92 (d, 1H, J=7.9 Hz, ArH); 6.95 (s, 1H, ArH)- 13 C NMR (CDCl 3 ) δ=16.6 (ArCH 3 ); 28.3 (C(CH 3 ) 3 ); 80.0 (C(CH 3 ) 3 ); 105.2 (ArC); 108.6 (ArC); 116.9 (ArC); 130.4 (ArC—CH 3 ); 137.2 (ArC—NH); 145.0 (ArC—NH 2 ); 152.8 (COOtBu)
[0216] MS ESI (m/z) (%): 223 (M+1), 167 (55, 100%).
N-(2-methyl-5-tert-butoxycarbonylamino)phenyl-thiourea
[0217] Benzoyl chloride (5.64 g, 80 mmol) was added dropwise to a well-stirred solution of ammonium thiocyanate (3.54 g, 88 mmol) in acetone (50 mL). The mixture was refluxed for 15 min, then, the hydrobromide salt of 2-methyl-5-tert-butoxycarbonylamino-aniline (8.4g, 80 mmol) was added slowly portionswise. After 4 h, the reaction mixture was poured into ice-water (350 mL) and the bright yellow precipitate was isolated by. filtration. This crude solid was then refluxed for 45 min in 70 mL of 2.5 N sodium hydroxide solution. The mixture was cooled down and basified with ammonium hydroxide. The precipitate of crude thiourea was recovered by filtration and dissolved in 150 mL of ethyl acetate. The organic phase was washed with brine, dried over Na 2 SO 4 , and concentrated under reduced pressure. The residue was purified by column chromatography (hexane/ethyl acetate, 1:1) to afford 63% of N-2-methyl-5-tert-butoxycarbonylamino)phenyl-thiourea as a white solid.
[0218] IR (neat): 3437, 3292, 3175, 2983, 1724, 1616, 1522, 1161, 1053 cm −1 - 1 H NMR (DMSO-d 6 ) δ=1.46 (s, 9H, tBu); 2.10 (s, 3H, ArCH 3 ); 3.60 (br s, 2H, NH 2 ); 7.10 (d, 1H, J=8.29 Hz, ArH); 7.25 (d, 1H, J=2.23 Hz, ArH); 7.28 (d, 1H, J=2.63 Hz, ArH); 9.20 (s, 1H, ArNH); 9.31 (s, 1H, ArNH- 13 C NMR (DMSO-d 6 ) δ=25.1 (ArCH 3 ); 28.1 (C(CH 3 ) 3 ); 78.9 (C(CH 3 ) 3 ); 116.6 (ArC); 117.5 (ArC); 128.0 (ArC); 130.4 (ArC—CH 3 ); 136.5 (ArC—NH); 137.9 (ArC—NH); 152.7 (COOtBu); 181.4 (C═S)-MS CI(m/z): 282 (M+1, 100%); 248 (33); 226 (55); 182 (99); 148 (133); 93 (188).
2-(2-methyl-5-tert-butoxycarbonylamino)phenyl-4-(3-pyridyl)-thiazole
[0219] A mixture of 3-bromoacetyl-pyridine, HBr salt (0.81g, 2.85 mmol), N-(2-methyl-5-tert-butoxycarbonylamino)phenyl-thiourea (0.8 g, 2.85 mmol) and KHCO 3 (˜0.4 g) in ethanol (40 mL) was heated at 75° C. for 20 h. The mixture was cooled, filtered (removal of KHCO 3 ) and evaporated under reduced pressure. The residue was dissolved in CHC 3 (40 mL) and washed with saturated aqueous sodium hydrogen carbonate solution and with water. The organic layer was dried over Na 2 SO 4 and concentrated. Column chromatographic purification of the residue (hexane/ethyl acetate, 1:1) gave the desired thiazole in 70% yield as an orange solid
[0220] IR(neat): 3380, 2985, 2942, 1748, 1447, 1374, 1239, 1047, 938- 1 H NMR (CDCl 3 ) δ=1.53 (s, 9H, tBu); 2.28 (s, 3H, ArCH 3 ); 6.65 (s, 1H, thiazole-H); 6.89 (s, 1H); 6.99 (dd, 1H, J=8.3 Hz, 2.3 Hz); 7.12 (d, 2H, J=8.3 Hz) ; 7.35 (dd, 1H, J=2.6 Hz, 4.9 Hz); 8.03 (s, 1H); 8.19 (dt, 1H, J=1.9 Hz, 7.9 Hz); 8.54 (br s, 1H, NH; 9.09 (s, 1H, NH)- 13 C NMR (CDCl 3 ) δ=18.02 (ArCH 3 ); 29.2 (C(CH 3 ) 3 ); 81.3 (C(CH 3 ) 3 ); 104.2 (thiazole-C); 111.6; 115.2; 123.9; 124.3; 131.4; 132.1; 134.4; 139.5; 148.2; 149.1; 149.3; 153.6; 167.3 (C═O)-MS CI (m/z) (%)383 (M+1, 100%); 339 (43); 327 (55) 309 (73); 283 (99); 71 (311).
2-(2-methyl-5-amino)phenyl-4-(3-pyridyl)-thiazole
[0221] 2-(2-methyl-5-tert-butoxycarbonylamino)phenyl-4-(3-pyridyl)-thiazole (0.40 g, 1.2 mmol) was dissolved in 10 mL of 20% TFA/CH 2 Cl 2 . The solution was stirred at rool temperature for 2 h, then it, was evaporated under reduced pressure. The residue was dissolved in ethyl acetate. The organic layer was washed with aqueous 1 N sodium hydroxide solution, dried over MgSO 4 , and concentrated to afford 2-(2-methyl-5-amino)phenyl-4-(3-pyridyl)-thiazole as a yellow-orange solid in 95% yield. This crude product was used directly in the next step.
[0222] A 2 M solution of trimethyl aluminium in toluene (2.75 mL) was added dropwise to a cold (0° C.) solution of 2-2-methyl-5-amino)phenyl-4-(3-pyridyl)-thiazole (0.42 g, 1.5 mmol) in anhydrous dichloromethane (10 mL) under argon atmosphere. The mixture was warmed to room temperature and stirred at room temperature for 30 min. A solution of methyl-4-(1-N-methyl-piperazino)-methyl benzoate (0.45 g, 1.8 mmol) in anhydrous dichloromethane (1 mL) and added slowly, and the resulting mixture was heated at reflux for 5 h. The mixture was cooled to 0° C. and quenched by dropwise addition of a 4 N aqueous sodium hydroxide solution (3 mL). The mixture was extracted with dichloromethane (3×20 mL). The combined organic layers were washed with brine (3×20 mL) and dried over anhydrous MgSO 4 . (2-(2-methyl-5-amino)phenyl-4-(3-pyridyl)-thiazole) is obtained in 72% after purification by column chromatography (dichloromethane/methanol, 3:1)
[0223] IR(neat): 3318, 2926, 1647, 1610, 1535, 1492, 1282, 1207, 1160, 1011, 843- 1 H NMR (CDCl 3 ) δ=2.31 (br s, 6H, ArCH 3 +NCH 3 ); 2.50 (br s, 8H, 2×NCH 2 CH 2 N); 3.56 (s, 2H, ArCH2N); 6.89 (s, 1H, thiazoleH) 7.21-7.38 (m, 4H); 7.45 (m, 2H); 7.85 (d, 2H, J=8.3 Hz); 8.03 (s, 1H); 8.13 (s, 1H); 8.27 (s, 1H); 8.52 (br s, 1H); 9.09 (s, 1H, NH)- 3 C NMR (CDCl 3 ) δ=17.8 (ArCH 3 ); 46.2 (NCH 3 ); 53.3 NCH 2 ); 55.3 (NCH 2 ); 62.8 (ArCH 2 N); 99.9 (thiazole-C); 112.5; 123.9; 125.2; 127.5; 129.6; 131.6; 133.7; 134.0; 137.6; 139.3; 142.9; 148.8; 149.1; 166.2 (C═O); 166.7 (thiazoleC-NH)-MS CI (m/z) (%): 499 (M+H, 100%); 455 (43); 430 (68); 401 (97); 374 (124); 309 (189); 283 (215); 235 (263); 121 (377); 99 (399).
[0224] In a third embodiment, the invention relates to a pharmaceutical composition comprising a compound as depicted above.
[0225] Such medicament can take the form of a pharmaceutical composition adapted for oral administration, which can be formulated using pharmaceutically acceptable carriers well-known in the art in suitable dosages. Such carriers enable the pharmaceutical compositions to be formulated as tablets, pills, dragees, capsules, liquids, gels, syrups, slurries, suspensions, and the like, for ingestion by the patient. In addition to the active ingredients, these pharmaceutical compositions may contain suitable pharmaceutically-acceptable carriers comprising excipients and auxiliaries which facilitate processing of the active compounds into preparations which can be used pharmaceutically. Further details on techniques for formulation and administration may be found in the latest edition of Remington's Pharmaceutical Sciences (Maack Publishing Co., Easton, Pa.).
[0226] The composition of the invention can also take the form of a pharmaceutical or cosmetic composition for topical administration.
[0227] Such compositions may be presented in the form of a gel, paste, ointment, cream, lotion, liquid suspension aqueous, aqueous-alcoholic or, oily solutions, or dispersions of the lotion or serum type, or anhydrous or lipophilic gels, or emulsions of liquid or semi-solid consistency of the milk type, obtained by dispersing a fatty phase in an aqueous phase or vice versa, or of suspensions or emulsions of soft, semi-solid consistency of the cream or gel type, or alternatively of microemulsions, of microcapsules, of microparticles or of vesicular dispersions to the ionic and/or nonionic type. These compositions are prepared according to standard methods.
[0228] The composition according to the invention comprises any ingredient commonly used in dermatology and cosmetic. It may comprise at least one ingredient selected from hydrophilic or lipophilic gelling agents, hydrophilic or lipophilic active agents, preservatives, emollients, viscosity enhancing polymers, humectants, surfactants, preservatives, antioxidants, solvents, and fillers, antioxidants, solvents, perfumes, fillers, screening agents, bactericides, odor absorbers and coloring matter.
[0229] As oils which can be used in the invention, mineral oils (liquid paraffin), vegetable oils (liquid fraction of shea butter, sunflower oil), animal oils, synthetic oils, silicone oils (cyclomethicone) and fluorinated oils may be mentioned. Fatty alcohols, fatty acids (stearic acid) and waxes (paraffin, carnauba, beeswax) may also be used as fatty substances.
[0230] As emulsifiers which can be used in the invention, glycerol stearate, polysorbate 60 and the PEG-6/PEG-32/glycol stearate mixture are contemplated.
[0231] As hydrophilic gelling agents, carboxyvinyl polymers (carbomer), acrylic copolymers such as acrylate/alkylacrylate copolymers, polyacrylamides, polysaccharides such as hydroxypropylcellulose, clays and natural gums may be mentioned, and as lipophilic gelling agents, modified clays such as bentones, metal salts of fatty acids such as aluminum stearates and hydrophobic silica, or alternatively ethylcellulose and polyethylene may be mentioned.
[0232] As hydrophilic active agents, proteins or protein hydrolysates, amino acids, polyols, urea, allantoin, sugars and sugar derivatives, vitamins, starch and plant extracts, in particular those of Aloe vera may be used.
[0233] As lipophilic active, agents, retinol (vitamin A) and its derivatives, tocopherol (vitamin E) and its derivatives, essential fatty acids, ceramides and essential oils may be used. These agents add extra moisturizing or skin softening features when utilized.
[0234] In addition, a surfactant can be included in the composition so as to provide deeper penetration of the compound capable of depleting mast cells, such as a tyrosine kinase inhibitor, preferably a c-kit inhibitor.
[0235] Among the contemplated ingredients, the invention embraces penetration enhancing agents selected for example from the group consisting of mineral oil, water, ethanol, triacetin, glycerin and propylene glycol; cohesion agents selected for example from the group consisting of polyisobutylene, polyvinyl acetate and polyvinyl alcohol, and thickening agents.
[0236] Chemical methods of enhancing topical absorption of drugs are well known in the art. For example, compounds with penetration enhancing properties include sodium lauryl sulfate (Dugard, P. H. and Sheuplein, R. J., “Effects of Ionic Surfactants on the Permeability of Human Epidermis: An Electrometric Study,” J. Invest. Dermatol., V.60, pp. 263-69, 1973), lauryl amine oxide (Johnson et. al., U.S. Pat. No. 4,411,893), azone (Rajadhyaksha, U.S. Pat. Nos. 4,405,616 and 3,989,816) and decylmethyl sulfoxide (Sekura, D. L. and Scala, J., “The Percutaneous Absorption of Alkylmethyl Sulfides,” Pharmacology of the Skin, Advances In Biolocy of Skin, (Appleton-Century Craft) V. 12, pp. 257-69, 1972). It has been observed that increasing the polarity of the head group in amphoteric molecules increases their penetration-enhancing properties but at the expense of increasing their skin irritating properties (Cooper, E. R. and Berner, B., “Interaction of Surfactants with Epidermal Tissues: Physiochemical Aspects,” Surfactant Science Series, V. 16, Reiger, M. M. ed. (Marcel Dekker, Inc.) pp. 195-210, 1987).
[0237] A second class of chemical enhancers are generally referred to as co-solvents. These materials are absorbed topically relatively easily, and, by a variety of mechanisms, achieve permeation enhancement for some drugs. Ethanol (Gale et. al., U.S. Pat. No. 4,615,699 and Campbell et. al., U.S. Pat. Nos. 4,460,372 and 4,379,454), dimethyl sulfoxide (U.S. Pat. Nos. 3,740,420 and 3,743,727, and U.S. Pat. No. 4,575,515), and glycerine derivatives (U.S. Pat. No. 4,322,433) are a few examples of compounds which have shown an ability to enhance the absorption of various compounds.
[0238] The pharmaceutical compositions of the invention can also be intended for administration with aerosolized formulation to target areas of a patient's respiratory tract.
[0239] Devices and methodologies for delivering aerosolized bursts of a formulation of a drug is disclosed in U.S. Pat. No. 5,906,202. Formulations are preferably solutions, e.g. aqueous. solutions, ethanoic solutions, aqueous/ethanoic solutions, saline solutions, colloidal suspensions and microcrystalline suspensions. For example aerosolized particles comprise the active ingredient mentioned above and a carrier, (e.g., a pharmaceutically active respiratory drug and carrier) which are formed upon forcing the formulation through a nozzle which nozzle is preferably in the form of a flexible porous membrane. The particles have a size which is sufficiently small such that when the particles are formed they remain suspended in the air for a sufficient amount of time such that the patient can inhale the particles into the patient's lungs.
[0240] The invention encompasses the systems described in U.S. Pat. No. 5,556,611:
liquid gas systems (a liquefied gas is used as propellent gas (e.g. low-boiling FCHC or propane, butane) in a pressure container, suspension aerosol (the active substance particles are suspended in solid form in the liquid propellent phase), pressurized gas system (a compressed gas such as nitrogen, carbon dioxide, dinitrogen monoxide, air is used.
[0244] Thus, according to the invention the pharmaceutical preparation is made in that the active substance is dissolved or dispersed in a suitable nontoxic medium and said solution or dispersion atomized to an aerosol, i.e. distributed extremely finely in a carrier gas. This is technically possible for example in the form of aerosol propellent gas packs, pump aerosols or other devices known per se for liquid misting and solid atomizing which in particular permit an exact individual dosage.
[0245] Therefore, the invention is also directed to aerosol devices comprising the compound as defined above and such a formulation, preferably with metered dose valves.
[0246] The pharmaceutical compositions of the invention can also be intended for intranasal administration.
[0247] In this regard, pharmaceutically acceptable carriers for administering the compound to the nasal mucosal surfaces will be readily appreciated by the ordinary artisan. These carriers are described in the Remington's Pharmaceutical Sciences” 16th edition, 1980, Ed. By Arthur Osol, the disclosure of which is incorporated herein by reference.
[0248] The selection of appropriate carriers depends upon the particular type of administration that is contemplated. For administration via the upper respiratory tract, the composition can be formulated into a solution, e.g., water or isotonic saline, buffered or unbuffered, or as a suspension, for intranasal administration as drops or as a spray. Preferably, such solutions or suspensions are isotonic relative to nasal secretions and of about the same pH, ranging e.g., from about pH 4.0 to about pH 7.4 or, from pH 6.0 to pH 7.0. Buffers should be physiologically compatible and include, simply by way of example, phosphate buffers. For example, a representative nasal decongestant is described as being buffered to a pH of about 6.2 (Remington's, Id. at page 1445). Of course, the ordinary artisan can readily determine a suitable saline content and pH for an innocuous aqueous carrier for nasal and/or upper respiratory administration.
[0249] Common intranasal carriers include nasal gels, creams, pastes or ointments with a viscosity of, e.g., from about 10 to about 3000 cps, or from about 2500 to 6500 cps, or greater, may also be used to provide a more sustained contact with the nasal mucosal surfaces. Such carrier viscous formulations may be based upon, simply by way of example, alkylcelluloses and/or other biocompatible carriers of high viscosity well known to the art (see e.g., Remington's, cited supra. A preferred alkylcellulose is, e.g., methylcellulose in a concentration ranging from about 5 to about 1000 or more mg per 100 ml of carrier. A more preferred concentration of methyl cellulose is, simply by way of example, from about 25 to about mg per 100 ml of carrier.
[0250] Other ingredients, such as art known preservatives, colorants, lubricating or viscous mineral or vegetable oils, perfumes, natural or synthetic plant extracts such as aromatic oils, and humectants and viscosity enhancers such as, e.g., glycerol, can also be included to provide additional viscosity, moisture retention and a pleasant texture and odor for the formulation. For nasal administration of solutions or suspensions according to the invention, various devices are available in the art for the generation of drops, droplets and sprays.
[0251] A premeasured unit dosage dispenser including a dropper or spray device containing a solution or suspension for delivery as drops or as a spray is prepared containing one or more doses of the drug to be administered and is another object of the invention. The invention also includes a kit containing one or more unit dehydrated doses of the compound, together with any required salts and/or buffer agents, preservatives, colorants and the like, ready for preparation of a solution or suspension by the addition of a suitable amount of water.
[0252] Another aspect of the invention is directed to the use of said compound to manufacture a medicament. In other words, the invention embraces a method for treating a disease related to unregulated c-kit transduction comprising administering an effective amount of a compound as defined above to a mammal in need of such treatment.
[0253] More particularly, the invention is aimed at a method for treating a disease selected from autoimmune diseases, allergic diseases, bone loss, cancers such as leukemia and GIST, tumor angiogenesis, inflammatory diseases, inflammatory bowel diseases (IED), interstitial cystitis mastocytosis, infections diseases, metabolic disorders, fibrosis, diabetes and CNS disorders comprising administering an effective amount a compound depicted above to a mammal in need of such treatment.
[0254] The above described compounds are useful for manufacturing a medicament for the treatment of diseases related to unregulated c-kit transduction including, but not limited to:
neoplastic diseases such as mastocytosis, canine mastocytoma, human gastrointestinal stromal tumor (“GIST”), small cell lung cancer, non-small cell lung cancer, acute myelocytic leukemia, acute lymphocytic leukemia, myelodysplastic syndrome, chronic myelogenous leukemia, colorectal carcinomas, gastric carcinomas, gastrointestinal stromal tumors, testicular cancers, glioblastomas, solid tumors and astrocytomas. tumor angiogenesis. metabolic diseases such as diabetes mellitus and its chronic complications; obesity; diabete type II; hyperlipidemias and dyslipidemias; atherosclerosis; hypertension; and cardiovascular disease. allergic diseases such as asthma, allergic rhinitis, allergic sinusitis, anaphylactic syndrome, urticaria, angioedema, atopic dermatitis, allergic contact dermatitis, erytliema nodosum, erythema multiforme, cutaneous necrotizing venulitis and insect bite skin inflammation and blood sucking parasitic infestation. interstitial cystitis. bone loss (osteoporosis). inflammatory diseases such as rheumatoid arthritis, conjunctivitis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions. autoimmune diseases such as multiple sclerosis, psoriasis, intestine inflammatory disease, ulcerative colitis, Crohn's disease, rheumatoid arthritis and polyarthritis, local and systemic scleroderma, systemic lupus erythematosus, discoid lupus erythematosus, cutaneous lupus, dermatomyositis, polymyositis, Sjogren's syndrome, nodular panarteritis, autoimmune enteropathy, as well as proliferative glomerulonephritis. graft-versus-host disease or graft rejection in any organ transplantation including kidney, pancreas, liver, heart, lung, and bone marrow. Other autoimmune diseases embraced by the invention active chronic hepatitis and chronic fatigue syndrome. subepidermal blistering disorders such as pemphigus. Vasculitis. melanocyte dysfunction associated diseases such as hypermelanosis resulting from melanocyte dysfunction and including lentigines, solar and senile lentigo, Dubreuilh melanosis, moles as well as malignant melanomas. In this regard, the invention embraces the use of the compounds defined above to manufacture a medicament or a cosmetic composition for whitening human skin. CNS disorders such as psychiatric disorders, migraine, pain, memory loss and nerve cells degeneracy. More particularly, the method according to the invention is useful for the treatment of the following disorders: Depression including dysthymic disorder, cyclothymic disorder, bipolar depression, severe or “melancholic” depression, atypical depression, refractory depression, seasonal depression, anorexia, bulimia, premenstrual syndrome, post-menopause syndrome, other syndromes such as mental slowing and loss of concentration, pessimistic worry, agitation, self-deprecation, decreased libido, pain including, acute pain, postoperative pain, chronic pain, nociceptive pain, cancer pain, neuropathic pain, psychogenic pain syndromes, anxiety disorders including anxiety associated with hyperventilation and cardiac arrhythmias, phobic disorders, obsessive-compulsive disorder, posttraumatic stress disorder, acute stress disorder, generalized anxiety disorder, psychiatric emergencies such as panic attacks, including psychosis, delusional disorders, conversion disorders, phobias, mania, delirium, dissociative episodes including dissociative amnesia, dissociative fugue and dissociative identity disorder, depersonalization, catatonia, seizures, severe psychiatric emergencies including suicidal behaviour, self-neglect, violent or aggressive behaviour, trauma, borderline personality, and acute psychosis, schizophrenia including paranoid schizophrenia, disorganized schizophrenia, catatonic schizophrenia, and undifferentiated schizophrenia, neurodegenerative diseases including Alzheimer's disease , Parkinson's disease, Huntington's disease, the prion diseases, Motor Neurone Disease (MND), and Amyotrophic Lateral Sclerosis (ALS). substance use disorders as referred herein include but are not limited to drug addiction, drug abuse, drug habituation, drug dependence, withdrawal syndrome and overdose. Cerebral ischemia Fibrosis Duchenne muscular dystrophy
[0274] Regarding mastocytosis, the invention contemplates the use of the compounds as defined above for treating the different categories which can be classified as follows:
[0275] The category I is composed by two sub-categories (IA and IB). Category IA is made by diseases in which mast cell infiltration is strictly localized to the skin. This category represents the most frequent form of the disease and includes : i) urticaria pigmentosa, the most common form of cutaneous mastocytosis, particularly encountered in children, ii) diffuse cutaneous mastocytosis, iii) solitary mastocytoma and iv) some rare subtypes, like bullous, erythrodermic and teleangiectatic mastocytosis. These forms are characterized by their excellent prognosis with spontaneous remissions in children and a very indolent course in adults. Long term survival of this form of disease is generally comparable to that of the normal population and the translation into another form of mastocytosis is rare. Category IB is represented by indolent systemic disease (SM) with or without cutaneous involvement. These forms are much more usual in adults than in children. The course of the disease is often indolent, but sometimes signs of aggressive or malignant mastocytosis can occur, leading to progressive impaired organ function.
[0276] The category II includes mastocytosis with an associated hematological disorder, such as a myeloproliferative or myelodysplastic syndrome, or acute leukemia These malignant mastocytosis does not usually involve the skin. The progression of the disease depends generally on the type of associated hematological disorder that conditiones the prognosis.
[0277] The category III is represented by aggressive systemic mastocytosis in which massive infiltration of multiple organs by abnormal mast cells is common. In patients who pursue this kind of aggressive clinical course, peripheral blood features suggestive of a myeloproliferative disorder are more prominent. The progression of the disease can be very rapid, similar to acute leukemia, or some patients can show a longer survival time.
[0278] Finally, the category IV of mastocytosis includes the mast cell leukemia, characterized by the presence of circulating mast cells and mast cell progenitors representing more than 10% of the white blood cells. This entity represents probably the rarest type of leukemia in humans, and has a very poor prognosis, similar to the rapidly progressing variant of malignant mastocytosis. Mast cell leukemia can occur either de novo or as the terminal phase of urticaria pigmentosa or systemic mastocytosis.
[0279] The invention also contemplates the method as depicted for the treatment of recurrent bacterial infections, resurging infections after asymptomatic periods such as bacterial cystitis. More particularly, the invention can be practiced for treating FimH expressing bacteria infections such as Gram-negative enterobacteria including E. coli, Klebsiella pneumoniae, Serratia marcescens, Citrobactor freudii and Salmonella typhimuriun.
[0280] In this method for treating bacterial infection, separate, sequential or concomitant administration of at least one antibiotic selected bacitracin, the cephalosporins, the penicillins, the aminoglycosides, the tetracyclines, the streptomycins and the macrolide antibiotics such as erythromycin; the fluoroquinolones, actinomycin, the sulfonamides and trimethoprim, is of interest.
[0281] In one preferred embodiment, the invention is directed to a method for treating neoplastic diseases such as mastocytosis, canine mastocytoma, human gastrointestinal stromal tumor (“GIST”), small cell lung cancer, non-small cell lung cancer, acute myelocytic leukemia, acute lymphocytic leukemia, myelodysplastic syndrome, chronic myelogenous leukemia, colorectal carcinomas, gastric carcinomas, gastrointestinal stromal tumors, testicular cancers, glioblastomas, and astrocytomas comprising administering a compound as defined herein to a human or mammal, especially dogs and cats, in need of such treatment.
[0282] In one other preferred embodiment, the invention is directed to a method for treating allergic diseases such as asthma, allergic rhinitis, allergic sinusitis, anaphylactic syndrome, urticaria, angioedema, atopic dermatitis, allergic contact dermatitis, erythema nodosum, erythema multiforme, cutaneous necrotizing venulitis and insect bite skin inflammation and blood sucking parasitic infestation comprising administering a compound as defined herein to a human or mammal, especially dogs and cats, in need of such treatment.
[0283] In still another preferred embodiment, the invention is directed to a method for treating inflammatory diseases such as rheumatoid arthritis, conjunctivitis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions comprising administering a compound as defined herein to a human in need of such treatment.
[0284] In still another preferred embodiment, the invention is directed to a method for treating autoimmune diseases such as multiple sclerosis, psoriasis, intestine inflammatory disease, ulcerative colitis, Crohn's disease, rheumatoid arthritis and polyarthritis, local and systemic scleroderma, systemic lupus erythematosus, discoid lupus erythematosus, cutaneous lupus, dermatomyositis, polymyositis, Sjogren's syndrome, nodular panateritis, autoimmune enteropathy, as well as proliferative glomerulonephritis comprising administering a compound as defined herein to a human in need of such treatment.
[0285] In still another preferred embodiment, the invention is directed to a method for treating graft-versus-host disease or graft rejection in any organ transplantation including kidney, pancreas, liver, heart, lung, and bone marrow comprising administering a compound as defined herein to a human in need of such treatment.
Example 1
In Vitro TK Inhibition Assays
[0286] Procedure
[0287] Experiments were performed using purified intracellular domain of c-kit expressed in baculovirus. Estimation of the kinase activity was assessed by the phosphorylation of tyrosine containing target peptide estimated by established ELISA assay.
[0288] Experimental Results on Tested Compounds
[0289] Result in Table 1 shows the potent inhibitory action of the catalytic activity of c-kit with an IC50<10 μM. Further experiments (not shown) indicates that at least one compound acts as perfect competitive inhibitors of ATP.
TABLE 1 In vitro Inhibition assay results c-kit Compounds IC50 (μM) 066; 074; 078; 084; 012; 016; 073; 021; 088; <10 μM 023; 025; 047; 048; 055; 049; 026; 087; 075; 089; 051; 082; 090; 060; 085; 052; 053; 096
Example 2
Ex Vivo TK Inhibition Assays
[0290] Procedures
[0291] C-Kit WT and Mutated C-Kit (JM) Assay
[0000] Proliferation Assays
[0292] Cells were washed two times in PBS before plating at 5×10 4 cells per well of 96-well plates in triplicate and stimulated either with hematopoietic growth factors (HGF) or without. After 2 days of culture, 37 Bq (1.78 Tbq/mmol) of [3H] thymidine (Amersham Life Science, UK) was added for 6 hours. Cells were harvested and filtered through glass fiber filters and [ 3 H] thymidine incorporation was measured in a scintillation counter. For proliferation assay, all drugs were prepared as 20 mM stock solutions in DMSO and conserved at −80° C. Fresh dilutions in PBS were made before each experiment. DMSO dissolved drugs were added at the beginning of the culture. Control cultures were done with corresponding DMSO dilutions. Results are represented in percentage by taking the proliferation without inhibitor as 100%.
[0000] Cells
[0293] Ba/F3 murine kit and human kit, Ba/F3 mkitΔ27 (juxtamembrane deletion) are derived from the murine L-3 dependent Ba/F3 proB lymphoid cells. The FMA3 and P815 cell lines are mastocytoma cells expressing endogenous mutated forms of Kit, i.e., frame deletion in the murine juxtamembrane coding region of the receptor-codons 573 to 579. The human leukaemic MC line HMC-1 expresses mutations JM-V560G;
[0000] Inmunoprecipitation Assays and Western Blotting Analysis
[0294] For each assay, 5.10 6 Ba/F3 cells and Ba/F3-derived cells with various c-kit mutations were lysed and immunoprecipitated as described (Beslu et al., 1996), excepted that cells were stimulated with 250 ng/ml of rmKL. Cell lysates were immunoprecipitated with a rabbit immunserum anti murine KIT, directed against the KIT cytoplasmic domain (Rottapel et al., 1991). Western blot was hybridized either with the 4G10 anti-phosphotyrosine antibody (UBI) or with the rabbit immunserum anti-murine KIT or with different antibodies (described in antibodies paragraph). The membrane was then incubated either with HRP-conjugated goat anti mouse IgG antibody or with HRP-conjugated goat anti rabbit IgG antibody (Immunotech), Proteins of interest were then visualized by incubation with ECL reagent (Amersham).
[0295] Experimental Results
[0296] The experimental results for various compounds according to the invention using above-described protocols are set forth at Table 2:
TABLE 2 IC50 Target (μM) Compounds c-Kit IC50 < 002; 005; 006; 007; 008; 009; 010; 012; 017; 019; 020; WT 10 μM 021; 023; 024; 025; 026; 028; 029; 030; 032; 042; 043; 045; 047; 048; 049; 050; 051; 052; 053; 054; 055; 056; 057; 059; 060; 061; 062; 063; 064; 065; 066; 067; 072; 073; 074; 075; 077; 078; 079; 080; 081; 082; 083; 084; 085; 086; 087; 088; 089; 090; 092; 093; 094; 095; 096; 097; 106; 105; 104; 103; 128; 129; 130; 131; 117; 110; 116; 124; 108; 122; 111; 113; 118; 107; c-Kit IC50 < 028; 074; 029; 009; 012; 073; 020; 042; 061; 065; 088; JM 1 μM 025; 048; 049; 050; 089; 051; 082; 090; 083; 059; 052; Δ27 053; 066; 103; 067; 104; 078; 079; 105; 081; 084; 030; 010; 021; 043; 054; 062; 106; 023; 024; 064; 047; 055; 026; 087; 075; 085; 005; 077; 092; 060; 032; 017; 063; 093; 094; 095; 086; 093; 096; 108; 117; 122; 008; 080; 111; 118; 113; 007; 072; 019; 056; 057; 107; 097;
Example 3
In Vivo Activity
[0297] Procedures
[0298] Gist
[0299] cells: Ba/F3 cells were transfected by c-kit gene having Δ27 mutation (GIST model). Ba/F3 expressing the mutated c-kit gene readily proliferate in the absence of IL3 or SCF and are tumorigenic in nude mice.
[0000] Protocol:
[0300] Mice were irradiated at J-1 (5 Gy)
[0301] Tumor cells (10 6 ) were subcutaneously grafted at Jo
[0302] Tumor size were daily measured from J14
[0303] Number of survival mice were daily estimated
[0304] In this experimental model, the tumor size at J14 is about 20 mm 3
[0305] Treated mice received per os twice a day a dose of 100 mg/kg of one compound of formula II-3 during 5 days (from J26 to J30).
[0306] Rhumatoid Arthritis
[0307] The mice were pretreated with the compound of formula II-3 (2×, 12.5 mg/kg) for two days (day-2, day-1) before induction of arthritis. Arthritis was induced by ip injection of 150-ul serums at days 0 and 2. The treatment with the compound (2×, 12.5 mg/kg) was continued for 14 days. The control mice were injected with, 1% PBS before the induction of arthritis and during the course of the disease. Ankle thickness and arthritis score was evaluated for 15 days. Arthritis Score: Sum of scores of each limb (0 no disease; 1 mild swelling of paw or of just a few digits; 2 clear joint inflammation; 3 severe joint inflammation) maximum score=12. Table 3A and Table 3B show the number of mice used in this study. Two sets of experiments were done with different number of mice, one with 4 mices the other with 8 mices.
TABLE 3 A Treated Mice C57B1/6 2×, 12.5 mg/Kg 6
[0308] TABLE 3 B Controls C57B1/6 2×, 1% PBS 6
Histology
[0309] At the end of the experiment the hind limbs were collected. The skin of the limb was removed and the limbs were subsequently fixed in 2% Para formaldehyde.
[0310] Experimental results
[0311] GIST
[0312] Treated mice (with one compound of formula II-3) displays significant decrease of tumor size at J30 and J33 compared to control.
[0313] When administrated per os, one tested compound of the formula II-3displays a significant antitumor activity against tumors cells expressing c-kit Δ27.
[0314] RA
[0315] A compound of the formula II-3 has demonstrated significant activity in the in vivo mouse model of arthritis. Results are shown on FIGS. 1, 2 , 3 , 4 .
FIGURE LEGENDS
[0316] FIG. 1 : Effect of the compound in serum transfer experiments, Protocol, ip daily treatment with the compound (2×12.5 mg/kg) and on days-2 and -1, set of experiment with 4 mices (T: treated, C: control)
[0317] FIG. 2 : Effect of the compound in serum transfer experiments, Protocol , ip daily treatment with the compound (2×12.5 mg/kg) and on days-2 and -1, set of experiment with 4 mices (T: treated, C: control)
[0318] FIG. 3 : Effect of the compound in serum transfer experiments, Protocol , ip daily treatment with the compound (2×12.5 mg/kg) and on days-2 and -1, set of experiment with 8 mices (T: treated, C: control)
[0319] FIG. 4 : Effect of the compound in serum transfer experiments, Protocol , ip daily treatment with the compound (2×12.5 mg/kg) and on days-2 and -1, set of experiment with 8 mices (T: treated, C: control) | Novel compounds selected from 2-(3-aminoaryl) amino-4-aryl-thiazoles of formula (I) that selectively modulate, regulate, and/or inhibit signal transductions mediated by certain native and/or mutant tyrosine kinases implicated in a variety of human and animal diseases such as cell proliferative, metabolic, allergic and degenerative disorders. More particularly, these compounds are potent and selective c-kit inhibitors. | 2 |
[0001] This application claims priority under 35 U.S.C. 119 from U.S. provisional application Serial No. 60/337,895 filed Nov. 8, 2001, and incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to a method and system of identifying skin conditions, and more particularly, to a method of identifying skin conditions using a knowledge database and selecting suitable treatment products. The present invention is also directed to a method for predicting or monitoring the efficacy of a product.
BACKGROUND OF THE INVENTION
[0003] Consumers purchase topical products to improve the characteristics of their skin. Such products may be obtained in a variety of forms, including oils, ointments, creams, lotions, and gels. The products may be used to treat a variety of conditions, such as acne, wrinkles, psoriasis, hair loss, age spots, and skin discoloration. Unfortunately, many consumers purchase topical products that do not work for their particular condition. For instance, a particular consumer may purchase a cream to treat acne and, not until after the product has been used for its intended use period, learn that the product does not work for them. The scientific basis for the existence of “responders” and “non-responders” to any particular product technology is unclear. Accordingly it is not possible to determine who will be a responder without actually testing the product on that individual. This leads to people having to self experiment with different products until they find one that works for them.
[0004] In the absence of a scientific, theory based, understanding of the basis of “responders” and “non-responders” it is possible in principle to identify such groups empirically by constructing a large correlation matrix between measured properties of the person and the response of that person to different technologies. Unfortunately, the fact that it is usually only possible to test one product at a time per person makes the size of studies needed to produce a statistically significant correlation totally impractical. Accordingly, no satisfactory predictive method to identify “responders” and “non responders” to a set of technologies has been established.
[0005] Measuring the skin needs of an individual and thereby recommending a generic product treatment is known. Examples would include establishing that an individual has acne and therefore recommending an acne treatment. Another example would be establishing that an individual has oily skin and therefore recommending an oil free moisturiser. Specific embodiments of this kind of “diagnostic” include the well known “Clinique Computer” found in department stores worldwide, as well as the Reflect.com website through which recommended products may be purchased. Further, WO 01/58238 (assigned to Collaborative Technologies) relates to a method and system for producing customized cosmetic and pharmaceutical formulations on demand based on retrieving a user profile associated with the user. There are also many examples of non invasive skin measurements that correlate with an individual having a particular type of skin problem such as sebumeters, skin impedance devices, profilometry and the like. Procter & Gamble's Visia Complexion Analysis System (a photographic imaging tool that provides clinical measurement and analysis of topical and subsurface facial skin conditions) is a specific example.
[0006] On their own however none of these systems can determine which of two technologies, each efficacious when tested on an “average” population, will work best on a particular individual. This remains an unachievable ambition in personal care and it is to this need that this invention is addressed.
SUMMARY OF THE INVENTION
[0007] The invention relates to a method of providing a system of selecting a treatment product for a skin condition of a consumer, including:
[0008] (a) collecting information from the consumer regarding a plurality of characteristics associated with the skin condition, the information collected through a computer;
[0009] (b) inputting the information into a computerized knowledge system that selects a product that will be effective for the consumer from at least two products that are effective against the skin condition; and
[0010] (c) providing the consumer with the treatment product for treating the skin condition.
[0011] The computerized knowledge system is derived from a correlation between responses of a population of individuals to a plurality of products and measured characteristics of each of the individuals taken prior to use of the plurality of products.
[0012] In another aspect, the invention is directed to a method of predicting the efficacy of a product.
[0013] In a still further aspect, the invention is directed to a method of providing feedback to the consumer as to how the product is working.
DETAILED DESCRIPTION OF THE INVENTION
[0014] As used herein, the following terms are intended to have the stated definitions.
[0015] The term “skin” as used herein includes the skin on the face, neck, chest, back, arms, hands, legs, and scalp. The term “skin” includes all layers of the human skin, including any reference to epidermis or keratinocytes.
[0016] As used herein, the term “comprising” includes made up of, composed of, including, consisting and/or consisting essentially of. Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts or ratios of material or conditions of reaction, physical properties of materials and/or use are to be understood as modified by the word “about”.
[0017] The present invention relates to a method of predicting which of a plurality of products will be most efficacious for a particular individual. Preferably, the present invention is based on a method for detecting a skin condition in a skin sample using gene arrays as markers of the skin condition. The method further relates to product selection and/or monitoring based on a computerized knowledge base that contains data from physical skin samples analyzed by various gene expression techniques, as well as data based on feedback from product selections. Part of the method is a knowledge base that is constantly updated with data from new skin samples and with data from ongoing product selections and feedback. The inventive method is based on a series of steps.
[0018] Step 1 is the creation of a computerised knowledge base correlating parameters of a population of individuals measured before any product treatment, with the efficacy of a range of different technologies measured simultaneously on each member of that population.
[0019] The measured parameters can include questionaire data (age, sex, history of skin problems, self description of skin type etc), clinical data (appearance of wrinkles, extent of blemishes, skin color and tone etc) and instrumental data (chemical analysis, electrical properties, optical properties, mechanical properties etc). Only those parameters which significantly correlate with response of individuals to the different treatments are used in the knowledge base.
[0020] The creation of this knowledge base is only practical if it is possible to simultaneously measure the skin improvement from multiple products at the same time on the same individual. Achievement of these simultaneous multiple measurements is a major challenge. It requires that the benefit of the product be measurable in a reasonable period of time after product applications and that the benefit be measurable when the product is applied to only a small area of skin so that multiple products can be simultaneously applied. This is particularly challenging when the benefit is one such as anti-aging, where, conventionally, efficacy of single products can only be assessed when tested on the whole face for several months. The invention encompasses the use of known techniques, for this multiple performance assessment such as:
[0021] Measuring change in skin color of a small area of skin to predict the performance of cosmetic skin lightening agents
[0022] Measuring the change in skin impedance of a small area of skin to assess the performance of dry skin treatment
[0023] Measuring changes in skin auto-fluorescence of a small area of skin following product treatment to predict the performance of anti-aging products
[0024] Electrical conductivity of the skin
[0025] Sebum measurement of the skin
[0026] Microscopic analysis of the skin
[0027] The essential characteristic of these assessment methods is that they can be reliably applied to a small area of skin and provide accurate predictions of the effect of the product when applied to the skin in the normal way.
[0028] In a preferred embodiment of the invention, a novel and inventive technique for measuring product efficacy is used. We have discovered that it is possible to measure changes in the expression levels of genes in the skin that occur soon after product application commences and that these changes are predictive of whether the product will produce good, average or poor efficacy when treatment is continued for much longer periods. This is particularly advantageous for skin conditions such as ageing where normally very long periods of treatment are needed to achieve measurable benefits. The changes in gene expression level can be detected in small biopsies taken from the treatment site which are analysed by any of the methods known in the literature such as gene arrays, RT PCR or multiplexed methods.
[0029] Step 2 is to measure the parameters shown in step 1 on a consumer who is seeking guidance as to which product will be most efficacious for her, to correlate with response to different products. Those parameters are entered into the computerized knowledge system and a prediction of which product will work best for her is generated. The product is then provided to the consumer.
[0030] The following specific examples further illustrate the invention, but the invention is not limited thereto.
EXAMPLE 1
[0031] In this example, DNA array technique is used to generate data on early changes in gene expression following product application.
[0032] DNA Array Technique. The following are the steps of this method.
[0033] 1. Plasmid DNA, cDNA (copy DNA) generally in the range of 200-1000 bp or oligonucleotides (ranging from 20-100 bp) is attached to a support (this is either glass or nylon membrane). Since DNA is negatively charged, the surface of glass or membrane is positively charged, allowing the DNA to be “spotted” onto this solid support and be retained. Each DNA can represent a different gene, so that hundreds or thousands of genes can be studied at a single timepoint.
[0034] 2. tRNA (total RNA) or mRNA (messenger RNA) is isolated from a sample (tissue, cells) and labeled either with a fluorescent tag, or radioisotope tag using a reverse transcription step. This serves as the probe.
[0035] 3. This probe is then incubated with the array in solution. Where the sequence of the probe is complementary to the sequence on the array, the 2 spots are said to hybridize. This is then detected by phosphoroimaging, or using laser or other fluorescent detection techniques.
[0036] 4. The signal from the detection system is analyzed via image analysis and quantified.
[0037] The probe may be used to test multiple products on a single skin sample of a single individual, as well as of a population. It may also be used to test different concentrations of an active component on a single skin sample of a single individual. Additionally, it may be used to test different combinations of actives on a single skin sample of a single individual.
EXAMPLE 2
[0038] This example demonstrates a predictive method to identify “responders” and “non responders” to a set of skin benefit technologies, which is one of the key elements of the methods of the present invention.
[0039] Six panelists applied a prototype anti-aging topical skin care cream product (retinol/glycolic acid, as set forth in the Table below) to one of their arms twice daily for 12 weeks. The product composition is set forth in the Table below. Skin biopsies were taken before and after just 7 days of using the product and the epidermal tissue analysed for the levels of expression of key genes on Integriderm™ nylon gene arrays (Research Genetics). The benefit achieved over the 12 weeks of use was judged by an expert grader on the Crepey grade (Weinkauf, R. L., et al., “Method for Assessing the Efficacy of Cosmetic Formulations Containing Alpha Hydroxy Acids on Photoaged Skin of the Forearms,” Poster Presentation at American Academy of Dermatology (AAD) Meeting , incorporated by reference herein) and expressed as an integrated effect over the 12 weeks of use compared to an untreated control site.
TABLE 1 CHEMICAL/ COMP. 1 PHASE CTFA NAME TRADE NAME (WT. %) A WATER, DI 44.0 A DISODIUM EDTA SEQUESTERENE Na2 0.05 A MAGNESIUM ALUMINUM VEEGUM ULTRA 0.6 SILICATE A METHYL PARABEN METHYL PARABEN 0.15 A SIMETHICONE ANTIFOAM EMULSION 0.01 A BUTYLENE GLYCOL - 1,3 BUTYLENE GLYCOL - 1,3 3.0 A HYDROXYETHYLCELLULOSE NATROSOL 250 HHR 0.5 A GLYCERIN USP GLYCERIN USP 2.0 A XANTHAN GUM KELTROL M 0.2 A TRIETHANOLAMINE 99% TEA 99% 1.2 B STEARIC ACID PRISTERENE 4911 3.0 B GLYCERYL NATURECHEM GMHS 1.5 HYDROXYSTEARATE 1 B STEARYL ALCOHOL LANETTE 18DEO 1.5 B CHOLESTEROL NF CHOLESTEROL NF 0.5 B SORBITAN STEARATE SORBITAN STEARATE 1.0 B PEG-100 STEARATE MYRJ 59 2.0 B ISOSTEARYL PALMITATE 2 PROTACHEM ISP 6.0 B C12-C15 ALCOHOLS HESTESTER FAO 3.0 OCTANOATE B DIMETHICONE SILICONE FLD 200 1.0 (50 CTS) B TOCOPHERYL ACETATE VITAMIN E ACETATE 0.10 B BUTYLATED BHT 0.05 HYDROXYTOLUENE B PROPYLPARABEN NF PROPYLPARABEN 0.1 C WATER, DI 3.0 D GLYCOLIC ACID 70% GLYPURE 70 11.4 D AMMONIUM HYDROXIDE 29% AMMONIUM HYDROXIDE 29% 2.5 D WATER, DI 99.51 A WATER, DI 44.0 E RETINOL (51.3%) 1 RETINOL BLEND (51.3%) 0.29 F ALPHA-BISABOLOL ALPHA-BISABOLOL 0.2
[0040] The following table shows the correlation of changes in levels of the key genes after just 7 days of products usage, with the ultimate clinical benefit achieved. Panelists showing improvement had one set of gene patterns, while those showing no improvement had another set of gene patterns. The Performance Quotient, shown in column 2 of the table, is a ratio of visual assessments made on a Crepey scale after treatment to that before treatment. Performance Quotient was calculated by integrating the differences in Crepey grade (Weinkauf et al.) recorded from the two arms of each panelist over the 12 weeks of treatment where one arm is treated and the other untreated). The lower the numbers on the Crepey scale and the smaller the performance quotient, the fewer wrinkles. With reference to columns 3-5, “day 0” indicates gene expression prior to product application.
TABLE 2 Relative fold change of gene expression between Performance ranking Performance day 0 and day 7 of treatment (1 = Best, 6 = Worst) Quotient Gene 1 Gene 2 Gene 3 1 11.5 0.43 2.11 1.32 2 11.5 0.85 1.24 1.24 3 10.0 0.51 1.64 1.32 4 6.0 0.96 0.72 1.02 5 4.5 1.35 0.96 0.37 6 3.0 2.65 0.53 0.29
[0041] The data show the relative fold change of gene expression between first and seventh day of treatment ranked against performance over full 12 weeks of treatment in terms of Performance Quotient. In other words, it is possible to tell in 7 days what will happen in 12 weeks. The data may be included in the knowledge base useful for the business method of the present invention. Specifically, this association between visual grading on a Crepey Grade scale with gene changes in response to product treatments, is entered into the knowledge base. Similar correlations may be made part of the knowledge base for measures of photodamage, mottle pigmentation, height of wrinkles, lipid matrix (e.g. to predict penetration), and other conditions of skin or personal care attributes.
EXAMPLE 3
[0042] This example demonstrates the business method of the present invention.
[0043] A consumer performs a non-invasive diagnostic test for a particular personal care condition and inputs the results into the computer system incorporating a knowledge base in accordance with the present invention. The knowledge base contains gene expression data to tell whether there is room for improvement. The computer system correlates the non-invasive diagnostic result to how others responded based on gene expression and recommends a suitable cosmetic product.
[0044] While the present invention has been described herein with some specificity, and with reference to certain preferred embodiments thereof, those of ordinary skill in the art will recognize numerous variations, modifications and substitutions of that which has been described which can be made, and which are within the scope and spirit of the invention. It is intended that all of these modifications and variations be within the scope of the present invention as described and claimed herein, and that the inventions be limited only by the scope of the claims which follow, and that such claims be interpreted as broadly as is reasonable. Throughout this application, various publications have been cited. The entireties of each of these publications are hereby incorporated by reference herein. | A method of providing a system of selecting a treatment product for a skin condition of a consumer, by collecting information from the consumer regarding a plurality of characteristics associated with the skin condition; inputting the information into a computerized knowledge system, based on gene expression and other data collected from a population of individuals, that selects a product that will be effective for the consumer from at least two products that are effective against the skin condition; and providing the consumer with the treatment product for treating the skin condition. The business method of this invention uses a system with an integrated database that allows for continuous updating and reviewing. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims the benefit of provisional patent application 60/550,835, filed on Mar. 5, 2004.
TECHNICAL FIELD
The present invention relates to charge air coolers of the type used in locomotive diesel engines for cooling air exiting the engine turbocharger, and more particularly to a charge air cooler having an absence of air by-pass therethrough.
BACKGROUND OF THE INVENTION
Locomotive diesel engines generally utilize a combustion intake turbocharger which provides combustion charge air for the engine, and which is rotatably powered by exhaust of the engine. After being compressed in the turbocharger, the combustion charge air is hot, and is in need of cooling. This cooling is supplied by a charge air cooler (sometimes also referred to as an after cooler), located downstream of the turbocharger and upstream of the engine air box combustion chamber. An example of a prior art charge air system 10 is depicted at FIGS. 1 through 3 , which should be referred to respecting the following description thereof.
Referring firstly to FIGS. 1 through 2 , a turbocharger 12 is interfaced with at least one prior art charge air cooler assembly 14 (two prior art charge air cooler assemblies 14 ′, 14 ″ being shown at FIG. 1 ). The prior art charge air cooler assembly 14 includes a heat exchange core assembly 16 having a plurality of coolant tubes 14 t arranged for a four-pass coolant path coolant tube arrangement, and having, for example, 26 to 27 coolant tubes deep, with a multiplicity of fins 14 f connected in perpendicular relation thereto, wherein coolant (which may be liquid water or a liquid water and anti-freeze solution) circulates through the tubes via an external coolant system 18 and thereby extracts heat of the compressed charge air A from the turbocharger 12 , whereupon cooled compressed charge air A′ now passes to an engine air box combustion chamber 20 .
Each prior art charge air cooler assembly 14 , 14 ′ further includes a cooler plenum 22 , 22 ′ an inlet duct 24 , 24 ′ integrally connected to the cooler plenum and an outlet duct 26 , 26 ′ also integrally connected to the cooler plenum. The heat exchange core assembly 16 is slid into the cooler plenum 22 , 22 ′ through a flanged opening 22 a (not visible, but clearly understood from FIG. 1 ) and then bolted thereto at a flange 22 f , 22 f ′ of the flanged opening 22 a . Additionally, each inlet duct 24 , 24 ′ has a flange 24 f , 24 f ′ for being sealingly connected to a flange 28 f , 28 f ′ of a respective outlet port 28 , 28 ′ of the turbocharger 12 ; and each outlet duct 26 , 26 ′ has a flange 26 f , 26 f ′ for being sealingly connected to a respective flange 20 f , (two such flanges being present, but only flange 20 f is shown in FIG. 2 ) of the engine air box combustion chamber 20 .
Now, referring to FIG. 2 , and with particularity to FIG. 3 , it will be seen that in order for the heat exchange core assembly 16 to be slidable into the cooler plenum 22 , 22 ′, a considerable amount of peripheral open space 32 exists between the heat exchange coolant core assembly and the cooler plenum. In operation, some air A B of the hot compressed charge air A from the turbocharger 12 by-passes the heat exchange core assembly 16 and is not cooled. As a result the cooled compressed charge air A′ is actually a mixture of cooled air A C that has passed through the heat exchange core assembly 16 and the by-pass air A B , that is A′=A C +A B .
To the extent by-pass air A B exists, the prior art charge air cooler 14 does not do its job of providing cooling of the hot compressed charge air exiting the turbocharger. Additionally, to the extent that the inlet and outlet ducts are integral with the cooler plenum, ease of interconnection with external components of the engine is limited.
Accordingly, what is needed in the art is some configuration of a charge air cooler which eliminates by-pass air, and further which provides for easy interconnection with inlet and outlet components.
SUMMARY OF THE INVENTION
The U.S. Environmental Protection Agency (EPA) has promulgated standards which require locomotive manufacturers to comply after Jan. 1, 2005 with “Tier 2” emissions standards. As a result, there is a need to achieve about a 50% reduction in particulate emissions along with about a 30% reduction in NO x , (nitrogen oxides) emissions for locomotive two-stroke internal combustion diesel engines, dictating need for engine optimization. In accordance with the Tier 2 mandate, one aspect of the locomotive diesel engine which is subject to modification in order to comply with Tier 2 emission standards is the charge air cooler so that by-pass air is eliminated, which aspect is satisfied by the improved charge air cooler according to the present invention.
The improved charge air cooler according to the present invention is designed to meet Tier 2 locomotive diesel engine standards, wherein the by-pass air is eliminated; and further, the heat exchange core is directly and readily connectable to any predetermined shape of inlet and outlet duct.
The improved charge air cooler according to the present invention includes a heat exchange core assembly which is sealably attached in a selectively removable manner with any suitably shaped, and diametrically opposed, inlet and outlet ducts such that all of the hot charge air coming from the turbocharger passes entirely through the heat exchange core. In this regard, the heat exchange core assembly has a preferably four-pass coolant path coolant tube arrangement, as for example 24 to 25 coolant tubes deep, with a multiplicity of fins connected in perpendicular relation thereto, wherein a coolant (which may be liquid water or a liquid water and anti-freeze solution) circulates through the coolant tubing via an external coolant system and thereby extracts heat of the air passing therethrough.
Accordingly, it is an object of the present invention to provide an improved charge air cooler which is designed to meet Tier 2 locomotive diesel engine standards, wherein by-pass air is eliminated; and further, the improved charge air cooler is readily connectable to any predetermined shape of inlet and outlet duct.
This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, exploded view of a prior art charge air system of a locomotive diesel engine, including pair of prior art charge air coolers and a conventional turbocharger.
FIG. 1A is a view of a subshaft cover assembly, seen along line 1 A- 1 A of FIG. 1 .
FIG. 2 is schematic view of a charge air system for a diesel locomotive, wherein a prior art charge air cooler of FIG. 1 is utilized.
FIG. 3 is a detail view of the prior art charge air cooler of FIGS. 1 and 2 , wherein by-pass charge air is permitted between the heat exchange core assembly and cooler plenum thereof.
FIG. 4 is a schematic view of an improved charge air system for a diesel locomotive according to the present invention, wherein an improved charge air cooler according to the present invention is utilized.
FIG. 5 is a detail view of the improved charge air cooler of FIG. 4 , wherein by-pass charge air is eliminated.
FIG. 6A is a perspective view of the improved charge air cooler according to the present invention.
FIG. 6B is a side view of the improved charge air cooler of FIG. 6A , showing now in particular the improved heat exchange core thereof.
FIG. 7A is a perspective view of a first improved charge air cooler according to the present invention, inclusive of examples of intake and outlet ducts attached thereto.
FIG. 7B is a side view of the first improved charge air cooler according to the present invention, inclusive of the examples of intake and outlet ducts attached thereto.
FIG. 8A is a perspective view of a second improved charge air cooler according to the present invention, inclusive of examples of intake and outlet ducts attached thereto.
FIG. 8B is a side view of the second improved charge air cooler according to the present invention, inclusive of the examples of intake and outlet ducts attached thereto.
FIG. 9A is a side view of a locomotive diesel engine showing a turbocharger and one of the first and second improved charge air coolers connected to the turbocharger.
FIG. 9B is a front view of the locomotive diesel engine of FIG. 8A , now showing the turbocharger and the first and second improved charge air coolers connected to the turbocharger.
FIG. 10 is a graphical representation of plots of thermal effectiveness versus mass flow for a prior art charge air cooler and an improved charge air cooler according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIGS. 4 through 9B depict an example of an improved charge air cooler 100 according to the present invention which is designed for meeting Tier 2 locomotive diesel engine standards for reduction of undesirable emissions, including NO x , without sacrificing fuel consumption. Such an optimized engine is, for example, an optimized General Motors Corporation Electromotive Division 710 locomotive diesel engine equipped with, among other optimizations, the improved charge air cooler according to the present invention which serves to lower the temperature of the hot, compressed charge air coming from the turbocharger by 15% over the prior art charge air cooler assembly discussed hereinabove with respect to FIGS. 1 through 3 .
FIG. 4 depicts a schematic view of a charge air system 102 which utilizes the improved charge air cooler 100 . In this regard, the improved charge air cooler 100 is configured so that an improved heat exchange core 104 thereof is directly sealed with any suitably shaped inlet and outlet ducts 106 , 108 , and is, elsewhere, provided with cover panels 110 which thereby collectively necessitate that all of the hot charge air AA coming from the turbocharger 12 pass entirely through the heat exchange core assembly so as to provide cooled charge air AA′ to the engine air box combustion chamber 20 .
More particularly, the improved heat exchange core 104 of the improved charge air cooler 100 includes a plurality of coolant tubes 104 t , preferably of copper, which are in intimate contact with a multiplicity of perpendicularly oriented cooling fins 104 f , also preferably of copper. In this regard, it is preferred for the coolant tubes 104 t to be arranged 24 to 25 coolant tubes deep in a four-pass coolant path arrangement of the coolant tubes, as shown at FIG. 6B .
A first tube sheet 115 a is connected to the coolant tubes 104 t adjacent a first end coolant fin 104 f ′, and a second tube sheet 115 b is connected to the coolant tubes adjacent an opposite second end coolant fin 14 f ″. The cover panels 110 include a first manifold 110 M 1 which is connected to the first tube sheet 115 a by fasteners 125 and has a single baffle 110 a , a second manifold 110 M 2 which is connected to the second tube sheet 115 b by fasteners 125 and has a pair of baffles 110 b , a coolant inlet 110 I and a coolant outlet 100 O. In this regard, the coolant circulates along arrows W in a counterflow, four-pass coolant path (as shown at FIG. 6B ), and is interconnected with an external coolant system 18 (as for example shown at FIG. 4 ). The cover panels 110 further include a first side cover 110 S 1 and a second side cover 110 S 2 , both being connected to the first and second tube sheets by fasteners. The peripheries of the first and second side cover 110 S 1 , 110 S 2 and the first and second tube sheets 115 a , 115 b provide a pair of generally identical, diametrically disposed mounting frames 112 having threaded fastener attachment holes 118 which are utilized to connect the inlet and outlet ducts thereto.
Operatively, coolant (which may be liquid water or a liquid water and anti-freeze solution) circulates through the coolant tubes 104 t via the external coolant system 18 and thereby extracts, in cooperation with the fins 104 f , heat of the compressed charge air AA coming from the turbocharger 12 , whereupon the cooled compressed charge air AA′ now passes to an engine air box combustion chamber 20 .
The improved heat exchange core 104 is preferably optimized to increase tube rows by thirty-three percent over the heat exchange core assembly of the prior art charge air cooler assembly discussed hereinabove with respect to FIGS. 1 through 3 , resulting in an increased thermal effectiveness of five percent for the improved charge air cooler over the prior art charge air cooler assembly 14 . Now, when this is added to an increase in thermal effectiveness of ten percent of the improved charge air cooler 100 over the prior art charge air cooler assembly 14 , due to elimination of by-pass air in the improved charge air cooler 100 , a total increase in thermal efficiency of fifteen percent, as mentioned hereinabove, is realized by the present invention over the prior art.
The improved charge air cooler 100 has a preferably symmetrical six-sided box shape. In this regard, the improved heat exchange core 104 is also preferably box-shaped, having the aforementioned mounting frames 112 at diametrically opposed sides thereof for mounting thereto the inlet and outlet ducts, respectively, via the attachment holes 118 , wherein a plurality of holes of mounting flanges 106 f , 108 f of each of the inlet and outlet ducts 106 , 108 , respectively, receive threaded fasteners 116 therethrough (see by way of example FIG. 7B ) which then threadably engage the attachment holes 118 so as to sealingly connect each mounting frame 112 to a respective one of the inlet and outlet ducts.
When all sides of the improved heat exchange core 104 are covered by either a duct 106 , 108 or a cover panel 110 , the collective result is a sealed plenum 122 surrounding the improved heat exchange core 104 such that all the air flowing thereinto from the inlet duct must entirely flow out through the outlet duct, passing entirely through the improved heat exchange core, without any air by-passing the improved heat exchange core. The inlet duct 106 directs hot, compressed charge air from the turbocharger discharge to the improved charged air cooler 100 , wherein one end of the inlet duct has a suitably configured turbocharger connection flange 106 f ′ for being sealingly connected to an outlet port of the turbocharger. The outlet duct 108 directs cooled, compressed charge air from the improved charge air cooler 100 to the engine air box combustion chamber 20 , wherein one end of the outlet duct has a suitably configured chamber connection flange 108 f ′ for being sealingly connected to a port of the engine air box combustion chamber.
Since the shape of the improved charge air cooler 100 is symmetrical, the inlet and outlet ducts 106 , 108 may be connected to the improved charge air cooler at selected opposing sides thereof. In this regard, the improved charge air cooler 100 may be connected in any direction to the turbocharger 12 and the engine air box combustion chamber 20 , via any suitable ducting 106 , 108 , without altering its heat exchange characteristics. Therefore, the air direction across the improved heat exchange core 104 can be one way, or the opposite way, as desired for a particular installation, wherein the coolant flows in a perpendicular plane with respect to either direction of air flow.
The inlet and outlet ducts 106 , 108 have been designed to improve air flow distribution to and from the improved charge air cooler 100 , and thereby assist in the charge air cooling efficiency thereof. The inlet and outlet ducts 106 , 108 also serve to support the charge air cooler 100 ; accordingly, the inlet and outlet ducts are configured and enhanced to withstand vibrations and shock which can cause fatigue structural failure of previous designs of the prior art charge air cooler assembly as recounted above with respect to FIGS. 1 through 3 . Additionally, the improved charge air cooler 100 and the inlet and outlet ducts 106 , 108 have been configured to provide ease of installation to the locomotive diesel engine, and to withstand misalignment during the installation process.
In that it is preferred for the turbocharger 12 to have two outlet ports, it is therefore preferred to provide two improved charge air coolers 100 , a first improved charge air cooler 100 ′ as shown at FIGS. 7A and 7B which interfaces with a first outlet port 28 of the turbocharger 12 (see FIG. 1 ), and a second improved charge air cooler 100 ″ as depicted at FIGS. 8A and 8B which interfaces with a second outlet port 28 ′ of the turbocharger (see FIG. 1 ). It will be seen that the first improved charge air cooler 100 ′ has associated therewith a first inlet duct 106 ′ and a first outlet duct 108 ′. Additionally, it will be noted that the second improved charge air cooler 100 ″ has associated therewith a second inlet duct 106 ″ and a second outlet duct 108 ″.
Referring now to FIGS. 9A and 9B , a typical installation example of the first improved charge air cooler 100 ′ (and its associated first inlet and outlet ducts 106 ′, 108 ′) and the second improved charge air cooler 100 ″ (and its associated inlet and outlet ducts 106 ″, 108 ″) are shown with respect to a turbocharger 12 and engine air box combustion chamber 20 of a locomotive diesel engine 130 , such as, for example, an optimized General Motors Corporation Electromotive Division Model 710 diesel engine.
Referring now to FIG. 10 , a pair of plots of thermal effectiveness versus mass flow, wherein plot 124 is for the improved charge air cooler 100 according to the present invention, and plot 126 is for the prior art charge air cooler assembly discussed hereinabove with respect to FIGS. 1 through 3 . It will be seen that the improved charge air cooler 100 is improved by at least ten percent over the prior art charge air cooler assembly.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims. | A charge air cooler is composed of a framed heat exchange core which is sealably attached in a selectively removable manner with any suitably shaped inlet and outlet ducts, and is, at the other sides thereof provided with cover panels which collectively necessitate that all of the hot charge air coming from the turbocharger pass entirely through the heat exchange core. In this regard, the heat exchange core is provided with a pair of opposingly disposed mounting frames, each of which being connected sealably to a commensurately sized and configured mounting flange of an inlet duct or an outlet duct. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fastener design, particularly to a screw capable of rapidly drilling and cutting.
2. Description of the Related Art
Referring to FIG. 1 , a conventional screw 1 comprises a shank portion 11 , a head portion 12 disposed at one end of the shank portion 11 , a drilling portion 13 disposed at the other end of the shank portion 11 , and a plurality of threaded units 14 spirally disposed around the shank portion 11 . Wherein, the drilling portion 13 is formed into a tapered end. Thus, the screw 1 directly enters an object 2 via the tapered drilling portion 13 , and the following threaded units 14 continue entering the object 2 so as to achieve a fastening effect.
Afore screw 1 might be smoothly fastened into the object 2 (such as plywood) by means of the drilling portion 13 piercing the object 2 . However, in practice, the object 2 is forcedly pierced by the tapered drilling portion 13 . Thus, it is difficult to completely sever fibers contained in the object 2 . That is to say, the fibers are just simply pushed and thrust by the tapered drilling portion 13 , so the screw 1 would be easily impeded by debris resulted from the object 2 in time of drilling. As a result, the debris can not be timely expelled, and the heaped debris incurs an increasing resistance on the screw 1 . Thereby, the operation of fastening the screw 1 is influenced and the object 2 may be easily broken.
Referring to FIG. 2 , the upright screw 1 in the object 2 might be subject to rustiness since water might pile on the head portion 12 . Therefore, in the practical application, the screw 1 is disposed tilting in the object 2 . Herein, if the cutting debris can not be timely expelled, the head portion 12 easily bulges out of the object 2 after screwing. Such abnormal operation is unbeneficial for further fastening. Therefore, the screw 1 needs improvements.
SUMMARY OF THE INVENTION
It is therefore the purpose of this invention to provide a screw that is capable of rapidly drilling and cutting so as to promote the screwing speed and the debris-guiding effect but decrease the screwing torque, thereby beneficial for succeeding operation.
The screw capable of rapidly drilling and cutting in accordance with the present invention comprises a shank, a head disposed at one end of the shank, a drilling portion disposed at the other end of the shank, and a plurality of threaded units spirally disposed around the shank. Two inclined cutting planes are formed on the drilling portion and the two inclined cutting planes are connected at a cutting edge. Wherein, a tapered positioning member extends outward from a convergence of the cutting planes for dividing the cutting edge into dual sub cutting edges. Each sub cutting edge is disposed by an inclined angle. A first included angle formed by the sub cutting edges is less than 180 degrees. The first included angle of the sub cutting edges is different from a second included angle of a taper of the tapered positioning member.
Preferably, a blank area defined on the shank divides the threaded units into a first section and a second section; a first diameter of the blank area is larger than a second diameter of the shank but smaller than a third diameter of the threaded units.
Preferably, the second included angle of a taper of the tapered positioning member is smaller than the first included angle of the sub cutting edges.
Preferably, the threaded units on the shank are spread to the sub cutting edges for connecting to one end of the sub cutting edges.
Preferably, a third section is defined on the shank and includes a plurality of auxiliary threaded units; the auxiliary threaded units are disposed between the threaded units; a fourth diameter of the auxiliary threaded units is smaller than a third diameter of the threaded units.
Preferably, a plurality of indented threads are formed on the auxiliary threaded units; a plurality of second guiding channels are partially defined on a part of the threaded units.
Preferably, the positioning member is formed by a plurality of inclined walls for structuring a pyramid.
Preferably, the positioning member is structured into a cone.
Accordingly, the positioning member helps the screw stably stand on a screwing object, which allows the sub cutting edges to provide a succeeding scraping effect in time of drilling. Further, the cutting planes guide cutting debris to smoothly enter the channels between the threaded units so as to rapidly expel the cutting debris therefrom. Thereby, the cutting debris does not pile into the vacancy of the threaded units, so that the screwing torque could be decreased but the screwing speed could be enhanced. Moreover, the screw is favorably embedded in a screwing object without any protrudent part. Therefore, such even screwing object is beneficial to be further fastened.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a conventional screw;
FIG. 2 is a schematic view showing the conventional screw in screwing;
FIG. 3 is a schematic view showing a first preferred embodiment of the present invention;
FIG. 4 is an end view of FIG. 3 ;
FIG. 5 is a partial view of the first preferred embodiment of the present invention;
FIG. 6 is a schematic view showing the first preferred embodiment of the present invention in screwing;
FIG. 7 is a schematic view showing a second preferred embodiment of the present invention;
FIG. 8 is a perspective view showing a third preferred embodiment of the present invention;
FIG. 9 is a schematic view showing a fourth preferred embodiment of the present invention; and
FIG. 10 is a schematic view showing a fifth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
Referring to FIGS. 3 and 4 , a first preferred embodiment of the present invention is shown. In order to clearly show the features of the screw 3 , the screw 3 in this figure and in the following embodiments is presented by one side. A screw 3 comprises a shank 31 , a head 32 disposed at one end of the shank 31 , a drilling portion 33 disposed at the other end of the shank 31 , and a plurality of threaded units 34 surroundingly disposed around the shank 31 . Wherein, a first guiding channel 341 is defined amid the threaded units 34 .
Further, two inclined cutting planes 331 are convergently formed on the drilling portion 33 , and a cutting edge 332 is formed on the connective cutting planes 331 . Additionally, a tapered positioning member 333 is integrally bulged outwards from the convergence of the cutting planes 331 to structure a tapered unit for dividing the cutting edge 332 into dual sub cutting edges 3321 . Each sub cutting edge 3321 is disposed by an inclined angle. A first included angle θ 1 formed by the sub cutting edges 3321 is less than 180 degrees. The first included angle θ 1 of the sub cutting edges 3321 is different from a second included angle θ 2 of a taper of the tapered positioning member 333 . Especially, the second included angle θ 2 of the taper of the tapered positioning member 333 is smaller than the first included angle θ 1 of the sub cutting edges 3321 (as shown in FIG. 5 ). Moreover, the positioning member 333 is assembled by a plurality of inclined walls 333 ′ bulged from the cutting planes 331 . In the figure, there are four inclined walls 333 ′ forming a square pyramid. Alternatively, while the positioning member 333 is structured by a cone that also integrally bulges from the cutting planes 331 , an oblate cone could be especially defined on the cutting planes 331 as preferably shown in FIG. 6 . Accordingly, however the positioning member 333 is designed outward protrudent from the cutting planes 331 , a precise positioning effect on an object 4 in time of drilling is provided. Continuingly, the sub cutting edges 3321 preferably scrapes the object 4 in time of drilling. Moreover, while the threaded units 34 around the shank portion 31 extend to the sub cutting edges 3321 and connect to an end 3322 of one of the sub cutting edges 3321 , the first guiding channel 341 is formed as an intercommunicated channel amid the threaded units 34 .
Referring to FIG. 7 , in operation, the positioning member 333 props the screwing object 4 (plywood is adopted in the figure) for the screw 3 to achieve a stable positioning effect. Thereby, the head 32 is imparted by a screwing torque for allowing the drilling portion 33 to enter the object 4 by means of the sub cutting edges 3321 scraping the object 4 . Namely, when the positioning member 333 is served as a pivot of the screw 3 , the sub cutting edges 3321 are able to steadily scrape and enter the object 4 . Moreover, since the threaded units 34 extend and connect to the end 3322 of one of the sub cutting edge 3321 , the cutting planes 331 thrust the cutting debris generated in time of drilling, so that the cutting debris further travels into the first guiding channel 341 amid the threaded units 34 that are connected to the end 3322 of one of the sub cutting edges 3321 . Accordingly, the cutting debris is promptly removed, and there is no redundant cutting debris obstructing and compressing the vacancy between the screw 3 and the object 4 , which promotes the screwing speed but decreases the screwing torque. Thus, however the screw 3 is disposed upright or tilting, it could be evenly embedded in the object 4 for a further combination.
Referring to FIG. 8 , a third preferred embodiment is shown. In order to clearly show the features of the screw 3 , the screw 3 in these figures and in the following embodiments are shown by another sides different from those of afore embodiments. Wherein, the screw 3 similarly comprises the shank 31 , the head 32 , the drilling portion 33 , and the threaded units 34 . Differently, a blank area 311 defined on the shank 31 divides the threaded units 34 into a first section A 1 and a second section A 2 . A first diameter R 1 of the blank area 311 is larger than a second diameter R 2 of the shank 31 but smaller than a third diameter R 3 of the threaded units 34 . Further, the second section A 2 of the threaded units 34 is spread to the sub cutting edges for connecting to one end 3322 of the sub cutting edges 3321 .
In operation, the positioning member 333 helps the screw 3 stably situates on the object 4 (not shown), and a screwing torque is imparted on the head 32 for bringing the drilling portion 33 to go through the object 4 . Herein, when the sub cutting edges 3321 contact the object 4 , the second section A 2 gradually gets in the object 4 . Thereby, cutting debris generated in time of drilling arrive at the second section A 2 along the cutting planes 331 . After that, the cutting debris are expelled rapidly through the first guiding channel 341 amid the threaded units 34 , the blank area 311 , and the first section A 1 . Obviously, no redundant cutting debris will accumulate and press the vacancy between the screw 3 and the object 4 . Moreover, the screw 3 could firmly stay in the object 4 since the first diameter R 1 of the blank area 311 is larger than the second diameter R 2 of the shank 31 . Preferably, the fastened screw 3 also promotes a subsequent combination.
Referring to FIG. 9 , a fourth preferred embodiment is shown. The screw 3 similarly comprises the shank 31 , the head 32 , the drilling portion 33 , and the threaded units 34 as those in the first and the second embodiments. Differently, a third section B is defined on the shank 31 and includes a plurality of auxiliary threaded units 35 . The auxiliary threaded units 35 are disposed between the threaded units 34 . A fourth diameter R 4 of the auxiliary threaded units 35 is smaller than the third diameter R 3 of the threaded units 34 . Whereby, the threaded units 34 and the auxiliary threaded units 35 contribute to a high-low threaded section on the shank. Accordingly, the screw 3 is able to sever the cutting fibers and expel the cutting debris faster and more efficient. Obviously, the screwing resistance is decreased since the vacancy between the object and the screw 3 is clear and not obstructed. Thus, the screw 3 provides a smooth screwing effect and a stable combination after fastened.
Referring to FIG. 10 , a fifth preferred embodiment is shown similar to that of fourth preferred embodiment. Differently, a plurality of indented threads 351 are formed on the auxiliary threaded units 35 . Moreover, a plurality of second guiding channels 342 are partially defined on a part of the threaded units 34 . Wherein, a drilling effect and a concurrent severing function could be brought about by the second guiding channels 342 and the indented threads 351 , which enhances the drilling effect of the drilling portion 33 and promotes the cutting efficiency as well as the fastening performance. Favorably, the cutting debris is still timely expelled, which allows the friction and the torque in time of drilling to be largely reduced. Thus, the screw 3 is preferably embedded in the object 4 , and a firm and stationary fastening performance is achieved.
To sum up, the present invention in particularly utilizes the positioning member formed on the cutting planes of the drilling portion to render a stable positioning effect. Namely, dual sub cutting edges are provided by the positioning member dividing the cutting edge of the drilling portion. Thereby, the positioning member properly positions the screw for proceeding to subsequent drilling, and the sub cutting edges as well as the cutting planes help guide the cutting debris generated in time of screwing for a speedy expelling via the cutting planes and the guiding channels amid the threaded units. Accordingly, no redundant cutting debris would pile the vacancy between the screw and the object, so the drilling torque could be decreased, but the drilling speed could be enhanced. Thus, the screw of the present invention could be firmly and smoothly embedded in the object for a further combination.
While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | A screw capable of drilling and cutting includes two inclined cutting planes with a cutting edge formed on a convergence of the cutting planes. A tapered positioning member extends from the convergence of the cutting planes, where the cutting edge is divided into dual sub cutting edges by means of the positioning member. Each sub cutting edge has an inclined angle. An included angle included by the sub cutting edges is smaller than 180 degrees. Threads spiral on a shank and extend to the sub cutting edges. Setting the positioning member against on an object permits a steady performance during the first stage of screwing. Subsequently, the sub cutting edges provides a scraping effect on the object during drilling. Torque is reduced and drilling speed is promoted. | 5 |
FIELD OF THE INVENTION
The present invention relates to pneumatic pumps for pumping fluids such as oil and water as well as solids that may be suspended in such fluids.
BACKGROUND OF THE INVENTION
Pneumatically powered pumps for pumping fluids have found applications in a variety of environments. Such pumps have commonly been utilized for pumping water for agricultural and residential uses, and less frequently, for pumping petroleum from beneath the earth's surface. Basic pneumatic pumps typically expel the fluid that has entered the pump's chamber by sending compressed gas from the surface down an intake tube to the chamber. The gas exerts pressure upon the fluid causing it to exit the chamber through an outlet tube and rise to the earth's surface. The gas is then exhausted from the pump chamber through an exhaust tube, the chamber is allowed to refill with the fluid and the cycle is repeated. While this system works, it is subject to some major hindrances. The compressor and other necessary equipment necessary for operating the pump is located at the surface. The entire length of the intake tube, therefore, must be filled with compressed gas before the gas exerts sufficient pressure upon the fluid so that the fluid will begin to exit the pump chamber. For deeper wells requiring expansive tube lengths, large lag times ca be created while the intake tube fills with gas. Even when the pump is at a shallower depth, the constant need to refill the intake tube before the fluid is pumped creates an inefficient method of operation. Furthermore, it is frequently difficult for the pump operator to determine the time of the cycle between the intake and exhaust strokes of the pump.
Numerous other drawbacks exist with prior pneumatic pumps. The equipment necessary to operate the pumps results in a large surface profile for the pumps. Furthermore, many pumps are unsuited for anything but ideal environmental conditions or for pumping the solids that commonly are suspended within the fluids and thus require expensive and frequent maintenance.
A need exists, therefore, for an efficient pneumatic pump capable of reliably pumping fluids in a variety of environments.
SUMMARY OF INVENTION
The application discloses an efficient and reliable submersible pneumatically operated and controlled pump. Constant intake pressure is maintained at the pump head allowing the pump to maintain its efficiency even at extreme depths. A spool and sleeve valve assembly, operated in response to a signal pressure, controls the cycling of the pump. The spool and sleeve valve assembly is located within the pump head. In one embodiment, the spool valve rests upon a spring. While in this position, the spool valve blocks the flow of the high pressure gas into the pump chamber and instead exposes an exhaust vent allowing any gas within the pump chamber to vent to the surface and further allowing the fluid to enter the chamber. When the signal pressure is activated, compressed gas acts upon the spool valve forcing it down upon and compressing the spring. In this position, the exhaust vent is blocked and the high pressure air is allowed to enter the chamber where it forces the fluid out of the pump chamber and up to the surface.
In an alternate embodiment, no spring is used with the spool valve. Instead, two signal pressures, one at the top and one at the bottom of the spool valve, work to slide the spool valve between its exhaust and power positions.
In both embodiments, a timing switch on the surface controls the occurrence of the signal pressure and thus the pump cycles, at preset intervals. This eliminates any lag time between cycles and the need for operator estimations of the cycle times. The pump is, therefore, virtually a closed system and self-contained unit.
The pump is fully submersible and can pump a great variety of fluids in a number of diverse environments. Many of the fluids desired to be pumped exist in conditions not conducive to pumping. The pump of the present invention, however, is able to pump most solids that may be suspended within the fluid. The inner cylinder of the pump up which the fluid travels can also be open-ended. This configuration allows for the pumping of larger solid objects which may exist in conjunction with the fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view showing the pump located within a well.
FIG. 2 is a cross-sectional view of the pump cylinder.
FIG. 3A is a cut-away view of the head and upper portion of the pump cylinder showing the pump in the exhaust phase.
FIG. 3B is a cross-sectional view of the lower portion of the pump cylinder showing the pump in the exhaust phase.
FIG. 4A is a cut-away view of the head and upper portion of the pump cylinder showing the pump in the power phase.
FIG. 4B is a cross-sectional view of the lower portion of the pump cylinder showing the pump in the power phase.
FIG. 5A is a cut-away view of the pump head and upper portion of the pump cylinder showing an alternative embodiment of the spool valve.
FIG. 5B is a cross-sectional view of the lower portion of the pump cylinder showing the pump in the exhaust position.
FIG. 6 is a cut-away view of the pump head and upper portion of the pump cylinder showing an alternative embodiment of the spool valve.
FIG. 7 is a top view of the intake valve.
FIG. 8 is a top view of the pump head.
FIG. 9 is a cross-sectional view of the pump head.
FIG. 10 is a schematic rendering of the pump operation.
DETAILED DESCRIPTION OF THE INVENTION
The present invention concerns a pneumatic pump generally designated 10 in FIG. 1. The pump includes a body 12 and a head 50. The body 12 has an elongated tubular outer chamber 14 which, in the preferred embodiment, is a hollow cylindrical member. The top end of the chamber 14 is attached to the head 50 and the end of the chamber 14 is closed off with an end cap 16. The end cap 16 is attached to the chamber 14 in a way which prohibits fluid from seeping between them and entering the chamber 14. In the preferred embodiment, an O-ring 18 is used as a seal between the end cap 16 and the base of the chamber 14. Also in the preferred embodiment, an anchor bolt 20 extends longituinally through the center of the end cap 16.
The end cap 16 contains openings to allow fluid to flow into the chamber 14. In the preferred embodiment, six generally circular vents 22 are symetrically spaced around the anchor bolt 20 attached to the end cap 16.
Within the chamber 14 attached to the anchor bolt 20 is a non-return intake valve 24. In the preferred embodiment, the intake valve 24 is generally circular and of sufficient area to completely cover the vents 22. The intake or "Flop" valve 24 allows fluid to pass through the vents 22 into the chamber 14 while preventing fluid from passing through the valve 24 from the chamber 14 in the reverse direction.
Within the chamber 14 is an elongated tubular inner cylinder 26 extending from the head 50 down to the lower portion of the chamber 14. The cylinder 26 is hollow and open at both ends. At the base of the cylinder 26 is attached a non-return outlet valve 28. The outlet or check valve 28 contains a generally circular plate 29 and an axially located shaft 30 extending through the plate 29. The outlet valve 28 allows fluid within the chamber 14 to pass into and up the inner cylinder 26 while preventing the reverse flow of fluid from the cylinder 26 back into the chamber 14. Such non-return or check valves are known in the industry, and in the preferred embodiment, a one inch check valve model number 1F-C63S-FE manufactured by Balon is used.
In the preferred embodiment, the outlet valve 28 is enclosed within a housing 32 attached to the base of the inner cylinder 26. A solid cylindrical plug 33 is inserted into the end of the housing 32 opposite the end attached to the cylinder 26. On the top end of the plug 33 is a collar 34 for receiving the shaft 30 of the outlet valve 28 when the outlet valve 28 is in its closed position. The other end of the plug 33 is drilled and tapped to accept the anchor bolt 20 in the end cap 16.
The housing 32 contains peripheral ports 35 positioned around its outer surface for allowing the fluid to flow from the chamber 14 into the housing 32 at a point below the outlet valve 28. An annular ring 36 encircles the shaft 30 and rests between the ports 35 and the plate 29. When the outlet valve 28 is in its closed position, the plate 29 rests upon the ring 26 thereby blocking the center opened region of the ring 36 and preventing fluid from passing to the cylinder 26. Conversely, when the outlet valve 28 is in its open position, the force of the fluid pushes the plate 29 off the ring 36 thereby allowing the fluid to pass around the plate 29 and into the cylinder 26. The upper movement of the plate 29 is restrained when in its opened position by L-shaped fins 37 circumfrentially located within the housing 32 below the open end of the cylinder 26.
Attached to the top of the chamber 14 is the pump head 50. The dimensions and shape of the head 50 will be configured to correspond to those of the chamber 14. In the preferred embodiment, the head 50 is cylindrically shaped so as to correspond to the body 12. Two O-rings 52 can be located around the top and bottom of the head 50 to act as a seal between the head 50 and the chamber 14.
In the preferred embodiment, left handed threading is added to the head 50 as an aid in positioning the pump within a well and for later recovery of the pump from the well.
In the center of the head is a fluid discharge hole 54. The hole 54 runs the entire longitudinal length of the head 50 and is threaded on both ends. The top of the inner cylinder 26 of the pump body 12 is desirably threadingly attached to the lower end of the fluid discharge hole 54.
Spaced around the fluid discharge hole 54 are four ports. In the preferred embodiment, the top of each port is threaded so as to receive an external conduit. The constant pressure port 56 contains an elongated longitudinal cavity 57 which extends from the top surface of the head 50, into the head 50 and intercepting a lateral cavity 58. This lateral cavity 58 empties into the first signal port 60.
The exhaust port 62 contains an upper section 63 and lower section 66. The upper exhaust section 63 contains an elongated longitudinal cavity 64 extending from the top surface of the head 50 and intersecting a lateral cavity 65. This lateral cavity 65 of the upper exhaust section 63 empties into the first signal port 60. A second lateral exhaust cavity 68, below and parallel with the first lateral exhaust cavity 65 runs from the first signal port 60 to a second longitudinal exhaust cavity 67 which extends to the lower exhaust section 66 at the base cf the head 50. The lower exhaust section 66 opens into the outer chamber 14 of the pump body 12. The lower exhaust section 66 desirably has a filter 70 threadingly attached to it. The filter 70 protects the spool valve 72 described below. The ends of all of the above lateral cavities 58, 65, 68 opposite the first signal port 60 are all plugged so that air passing through them has only a single outlet.
A spool valve 72 is placed within the first signal port 60. This spool valve 72 contains a sleeve 74 and a plunger 76. The sleeve 74 is a tubular annular member which in the preferred embodiment is of a generally circular cross-section and hollow. A plurality of recesses 77 are located around the outside surface of the sleeve 74. In the preferred embodiment, three recesses 77 are used. Paired apertures 78 exist on each recess 77. Each pair of apertures 78 is dimerically opposed to each other. Two smaller apertures 79 are located at the bottom of the sleeve 74. The positions of the apertures 78, 79 are such that when the sleeve 74 is properly placed within the first signal port 60, the apertures 78, 79 line up with the lateral cavities 58, 65, 68.
The plunger 76 consists of two tubular members 80, 81 connected to each other through their longitudinal axis by a support 82. In the preferred embodiment, the two tubular members 80, 81 and the support 82 are all generally circular in cross-section with the diameter of the support 82 being less than that of the tubular members 80, 81.
One end of the plunger 76 has an elongated appendage extending outwardly therefrom. The other end of the plunger 76 may be threadingly attached to a rod (not shown) for use in inserting the plunger 76 into the sleeve 74.
In the preferred embodiment, a plurality of O-rings are used to secure the sleeve 74 to the inside of the first signal port 60. The plunger 76 fits snuggly within the sleeve 74 but is able to axially slide along its longitudinal axis. The outer walls of the tubular members 80, 81 of the plunger 76 are in contact with the interior walls of the sleeve 74 when the plunger 76 is within the sleeve 74.
The second signal port 86 contains a longitudinal cavity 87 that extends from the surface of the head 50 into the head 50 intersecting a lateral cavity 88. This lateral cavity 88 opens to the outer surface of the head 50. A second lateral cavity 89 extends from the outer surface of the head 50 through the head 50 and opens into the lower region of the first signal port 60.
Conduits are desirably attached to the ports in the head 50. One end of a fluid discharge conduit 90 may be attached from the fluid discharge hole 54 to a surface tank for holding the pumped fluid. An exhaust conduit 91 may be attached from the exhaust port 62 and run up to a point above the level of the fluid external of the pump. A constant pressure conduit 92 may be attached from the constant pressure port 56 to a high pressure gas source, compressor or pressurized gas reserve. A first signal conduit 93 may be attached from the first signal port 60 to a first signal outlet 94 on a surface timing controller 95. And finally, a second surface conduit 96 may be attached from the second signal port 86 to a second surface outlet 97 on a surface timing controller 95.
The surface timing controller 95 is a pneumatically operated timing controller as is known in the industry. In the preferred embodiment, the surface timing controller consists of a quarter-inch 0-200 lb gauge model number 47101 manufactured by AMETEK a 200 PSIG filter model number 125221 manufactured by ARO Corporation, a quick exhaust valve model number A212PD manufactured by ARO Corporation, and a 300 PSIG regulator number 73M2CIB000 manufactured by NORRISEAL and a model number 59861 timer manufactured by ARO Corporation enclosed within a Type 3R enclosure manufactured by HOFFMAN.
The pump disclosed is capable of pumping a variety of fluids. As the pumping of oil, however, is a common application for such a pump, the following operation of the pump will be described in terms of the pumping of oil from beneath the earth's surface.
In operation, after the pump is assembled, the conduits that will run from the surface are attached to the ports located on the pump head 50. The conduits are frequently bundled together for convenience. The pump assembly is then submerged desirably below the surface of the oil to be pumped. The pump will typically be maintained in a generally vertical orientation due to the conduits extending from the pump head 50 up to the surface and to their respective sources or outlets.
In one embodiment, a flow of regulated compressed gas from the surface timing controller 95 is sent down the second signal conduit 96 to the head 50 where it enters the top of the second signal port 86. After entering the second signal port 86, the compressed gas exits the second signal port 86 via the first lateral cavity 88. The compressed gas then re-enters the head 50 via the second lateral cavity 89 and travels to the base of the first signal port 60. The compressed gas entering the bottom of the first signal port 60 produces an upward force upon the plunger 76. The plunger 76 slides longitudinally upward within the sleeve 74 until it reaches the top of the first signal port 60 where it is prevented from further upward movement. The position in which the plunger 76 comes to rest at the top of the first signal port 60 is known as the full exhaust position P 1 . When the plunger 76 is in position P 1 , the lower tubular member 81 of the plunger 76 blocks the aperture in the recess 77 of the sleeve 74 corresponding to the constant pressure port lateral cavity 58. Correspondingly, the support member 82 of the plunger 76 is perpendicular to the apertures 83 and the recesses 77 of the sleeve 74 corresponding to the upper and lower lateral cavities 65, 68 of the exhaust port 62. Thus, in position P 1 , the exhaust port 62 is open allowing gases to vent from the outer chamber 14 through the head 50 and to the surface via the exhaust conduit 91.
The relative positive hydrostatic pressure of the oil surrounding the pump is sufficient to overcome the atmospheric pressure now existing within the outer chamber 14 causing the intake flop valve 24 to open exposing the vents 22 in the end cap 16. Oil then enters the outer chamber 14 through the vents 22.
At an interval preset by the operator, the surface timing controller 95 ceases sending compressed gas to the second signal port 86 and begins sending a flow of regulated compressed gas down the first signal conduit 93 to the head 50 where it enters the top of the first signal port 60. The lack of compressed gas in the base of the first signal port 60 in conjuncture with the compressed gas now being supplied to the top of the signal port 60 causes the plunger 76 to descend within the sleeve 74. The plunger 76 stops its descent upon reaching the base of the first signal port 60. The plunger 76 is now in its full power position P 2 . In position P 2 , the upper tubular member 80 of the plunger 76 blocks the aperture 83 in the recess 77 of the sleeve 74 corresponding to the upper latitudinal cavity 65 of the exhaust port 62. The lower latitudinal cavity 68 as well as the constant pressure latitudinal cavity 58 of the constant pressure port 56 is now exposed. The supply of constant pressure sent from a surface compressor to the constant pressure port 56 is allowed to flow through the first signal port 60 into the lower section 66 of the exhaust port 62 and into the outer chamber 14.
The positive force of the compressed gas on the surface of the oil occupying the outer chamber 14 causes the relative pressure balance to shift creating a greater combined interior pressure than the hydrostratic pressure. This shift in relative pressure forces the intake flop valve 24 against the end cap 16 thereby closing the vents 22 and preventing the oil from exiting the outer chamber 14 via the vents 22.
The force of the compressed gas upon the oil causes the oil to flow through the ports 35 within the housing 32 and opening the outlet valve 28 at the base of the inner cylinder 26. The oil then flows up the inner cylinder 26 through the fluid discharge hole 54 within the head 50 and through the fluid discharge conduit 90 to the surface. The inner cylinder 26 vents freely to the surface and thus only exerts the force of the weight of the column of oil contained within the fluid discharge conduit 90.
As the oil is forced through the outlet valve 28 and into the inner cylinder 26 the volume once occupied by the oil in the outer chamber 14 is replaced with compressed gas.
At another predetermined time set by the operator of the pump, the surface timing controller 95 cuts off the supply of compressed gas to the top of the first signal port 60 and re-establishes the flow of compressed gas to the second signal port 86. The plunger 76 is repositioned to P 1 and the air within the outer chamber 14 is again vented to the surface through the exhaust port 62. The oil that remains within the fluid discharge conduit 90 and the inner cylinder 26 is prevented from re-entering the outer chamber 14 by the outlet check valve 28. These two part cycles controlled by the surface timing controller 95 are repeated until such time as the signal timing cycle system is ended.
In an alternate embodiment, the second signal port 86 is plugged and a spring 40 is located at the base of the first signal port 60. The appendage 83 of the plunger 76 rests within the top of the spring 40. When the pump is first submerged within the oil, the spring 40 is uncompressed and the plunger 76 is in the full exhaust position P 1 . When the full power cycle begins, the compressed gas entering the top of the first signal port 60 produces a downward force upon the plunger 76. The plunger 76 slides longitudinally within the sleeve 74 in a downward direction thereby compressing the spring 40. When the spring 40 reaches it maximum compression, the plunger 76 comes to rest. This position is the full power position P 2 .
In another embodiment, a closed charged gas recovery system is provided for recycling the pressurized gas utilizing a scrubber and vapor return system to recover the hydrocarbons present in the compressed gas.
In another embodiment, the continual volume of gas present in the constant pressure port acts as a reservoir to moderate the demand between the first and second signal ports. This allows the pumps to be "ganged" or operated by the same gas supply in either a manual or automatic mode from the surface controls.
The pump components may be constructed from a variety of materials chosen to withstand the physical, chemical or other properties of the fluids to be pumped or the atmosphere in which the fluids are found. In the preferred embodiment, the pump chambers, head and most other components are constructed of stainless steel. The nonreturned valves and conduits can be made of a noncorrosive plastic or composite material as desired. The depth limitation for the pumping system is regulated by the pressure capacity of the materials the pump is constructed from and the available gas pressure's ability to lift the column of fluid.
While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | A pneumatically operated and controlled pump which is capable of maintaining its efficiency and reliability in various environments. The pump head contains a spool and sleeve valve assembly operated in response to a signal pressure. The assembly controls the cycling of the pump through a pumping phase and a pump filling phase. A timing switch on the surface controls the occurrence of the signal pressure and thus the pump cycles, at preset intervals thus eliminating any lag time between the cycles and the need for operator estimations of the cycle times. This results in a virtually closed system and self contained unit. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to a subsea well. More particularly, embodiments of the invention relate to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well.
[0003] 2. Description of the Related Art
[0004] After the production of a subsea well is finished, the subsea well is closed and abandoned. The subsea well closing process typically includes recovering the wellhead from the subsea well using a conventional wellhead retrieval operation. During the conventional wellhead retrieval operation, a retrieval assembly equipped with a casing cutter is lowered on a work string from a floating rig until the retrieval assembly is positioned over the subsea wellhead. Next, the casing cutter is lowered into the wellbore as the retrieval assembly is lowered onto the wellhead. The casing cutter is actuated to cut the casing by using the work string. The cutter may be powered by rotating the work string from the floating rig. Since the work string is used to manipulate the retrieval assembly and the casing cutter, the floating rig is required at the surface to provide the necessary support and structure for the work string. Even though the subsea wellhead may be removed in this manner, the use of the floating rig and the work string can be costly and time consuming. Therefore, there is a need for an improved method and apparatus for subsea wellhead retrieval.
SUMMARY OF THE INVENTION
[0005] The present invention generally relates to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one aspect, a method of performing an operation in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a downhole assembly. The method also comprises the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. The method further comprises the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead. Additionally, the method comprises the step of performing the operation in the subsea well by utilizing the down hole assembly.
[0006] In another aspect, an apparatus for use in a subsea well is provided. The apparatus comprises a grip member movable between an unclamped position and a clamped position, wherein the grip member in the clamped position applies a grip force to a profile on the subsea wellhead. Additionally, the apparatus comprises a lifting assembly configured to generate an upward force which increases the grip force applied by the grip member.
[0007] In yet another aspect, a method of performing an operation in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and a lock member. The tool is also attached to a downhole assembly. The method further comprises the step of moving the at least one grip member from an unclamped position to a clamped position in which the grip member engages the subsea wellhead. The method also comprises the step of hydraulically activating the lock member such that the lock member engages a portion of the grip member thereby retaining the grip member in the clamped position. Additionally, the method comprises the step of performing the operation in the subsea well by utilizing the downhole assembly.
[0008] In a further aspect, an apparatus for use in a subsea well is provided. The apparatus comprises a grip member for engaging a subsea wellhead, wherein the grip member is movable between an unclamped position and a clamped position. The apparatus further comprises a lock member movable between an unlocked position and a locked position upon activation of a hydraulic cylinder, wherein the lock member in the locked position retains the grip member in the clamped position.
[0009] In a further aspect, a method of cutting a casing string in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a cutting assembly. The method further comprises the step of operating the at least one grip member to clamp the tool to the subsea wellhead. The method also comprises the step of cutting the casing string below the subsea wellhead by utilizing the cutting assembly. Additionally, the method comprises the step of applying an upward force to the tool during the cutting of the casing string which is at least equal to an axial reaction force generated from cutting the casing string, wherein at least a portion of the upward force is created by a cylinder member in the tool that acts on the subsea wellhead.
[0010] In yet a further aspect, an apparatus for cutting a casing string in a subsea well is provided. The apparatus comprises a cutting assembly configured to cut the casing string. The apparatus also comprises a grip member for engaging a subsea wellhead, the grip member movable between an unclamped position and a clamped position. Additionally, the apparatus comprises a lifting assembly configured to generate an upward force which is at least equal to an axial reaction force generated from cutting the casing string, wherein the lifting assembly comprises a cylinder and piston arrangement that is configured to act upon a portion of the subsea wellhead.
[0011] Additionally, a method of gripping a subsea wellhead is provided. The method comprises the step of positioning a tool proximate the subsea wellhead. The tool has at least one grip member. The method further comprises the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. Additionally, the method comprises the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0013] FIG. 1 is an isometric view of a subsea wellhead intervention and retrieval tool according to one embodiment of the invention.
[0014] FIG. 2 is a view illustrating the placement of the tool on a wellhead.
[0015] FIG. 3 is a view illustrating the tool engaging the wellhead.
[0016] FIG. 4 is a view illustrating the tool cutting a casing string below the wellhead.
[0017] FIGS. 5A and 5B are enlarged views illustrating the components of the tool.
[0018] FIG. 6 is a view illustrating the tool after the casing string has been cut.
[0019] FIG. 7 is a view illustrating a subsea wellhead intervention and retrieval tool with a perforating tool.
[0020] FIG. 8 is a view illustrating a subsea wellhead intervention and retrieval tool with the perforating tool disposed on a wireline.
[0021] FIG. 9 is a view illustrating a subsea wellhead intervention and retrieval tool with the perforating tool.
[0022] FIG. 10 is a view illustrating a subsea wellhead intervention and retrieval tool with a cutter assembly.
[0023] FIG. 11 is a view illustrating a subsea wellhead intervention and retrieval tool with an explosive charge device.
DETAILED DESCRIPTION
[0024] Embodiments of the present invention generally relate to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. To better understand the aspects of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
[0025] FIG. 1 shows a subsea wellhead intervention and retrieval tool 100 according to one embodiment of the invention. As shown, the tool 100 includes a shackle 210 and a mandrel 195 for connection to a conveyance member 202 , such as a cable. The use of cable with the tool 100 allows for greater flexibility because the cable may be deployed from an offshore location that includes a crane rather than using a floating rig with a work string as in the conventional wellhead retrieval operation. In another embodiment, the conveyance member may be an umbilical, coil tubing, wireline or jointed pipe.
[0026] The conveyance member 202 is used to lower the tool 100 into the sea to a position adjacent the subsea wellhead. A power source (not shown), such as a hydraulic pump, pneumatic pump or a electrical control source, is attached to the tool 100 via an umbilical cord (not shown) connected to connectors 205 to manipulate and/or monitor the operation of the tool 100 . The power source is attached to a control system 230 of the tool 100 . The control system 230 may include a manifold arrangement that integrates one or more cylinders of the tool 100 . The manifold arrangement may include a filtration system and a plurality of pilot operated check valves which allows the cylinders of the tool to function in a forward direction or a reverse direction. In one embodiment, the manifold arrangement allows the cylinders to operate independently from the other components in the tool 100 . The functionality of the cylinders will be discussed herein. The control system 230 may also include data sensors, such as pressure sensors and temperature sensors that generate data regarding the components of the tool 100 . The data may be used to monitor the operation of the tool 100 and/or control the components of the tool 100 . Further, the data may be used locally by an onboard computer or by the ROV. The data may also be used remotely by sending the data back to the surface via the ROV or via an umbilical attached to the tool.
[0027] The power source for controlling the control system 230 of the tool 100 is typically located near the surface. The power source may be configured to pump fluid from the offshore location through the umbilical cord connected to the connectors 205 in order to operate the components of the tool 100 such as arms 125 and wedge blocks 150 as described herein. In another embodiment, the tool 100 may be manipulated using a remotely operated underwater vehicle (ROV). In this embodiment, the ROV may attach to the tool 100 via a stab connector 215 and then control the control system 230 of the tool 100 in a similar manner as described herein. The ROV may also manipulate the position of the tool 100 relative to the wellhead by using handler members 220 .
[0028] As illustrated in FIG. 1 , the tool 100 may be attached to a downhole assembly such as a motor 115 and a rotary cutter assembly 105 . The motor 115 may be an electric motor or a hydraulic motor such as a mud motor. The rotary cutter assembly 105 includes a plurality of blades 110 which are used to cut the casing. The blades 110 are movable between a retracted position and an extended position. In another embodiment, the tool 100 may use an abrasive cutting device to cut the casing instead of the rotary cutter assembly 105 . The abrasive cutting device may include a high pressure nozzle configured to output high pressure fluid to cut the casing. The use of abrasive cutting technology allows the tool 100 to cut through the casing with substantially no downward pull or torque transmission to the wellhead which is common with the rotary cutter assembly 105 . In another embodiment, the tool 100 may use a high energy source such as laser, high power light, or plasma to cut the casing. The high energy cutting system may be incorporated into the tool 100 or conveyed to or through the tool 100 via a transmission system. Suitable cutting systems may use well fluids, and/or water to cut through multiple casings, cement and voids. The cutting systems may also reduce downward pull and subsequent reactive torque transmission to the wellhead.
[0029] FIG. 2 is a view illustrating the placement of the tool 100 on a wellhead 10 . The tool 100 is lowered via the conveyance member until the tool 100 is positioned proximate the top of the wellhead 10 disposed on a seafloor 20 . As the tool 100 is positioned relative to the wellhead 10 , the motor 115 and the cutter assembly 105 are lowered into the wellhead 10 such that the blades 110 of the cutter assembly 105 are adjacent the casing string 30 attached to the wellhead 10 . Generally, the wellhead 10 includes a profile 50 at an upper end. The profile 50 may have different configurations depending on which company manufactured the wellhead 10 . The arms 125 of the tool 100 include a matching profile 165 to engage the wellhead 10 during the wellhead retrieval operation. It should be noted that the arms 125 or the profile 165 on the arms 125 may be changed (e.g., removed and replaced) with a different profile in order to match the specific profile on the wellhead 10 of interest. The arms 125 are shown in an unclamped position in FIG. 2 and in a clamped position in FIG. 3 .
[0030] FIG. 3 illustrates the tool 100 engaging the wellhead 10 . The tool 100 includes an actuating cylinder 135 (e.g. piston and cylinder arrangement) that is attached to the arm 125 . As the cylinder 135 is actuated by the power system, the arms 125 rotate around pivot 130 from the unclamped position to the clamped position in order to engage the wellhead 10 . It must be noted that the arms 125 may be individually activated by a respective cylinder 135 or collectively activated by one or more cylinders. As shown, the profile 165 on the arms 125 mate with the corresponding profile 50 on the wellhead 10 . After the arms 125 have engaged the wellhead 10 , the arms 125 are locked in place by activating a locking cylinder 155 (e.g. piston and cylinder arrangement) which causes a wedge block 150 to slide along a surface of the arm 125 as shown in FIG. 4 . The movement of the wedge block 150 prevents the arms 125 from rotating around the pivot 130 to the clamped position. It must be noted that the wedge blocks 150 may be individually activated by the respective cylinder 155 or collectively activated by one or more cylinders.
[0031] FIG. 4 is a view illustrating the tool 100 cutting a casing string 30 below the wellhead 10 . After the arms 125 are locked in place by the wedge block 150 , an optional cylinder 180 (e.g. piston and cylinder arrangement) is activated that causes a shoe 175 to act upon a surface 25 of the wellhead 10 and axially lift the tool 100 relative to the wellhead 10 . The axial movement of the tool 100 relative to the wellhead 10 allows for active clamping of the tool 100 on the wellhead 10 . For instance, as the tool 100 moves relative to the wellhead 10 , the profile 165 on the arms 125 moves into maximum contact with the profile 50 on the wellhead 10 such that the tool 100 is clamped on the wellhead 10 and will not rotate (or spin) relative to the wellhead 10 when the rotary cutter assembly 105 is in operation. In this respect, reactive torque resistance is provided for the mechanical cutting system. After the tool 100 is fully engaged with the wellhead 10 , the motor 115 activates the rotary cutter assembly 105 and the blades 110 move from the retracted position to the extended position as illustrated in FIG. 3 to FIG. 4 . Thereafter, the casing string 30 is cut by the rotary cutter assembly 105 . It should be noted that the cylinders 135 , 155 , 180 may be independently operated by the power source or by the ROV. Additionally, it is contemplated that cylinders 135 , 155 , 180 may include any suitable number of cylinders as necessary to perform the intended function.
[0032] FIGS. 5A and 5B are enlarged views illustrating the components of the tool 100 . The conveyance member may be pulled from the surface to enhance the clamping of the tool 100 on the wellhead 10 . The upward force applied to the tool 100 by the conveyance member causes an inner mandrel 170 to move from a first position ( FIG. 5A ) to a second position ( FIG. 5B ). As illustrated in FIGS. 5A and 5B , the inner mandrel 170 includes a key member 190 . It should be noted that the key member 190 may be a separate component attached to the inner mandrel 170 as illustrated or the key member 190 may be formed as part of the mandrel 170 as a single piece. As shown in FIG. 5B , the inner mandrel 170 has moved axially up relative to the wellhead 10 . As a result, the inner mandrel 170 (and/or the key member 190 ) contacts and applies a force to a surface 120 of the arms 125 which increases (or enhances) the gripping force applied by the arms 125 to the profile 50 on the wellhead 10 . In other words, the inner mandrel 170 applies the force to the arms 125 and that force is transferred due to the shape of each arm 125 (i.e. lever) and the pivot 130 into the gripping surface which grips the profile 50 , thereby enhancing the grip on the profile 50 .
[0033] The conveyance member connected to the tool 100 may also be pulled from the surface (i.e., offshore location) to create tension in the wellhead 10 and the casing string 30 . As the conveyance member is pulled at the surface, the tool 100 , the wellhead 10 , and the casing string 30 are urged upward relative to the seafloor 20 which creates tension in the wellhead 10 and the casing string 30 . The tension created by pulling on the conveyance member may be useful during the cutting operation because tension in the casing string 30 typically prevents the cutters 110 of the rotary cutter assembly 105 from jamming (or become stuck) as the cutters 110 cut through the casing string 30 . The upward force created by pulling on the conveyance member is preferably at least equal to any downward force generated during the cutting operation. The upward force is typically maintained during the cutting operation. Optionally, the upward force may also be sufficient to counteract the wellhead assembly deadweight.
[0034] During the wellhead retrieval operation, the inner mandrel 170 in the tool 100 may move between the first position as shown in FIG. 5A and the second position as shown in FIG. 5B . In the first position, a portion of the inner mandrel 170 (and/or the key member 190 ) is positioned proximate a stop block 185 as shown in FIG. 5A . In this position, the inner mandrel 170 has moved axially down relative to the wellhead 10 which typically occurs when the tension in the conveyance member attached to the tool 100 has been minimized. In the second position, a portion of the inner mandrel 170 is positioned proximate the surface 120 of the arms 125 . In this position, the inner mandrel 170 has moved axially up relative to the wellhead 10 which typically occurs when the tension in the conveyance member attached to the tool 100 has been increased. Further, in the second position, the inner mandrel 170 (and/or the key member 190 ) contacts and applies a force to the surface 120 of the arms 125 which increases (or enhances) the gripping force applied by the arms 125 to the profile 50 on the wellhead 10 . In other words, the inner mandrel 170 applies the force to the arms 125 and that force is transferred due to the shape of each arm 125 (i.e. lever) and the pivot 130 into the gripping surface which grips the profile 50 , thereby enhancing the grip on the profile 50 .
[0035] FIG. 6 is a view illustrating the tool 100 after the casing string 30 has been cut. The cutters 110 on the rotary cutter assembly 105 continue to operate until a lower portion of the casing string 30 is disconnected from an upper portion of the casing string 30 . At this point, the rotary cutter assembly 105 is deactivated which causes the cutters 110 to move from the extended position to the retracted position. Next, the tool 100 , the wellhead 10 , and a portion of the casing string 30 are lifted from the seafloor 20 by pulling on the conveyance member attached to the tool 100 until the wellhead 10 is removed from the sea. After the wellhead 10 is located on the offshore location, such as the floating vessel, the cylinders 135 , 155 , 180 may be systematically deactivated to release the tool 100 from the wellhead 10 .
[0036] In operation, the tool 100 is lowered into the sea via the conveyance member until the tool 100 is positioned proximate the top of the wellhead 10 disposed on the seafloor 20 . Next, the cylinder 135 is actuated to cause the arms 125 to rotate around pivot 130 to engage the wellhead 10 . Subsequently, the arms 125 are locked in place by actuating the cylinder 155 which causes the wedge block 150 to slide along the surface of the arms 125 to prevent the arms 125 from rotating around the pivot 130 to the unclamped position. Thereafter, the cylinder 180 is activated which causes the shoe 175 to act upon the surface 25 of the wellhead 10 and axially lift the tool 100 relative to the wellhead 10 . The axial movement of the tool 100 relative to the wellhead 10 allows for active clamping of the tool 100 on the wellhead 10 . This sequential function is automatically controlled by the onboard manifold or can be manually sequenced as required by the operator or via a ROV. Next, the conveyance member connected to the tool 100 is pulled from the surface (i.e. offshore location) to create tension on the wellhead assembly 10 and the casing string 30 . The motor 115 activates the rotary cutter assembly 105 and the blades 110 move from the retracted position to the extended position to cut through the casing string or multiple casing strings 30 . The wellhead assembly deadweight is born mechanically to leverage the load for increased clamping force on the external wellhead profile to maximize reactive torque resistance capability for high torque cutting. Axial load cylinder 180 function to stabilize and preload grip arms during cutting operation. After the casing string 30 is cut, the tool 100 , the wellhead 10 and a portion of the casing string 30 is lifted from the seafloor 20 by pulling on the conveyance member attached to the tool 100 . When the wellhead 10 is safely located on the offshore location, such as the floating vessel, the cylinders 135 , 155 , 180 may be systematically deactivated to release the tool 100 from the wellhead 10 . At any time during operation, the cylinder function sets 135 , 155 , 180 may be independently controlled and shut down or reversed for function testing, unsuccessful wellhead release, or maintenance as required through surface controls or remotely using a ROV in case of umbilical failure.
[0037] FIG. 7 is a view illustrating a subsea wellhead intervention and retrieval tool 200 attached to a perforating tool 215 . For convenience, the components of the tool 200 that are similar to the components of the tool 100 will be labeled with the same reference indicator. As shown in FIG. 7 , the tool 200 has engaged the wellhead 10 in a similar manner as described herein.
[0038] The tool 200 may be attached to an optional packer member 205 that is configured to seal an annulus formed between a tubular member 220 and the casing string 30 attached to the wellhead 10 . The packer member 205 may be any type of packer known in art, such as a hydraulic packer or a mechanical packer. The packer member 205 may be used for isolation or well control. Upon activation of the packer member 205 , the packer member 205 moves from a first diameter and a second larger diameter. Upon deactivation, the packer member 205 moves from the second larger diameter to the first diameter. The packer member 205 may be activated and deactivated multiple times.
[0039] The tool 200 may be attached to an optional ported sub 210 and the perforating tool 215 mounted on a pipe 225 . It is to be noted that the pipe 225 , the ported sub 210 and the perforating tool 215 may be an integral part of the tool 200 or a separate component that is lowered through the tool 200 via a conveyance member, such as pipe, coiled tubing or an umbilical. Generally, the ported sub 210 may be used in conjunction with the packer member 205 to monitor, control pressure or bleed-off pressure, gas or liquid. The ported sub 210 may also be used to pump cement into the wellbore. In one embodiment, the ported sub 210 is selectively movable between an open position and a closed position multiple times.
[0040] The perforating tool 215 is generally a device used to perforate (or punch) the casing string 30 or multiple casing strings, such as casing strings 30 , 40 . Typically, the perforating tool 215 includes several shaped explosive charges that are selectively activated to perforate the casing string. It is to be noted that the perforating tool 215 may also be used to sever or cut the casing string 30 so that the wellhead 10 may be removed in a similar manner as described herein.
[0041] In operation, the tool 200 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated. The ported sub 210 may also be activated and used as set forth herein. Additionally, the perforating tool 215 may be used to perforate (or cut) the casing string. The tool 200 may further be used to remove the wellhead 10 in a similar manner as described herein.
[0042] FIG. 8 is a view illustrating a subsea wellhead intervention and retrieval tool 250 with the perforating tool 215 disposed on a wireline 255 . For convenience, the components of the tool 250 that are similar to the components of the tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 8 , the tool 250 has engaged the wellhead 10 in a similar manner as described herein. As also shown in FIG. 8 , the perforating tool 215 has been positioned in the casing string 30 by utilizing the wireline 255 . This arrangement may be useful if multiple areas are to be perforated by the perforating tool 215 . Further, the use of wireline 255 allows the capability of running the perforating tool 215 in and out of the wellbore multiple times (or runs). Additionally, the tubular member 220 is open ended thereby allowing fluid flow to be pumped through the tubular member 220 .
[0043] In operation, the tool 250 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated to create a seal between the tubular member 220 and the casing string 30 . Thereafter, the perforating tool 215 may be positioned in the casing string 30 by utilizing the wireline 255 and then activated to perforate (or cut) the casing string. The tool 250 may further be used to remove the wellhead 10 in a similar manner as described herein.
[0044] FIG. 9 is a view illustrating a subsea wellhead intervention and retrieval tool 300 with the perforating tool 215 . For convenience, the components of the tool 300 that are similar to the components of tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 9 , the tool 300 has engaged the wellhead 10 in a similar manner as described herein. The tool 300 includes the ported sub 210 and the perforating tool 215 . As set forth herein, the perforating tool 215 may be used to perforate (or sever) the casing string 30 or any number of casing strings, such as casing strings 30 , 60 . Additionally, the ported sub 210 may be used in a pressure test and/or to distribute cement 55 which is pumped from the surface.
[0045] In operation, the tool 300 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated and the ported sub 210 may used as set forth herein. Additionally, the perforating tool 215 may be operated to perforate (or cut) the casing string. The tool 300 may further be used to remove the wellhead 10 in a similar manner as described herein.
[0046] FIG. 10 is a view illustrating a subsea wellhead intervention and retrieval tool 350 attached to a cutter assembly 360 . For convenience, the components of the tool 350 that are similar to the components of the tool 100 will be labeled with the same reference indicator. As shown in FIG. 10 , the tool 350 has engaged the wellhead 10 in a similar manner as described herein.
[0047] The cutter assembly 360 uses a cutting stream 365 to cut the casing string 30 . In one embodiment, the cutter assembly 360 is a laser cutter. In this embodiment, the laser cutter would be connected to the surface via a fiber optic bundle (not shown). The fiber optic bundle would be used to transmit light energy to the cutter assembly 360 from lasers on the surface. The cutter assembly 360 would direct the light energy by using a series of lenses (not shown) in the cutter assembly 360 toward the casing string 30 . The light energy (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 .
[0048] In another embodiment, the cutter assembly 360 is a plasma cutter. In this embodiment, the plasma cutter would be connected to the surface via a conduit line (not shown). The conduit line would be used to transmit pressurized gas to the cutter assembly 360 . The gas is blown out of a nozzle in the cutter assembly 360 at a high speed, at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal of the casing string 30 . The plasma (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 .
[0049] In a further embodiment, the cutter assembly 360 is an abrasive cutter. In this embodiment, the abrasive cutter would be connected to the surface via a fluid conduit (not shown). The fluid conduit would be used to transmit pressurized fluid having abrasives to the cutter assembly 360 . The pressurized fluid (with abrasives) is blown out of a nozzle in the cutter assembly 360 . The pressurized fluid (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 . In another embodiment, a chemical or a high energy media may be used with the cutter assembly 360 to cut (or perforate) the casing string 30 .
[0050] The tool 350 includes an optional rotating device 355 configured to rotate the cutter assembly 360 . The rotating device 355 may be controlled at the surface or downhole. The rotating device 355 may be powered by electric power or hydraulic power. Generally the rotating device 355 will rotate the cutter assembly 360 in a 360 degree rotation in order to cut the casing string 30 . The speed, direction and the timing of the rotation will also be controlled by the rotating device 355 in order to allow the cutting stream 365 to sever (or perforate) the casing string 30 .
[0051] The tool 350 may be attached to an optional anchor device 370 to anchor the tool 350 to the casing string 30 . The anchor device 370 may include radially extendable members that grip the casing string 30 upon activation of the anchor device 370 . Generally, the anchor device 370 is used to stabilize (or centralize) the cutter assembly 360 in the casing string 30 .
[0052] In operation, the tool 350 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional anchoring device 370 may be used to stabilize (or centralize) the cutter assembly 360 in the casing string 30 . Thereafter, the cutter assembly 360 may be activated to perforate (or cut) the casing string and the cutter assembly may be rotated by using the rotating device 355 . The tool 350 may further be used to remove the wellhead 10 in a similar manner as described herein.
[0053] FIG. 11 is a view illustrating a subsea wellhead intervention and retrieval tool 400 with an explosive charge device 405 . For convenience, the components of the tool 400 that are similar to the components of tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 11 , the tool 400 has engaged the wellhead 10 in a similar manner as described herein.
[0054] The tool 400 includes the explosive charge device 405 for cutting (or perforating) the casing string 30 or any number of casing strings. Generally, the explosive charge device 405 includes several shaped explosive charges that are selectively activated to cut (or perforate) the casing string 30 . The explosive charge device 405 may also include a single massive explosive charge. If the casing string 30 is to be cut, the explosive charge device 405 may include a 360 degree charge which will cut (or sever) the casing string 30 upon activation. In the embodiment illustrated in FIG. 11 , the explosive charge device 405 is part of the tool 400 . It is to be noted, however, that the explosive charge device 405 could be a separate device that is lowered through the tool 405 via a wireline or another type of conveyance member, such as coil tubing, jointed pipe or an umbilical.
[0055] In operation, the tool 400 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the explosive charge device 405 may activated to perforate (or cut) the casing string. The tool 400 may also be used to remove the wellhead 10 in a similar manner as described herein.
[0056] The subsea tool described herein may be used for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one embodiment, one or more systems or subsystems of the subsea tool may be controlled, monitored or diagnosed via Radio Frequency Identification Device (RFID) or a radio antenna array. In another embodiment, the components of the subsea tool may be activated by using a RFID electronics package with a passive RFID tag or an active RFID tag. In this embodiment, one or more components in the subsea tool, such as cylinders or an attached downhole assembly such as a cutter assembly, perforating tool, ported sub, anchoring device, etc., may include the electronics package that activates the component when the active (or passive) RFID tag is positioned proximate a suitable sensor. For instance, the subsea tool having a component with the electronics package is lowered into the sea via the conveyance member and positioned proximate the wellhead disposed on the seafloor in a similar manner as set forth herein. Thereafter, the active (or passive) RFID tag is pumped through an umbilical connected to the tool or lowered into the sea. When the active (or passive) RFID tag is detected, the relevant component may be activated. For example, the electronics package in the tool may sense the active (or passive) RFID tag then send a control signal to actuate the gripping arm. The same electronics package may sense another active (or passive) RFID tag and then send another control signal to actuate the wedge block assembly. The same electronics package may sense a further active (or passive) RFID tag and then send a further control signal to actuate the lifting cylinders. In this manner, the tool may be controlled by using the electronics package with the active (or passive) RFID tags. In a similar manner, an electronics package with the active (or passive) RFID tags may be used to activate and control a downhole assembly attached to the tool.
[0057] The embodiments describe herein relate to a single subsea wellhead intervention and retrieval tool. However, it is contemplated that multiple subsea wellhead intervention and retrieval tools may be used together in a system. Each subsea wellhead intervention and retrieval tool may be independently powered or linked to a primary subsea power source for simultaneous onsite multiple unit operation.
[0058] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention generally relates to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one aspect, a method of performing an operation in a subsea well is provided. The method comprising the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a downhole assembly. The method also comprising the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. The method further comprising the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead. Additionally, the method comprising the step of performing the operation in the subsea well by utilizing the downhole assembly. | 4 |
BACKGROUND OF THE INVENTION
In the use of continuous filament synthetic textile yarns, it has become increasingly important to overcome the smooth texture of the yarns as initially spun and to obtain an appearance more similar to the natural fibers such as cotton and wool, by a process of texturing or permanently distorting the filaments. Objectives of texturing are to achieve improved bulk, cover, warmth, crisp or soft hand, and, in some instances, to increase the elastic stretch of the filaments. A great variety of methods have been developed to texture the synthetic yarns, among which may be mentioned false twist texturing, knit-de-knit, steam stuffer box crimping, air jet texturing, and gear crimping using crimping wheels. This invention relates to the latter system.
Gear crimping of synthetic filaments consists of passing the filaments through wheels having intermeshing gear teeth which have sufficient peripheral spacing between the teeth to admit the filament without applying any pressure thereto. The crimping wheels may be, but are not necessarily, combined with other yarn processing apparatus such as drawing and twisting apparatus.
A principal difficulty in gear crimping lies in adjusting the spacing between the meshing teeth of the crimping wheels evenly in order to prevent damage to the filaments by pinching of the filaments between the wheels. Previous methods of adjusting the spacing have been tedious and cumbersome due to the fineness of the crimping teeth and the difficulty of making slight adjustments of a gear or crimping wheel on its shaft.
In my copending application Ser. No. 594,938 filed on even date herewith, an apparatus for adjusting the peripheral spacing between the teeth of yarn crimping wheels is described.
In accordance with the invention described therein, a pair of intermeshing gears fixedly attached on separate rotatable parallel shafts drive a pair of intermeshing crimping wheels also fixedly attached on the shafts. The gear and crimping wheel on each shaft are positioned so that rotation of the gear produces similar rotation of the crimping wheel. The number of teeth on each gear preferably is the same, as is the number of the teeth on each crimping wheel, although there usually are several times more crimping teeth than gear teeth. At least one drive shaft may be movable in order to disengage both the gears and crimping wheels.
The relationship between the tooth count of the gears and crimping wheels is such that when the gears and wheels are disengaged and one gear rotated a predetermined amount with respect to the other, reengaging the gears and wheels in the new position will result in a relatively small adjustment of the peripheral spacing between the teeth of the crimping wheels.
SUMMARY OF THE INVENTION
In accordance with this invention, a device with graduated markings, which may be about the size and general shape of the crimping wheel described above, is provided to be attached to one crimping wheel during adjustment of the spacing between adjacent teeth of meshing crimping wheels. Since the spacing adjustment is done by rotating one crimping wheel with respect to the other a distance equivalent to multiples of a calculated number of driving gear teeth, the device is marked with lines a corresponding distance apart. An index line is also marked directly on the other meshing crimping wheel. The device is provided with means for rotation with respect to the crimping wheel on which it is mounted for purposes of initial adjustment, and with means for fixedly attaching the device to the crimping wheel after the initial adjustment is made. Where N is the number of teeth in the driving gear for the crimping wheel, and where N is properly chosen as hereinafter described, a small adjustment of 1/N of the distance between crimping wheel teeth may be made by rotating one crimping wheel a predetermined amount with respect to the other and moving from one line marked on the graduated device to the next line. A convenient number of lines is marked on the device spaced predetermined distances apart.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described with reference to the appended drawings, in which:
FIG. 1 is a perspective view of the driving gears, the driven crimping wheels associated therewith, and the graduated device;
FIG. 2 is a magnified view of the meshing of the teeth on the crimping wheels when the spacing of the meshing teeth is uneven;
FIG. 3 is a view similar to FIG. 2 but showing even spacing of the meshing teeth; and
FIG. 4 is an end view of the crimping gears and the graduated device.
DESCRIPTION OF THE INVENTION
In FIG. 1, the crimping wheels 10 and 11 and the gears 12 and 13 are shown, along with the indicating device 21. Crimping wheel 10 and driving gear 12 are fixedly mounted on a common shaft 14 which is driven from an external drive, not shown. Gear 12 meshes with and drives gear 13. Crimping wheel 11 and driving gear 13 are fixedly mounted on a common shaft 15. The shafts are supported by conventional bearing means. The teeth of crimping wheels 10 and 11 mesh but do not touch and this clearance permits passage of the yarn 16 to be crimped therebetween, as also shown in FIG. 3.
Shaft 14 is supported by bearing means and support rods 19 and 22 and 20 and 24, each in turn being attached to bearing housings 28 and 26. Bearing housings 28 and 26 are rotatably mounted on a pivot shaft 25 rigidly attached to a frame (not shown). Shaft 15 is supported by bearing means 21 and support rod 23, which in turn is connected to a bearing housing 27, also rotatably mounted on pivot shaft 25, and is spaced apart from the bearing housings 28 and 26 by spacers 29. When out of mesh, wheel 11 and gear 13 are held stationary while the wheel 10 and gear 12 are rotated a predetermined amount to a new position with respect to wheel 11 and gear 13. The indicating device 21 is attached to crimping wheel 10 as shown. At least one index line 22 (see FIG. 4) is marked on crimping wheel 11, and graduated lines 23 are marked at predetermined intervals on the indicating device.
In FIG. 2, an illustration is given of the relationship between the teeth 17 and teeth 18 of meshing crimping wheels 10 and 11, respectively, when the crimping teeth are not evenly spaced. The distance between the center of any two adjacent teeth of either wheel (i.e., the circular pitch) is designated X. The peripheral spacing between the teeth 17 of one crimping wheel and the teeth 18 of the other crimping wheel on one side is represented by Y and on the other side Y' (also see FIG. 3). Under normal conditions, the crimping wheels 10 and 11 should be adjusted so that Y and Y' are as nearly equal as possible.
In FIG. 3, an illustration is given of the relationship between the teeth 17 and teeth 18 of meshing crimping wheels 10 and 11 when the teeth 17 and 18 are evenly spaced, i.e., the distances Y and Y' are equal. The position of the yarn 16 being crimped is also shown.
Referring to FIGS. 2 and 3, when the crimping wheel 10 with teeth 17 is rotated to a new position with respect to the crimping wheel 11 with teeth 18 in accordance with the invention herein, the peripheral distances Y and Y' between the meshing crimping gear teeth will change, as will be described more fully hereinafter.
When the dividend D of the number of crimping wheel teeth divided by the number of driving gear teeth (i.e., the number of crimping wheel teeth per driving gear tooth) is an integer, the mesh of the crimping teeth will always be the same regardless of the rotational positioning of the driving gears relative thereto. For example, for crimping wheels of tooth count each of 300 and driving gears of 60 tooth count each, D = 300 ÷ 60 = 5; i.e., for each relative movement of one tooth between the driving gears, the crimping teeth will be displaced exactly five teeth, and the mesh spacing Y and Y' or position of the crimping teeth of one wheel relative to the teeth of the other crimping wheel will remain the same.
When the dividend D of the number of crimping wheel teeth over the number of driving gear teeth is a combination of an integer and a fraction, however, the crimping teeth mesh spacing will vary upon relative repositioning of the driving gear teeth. For example, assume that the tooth count of the crimping wheel is 300 and the driving gear tooth count is 79. Then, D = 300 ÷ 79 = 3 63/79.
The dividend number D represents the number of crimping wheel teeth per driving gear tooth, that is, the relative rotational positioning of the teeth of the crimping wheels for a relative shift of one tooth between driving gears. This invention recognizes that minute adjustment of the position of the teeth on one crimping wheel relative to the teeth on the other crimping wheel can be made by the positioning of the gear teeth. From the above example having gearing of 79 teeth, it can be seen that a relative rotation of the gear equal to five gear teeth corresponds to a relative rotation of 5 × 3 63/79 or 18 78/79 crimping wheel teeth; e.g., the relative position of the crimping wheels has changed 19 teeth before remeshing and, also, the mesh spacing of the crimping wheel teeth has changed by 19 - (18 78/79) or 1/79 of the crimping wheel tooth spacing X.
Relative rotation of 10 driving gear teeth, therefore, represents a relative positioning of the crimping wheel teeth of 10 × 3 63/79 or 37 77/79; e.g., the mesh spacing of the crimping wheel teeth has changed by 2/79 of the crimping wheel tooth spacing X. Similarly, relative rotation of 15 driving gear teeth changes the mesh spacing 3/79 of the crimping wheel tooth spacing X; and, in general, for this particular ratio gearing, a relative rotation of 5N driving gear teeth changes the mesh spacing by N/79 (N being a whole number).
In FIG. 4, an end view illustration is given of one embodiment of this invention. The indicating device 21 is about the size and shape of the crimping wheel 10, except that the periphery of the device is smooth, with no gear teeth. The device 21 has a hub 24 in the center of the rear face for engagement with a matching recess in the center of shaft 14. The device 21 is fastened to the crimping wheel 10 by means of a screw or other fastener 25 in the arcuate slot 26. An initial adjustment may be made by aligning one of the lines 23 on the device with the index line 22 on the crimper wheel 11 by a limited rotation of the device 21 with respect to crimper wheel 10 around the hub 24 as a center. During this limited rotation, the arcuate slot 26 in which the fastener 25 is placed changes position in relation to the fastener 25. When the index line 22 on the crimping wheel 11 is aligned with one of the lines 23 on the device 21, the fastener 25 is tightened to hold the device 21 fixedly in position, attached to the crimping wheel 10.
The adjustment of the peripheral spacing between the teeth of the yarn crimping wheels 10 and 11 may then be done as follows. On observation of the spacing of the intermeshing teeth of yarn crimping wheels 10 and 11, if the teeth are not evenly spaced in relation to each other, the crimping wheel 11 is moved out of mesh with crimping wheel 10, and wheel 10 is rotated with respect to wheel 11 until the index line 22 on the wheel 11 is aligned with the next adjacent line 23. The crimping wheels 10 and 11 are then remeshed, and the teeth of wheels 10 and 11 will have moved in relation to each other by a small increment. As previously explained, this increment is typically equal to 1/N of the distance from one tooth to an adjacent tooth on a crimping wheel, where N is the number of teeth on a driving gear.
The increment movement is small enough so that the spacing between the crimping teeth may be satisfactorily adjusted by moving the crimping wheel 10 and the attached device 21 with respect to crimping wheel 11, matching successive lines 23 with index line 22 until the spacing between the crimping teeth is even. | In synthetic yarn texturing using crimping wheels, an indicating device is provided to aid in adjusting the peripheral spacing between the teeth of the wheels. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of awnings and specifically to a vehicle awning with components facilitating improved assembly and operation.
2. Description of the Related Art
There are a number of known retractable assemblies that support an awning to create a sheltered area. The awning is usually supported in a generally horizontal position with a slight slope to facilitate runoff of rainwater. Commonly, one edge of the awning is attached to a wall. The opposite edge is attached to a tube, rod, rail or other similar elongated member, which is supported by two support arms. The support arms rest on the ground or are mounted to a lower part of the wall. Tension rafter arms are disposed between the wall and the tube or rail to stretch the awning and hold it in position. In this way, a convenient shelter is formed adjacent the wall to protect people and objects beneath the wall from rain and direct sun.
Shifting roll type awnings have a roller tube suspended between the support arms. The tube is moved laterally to unroll or roll the awning on the tube. One edge of the awning is rigidly attached to the wall. It is less common, but still possible, for this type of awning to be enclosed in a case in its retracted position. U.S. Pat. No. 4,658,877 to Quinn shows an example of such an awning assembly. In both types the roller tube may be spring balanced or spring biased to aid rolling.
Retractable awnings can be divided into two general classes. Box type awnings have a stationary roller tube mounted to the wall. The awning is rolled around the tube for storage. The box comprises a stationary enclosure for the awning, a cover of which is opened to permit access to the awning which is unrolled to an extended position. Alternatively, a movable cover is attached to the free end of the awning to complete the enclosure when the awning is retracted.
A popular application for such awnings is on recreational vehicles. The awning creates a convenient outdoor shelter next to the vehicle. Simple and fast assembly and disassembly of the awning are important, especially in vehicle applications. Vehicle awnings also must be rugged and durable because they are constantly exposed to the elements.
Different hardware and assemblies are used to construct and mount the awning assemblies. The need exists for improvements in the hardware and assemblies to facilitate mounting, assembly, and erection of the awning and to improve the operation of the awning.
SUMMARY OF THE INVENTION
The present invention provides improved features for awning assemblies including a roller for an awning having a bead along an edge of the awning. The roller is an elongated member having a longitudinal channel adapted for receiving and retaining the bead therein. A notch is disposed at an end of the channel, said notch being adapted for receiving an end of the bead therein in a compressed state, frictionally retaining the end of the bead, and preventing substantial longitudinal movement thereof.
An awning assembly according to the invention includes an awning having a leading edge and a trailing edge, said trailing edge being attachable at a wall. A support arm is adapted for supporting the leading edge of the awning and has an upper end spaced from the wall in a retracted position of the awning. A rafter is disposable between the support arm and the wall. A pivot support having an end of the rafter pivotably attached thereto is mounted at the wall and spacing the rafter from the wall substantially the same distance as support arm is spaced from the wall. A mounting bracket has a flange and is adapted for securing the pivot support to the wall. The pivot support includes a plurality of slots adapted for receiving the flange of the mounting bracket, each of said slots being adapted for positioning the mounting bracket differently depending on a desired mounting configuration. An awning rail is used for attaching the trailing edge of the awning at the wall. The pivot support includes a locating tab adapted for positioning the pivot support relative to the awning rail.
Another construction of the awning assembly includes an awning having a leading edge and a trailing edge, said trailing edge being attachable at a wall. A support arm is adapted for supporting the leading edge at a support axis of the awning and having a slide channel on an external face thereof. A rafter is disposable between the support arm and the wall. A slider is pivotably attached to the rafter at a pivot axis and adapted for sliding in the slide channel. A stop is adapted for positioning the pivot axis collinearly with the support axis in an extended position of the awning.
The invention also comprehends a lock assembly for an awning roller. A roller adapted for having an awning rolled thereon has an end cap mounted on an end of the roller. A rod defines a longitudinal axis of rotation of the roller. A stop is rigidly mounted to the rod. A lock has a pawl adapted for engaging the stop so as to prevent relative rotation of the roller and rod in at least one direction. Spring means is provided for biasing the lock toward engagement with the stop.
The description of the invention refers to a shifting roll type awing assembly. However, the features and components can be adapted to other types of awnings, as well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vehicle having an awning assembly according to the invention mounted thereon;
FIG. 2 is a top view of a mounting bracket according to the invention;
FIG. 3 is an end view of the mounting bracket of FIG. 2;
FIG. 4 is a top view of a pivot support according to the invention;
FIG. 5 is a side view of the support of FIG. 4;
FIG. 6 is a perspective view of an end of the awning assembly showing the manner of mounting to the vehicle;
FIG. 7 is an end view of the mounting components of FIG. 6;
FIG. 8 is an end view of the mounting components of FIG. 6 according to another embodiment;
FIG. 9 is an end view of the mounting components of FIG. 6 according to a third embodiment;
FIG. 10 is an end view of a roller tube having an awning attached thereto;
FIG. 11 is a partial front view showing an end of the roller tube shown in FIG. 10;
FIG. 12 is a partial end view of the roller tube shown in FIG. 10;
FIG. 13 shows a section of the roller tube and awning taken from line 13--13 of FIG. 12;
FIG. 14 shows the view of FIG. 13 with the awning omitted;
FIG. 15 is an end view of the awning assembly in a partially assembled, partially retracted position;
FIG. 16 is a top view of an end of the awning assembly showing the roller tube, a support arm, and a rafter arm according to the invention taken from line 16--16 in FIG. 15;
FIG. 17 is a front view of the end of the awning assembly taken from line 17--17 in FIG. 15;
FIG. 17A is an exploded view of the rafter arm, support arm, and a slider assembly;
FIG. 18 is an end view of the awning assembly in a fully extended position;
FIG. 19 is an end view of the awning assembly is a partially retracted position;
FIG. 20 is a front elevational view of a support arm and a rafter arm in a retracted position;
FIG. 21 is an end view of the support arm and rafter arm in a retracted position;
FIG. 22 shows an inside face of an end cap of the roller tube and roller lock components mounted therewith;
FIG. 23 is a front section of the end cap and a torsion rod taken from line 23--23 of FIG. 22;
FIG. 24 shows the roller lock in a "roll up" position; and
FIG. 25 shows the roller lock in a "roll down" position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a vehicle 10 has a generally vertical wall 12 with an awning assembly 14 mounted thereon. Generally, the awning assembly 14 includes an awning rail 16 mounted on the wall 12 and an awning 18 rollable on a roller 20 such as a roller tube. A leading edge of the awning 18 is supported by respective support arms 22. The support arms are preferably secured to ends of the roller 20 and are removably mounted on the wall 12 or rested on a ground surface. Rafter arms 24 are disposed between leading and trailing edges of the awning 18 to maintain the awning in tension.
Referring to FIGS. 2 and 3, a mounting bracket 30 is preferably made of corrosion resistant steel or other durable, rigid material. The bracket 30 has a mounting flange 32 and a support flange 34 disposed at opposite ends of a body 36 of the bracket 30. Reinforcing flanges 38 are provided at ends of the body 36. Downwardly projecting dimples 40 are provided on the body 36. First and second pairs of oval mounting holes 42, 44 are located through the bracket 30 at or near the respective flanges 34, 32.
Referring to FIGS. 4 and 5, a pivot support 46 is made with aluminum or other durable, rigid material. The pivot support 46 has a body 48 with first, second, and third slots 50a, 50b, and 50c located on upper and lower faces thereof. The slots 50 are adapted to receive the support flange 34 of the mounting bracket 30. A positioning tab 52 projects from a recess 54 on an inboard face of the body 48. A brace arm 56 having a foot 58 extends from below the positioning tab 52. A generally cylindrical pivot slot 60 is located at an outboard end of the pivot support 46.
Referring to FIGS. 6 and 7, the rafter arm 24 is mounted to the pivot support 46 by a pivot pin 62 extending through the pivot slot 60. The awning rail 16 is mounted to a frame or brace 64 of the vehicle wall 12 in a conventional manner. The awning rail 16 defines a C-channel adapted for mounting awning components.
Referring to FIG. 7, the positioning tab 52 projects into the C-channel of the awning rail 16. The recess 54 receives the awning rail 16 therein. A plastic pad 66 is provided over the foot 58 to prevent marring of the wall 12. The foot 66 preferably rests against the wall 12. The support flange 34 of the mounting bracket 30 is located in the first slot 50a of the pivot support 46. The pivot support 46 and bracket 30 are held in place by a pair of lag screws 68 extending through the holes 42 and the wall 12 into the brace 64.
Referring to FIG. 8, for a different orientation of the awning rail 16, the mounting bracket 30 is located above the pivot support 46 with the support flange 34 inserted in the second slot 50b. The screws 68 extend through the mounting holes 44 into the brace 64 above the rail 16. The dimple 40 rests beside the body 48 of the pivot support.
Referring to FIG. 9, for a differently constructed awning rail 16 having the C-channel spaced from the wall 12, the support flange 34 is inserted in the third slot 50c. The foot 58 is spaced from the wall or can be braced against a spacer (not shown).
The pivot support 46 and mounting bracket 30 are adapted for use with different configurations of awning rails 16 and advantageously space the pivot of the rafter arm 24 from the wall, as described below.
Referring to FIG. 10, the roller 20 is a roll-formed, steel tube, as described, for example, in U.S. Pat. No. 5,351,736. An edge of the awning 18 (the leading edge in the example shown) has a pocket 70 defined by a hem 72. A flexible, compressible, cylindrical rope 74, preferably made of polypropylene, is located in the pocket 70 and extends slightly beyond both ends of the pocket 70. The rope 74 and pocket 72 define a bead disposed in a slideway 76 of the roller 20. The diameter of the rope and the dimensions of the slideway are such that the rope retains the edge of the awning in the slideway.
Referring to FIGS. 11 through 14, a notch 78 is provided in a side wall 80 of the slideway 76. Alternatively, the notch 78 can be provided in a base wall or a corner of the slideway 76, for example. The notch 78 is slightly narrower than the diameter of the rope. The end of the rope 74 is compressed and wedged into the notch 78 and retained therein by friction to prevent longitudinal movement of the rope. Preferably, complementary notches are provided at opposite ends of the roller 20 so that the edge of the awning can be pulled taut and opposite ends of the rope 74 wedged into the respective notches 78 to hold the awning taut in the slideway 76.
Referring to FIG. 15, each of the support arms 22 includes an upper arm 82 and a lower arm 84 slidingly received therein. The arms 82, 84 are frictionally locked relative to each other by a screw and knob assembly 86. Each of the rafter arms 24 includes an inboard arm 88 and an outboard arm 90 slidingly received therein. The arms 88, 90 are frictionally locked relative to each other by a screw and knob assembly 92. As previously described, the inboard end of the rafter arm 24 is pivotably mounted at the wall 12 on the pivot support 46. The lower end of the support arm 22 has a foot 94 removably and pivotably mountable at the wall in a foot bracket 96. The outboard arm 90 is slidingly and pivotably mounted to the upper arm 82, as described in more detail below. The roller 20 is rotatably mounted near the top of the support arm 22.
Referring to FIGS. 16 and 17, the roller 20 is rotatably supported on a torsion rod 98, which can be solid or hollow. The torsion rod 98 extends longitudinally through the center of the roller 20 and through end caps 100 disposed at ends of the roller. The torsion rod 98 defines collinear support and rotational axes of the roller 20. Ends of the torsion rod 98 are supported on the upper arm 82 and secured by a nut and bolt assembly 102.
An outside face of each upper arm 82 is provided with a pair of arm flanges 104 defining a longitudinal slide channel 106. A slider 108 is pivotably mounted to the outboard arm 90 on a post 110, such as a rivet. The slider 108 is made of a durable, low friction material, such as plastic. The slider has pairs of inner flanges 112 and outer flanges 114 cooperating with the arm flanges 104 to retain the slider in the slide channel 106 and permit longitudinal sliding therein. A support arm cap 116 is disposed on the top end of the upper arm 82 to limit upward travel of the slider 108. Alternatively, another blocking member, such as a screw, can be used to limit upward travel of the slider 108. As shown in FIG. 18, when the slider 108 abuts the cap 116, the post 110 defines a pivot axis substantially collinear with the torsion rod 98 and support axis of the roller 20.
As shown in FIGS. 17 and 17A, a slider stop 118 is mounted on the post 110 between the slider 108 and the upper arm 82. The slider stop 118 has a detent 120 projecting from an inner face of the stop toward the upper arm 82. An exposed end of the stop 118 defines a lever 122 projecting from behind the slider 108 to a manually accessible location. The detent 120 is biased toward the upper arm 82 by a compression spring 124, for example. As shown in FIGS. 17 and 19, a slot 126 adapted to receive the detent 120 is located near the top of the slide channel 106 of the upper arm 82. The slot 126 is positioned such that the detent 120 is biased into the slot and locks the rafter 24 in the position shown in FIG. 18 when the slider abuts the support arm cap 116. The rafter 24 is releasable by actuating the lever 122 to remove the detent 120 from the slot 126.
The rafter arms 24 and support arms 22 are relatively slidable and pivotable between an extended position, shown in FIG. 18, and a retracted position, shown in FIGS. 20 and 21. The rafter and support arm assemblies at opposite ends of the roller 20 are mirror images of each other.
Referring to FIGS. 22 and 23, idler bearings 128 are rotatably mounted on the torsion rod 98 and support the roller 20 for rotation about the rod. A coiled torsion spring (not shown) is connected between the torsion rod and the idler bearing to bias the roller toward a retracted position with the awning rolled thereon. The end caps 100 close the ends of the roller. One of the end caps 100 is provided with a roller lock assembly 130. As shown and described below, the lock assembly is located in the right hand end cap 100, as viewed in FIG. 1. A gear 132 having a plurality of teeth defining stops is mounted on the torsion rod 98. A pin 134 extending through the rod 98 prevents relative rotation of the rod and gear 132.
A truss 136 is rotatably mounted on the torsion rod 98 adjacent the gear 132. The end cap 100 is fastened to the truss 136 by a pair of screws 138 threaded into apertures 140 of the truss 136. A lock 142 having a first pawl 144 and an opposed second pawl 146 is pivotably mounted on the truss 136 by a post 148 extending through a passage 150 through the truss and the end cap 100. The lock 142 is operable by a handle 151 disposed on an end of the post 148 outside the end cap 100. Opposed elements of a torsion spring 152 or leaf springs bear against bushings 154 mounted on the lock 142. The bushings 154 are symmetrically on opposite sides of the post 148 by a pair of shoulder screws 156. The elements of the spring 152 bear inwardly against the bushings 154 to resist any tendency of the lock to remain in the neutral position shown in FIG. 22.
Referring to FIG. 24, by operation of the handle 151, the lock is movable to a "roll up" position wherein the roller and end cap 100 are rotatable clockwise about the torsion rod 98. In this position, the first pawl 144 engages a tooth of the gear 132 to prevent counter-clockwise rotation of the roller and end cap about the torsion rod. The opposed elements of the spring 152 bear inwardly against the bushings 154 of the lock 142 to keep the lock in position.
Referring to FIG. 25, by operation of the handle 151, the lock is also movable to a "roll down" position wherein the roller and end cap 100 are rotatable counter-clockwise about the torsion rod 98. In this position, the second pawl 146 engages a tooth of the gear 132 to prevent clockwise rotation of the roller and end cap about the torsion rod. The opposed elements of the spring 152 bear inwardly against the bushings 154 of the lock 142 to keep the lock in position.
In operation, the support arms 22 and rafter arms 24 are normally stowed as shown in FIGS. 20 and 21. The arms 22, 24 are spaced from the vehicle wall 12 by the feet 94 and pivot support 46 so that the arms are generally parallel. A releasable strap and buckle assembly 158 holds the arms in the parallel, stowed position. To extend the awning, the strap and buckle 158 are released, the rafter knob 92 is loosened, and the lock assembly 130 is moved to the roll down position shown in FIG. 25. As shown in FIG. 19, the roller 20 is pulled away from the vehicle and the awning unrolls therefrom. Each outboard arm 90 slides out from its inboard arm 88 to extend the rafters 24. When the awning 18 is fully extended, the rafter arms 24 are slid to the tops of the support arms 22 until the slider stop 118 engages in the slot 126, as shown in FIG. 18. The awning is pulled to a desired tension and the rafter knobs 92 are screwed in to lock the rafters 24. The supports arms 22 are extended to a desired length and locked with the support arm knobs 86. As shown in FIG. 1, the support arms 22 can remain locked in the foot brackets 96 or the feet 94 can rest on the ground. Referring to FIGS. 1 and 18, because the outboard pivot axis of the rafter 24 and support arm 22 defined by the post 110 is coaxial with the support axis of the roller 20, pivoting the support arms 22 between the wall 12 and the ground does not substantially change the tension of the awning 18.
To retract the awning, the feet 94 are replaced in the foot brackets 96 and the support arms 22 are shortened. The rafter knob 92 is loosened and the slider stop is released by lifting the lever 122, shown in FIGS. 17 and 18. The outboard end of the rafters 24 are slid down to the support arm knobs 86. The lock assembly 130 is moved to the roll up position shown in FIG. 24 by operation of the handle 151. The awning 18 is then rolled on the roller 20 as the roller is moved toward the vehicle wall. The arms 22, 24 are returned to the positions shown in FIGS. 21 and 22, the knobs 92 and 86 are tightened, and the strap and buckle assemblies 158 are used to secure the arms in the parallel, stowed position.
The present disclosure describes several embodiments of the invention, however, the invention is not limited to these embodiments. Other variations are contemplated to be within the spirit and scope of the invention and appended claims. | A retractable awning is provided with a multiple position pivot support adapted for mounting the awning in different installations. A flange of a mounting bracket fits in one of several slots in the support according to a wall and awning rail structure. A roller is provided with a notch into which is wedged a rope in a hem pocket of the awning. The notch retains the rope and holds the awning taut. Rafter arms a pivotably attached to slides held in slideways on external faces of support arms. A stop and latch mechanism hold the rafter in an extended position so that pivoting of the support arms does not change tension of the awning. An improved roller lock uses a pair of pawls engaging a gear. A spring biases the lock to either of two engaged positions. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/199,819, filed Apr. 26, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to covers for receptacles, and more particularly to a cover for waste containers designed to reduce odors and to conceal unsightly waste container items.
[0004] 2. Description of Related Art
[0005] Waste receptacles frequently contain unsightly items that are capable of producing unpleasant odors. Some waste containers come with a top lid to cover the mouth of the waste receptacle. However, many of the top lid covers can be difficult to repeatedly open and close. Furthermore, the top lid can become dirty and unsightly due to frequent contact with the items being disposed. In addition, most top lids of waste containers do a poor job in preventing unpleasant odors generated by the waste container contents from escaping, which results in a room full of unpleasant odors.
[0006] The relevant art of interest describes different types of covers used to cover a waste receptacle, but none discloses the present invention. There is a need for an economical, simple-to-use coverlet for minimizing the escape of obnoxious waste material in receptacles. The following relevant art will be discussed in the order of perceived relevance to the present invention.
[0007] European Patent Application No. 0 339 729 A1, published Nov. 2, 1989, describes a closure for a waste receptacle. The cover is completely open at the upper side and consists of two flexible plates arranged above each other. Each plate has radial slits whereby the slits in both plates are staggered. The closure is distinguishable for requiring two plastic radially slit covers arranged in layers.
[0008] U.S. Pat. No. 5,025,947, issued on Jun. 25, 1991 to Marcello Leone, describes a single-dose beverage cup and a rectangular cross-sectioned straw assembly comprising a cup lid with breakage-facilitating weakened lines varying from two V-cuts joined by a line, four radial intersecting lines, and an X-shaped cut. The cup lid assemblies are distinguishable for requiring a straw with a rectangular cross-section.
[0009] U.S. Pat. No. 2,080,108, issued on May 11, 1937 to Samuel J. Brandstein, describes a cover for bowl containers of different sizes comprising a circular or polygonal cover made from textile fabric, leather, rubber, oiled silk or cellophane with a peripheral drawstring made of rubber. The cover is distinguishable for its imperforated surface.
[0010] U.S. Pat. No. 2,903,034, issued on Sep. 8, 1959 to Charles Vrana, describes a ventilated food receptacle and cover comprising a square sheet with its corners folded back and heat welded to firm a tubular passageway for an elastic band and leaving four spaces for ventilation. The corners are placed over the bowl. The cover is distinguishable for its four-corner structure.
[0011] U.S. Pat. No. 3,315,402, issued on Apr. 25, 1967 to Charles D. Scott et al., describes a live bait container with an improved cover containing a longitudinal slit. The elastic cover is distinguishable for its single slit to permit entry of fingers and prevent exiting of the bait.
[0012] U.S. Pat. No. 4,328,904, issued on May 11, 1982 to Elaine J. Iverson, describes a spill-proof container and closure comprising a rubber closure having two to four overlapping arcuate flaps. The closure is distinguishable for requiring overlapping rubber flaps.
[0013] U.S. Pat. No. 2,436,291, issued on Feb. 17, 1948 to Lewis H. Daniel, describes a self-sealing closure for containers comprising a threaded cover made from a layer of rubber having crossed slits held between rings of hard rubber, plastic, wood, and metal. An applicator having a pledget of cotton can be inserted through the closure for liquid material in the container having a threaded neck. The closure is distinguishable for its requirement for a cover containing rings and threading.
[0014] U.S. Pat. No. 4,427,110, issued on Jan. 24, 1984 to Kenneth N. Shaw, Jr., describes an apparatus for handling used disposable diapers having a canister with a rim and a seal insert supported by the rim of the canister base. The seal insert has a plurality of radial slits. The top has a depending flange and a frustoconical plunger to flex the seal open. The apparatus is distinguishable for its required plunger structure.
[0015] U.S. Pat. No. 5,865,407, issued on Feb. 2, 1999 to Gerald I. Effa, describes covers to both shield an unsightly structure and to provide a waste receptacle or an inner liner for a waste container. The cover is installed by displacing it downwardly over the container or tray jack to conceal the latter. Then, the closed end segment of the cover is displaced downwardly through the opening defined by the crosspieces and flexible straps of a tray jack to form a waste-receiving pouch or receptacle. The covers are distinguishable for requiring cross-pieces and flexible tray jack straps, and failing to recognize the covering of the container opening.
[0016] E.P.O. Patent Application No. 0 436 839 A1, published on Jul. 17, 1991, describes an improved lid for plastic packages with a carrying handle, comprising a lid having a cut to define two flaps for inserting a band-like element to be inserted into the cut, so that the band-like element is raised to a carrying position. The lid is distinguishable for its handle structure.
[0017] None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
[0018] The present invention provides a disposable coverlet for waste containers that is designed to trap odors and to conceal the unsightly contents of a waste container. The disposable coverlet of the prevent invention can be used in any setting, e.g., in the home, in the office and in hospitals. The disposable coverlet has a very thin unwoven cloth body portion and a centrally disposed plastic portion with perforations. The plastic portion enhances the odor trapping properties of the coverlet, and the perforations allow the size of the opening in the coverlet to be varied. The coverlet has an elastic band incorporated within its peripheral edge for securing the coverlet to a waste container.
[0019] The waste container coverlet is easy and convenient to use. The expandable elastic portion of the coverlet allows the coverlet to be easily installed on a waste container and readily removed from a waste container. Therefore, a person can quickly remove a used coverlet from a waste container and promptly install a new coverlet on the waste container with a minimum amount of time and effort.
[0020] In an alternate embodiment, the disposable coverlet has an unwoven cloth portion, but does not have a plastic portion. This embodiment is also very effective in trapping unwanted odors and in concealing unsightly waste container items. The perforations for the coverlet opening are made in the unwoven cloth portion. The coverlets of the present invention are fast to attach, convenient, effective, disposable, and cost efficient.
[0021] Accordingly, it is a principal object of the invention to provide a waste receptacle cover that is decorative, functional, and disposable.
[0022] It is another object of the invention to provide a waste receptacle cover that reduces the unpleasant odors emanating from a waste container.
[0023] It is a further object of the invention to provide a waste receptacle cover that neatly conceals unsightly waste container items.
[0024] Still another object of the invention is to provide a waste receptacle cover that is easily installed on and removed from a waste receptacle.
[0025] It is an object of the invention to provide improved elements and arrangements thereof in a disposable coverlet for waste receptacles for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0026] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1A is an environmental, perspective view of a first embodiment of a disposable coverlet covering a container with a rectangular opening according to the present invention.
[0028] [0028]FIG. 1B is an environmental, perspective view of a second embodiment of a disposable coverlet covering a container with a circular opening.
[0029] [0029]FIG. 2A is an environmental, perspective view of a third embodiment of a disposable coverlet without a plastic center covering a container with a rectangular opening.
[0030] [0030]FIG. 2B is an environmental, perspective view of a fourth embodiment of a disposable coverlet without a plastic center covering a container with a circular opening.
[0031] [0031]FIG. 3A is an exploded top plan view of the first embodiment of a disposable rectangular coverlet.
[0032] [0032]FIG. 3B is an exploded top plan view of the third embodiment of a disposable rectangular coverlet.
[0033] [0033]FIG. 4A is a top plan view of the first step in the method of making the first embodiment in FIG. 1A of a disposable rectangular coverlet.
[0034] [0034]FIG. 4B is a top plan view of the second step in the method of making the first embodiment in FIG. 1A of the disposable rectangular coverlet.
[0035] [0035]FIG. 4C is a top plan view of the third step in the method of making the first embodiment in FIG. 1A of the disposable rectangular coverlet.
[0036] [0036]FIG. 4D is a top plan view of the fourth step in the method of making the first embodiment in FIG. 1A of the disposable rectangular coverlet.
[0037] [0037]FIG. 4E is a top plan view of the fifth step in the method of making the first embodiment in FIG. 1A of the disposable rectangular coverlet.
[0038] [0038]FIG. 4F is a top plan view of the sixth and final step in the method of making the first embodiment in FIG. 1A of the disposable rectangular coverlet.
[0039] [0039]FIG. 5 is a top plan view of the method of making the third embodiment in FIG. 2A of the disposable rectangular coverlet.
[0040] [0040]FIG. 6A is a top plan view of the second embodiment in FIG. 1B of a disposable coverlet for a round container.
[0041] [0041]FIG. 6B is a top plan view of the fourth embodiment in FIG. 2B of a disposable coverlet for a round container.
[0042] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The present invention, as depicted in FIGS. 1A, 1B, 2 A, 2 B, 3 A, 3 B, 4 A through 4 F, 5 , 6 A, and 6 B is a disposable coverlet 100 for waste receptacles or containers 108 . The disposable coverlet 100 of the present invention easily slips over the mouth 110 of a waste container 108 and conveniently covers the unsightly and odorous items routinely found in waste containers 108 . The elastic cord portion 106 of the disposable coverlet 100 ensures that the coverlet 100 securely and snugly fits the contour of the waste container 108 . The tight fit provided by the elastic cord portion 106 of the coverlet 100 virtually eliminates the escape of any unpleasant odors from the waste container 108 even though there are perforations in the coverlet.
[0044] [0044]FIG. 1A shows an environmental, perspective view of a first embodiment of the disposable waste container coverlet 100 covering a waste container 108 that has a rectangular opening or mouth 110 and a flat bottom 114 . The disposable coverlet 100 is configured to conform to the contour of the waste container mouth 110 . The disposable coverlet 100 is primarily made of an unwoven cloth material 102 , and has a centrally disposed perforated plastic portion 104 having radial slits 196 . The cloth body 102 is made of a strong and durable unwoven cloth material that is capable of withstanding the rigors of repeated use prior to disposal, such as “interface” Pellon® and the like materials made of either polyester or rayon, colored white or black, and comes in different weights such as light, medium or heavy).
[0045] The centrally disposed perforated plastic portion 104 allows the size of the opening of the coverlet 100 to be varied depending upon the needs or requirements of the waste container 108 . For example, a waste container 108 in an business office would have an opening large enough to accommodate pieces of discarded paper while a waste container 108 in a hospital would have a limited opening to accommodate discarded needles. The plastic portion 104 of the coverlet 100 enhances the odor retention properties of the coverlet 100 .
[0046] [0046]FIG. 1B shows an environmental, perspective view of a second embodiment of a disposable coverlet 100 with an elastic cord portion 106 covering a cylindrical waste container 108 with a circular opening 112 and a closed bottom 114 . The second embodiment of the disposable coverlet 100 also has a cloth body 102 having a centrally disposed plastic portion 104 with radial slits 196 .
[0047] [0047]FIG. 2A is an environmental, perspective view of a third embodiment of a disposable coverlet 100 with an elastic cord portion 106 covering a waste container 108 with a rectangular opening 110 . The third embodiment of the disposable coverlet 100 does not have a plastic portion 104 . In this embodiment, the perforations 186 (widthwise slit), 188 (length-wise slit) in a heavy weight cloth material 102 are made in the shape of an H.
[0048] [0048]FIG. 2B is an environmental, perspective view of a fourth embodiment of a disposable coverlet 100 having an elastic cord portion 106 covering a cylindrical waste container 108 with a circular opening 112 . The fourth embodiment of the disposable coverlet 100 , again does not have a plastic portion 104 , and the perforations 196 for the disposable coverlet opening are in the heavy weight cloth material 102 .
[0049] [0049]FIG. 3A is an exploded view of the first embodiment of a disposable rectangular coverlet 100 showing the cloth body 102 with an oval cutout portion 142 . The elastic cord 106 is laid out and slightly less in size with the cloth body 102 to provide a narrowed but stretchable region. An oval perforated plastic portion 104 slightly larger in size than the oval cutout portion 142 is shown with radial slits 196 extending short of the edge.
[0050] [0050]FIG. 3B is an exploded view of the third embodiment of a disposable coverlet 100 showing the heavy weight cloth portion 102 having its H-shaped perforation having a pair of widthwise or vertical slits 186 and a lengthwise or horizontal slit 188 . There is no perforated plastic portion 104 utilized in this embodiment. The elastic cord 106 of the disposable coverlet 100 is again shown laid out. The preparation of this embodiment will be discussed fully with reference to FIG. 5 below.
[0051] FIGS. 4 A- 4 F illustrate the manufacturing steps for making the embodiments of the disposable coverlet 100 that employ a plastic center 104 . FIG. 4A shows a top plan view of the first step in the method of making the plastic center 104 embodiment of the disposable coverlet 100 for a waste container 108 with a rectangular opening. The waste container 108 is inverted to place the mouth of the waste container on the central portion 116 of the rectangular piece of cloth material 102 to mark the rectangular outline 118 of the container's mouth. Next, measure 2 inches out from the outline 118 of the waste container 108 , and mark each side to form a dashed rectangular outline 120 on the cloth material 102 . Then, cut the cloth material 102 along the dashed outline 120 to produce a smaller rectangular piece 118 having an upper edge 124 , a right side edge 126 a , a left side edge 126 b , and a lower edge 128 to define the outside edges of the precursor coverlet 100 for the next step. The same procedure also applies to the making of the disposable coverlet 100 for a waste container with a round mouth, except a circular cut of the cloth material is made.
[0052] In step 2 , the resulting smaller rectangular piece of cloth material 102 is folded in half lengthwise so that the edges 124 and 128 meet as shown in FIG. 4B. Next, measure along the folded edge 130 of the cloth 102 inwards from the side edges 126 a , 126 b 4 inches and mark oval cutout points 134 a , 134 b . Next, measure 3½ inches from the middle 138 of the upper edges 124 , 128 of the cloth downwards and mark oval cutout point 136 . The marks 134 a , 134 b and 136 indicate where the oval shape 132 and cut is made as depicted in FIG. 4B. The half-oval 140 is cut out of the cloth material 102 as shown in FIG. 4C.
[0053] In step 3 , the cloth material 102 is opened up to reveal a full size oval 142 as shown in FIG. 4C. The next step in the preparation process is preparation of the plastic center portion 104 . Place a rectangular piece of plastic material 104 evenly over the centrally disposed full size oval cut 142 as shown in FIG. 4C (step 4 ). Measure 1 inch outward from the upper boundary 144 , the lower boundary 146 , the right lateral boundary 148 a , and the left lateral boundary 148 b of the oval shaped opening 142 to mark the dashed rectangle having sides 150 (upper), 152 (lower), 154 a (right), and 154 b (left), respectively, as depicted in FIG. 4C, and cutting the rectangular piece of plastic portion 104 at the designated markings 150 , 152 , 154 a , and 154 b to produce a smaller rectangular piece of plastic 104 .
[0054] As shown in FIG. 4D, place the cut smaller rectangular piece of plastic portion 104 over the oval shaped opening 142 , and making certain that there is a spacing of at least an inch of plastic portion 104 on each side of the oval shaped opening 142 . Marking the cloth material 102 at the straight edges 156 (upper), 158 (lower), 160 a (right), and 160 b (left), respectively, of the plastic portion 104 , so that the plastic portion 104 can be readily replaced after an adhesive such as glue is applied to the cloth material 102 . Next, place a mark at the center 162 of the piece of plastic portion 104 .
[0055] After radiating perforations or slits 164 have been made in the plastic portion 104 as shown in FIG. 4D, remove the plastic portion 104 from the cloth material 102 , and apply an adhesive to the area adjacent and outside the oval shaped opening 142 . Place the plastic portion 104 back over the oval 142 using the plastic portion's edge marks 156 , 158 , 160 a , and 160 b as a guide. The side of the cloth material 102 to which the plastic portion 104 is adhesively applied constitutes the bottom surface of the coverlet 100 .
[0056] In steps 5 and 6 illustrated in FIG. 4E, with the bottom surface 166 of the cloth material 102 up, fold each side 124 (upper), 126 a (right), 126 b (left), and 128 (lower) of the cloth material 102 over an inch.
[0057] Referring to FIG. 4F, unfold the cloth material 102 and place elastic cord 106 in the bend 168 of the fold 174 (FIG. 4E). Fold the cloth material 102 back over the elastic portion 106 , and place a pin 172 through the top 170 of the fold 174 to hold the elastic cord 106 in place as shown in FIG. 4F (step 7 ). Pin the cloth material 102 together with the elastic cord 106 still in the fold 174 . All four sides will have the elastic cord 106 enclosed.
[0058] Using an edger stitch machine, place the edge of material fold 176 under the machine's sewing foot, making certain that the elastic 106 is also under the sewing machine's foot, and stitch the edge of the material fold 176 and the elastic 106 together (step 8 ). It is critical to maintain the elastic 106 stretched during sewing. As one side 182 (right) is finished, sew past the end of the cloth material 102 . Repeat the procedure for the remaining sides 178 (upper edge), 180 (left side edge), 182 (right side edge), and 184 (lower edge) of the cloth material 102 . After sewing is completed, cut off any excess elastic cord 106 . The edger stitching automatically creates a ruffle and a tensioning of the borders of the coverlet 100 to secure to the container rim.
[0059] [0059]FIG. 5 is a top plan view illustrating the method for making the third embodiment, i.e., FIG. 2A, of the rectangular disposable coverlet 100 with an H-shaped perforation 188 . The third embodiment of the disposable coverlet 100 does not have a plastic portion 104 , and is made for a waste container 108 with a rectangular mouth or opening 110 . The first step in making the third embodiment of the disposable coverlet 100 is the perforation of the disposable coverlet 100 to form an H-shaped perforation. Two vertical and parallel perforations 186 (dashed lines) are made along the width of the cloth 102 beginning approximately 4 inches from the edges 124 (upper), 126 a (right) 126 b (left), and 128 (lower) of the cloth 102 as shown in FIG. Perforation 188 is then made horizontally down the center 190 of the cloth 102 connecting the vertical perforations 186 as depicted in FIG. 5. The remaining steps in the making of the third embodiment of disposable coverlet 100 are the same as steps 6 , 7 , and 8 in the making of the first embodiment of the disposable coverlet 100 .
[0060] [0060]FIG. 6A is a top view of the second embodiment of a disposable coverlet 100 for a cylindrical waste container 108 with a round mouth or opening 112 . The steps involved in making the second embodiment of the disposable coverlet 100 are the same as the steps in making the first embodiment of the disposable coverlet 100 except that a circular opening 192 is made in the cloth 102 , and a circular overlapping piece of radially perforated plastic portion 194 is sewn into the center of the cloth body 102 . An elastic cord 106 is sewn around the periphery of the cloth body 102 , and radial cuts 196 (dashed lines) are made to complete the coverlet 100 .
[0061] [0061]FIG. 6B is a top plan view of the fourth embodiment (FIG. 2B) of a heavy weight disposable coverlet 100 for a waste container 108 with a round mouth or opening 112 . The steps involved in making the fourth embodiment of the disposable coverlet 100 are the same as the steps in making the fourth embodiment (FIG. 2B) of the disposable coverlet 100 except that the radial perforations 196 do not have a plastic backing as shown in FIG. 6B.
[0062] The disposable coverlets of the present invention can be used in a wide variety of settings such as department stores, supermarkets, and office buildings. Hospitals and nursing homes would find the disposable coverlet to be extremely beneficial. The disposable coverlet is very effective in trapping unpleasant odors and in concealing unsightly waste container items, and the decorative exterior of the disposable coverlet enhances the decor of a room.
[0063] The preferred embodiments of the present invention disclosed herein are intended to be illustrative only and are not intended to limit the scope of the invention. It should be understood by those skilled in the art that various modifications and adaptations of the present invention as well as alternative embodiments of the present invention may be contemplated.
[0064] It is to be understood that the present invention is not limited to the sole embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | Disposable coverlets for waste containers having various cross-sections that trap unwanted odors and conceal the unsightly items in a waste container. The disposable coverlets are made of heavy interliner cloth material and have an elastic edge portion that ensures a snug fit over the mouth of the waste container. The disposable coverlet has perforations in the form of radiating slits or an H-shaped slit to form a decorative appearance making the coverlets both attractive and functional. The slits can be formed in an optional plastic layer attached to the coverlets. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. No. 13/090,596, filed Apr. 20, 2011, which is a continuation of Ser. No. 12/477,278, filed on Jun. 3, 2009, which issued as U.S. Pat. No. 8,001,569, which is a continuation of U.S. patent application Ser. No. 10/931,386, filed on Sep. 1, 2004, which issued as U.S. Pat. No. 7,559,073, which is a continuation of U.S. Ser. No. 09/429,057, filed on Oct. 29, 1999, now abandoned.
BACKGROUND
The invention relates to communicating ancillary information associated with a plurality of audio/video programs, such as television content associated with a plurality of channels.
Ancillary information, such as program sub-titles, emergency messages, closed caption messages, and program guide information, may be transmitted with regular television content. Other types of ancillary information that may be sent with television content include enhancement data such as web pages, multimedia information, or other digital data files. Ancillary information may be sent in the vertical blanking interval (VBI) of an analog television broadcast signal. Alternatively, the ancillary information may be sent with digital television content over a digital transport medium.
Various standards exist that provide for transmission of ancillary information with television content. One standard is the Advanced Television Enhancement Forum (ATVEF) Specification, Draft Version 1.1r26, dated Feb. 2, 1999. The ATVEF Specification is designed to provide for transmission of enhancement data along with television content in both analog and digital systems, such as cable systems, satellite systems, terrestrial systems, and so forth. The combination of the enhancement data and the television content may be referred to as enhanced television content. Enhanced television content provides more information and options to viewers. For example, a viewer may be presented with the option of viewing advertisements, educational information, and so forth, while watching regular television programming.
The transmission of ancillary information may be signified to the user by displaying an icon indicating that enhanced information accompanies the programming currently displayed. This alerts the user to the possibility that additional information is available but provides nothing useful to help the user decide whether or not the user wishes to review the information.
Thus there is a continuing need for better ways to give the user more information about the ancillary information that may have been transmitted with television content.
SUMMARY
In accordance with one aspect, a method may include transmitting video data. Ancillary information associated with the video data is also transmitted. Information may be transmitted that may be used to identify the content included in the ancillary information.
Other features and embodiments will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of one embodiment of an information delivery system in accordance with the present invention;
FIG. 2 is a block diagram of a transport operator system, receiving system, and server according to one embodiment of the information delivery system of FIG. 1 ;
FIG. 3 is a view of a screen display in accordance with one embodiment of the present invention;
FIG. 4 is a flow chart showing software resident on the content creator in accordance with one embodiment of the present invention; and
FIG. 5 is a flow chart showing software resident on a receiver in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1 , an information delivery system 10 according to one embodiment of the invention includes a content creator 12 , a transport operator system 14 , and a plurality of receivers 16 . The receivers 16 may be located at various receiving sites, including homes, offices, entertainment facilities, or other locations. The content creator 12 originates enhancement data (or other type of ancillary information) and television content (or other type of content including audio and/or video data) to be transmitted by the transport operator system 14 . Alternatively, the content creator 12 may create enhancement data with television content provided by another source to the transport operator system 14 . Enhancement data may include graphics (e.g., web pages, multimedia information, or other digital data files), presentation layout, and synchronization information. The combination of the enhancement data and television content is referred to as enhanced television content.
The transport operator system 14 provides an enhanced television content delivery infrastructure that may include terrestrial, cable, satellite, or other types of transmission facilities (either analog or digital). The television content and enhancement data may be transmitted over a transport medium 22 , which may be a terrestrial, cable, satellite, or other type of link, to the receivers 16 . The receivers 16 may include televisions, set-top boxes, personal computers, or other types of systems adapted to receive television content and associated enhancement data.
As used in this description, the term audio/video (A/V) content is intended to include any type of audio and/or video data that may be transmitted or distributed to one or more receiving sites for presentation to viewers and/or listeners. As used here, A/V content may refer to content that may include both an audio and a video portion or one of an audio or video portion. Further, ancillary information other than enhancement data may be transmitted with the A/V content. For example, ancillary information may include program sub-titles, emergency messages, closed caption messages, and program guide information.
The receivers 16 may further be coupled to a secondary link 20 that may be a data delivery communications channel such as the Internet, a DOCSIS network (which is an interface for cable modems), or other communications link (whether uni-directional or bi-directional). DOCSIS stands for Data Over Cable Systems Interface Specifications, and is described in DOCSIS, Version 1.0, dated March 1998, as provided by the International Telecommunication Union (ITU). The secondary link 20 may be coupled to the transport operator system 14 and/or to one or more servers 18 . According to some embodiments, portions of enhancement data associated with the A/V content transmitted over the transport medium 22 may be communicated over the secondary link 20 from the transport operator system 14 , the one or more servers 18 , or some combination of such systems.
In an alternate embodiment, another type of secondary data path can be part of the A/V transmission itself, but not tightly tied to a particular A/V channel. For instance, in MPEG-2 based systems such as ATSC (Advanced Television Systems Committee) or DVB (Digital Video Broadcasting), transport stream programs correspond to what is commonly thought of as TV channels. MPEG stands for Moving Picture Experts Group, and the MPEG-2 standard is described in ISO/IEC 13818-1 (MPEG-2 Systems), ISO/IEC 13818-2 (MPEG-2 Video) and ISO/IEC 13818-3 (MPEG-2 Audio), dated in 1994 and provided by the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC). A description of ATSC may be found in “Guide to the Use of the ATSC Digital Television Standard,” dated October 1995. DVB standards may be available from the web site {http://www.etsi.org}.
These transport stream programs can contain audio, video, and data (e.g., ancillary information), with all of them tightly associated with that single transport stream program. When a user tunes to the transport stream program, the receiving device knows the audio, video, and data that are associated because they are marked as all being part of the same program.
One standard for describing transmission of enhancement data with television content is the ATVEF specification, with one version described in ATVEF Specification, Draft Version 1.1r26, dated Feb. 2, 1999. Enhancement data may be transmitted in a number of different ways from the transport operator system 14 to the receivers 16 , depending on the type of transport medium 22 . For example, with an analog transport medium such as the National Television System Committee (NTSC) Standard of the Electronics Industries Association, portions of the enhancement data may be sent in the vertical blanking interval (VBI) of the NTSC transmission. A description of NTSC may be found in the book, “Video Demystified: A Handbook For the Digital Engineer” by Keith Jack, published by HighText Publications (2d Ed. 1996). Other types of transport media (analog or digital) may provide different mechanisms of communicating the enhancement data.
Enhancement data according to the ATVEF Specification may include enhancements each having the following components: an ATVEF announcement, a resource, and a trigger. The three components may be transmitted using Internet Protocol (IP) multicast to the receivers. An IP multicast standard is described in Request for Comment (RFC) 1301, entitled “Multicast Transport Protocol.” RFCs may be available at website address {http://www.ietf.org/rfc.html}.
Generally, an ATVEF announcement indicates that enhancement data is being transmitted, a resource includes one or more files that contain the enhancement data, and a trigger synchronizes the enhancement data with the TV transmission. An announcement may describe the location of both the resource stream and the trigger stream. For each television (TV) channel, one or more enhancements may be offered as choices presented to the user, who can select which of the enhancements, if any, to view. The ATVEF Specification may utilize a one-way transmission protocol (the Unidirectional Hypertext Transfer Protocol or UHTTP, described in the ATVEF Specification) to deliver resource data.
The announcements, resources, and triggers associated with an A/V channel may be delivered at about the same time as, and with the transmission of, the A/V content on that channel. Conventionally, for each enhancement, the resource stream may be delivered along with the announcement, with the resource stream stored locally in the receiver 16 . If a viewer so desires, the enhancement data can be retrieved at the receiver from local storage for viewing.
To provide for greater flexibility and/or to alleviate bandwidth concerns of the transport medium 22 , some embodiments of the invention transmit (using IP multicast) enhancement data associated with multiple A/V channels (e.g., TV channels) over a link that is separate from the transport medium used to transmit A/V content. Alternatively, the link may be part of the same delivery mechanism as the A/V content but is not associated with any A/V channel, e.g., an MPEG-2 transport stream with ancillary information in a data-only program separate from the A/V programs. The separate delivery mechanism to deliver the A/V content may be a separate transport stream or a separate link 20 such as a general purpose data link or some other type of communications link. Thus, according to some embodiments, enhancement data is separated from the A/V data at the transport operator system 14 (or alternatively, at another source), with the A/V content transmitted over the transport medium 22 and the enhancement data transmitted over the secondary link 20 (or a separate transport stream).
In the ensuing description, reference is made to receiving enhancement data received over the secondary link 20 ; however, it is contemplated that the enhancement data or other type of ancillary information may be received over a separate transport stream such as that used with MPEG-2 delivery systems. In addition, reference is made to tuning to a specific A/V channel (e.g., TV channel) at the receiving end. It is contemplated, however, that the receiver system can be tuning instead to one of the A/V transport stream programs in an MPEG-2 based systems.
Thus, generally, tuning to an A/V program may include tuning to A/V channels (e.g., TV channels), to transport stream programs (e.g., in an MPEG based system), or to other separations or segments of A/V content. Also, associating ancillary information with an A/V program can thus refer to associating ancillary information with an A/V channel, a transport stream program, or other A/V separations or segments.
Referring to FIG. 2 , the transport operator system 14 , receiving system 16 and the server 18 in the system 10 of FIG. 1 are illustrated. The transport operator system 14 may include a receiving port 102 to receive information from the content creator 12 over a link 24 . The received enhancement data may be provided to a controller 106 in the transport operator system 14 . A/V content may be received with the enhancement data through port 102 or through a separate A/V receive port (not shown). The controller 106 may be run under control of a software routine 108 (referred to as a transport routine). The transport routine 108 may initially be stored in a storage medium 104 and loaded by the controller 106 for execution. Instructions and data of the transport routine 108 may also be stored in the storage medium 104 . The controller 106 may create special announcements to be transmitted with enhancement data over a separate link (e.g., link 20 ). The enhancement data and special announcements may be stored in a storage medium 113 , which may be transmitted over the secondary link 20 through a transceiver 112 .
Alternatively, the enhancement data and special announcements may be transmitted over the transport medium 22 with the A/V content but in a separate transport stream program. In the latter embodiment, different parts of the transport routine 108 (or alternatively, different routines) may handle transmission of both the A/V content and the enhancement data and special announcements. The transceiver 112 may be a telephone modem, a cable modem, or any other type of analog or digital transceiver or transmitter, including a satellite transmitter, adapted to communicate over the secondary link 20 .
Enhancement data may be stored in a storage medium 126 in the server 18 in addition to, or instead of, the enhancement data stored in the transport operator system 14 . The server 18 further includes a transceiver 124 coupled to the secondary link 20 and a control device 128 . More than one server 18 may be coupled to the secondary link 20 to store additional enhancement data. Alternatively, a plurality of servers 18 may be coupled to the receivers 16 over separate links.
In the receiving system 16 , a receiver circuit 114 (e.g., a TV tuner card) is adapted to receive content over the transport medium 22 and a transceiver 116 is adapted to communicate over the secondary link 20 . The receiving circuit 114 may be associated with an A/V device driver routine 130 that forwards the received A/V content to application software adapted to process and present the A/V content in the receiving system. The transceiver 116 may be associated with a network device driver 132 to receive enhancement data from the link 20 .
In one embodiment, the network device driver 132 may send received data to a TCP/IP (Transmission Control Protocol/Internet Protocol) stack 134 . TCP is described in RFC 793, entitled “Transmission Control Protocol,” dated September 1991. Data flows through the TCP/IP stack 134 to application software, including an enhancement routine 138 for receiving and processing enhancement data and a special announcement routine (SA process) 136 to receive and process special announcements. In an alternative arrangement, the SA process 136 may be part of the enhancement application 138 . The application routines, device drivers, and other routines or programs may be executable on a controller 120 . Such routines or programs may be initially stored in a storage medium 118 and loaded by the controller 120 for execution. The SA process 136 is capable of associating enhancement data received over the secondary link 20 to the currently tuned A/V channel. The SA process 136 may then combine the associated enhancement data with the A/V content of the currently-tuned TV channel for presentation. Alternatively, the enhancement data and special announcements may arrive in a separate transport stream program (e.g., such as those in MPEG based systems) over the transport medium 22 , in which case it may be different parts of the SA routine 136 (or different routines) that process receipt of the enhancement data and A/V content.
Referring next to FIG. 3 , in accordance with one embodiment of the present invention, the user may be given information about the ancillary information that may have been transmitted with the television content. For example, in accordance with one embodiment of the present invention, a chevron-shaped indicator 32 may be displayed on the display 30 of a receiver 16 to indicate the transmission of ancillary information in general. An additional indicator 34 may be provided to give information about the particular type of content provided as ancillary information. Thus, the indicator 34 may be indicative of children's content. An additional indicator 36 may be provided to indicate that the children's content is available in Spanish. Additional indicators may be provided as well.
The indicators may provide information about the ancillary information, such as enhancement data, that has been provided with the television content. This gives the user greater information about the ancillary information, enabling the user to make an informed decision about whether or not to access the ancillary information. In some cases, the icons 32 , 34 , and 36 may be hyperlinks that allow the user to mouse click on the icon (or use another pointing device) and to jump immediately to the ancillary information.
Software 52 resident on the server 18 or content creator 12 , for example, may begin by receiving content to be transmitted as indicated in block 54 of FIG. 4 . Next, as indicated in block 56 , the content creator receives the ancillary information that is to be transmitted in association with the content previously received. Based on the content of the ancillary information, an icon locator is developed as indicated in block 58 . The icon locator provides a pointer to the location of information about a content-identifying icon. The icon may be a graphical symbol that indicates the nature of all or part of the content in the ancillary information. Finally, the content, the ancillary information, and the icon locator are transmitted through the transport operator 14 to the receivers 16 (block 60 ).
FIG. 5 illustrates implementing one embodiment of the present invention. Software 40 , resident on a receiver 16 , begins by receiving an announcement stream as indicated in block 42 . The announcement stream is parsed to locate an icon locator, as indicated in block 44 .
The icon locator may take a variety of forms. In one embodiment of the present invention, the icon locator may be a uniform resource locator (URL). The URL may point to an Internet web address containing information about a suitable icon that may be displayed to provide the user with information about the content contained within the ancillary information. Alternatively, the URL may point to a location in the transmitted ancillary information that may be utilized to access and then display a suitable icon.
Alternatively, a local identifier (LID) may be provided. Particularly where the information is not necessarily available on an on-demand basis, a local identifier or LID may be utilized to provide a name for a resource such as a content-identifying icon. The use of a LID supports cross-references within the content to the resource. The LID may be useful in creating hyperlinks or embedding one piece of content in another. The LID scheme enables content creators to assign unique identifiers to each resource relative to a given name space.
Thus, the LID may be utilized to access the icon information repeatedly. Once the icon has been stored on the receiver and is identified through the LID, it can be called up repeatedly and used over and over again. For example, in one embodiment of the present invention, the receiver may be loaded with a plurality of content-identifying icon images before those images are actually needed. The icon code for one of those icons may be sent with an announcement stream that identifies the icon already on the receiver.
A LID or URL may be transmitted as part of a trigger. Triggers are real time events delivered for enhanced television programs. A receiver may set its own policy for allowing users to enable or disable enhanced television content and triggers may be utilized as a signal to notify users of enhanced content availability. Triggers generally include a URL and may optionally also include a human readable name, an expiration date, and script. The expiration date in connection with triggers utilized to announce the arrival of a particular type of content may provide for a limited duration of display of the icon. For example, the expiration date may also cause the icon to disappear and reappear periodically.
In some embodiments of the present invention, the user may select from among a plurality of pre-received icons that identify content that the user is interested in knowing about. Other icons may be left unselected. When information of a type corresponding to a selected icon is received, the pre-selected icon may be displayed.
In accordance with one embodiment of the present invention, the announcement stream may include script that causes a transparent overlay to be produced over the display image on the display 30 of a receiver 16 . The transparent overlay may include one or more icons to identify the content that accompanies the enhanced television content. In one embodiment of the invention, a plurality of icons indicating available content may be displayed alternately.
Thus, returning to FIG. 5 , after the icon locator has been parsed, the icon information may be accessed (block 46 ) either from the local system or from the Internet as two examples. One or more icons are then displayed as indicated in block 48 . If an expiration time was transmitted with the trigger data, a check at diamond 50 determines whether the expiration time has occurred. If so, the flow ends. Otherwise, the icon persists.
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | A system communicates video information including television content associated with a plurality of channels and ancillary information. Information may be transmitted with the ancillary information that is indicative of the type of content included in the ancillary information. This provides the user, in one embodiment of the present invention, with a visual indication of the type of information that accompanies television content. This helps the user to decide whether the user wishes to view the ancillary information and provides the opportunity to select that enhancement for viewing. | 7 |
This is a division of application Ser. No. 615,297, filed Sept. 22, 1975 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a catalyst for use in partially oxidizing hydrocarbons to hydrogen and carbon monoxide.
2. Description of the Prior Art
Processes for partially oxidizing hydrocarbons such as naphtha, gasoline, heavy oil and the like are known as partial oxidation processes, i.e., partial combustion processes for hydrocarbons. Hydrogen and carbon monoxide produced in these processes are used as starting gases in ammonia synthesis, methanol synthesis, oxo synthesis and the like as town gas or as fuel for internal combustion engines such as those of motor vehicles.
In the past, partial oxidation of hydrocarbons has been carried out by bringing hydrocarbons into reaction with air or oxygen at a high temperature.
Conventionally, nickel and cobalt catalysts have been used for such partial oxidations. However, such catalysts have drawbacks in that their catalytic activities are impaired in quite a short period of time of service. This occurs because (1) carbon is deposited on the catalysts during the reaction and (2) spinels are produced due to the reaction of the catalytic element, such as nickel or cobalt, with a carrier such as alumina or the like supporting the catalytic element. Consequently, there is a need for a catalyst free from these disadvantages.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a catalyst and a process for partially oxidizing hydrocarbons to hydrogen and carbon monoxide which are highly efficient.
It is another object of this invention to provide a catalyst having high activity and high durability.
It is still another object of this invention to provide a catalyst which does not cause deposition of carbon during the reaction.
It is a further object of this invention to provide a process for achieving a high conversion rate for oxidation of hydrocarbons even at an extremely high space velocity.
It is a still further object of this invention to provide a process for achieving a high conversion rate for oxidation of hydrocarbons in a wide range of excess air ratios.
Briefly, these and other objects of this invention, as will hereinafter be made clear from the ensuing discussion, have been attained by providing a catalyst for partially oxidizing hydrocarbons to hydrogen and carbon monoxide which consists essentially of rhodium and a process for partially oxidizing a hydrocarbon to hydrogen and carbon monoxide, comprising forming a gas mixture of the hydrocarbons and an oxidizer, and contacting said gas mixture with a catalyst consisting essentially of rhodium at an elevated temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily attained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying Drawings, wherein:
FIG. 1 and FIG. 2 are plots showing the relationship between amounts of hydrogen and carbon monoxide, respectively produced, and the excess air ratio in Example 2;
FIG. 3 is a plot depicting the relationship between the amount of gas produced, and the LHSV (liquid hourly space velocity); and
FIG. 4 is a plot showing the relationship between the amount of hydrogen produced and the ratio of steam added.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to avoiding the aforesaid drawbacks of the prior art catalysts by providing catalysts which afford a high conversion rate. The superior features of the present invention reside in the use of rhodium as the catalytic element for partially oxidizing hydrocarbons.
The catalysts of the present invention enable the partial oxidation of hydrocarbons at a high conversion rate without causing deposition of carbon and without producing spinels due to the reaction of the catalytic elements with the carrier. In addition, the catalysts achieve a high conversion rate even at extremely high space velocities, thereby enabling a highly efficient partial oxidation.
The catalysts of the present invention include rhodium as the catalytic element. Rhodium exhibits consistent activity either in the form of a metal or in the form of an oxide. In this respect, rhodium may be used alone as the catalyst, for example, in the form of a screen of metallic rhodium. Since rhodium is expensive but has high activity, it is preferred, as is the case with general catalysts, that rhodium be supported on a carrier having, for example, a granular form or a honeycomb structure. Suitable such carriers are α-alumina, γ-alumina, α-alumina-magnesia, zirconia and the like. It is preferred that the amount of metallic rhodium to be supported on the carrier be in the range of 0.005% to 1.0% by weight. If the rhodium content is less than 0.005% by weight, a lowering in the catalytic activity results, thereby presenting the possibility of carbon depositing on the catalyst because of the attendant need to use a high temperature for the partial oxidation. On the other hand, when the rhodium content is greater than 1.0% by weight, there is no corresponding increase in the catalytic activity, even when the content is increased by a considerable degree.
Upon partial oxidation of hydrocarbons by using the catalyst of the present invention, the primary starting material hydrocarbon is first vaporized. Thereafter, air is added as an oxidizer, followed by mixing. The mixture obtained is then fed to a layer of catalyst maintained at a high temperature. As a result, the hydrocarbon is partially oxidized by the oxygen contained in the air, so that the hydrocarbon is primarily converted into hydrogen and carbon monoxide with a small amount of methane. Suitable hydrocarbons for use in this invention include heavy oil, fuel oil, naphtha, light oil, kerosene, gasoline, propane and the like. It is preferred that the reaction temperature at the catalyst bed at the time of the partial oxidation be in the range of 690° to 900° C. If the temperature is less than 690° C, there results insufficient conversion of the hydrocarbon into hydrogen and carbon monoxide, thereby failing to produce a yield of over 80%. On the other hand, if the temperature is greater than 900° C, thermal decomposition ensues producing ethylene or acetylene, thereby lowering the conversion efficiency of the hydrocarbon into hydrogen and carbon monoxide.
The amount of air used relative to the amount of hydrocarbon should provide an excess air ratio in the range of 0.34 to 0.51. The excess air ratio A/A o is the ratio of the amount of air (A) used in the reaction to the amount of air (A o ) which is required for the complete combustion of the hydrocarbon. If this ratio is less than 0.34, the desired partial oxidation will not be achieved. On the other hand, if the mixing ratio is greater than 0.51, there results a lowering in the yield of hydrogen and carbon monoxide.
The space velocity of the partial oxidation should preferably range from 0.5 to 25 l/hour in terms of "LHSV", the "Liquid Hourly Space Velocity", i.e., the liquid equivalent quantity (cc) of hydrocarbon passing through a catalyst bed of unit capacity (cc) in an hour. A space velocity of less than 0.5 l/hour yields an impractical conversion rate which is too small. On the other hand, a space velocity of greater than 25 results in incomplete partial oxidation, making possible a lower yield.
It is preferable to use air as the oxidizer from the viewpoint of economy. However, air may be substituted by an oxidizer which is abundant in oxygen such as oxygen or a mixture of oxygen and air. Air and/or oxygen mixed with steam may also be used as an oxidizer. In this case, the steam is decomposed by the catalyst so that the hydrogen of the water molecule is converted to hydrogen gas, while the oxygen serves as the oxidizer for the hydrocarbon. Furthermore, steam also serves the purpose of a coolant when the temperature of the catalyst bed reaches an abnormally high temperature. The quantity of steam to be added should preferably be not more than 0.5 by volume relative to the volume of the liquid hydrocarbon, in terms of the equivalent amount of water. In the case of steam addition, if the quantity of steam is increased, the quantity of hydrogen obtained due to the partial oxidation will also be increased accordingly. On the other hand, the yield of carbon monoxide will remain substantially constant in spite of the additional steam. When steam is added coupled with air for the partial oxidation, the catalyst temperature, excess air ratio, and LHSV should preferably have values which are the same as those for the case when air is used alone.
Having generally described the invention, a more complete understanding can be obtained by reference to certain specific Examples, which are provided for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
The hydrocarbon, gasoline was subjected to partial oxidation by using air with the aid of a rhodium catalyst according to the present invention. In addition, a prior art nickel catalyst and cobalt catalyst were used in the partial oxidation for comparison purposes.
More particularly, 100 cc samples of spherical γ-alumina catalyst carriers (diameter about 3 mm, surface area 140 m 2 /g, packing density 0.72 g/cc), were immersed for one hour at room temperature in 100 cc of rhodium chloride solutions each having three different concentrations. The alumina was then removed from the solutions and baked at 800° C for three hours after drying for 20 hours at 110° C. Thereby, three different rhodium catalysts were prepared.
The rhodium catalysts thus obtained were filled into a tubular quartz converter having an inner diameter of about 30 mm. The catalyst bed was heated to 600° C. A mixed gas of commercially available gasoline (of average composition C 7 H 10 .8) and air was fed to the catalyst bed for partial oxidation. The compositions of the converted gases were measured. Gasoline was gasified at about 250° C beforehand, and the gas was mixed with air. An excess air ratio of 0.41 (air fuel ratio of 6.0) and an LHSV of 2 l/hour were used. The catalyst bed at the time of the partial oxidation was maintained at about 700° C reaction temperature. The term "air fuel ratio" as used herein is the ratio of the amount (by weight) of air to the amount of gasoline (by weight). The excess air ratio is obtained by dividing the air fuel ratio by the theoretical air fuel ratio (14.7 in the case of gasoline in this Example).
The amounts of rhodium supported on the carrier and the results of the partial oxidation are given in Table 1. In addition, the results of the partial oxidation by using a prior art nickel catalyst and a cobalt catalyst are also given in Table 1. The latter two catalysts were prepared under the same conditions as for the rhodium catalyst, by subjecting the same to immersion, drying and baking and by using aqueous solutions in which 25% by weight of nickel nitrate or cobalt nitrate was dissolved.
TABLE 1__________________________________________________________________________ Amount of ChangeCatalystCatalytic element loaded Composition of gas converted (%) rateNo. element (wt.%) H.sub.2 CO CH.sub.4 N.sub.2 Others (%)__________________________________________________________________________1 Rh 0.05 16.5 18.3 1.5 54 9.7 100 Present invention2 " 0.12 19.0 21.0 1.4 51 7.6 1003 " 0.2 19.5 22.0 1.0 50 7.5 100C.sub.1Ni 7 10.0 12.2 1.8 63 13.0 90 Comparative examplesC.sub.2Co 7 7.0 8.3 1.2 67 16.5 80__________________________________________________________________________
In Table 1, "others" denotes gases of C 2 compounds such as ethylene, ethane and the like, plus carbon dioxide and steam. The term "change rate" denotes the percentage of gasoline changed to materials other than gasoline. The term "Amount of element loaded" is defined as the ratio of the amount of rhodium to the amount of carrier by weight.
Table 2 shows the amount (l) of gas produced per unit amount (cc) of starting liquid gasoline for hydrogen, carbon monoxide and methane as given in Table 1. The values of those amounts refer to the volumes at 20° C.
Table 2 also indicates the yields of hydrogen and carbon monoxide. The term "yield" as used herein is the amount actually obtained relative to the theoretical amount which would be obtained if the gasoline were completely converted into hydrogen and carbon monoxide. The theoretical amount of hydrogen is 0.93 (l/gasoline cc), while that of carbon monoxide is 1.2 (l/gasoline cc).
TABLE 2______________________________________ Amount of gas produced Yield (l/gasoline cc) (%)Catalyst No. H.sub.2 CO CH.sub.4 H.sub.2 CO______________________________________1 0.77 0.97 0.10 83 812 0.88 1.12 0.10 95 943 0.89 1.15 0.10 96 96C.sub.1 0.33 0.43 0.07 36 36C.sub.2 0.28 0.35 0.06 30 29______________________________________
As can be seen from Tables 1 and 2, the catalysts of the present invention exhibit high conversion rates and extremely high yields of hydrogen and carbon monoxide even when only a small amount of catalytic element is supported as compared to the prior art catalysts. Furthermore, no deposition of carbon was observed during the use of the catalysts of the present invention.
EXAMPLE 2
Gasoline was subjected to partial oxidation at varying excess air ratios (or air fuel ratios) and at varying catalyst temperatures, using a rhodium catalyst containing 0.12% by weight of rhodium. The amounts of hydrogen and carbon monoxide were measured.
The LHSV was 2 l/hour and the starting gasoline was of the same composition as used in Example 1. The partial oxidation was carried out in such a manner that the catalyst layer was heated to 400°, 500° or 600° C beforehand, and then a mixture gas of gasoline and air was fed to each catalyst bed.
FIG. 1 indicates the results of the measurements of hydrogen, while FIG. 2 indicates those of the measurements of carbon monoxide. In FIGS. 1 and 2, the excess air ratio (or air fuel ratio) is represented by the abscissa, while the amount of hydrogen or carbon monoxide produced (l/gasoline cc) is represented by the ordinate. The curves 1 and 1', 2 and 2', and 3 and 3' indicate the amounts of the gases produced at preheating temperatures of 400° C, at 500° C, and 600° C, respectively. The reference numerals such as 690, 700 and the like denoted on the curves of FIG. 1 represent the catalyst temperatures at the time of the partial oxidations under the aforesaid conditions. The catalyst temperatures are omitted from FIG. 2, since these temperatures correspond to those of FIG. 1. For instance, for an excess air ratio of 0.41 and a catalyst preheating temperature of 500° C (curve 2' in FIG. 2), the catalyst temperature is 700° C. FIG. 1 illustrates that, for example, with an excess air ratio of 0.41 (air fuel ratio of 6.0) and a catalyst preheating temperature of 500° C (curve 2), the catalyst temperature is 700° C and the amount of hydrogen produced is 0.76 l/gasoline cc. In this case, the yield of hydrogen is 0.76 × 100/0.93 = 82%.
As is clear from FIGS. 1 and 2, large amounts of gases are produced showing that high yields can be obtained throughout a wide range of excess air ratios. On the other hand, in order to obtain a yield of over 80% for hydrogen (0.93 × 0.8 = 0.744 l/gasoline cc and above), it is necessary that the catalyst temperature be above 690° C and the excess air ratio be in the range of about 0.34 to 0.51. Similarly, for obtaining a yield of over 80% for carbon monoxide (1.2 × 0.8 = 0.96 l/gasoline cc and above), the same conditions as above are required.
EXAMPLE 3
The partial oxidation was carried out using an excess air ratio of 0.41 (air fuel ratio of 6.0) and a catalyst temperature of 725° C while varying the LHSV and using the catalysts and gasoline of Example 2. The amounts of hydrogen, carbon monoxide and methane produced were measured.
In FIG. 3, LHSV (l/hour) is represented on the abscissa, while the amounts of gases measured (l/gasoline cc) are represented by the ordinate. In FIG. 3, curves 4, 5, and 6 represent the respective amounts of hydrogen, carbon monoxide and methane.
As can be seen from FIG. 3, substantially consistent high yields, such as 97% for hydrogen and 95% for carbon monoxide, are obtained throughout a wide range of LHSV. Such high yields are possible even at LHSV as high as 20. The fact that such a high yield can be achieved at such a high LHSV suggests an extremely high production rate, demonstrating the excellence of the catalysts of the present invention. If LHSV 20 is represented in terms of a space velocity of a mixture gas of air and gasoline, there results a value as high as 75,000 l/hour.
In addition, it can be seen that there is produced only a small amount of methane as a byproduct, even over a wide range of variation in LHSV.
EXAMPLE 4
The partial oxidation was carried out by adding steam to a mixture of air and gasoline using the catalysts and gasoline of Example 2. Catalyst temperatures of 700° or 800° C and an LHSV of 2 l/hour were used. The addition of steam was such that the excess air ratio was first set at 0.41 (air fuel ratio 6.0); the amount of air was gradually reduced; and the amount of oxygen contained in the mixture gas, which had been reduced due to the decrease in the amount of air, was compensated for by the oxygen contained in steam. For instance, when the excess air ratio was reduced by 0.1, i.e., the air fuel ratio was reduced by 1.4, the amount of steam to be fed was 0.22 cc/gasoline cc. in terms of the water equivalent amount.
FIG. 4 shows the results of the partial oxidation in which the ratio of steam added (i.e., the amount of water (cc) added relative to 1 cc of liquid gasoline) is represented by the abscissa, while the amount of hydrogen produced (l/gasoline cc) is represented by the ordinate. Lines 7 and 8 show the results for catalyst temperatures of 700° and 800° C, respectively. The line T represents the theoretical amount of hydrogen, assuming that the hydrogen contained in the hydrocarbon and steam molecules was all converted to hydrogen gas. The amounts of the water and gasoline are values calculated at 20° C.
The amount of carbon monoxide produced in the aforesaid partial oxidation falls in the range of 1.00 to 1.05 l/gasoline cc, irrespective of the ratio of steam added and the catalyst temperature. The yield thereof ranges from 83 to 87%.
As can be seen from FIG. 4, the yield of hydrogen can be increased by the addition of steam. (This is based on a comparison of the case wherein steam is added, with the case wherein steam is absent, as shown by point 0 in FIG. 4.) The catalyst temperature of 800° C results in a yield of hydrogen as high as about 93%. Although the catalyst temperature of 700° C results in a decrease in the yield of hydrogen with an increase in the ratio of steam added, a yield of about 80% for hydrogen is still achieved even when the ratio of steam added is 0.4. Furthermore, if the ratio of steam added is 0.35, there can be achieved an increase in hydrogen yield, such as of about 45% at 800° C and about 25% at 700° C, in contrast to the case where steam is absent.
On the other hand, a yield of carbon monoxide as high as about 85% can be achieved, irrespective of the ratios of steam added.
EXAMPLE 5
The partial oxidation was carried out by using a rhodium catalyst (amount of rhodium loaded, 0.12%) of the present invention under the same conditions as in Example 1, with naphtha used as the hydrocarbon.
The naphtha used had an average composition of C 7 H 14 .4, a density of 0.68 g/cm 3 , an octane number of 60.0, and a vapor pressure of 0.69 kg/cm 2 (at 20° C).
As a result, there were obtained a yield of 96% for hydrogen and a yield of 95% for carbon monoxide, the change rate of naphtha being 100%.
EXAMPLE 6
Columnar granules of zirconia (diameter about 3 mm, length 3 mm, surface area 50 m 2 /g, packing density 1.9 g/cc) were used as a carrier. The catalysts of the present invention were prepared as in Example 1, in which the amount of rhodium loaded was 0.05%.
Subsequently, the partial oxidation was carried out for gasoline of the same composition as used in Example 1, using an excess air ratio of 0.41 (air fuel ratio 6.0), an LHSV 2, and a catalyst temperature of 725° C.
As a result, a yield of 98% was obtained for hydrogen, and a yield of 85% was achieved for carbon monoxide.
EXAMPLE 7
Catalysts of the present invention, in which the amount of rhodium loaded is 0.1%, were prepared in the same manner as in Example 1, by using a honeycomb carrier of α-alumina-magnesia. The carrier used had a water absorbing rate of 40%, while the honeycomb structure had square holes (1.5 × 1.5 mm) and a wall thickness of about 0.4 mm. Meanwhile, when rhodium was supported on the carrier, an alcohol solution of rhodium chloride was used to uniformly support rhodium on the honeycomb structure.
Subsequently, the partial oxidation was carried out under the same conditions as in Example 6, except for using a catalyst temperature of 820° C.
As a result, a yield of 98% was achieved for hydrogen, and a yield of 98% was achieved for carbon monoxide.
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein. | A catalyst and a process for partially oxidizing hydrocarbons to hydrogen and carbon monoxide is provided. The catalyst consists essentially of rhodium, the rhodium being usually supported on a carrier. In the process, a mixture gas of a hydrocarbon such as naptha, gasoline and propane and an oxidizer such as air and/or oxygen is contacted with the rhodium catalyst at an elevated temperature. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/045,062, filed on Apr. 15, 2008, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention is directed to methods and apparatus to inject high energy density substances into subterranean environments where they react. More specifically, this invention is directed to methods and apparatus to inject high energy density fluids like reactive mono-propellants and other hypergolic fluids into subterranean environments through wellbores into the earth.
BACKGROUND OF THE INVENTION
[0003] When a fluid, such as oil and natural gas, is being produced from a subterranean reservoir through a wellbore the reservoir's ability to produce such fluids is often enhanced by processes that inject fluids and solids from the surface through a wellbore into subterranean reservoirs. There is one field of work that uses these fluids and is known to those familiar with the art of oil and gas production as stimulation fluids or hydraulic fracturing fluid, and the process involving these fluids is often referred to as hydraulic fracturing job or stimulation job. It is commonly believed that fracturing the subterranean rock in the reservoir will enhance hydrocarbon production from the well. This is accomplished by pumping the fluids at very high pressures that are greater than the fracture pressure of the subterranean reservoir, thus cracking the rock.
[0004] In early days explosives like nitroglycerin were dropped in wells to break up, crack, or otherwise stimulate the subterranean rock to produce fluids. These explosives had the limitation of only cracking the rock near the wellbore. Therefore, the idea of extending the fractures and cracks in the rocks far afield from the wellbore was developed using the injection of high pressure hydraulic fracturing fluids. The fluids injected as stimulation or fracture fluids are often mixed at surface with a variety of chemicals and solids prior to injection. Many fluid types are used including freshwater, saltwater, nitrogen, carbon dioxide, hydrogen peroxide, monopropellants, hydrogen fluoride, acids, bases, surfactants, alcohols, diesel, propane, liquid natural gas, with many combinations of these fluids and many more fluids. Some of these fluids are blended with solids like sand, bauxite, ceramic proppants, propellants, proppants, and/or catalysts and the fluid and solids are pumped as a slurry into the wellbore and reservoir rocks.
[0005] There are further chemicals and fluids mixed at the surface and injected with stimulation processes like acid stimulation jobs or steam injection stimulations to improve the reservoir's ability to produce back the injected stimulation fluids to surface and enhance the reservoir production of hydrocarbon fluids. This is because the stimulation fluids remaining in the rock matrix of the subterranean reservoir or the chemicals transported by the fluids reduce the reservoirs ability to produce commercial hydrocarbon fluids. Additionally, those familiar with the art of stimulation or fracture technology in the oil and gas industry often mix at surface viscosifier agents and/or cross-linkers to the stimulation fluid, enhancing the fluid's ability to transport solids into the reservoirs. What is needed is a method and apparatus to add large amounts of heat generated inside the well during well stimulation as opposed to generating heat at surface and transporting the heat down the well.
[0006] Further, current industry practice of adding to stimulation fluids chemicals such as hydroxypropyl guars, polyacryl imides, and cellulose gelling agents reduces the hydraulic friction between the fluids being pumped and the well conduits that transport the fluids from surface to the subterranean reservoir. These are often referred to as friction reducer chemicals. As the oil and gas industry continues to find more gas and oil in lower permeability rocks, and in ever lower pressured “resource plays,” like shale gas and coal bed methane, shale oil, and tar sands, it becomes ever more important to find substances to pump into the reservoir rock to enhance the hydrocarbon production by reducing the detrimental effects of the chemicals added for friction reduction.
[0007] Moreover, there is a problem with these methods when the fluids, particularly water, are produced back from the wells because they must be treated to re-use in subsequent wells or safely and environmentally disposed. There are many detrimental issues with this produced back fluid. For example, while flowing back from the subterranean environment, injected fluids containing friction reduction chemicals, gelling agents, scale inhibitors surfactants, crosslinkers, and hydrogen sulfide gas often contain bacteria that feed on the gels and poly acrylimdes and thus are not suitable for surface disposal or re-injection into subsequent wells during a subsequent stimulation, enhanced oil recovery method, or hydraulic fracture treatment. In the case of hydrogen sulfide gas production while flowing fluids from the wells, the ability to neutralize and treat this gas in the wellbore system would be a great improvement over the current art of flowing to facilities where the hydrogen sulfide (H 2 S) gas is stripped out with various ammine solutions. Moreover, the lack of water resources in areas of large hydrocarbon recovery restricts the use of water as a treatment fluid.
[0008] Before the current invention, methods to enhance production of hydrocarbons from wells used by those familiar with the art of treating stimulation fluids mixed friction reducers, gelling agents, cross linkers, and/or surfactants into water at surface prior to injecting the fluid and chemicals down a well casing or tubing. These chemicals are typically batch mixed into the stimulation fluids to be injected at the surface into large holding tanks, known as frac tanks, or the chemicals are added “on the fly” at surface to the stimulation or fracture fluid by injecting them into the discharge of a large centrifugal pump at the surface. The mixed fluid is then pumped through high pressure pumps and injected into the well and the reservoir at very high pressures and normally high injection rates thereby exceeding the fracture pressure of the reservoir rock. Hence the stimulation or rock fracturing is largely done with hydraulic forces.
[0009] This process, often referred to as “hydraulic fracturing,” is thought to crack or break the subterranean rock in the reservoir giving the reservoir more conductivity for the production of reservoir fluids like oil and gas. The objective is to put as much energy out away from the wellbore into the formation rock well beyond the wellbore to crack rock far field from the wellbore thereby improving the fluid conduction path from the far afield rock to the wellbore. Using current methods the hydraulic energy is highest at the wellbore where the stimulation or fracture chemicals enter into the well, and the energy available to crack and stimulate becomes progressively less as the stimulation and fracture fluids travel out beyond the wellbore. The typical method of treating heavy oil, tar sands, and depleted light oil reservoirs is to heat fresh water into steam and inject the steam into the wellbore once again concentrating most of the energy injected into the reservoir rock to near the wellbore. This stimulation or enhanced oil recovery method requires large amounts of fresh water, and the process loses considerable amounts of the heat energy in the transportation of the steam from surface to the subterranean environment.
[0010] A still further method of fracturing or stimulating subterranean rock reservoirs or stimulating subterranean reservoirs has been the dropping of explosives into the wells or injecting liquid and solid propellants, like nitroglycerin, dynamite and high grades of hydrogen peroxide, directly into reservoir rock. Hydrogen peroxide is known to decompose into hot water and oxygen in many reservoir rocks where the rocks act as a catalyst for the decomposition and no oxygen is required. The problem with this method is the very rapid and uncontrolled decomposition rate of hydrogen peroxide near the wellbore and the unpredictability of the reactivity of the reservoir rock as a catalyst.
[0011] It is desirable to use fluids with large chemical energy storage that do not require an oxygen environment to combust or decompose so that more chemical energy is available in the subterranean environment and may be placed far underground and far afield from the wellbore out into the reservoir to stimulate the subterranean reservoir with energy other than solely hydraulic energy, like heat and the expanding products of the fluids combustion and decomposition in the presence of catalyst, ignitors, and geothermal temperatures.
[0012] When a fluid, such as oil and natural gas, is being produced from a subterranean reservoir the reservoir energy depletes with time. It has been found that by the injection of certain fluids from the surface such as, nitrogen, water, steam, carbon dioxide, flue gas, air, and combinations of these fluids into a depleted or mature hydrocarbon reservoir the production of hydrocarbons from the depleted reservoir can be enhanced. There is one field of work that uses these fluids and is known to those familiar with the art of oil and gas production as Enhanced Oil Recovery, EOR. It is also known that the injection of heat can greatly enhance the injected fluid's ability to recover hydrocarbons from the depleted or mature reservoirs. This is particularly the case in “steam floods” and “steam assisted gravity drainage methods”, known as SAGD to those in the field of EOR, which uses injected steam from the surface but suffer from the heat loss as the steam is injected from surface and heat is lost along the length of the well and the surface pipe infrastructure in a field thereby delivering less heat energy to the subterranean reservoir. What is needed is a method to generate heat in-situ.
[0013] It has been found that by the injection of certain fluids like air, natural gas, oxygen, and combinations of these fluids into a depleted or mature hydrocarbon reservoir the production of hydrocarbons from the depleted reservoir can be enhanced by igniting the oil, natural gas, coal, tar sand, shale oil, shale gas, or kerogen located in-situ in the reservoir. The field of work that uses these burning fluids is known to those familiar with the art of oil and gas production as Fire Flooding or In-Situ retorting. It is known that the placement of heat in-situ can greatly enhance the fuel in-situ to ignite. This is particularly the case in tar sands and shale oil reservoirs. What is needed is a method to generate heat in-situ in the reservoir as far from the wellbore as possible with ignitable fluids or with fluids that will assist in the ignition of the in-situ reservoir fluids.
[0014] Additionally, enhanced oil recovery projects, in-situ retorting of shale oil, fire floods, and fracture and stimulation treatments are often performed in parts of the world that have high ambient surface temperatures, where the use of explosive and reactive fluids like hydrogen peroxide becomes more dangerous as these fluids become more reactive as their temperature increases at surface. Likewise, enhanced oil recovery projects, in-situ retorting, fire floods, fracture, and stimulation treatments are often performed in parts of the world that have low surface temperatures, such that the reactive fluids like hydrogen peroxide might freeze, rendering them unpumpable. Currently, when using water as the work fluid this cold condition is easily resolved by heating the working fluid, e.g. water, with heat exchangers for stimulation or EOR projects. The methods to maintain the temperatures on the surface of highly reactive mono-propellants for example is not currently available. What is needed are methods and apparatus to allow for the temperature control of high energy density fluids to allow them to be injected safely at well sites into wells.
[0015] For example currently, a hot oiler truck comes to the well that is to be stimulated with water fracture based fluids and, by burning propane on the truck's heat exchangers and passing the working fluid to be pumped into the well, the truck heats up the working fluid on the truck such that heated fluid passes through heat exchangers on the truck and at the same time passes the working fluid, usually water, to be used for the stimulation treatment over the truck's heat exchanger and then re-circulates the fracture treatment water back to a heated holding tank. In this way the fracture treatment water is heated in cold weather such that it can be pumped and does not get solid on the surface. However, this heating method of pumping the fluids into a heat exchanger on a truck that is burning propane is exceedingly dangerous when the fluids to be pumped are mono-propellants like hydrogen peroxide or hydrazine.
[0016] A still further need to transmit large amount of energy beyond the wellbore in an interval is known to those familiar with the art of enhanced oil recovery, EOR, and in-situ retorting of hydrocarbons. This need to get energy out into the subterranean reservoirs beyond the wellbore can also be extended to the new and evolving field of enhanced gas recovery, EGR, and fluid sequestering like CO2. In both EOR and EGR, there is a need to get energy down wellbores and out into the reservoir. Indeed, the method of horizontal wells for steam flooding was developed to allow the steam energy to contact larger portions of the subterranean reservoir.
[0017] A still further method of enhanced oil recovery, or indeed subterranean in-situ retorting of oil is to place large heaters in the earth to heat hydrocarbons and kerogens such that they can be produced from the subterranean intervals. Subterranean heaters, however, cannot heat large areas of the subterranean reservoir far afield from the wellbore because the heater is located in wellbore and the earth is a great heat sink. To improve the heating of the subterranean reservoir, one must drill either a large number of heater wells and add exceeding large amounts of heat in these wells from surface or drill very expensive and long horizontal wells in which heaters are placed. In all cases the desire is to get energy, and in the case of enhanced oil and gas recovery, heat energy large distances from the wellbore. In the case of oil shale, the immense amount of heat needed to remove the oil from the shale is not cost effective, hence a method is needed to ignite and to feed oxygen to the oil shale, using the in-situ generated heat from the combustion of some of the oil shale or kerogen to heat the oil shale reservoir. However, getting oxygen to the oil shale is not easy due to the shale's low inherent permeability which makes the injection of oxygen into the rock away from the wellbore very difficult. What is needed is a fluid that can heat the rock, ignite in the rock, and deliver oxygen to the rock while assisting in the burning of in-situ fluids.
[0018] What is needed is a method to transmit large amounts of energy beyond the wellbore in a subterranean interval being stimulated to enhance oil or gas production. A further need is to accomplish this far field from the injection wellbore for enhancement effect in the subterranean reservoir with substances that will not reduce the permeability of the reservoir or otherwise inhibit the reservoir to produce fluids back to the wellbore and to the surface. A further need is to reduce the environmental damage done on the surface of the earth and sea by the flow back to surface of stimulation and fracture fluids containing chemicals and bacteria. A still further need is to have available methods and apparatuses to safely handle and control the rate of reaction of reactive fluids and solids such as propellants, catalyst, and fuels pumped into subterranean environments like reservoir rocks at outdoor well sites that may have cold and hot surface environments. Many wells are located in locations on the earth where the surface temperatures are below the sublimation temperatures of many reactive mono-propellant fluids like hydrogen peroxide or hydrazine. What is needed is a method to keep these reactive high energy density substances, like liquid propellants, from freezing at well sites with cold surface temperatures.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention is directed to new methods and apparatuses to treat subterranean reservoirs through wellbores with reactive high energy density substances. This invention teaches methods and apparatuses that allow substances such as mono-propellants, oxidizers, catalysts, and fuels to be injected into subterranean environments to release large amounts of energy into the subterranean environment by controlling their temperature, thus allowing these fluids to be injected safely.
[0020] In one aspect of the present invention, surface vessels, conduits, and/or pumps are designed to perform a process that maintains the highly reactive substances and their transport fluids in a low reactive state by controlling their temperature while at surface.
[0021] In a further aspect of the present invention highly reactive high energy density substances are frozen into solid form and mixed into cold fluids to allow the solid substances to be delivered to a well site, pumped and transported as a slurry into the well and out into the reservoir with the transport fluids that keep the substances cold. The invention further teaches methods to blend the substances with fuels, oxidizers, mono-propellants, and catalysts at low temperatures to keep the blend in a low reaction state.
[0022] In another aspect of the present invention highly reactive high energy density fluids are heated, and monitored to maintain them in a liquid state on surface at a well site where cold surface environment temperatures are below the propellants freezing point, to allow the propellant to be pumped as a liquid into the well.
[0023] In a still further aspect of the present invention a method is presented to form solid reactive materials from liquid reactive materials using cold solids to seed the formation of the reactive fluids.
[0024] In a still further aspect of the present invention a method is presented to ignite highly reactive high energy density fluids in a down hole reaction chamber connected to a coiled tubing thereby directing said fluids to be pumped from an appropriately temperature controlled surface storage vessel, through surface lines, through a coiled tubing string disposed in a well through a wellhead sealing pack off elastomeric device with a reaction chamber on the coiled tubing distal end that atomizes high energy density fluid and ignites the fluid allowing the coiled tubing to articulate in the well bore the position of the reaction chamber while pumping the fluid from surface thereby releasing heat and or decomposition products from the reaction chamber into the subterranean environment.
[0025] In a still further aspect of the present invention a method is presented to provide energy to a subterranean environment by directing a reactive high energy density fluid from a surface storage vessel (that is optionally temperature controlled), through surface lines, through a conduit such as a coiled tubing string disposed in a wellbore, and into the wellbore where the fluid decomposes or reacts. In some embodiments, upon exiting the conduit, the fluid enters a down hole reaction chamber connected to the conduit. In the reaction chamber, the high energy density fluid is ignited, and may atomized to assist in ignition. The reaction chamber can have a one-way valve that allows the fluid and/or reaction/decomposition products to exit the chamber and enter the formation, but prevents flow in the reverse direction.
[0026] The method can include reciprocating the reaction chamber (such as by reciprocating the conduit) to release heat or reaction/decomposition products along a length of the wellbore. At or near the wellhead, the conduit can be directed through an appropriate pack off elastomeric device to provide a seal.
[0027] In another aspect, a method is provided for the in situ treatment of hydrogen sulfide, comprising pumping a reactant that reacts with hydrogen sulfide to produce desirable products such as elemental sulfur into a wellbore via a stainless steel (as opposed to carbon steel) conduit and reacting the reactant with the hydrogen sulfide to produce desirable products. In some embodiments, the reactant comprises hydrogen peroxide and the product comprises elemental sulfur.
[0028] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the 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 of hydrocarbon production enhancement from wells that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures and methods for carrying out well hydrocarbon production enhancement. For example the well production enhancement for enhanced oil recovery, in-situ processing of shale oil, coal, coal bed methane, shale gas, and tar sands, as well as other well enhancement fields, can use the methods and apparatuses of this invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0030] FIG. 1 is a schematic showing the well site and equipment of the present invention;
[0031] FIG. 2 is a schematic of the well site and equipment of the present invention;
[0032] FIG. 3 is a schematic of an apparatus used to ignite monopropellants in a subterranean environment in a reaction chamber attached to a stainless steel coiled tubing while reciprocating the reaction chamber; and,
[0033] FIG. 4 is a schematic of hydrogen sulfide gas sweetened in-situ.
DETAILED DESCRIPTION OF THE INVENTION
[0034] As used herein, “a” or “an” means one or more. Unless otherwise indicated, the singular contains the plural and the plural contains the singular.
[0035] In many aspects and embodiments, the present invention uses reactive high energy density substances that can deliver a relatively high amount of energy per unit weight. Examples of such substances include 10% hydrogen peroxide, 100% hydrogen peroxide, hydrazine mixtures, and other substances.
[0036] In the embodiment of FIG. 1 , tank 1 holds a reactive fluid 50 and has shroud 3 located around inner tank 2 . Many reactive fluids may be used, including but not limited to hydrogen peroxide, hydrazine, monopropellants, hydrogen fluoride, hypergolic fluids (i.e., combustible without an ignition source), acids, bases, alcohols, diesel, propane, liquid natural gas, and combinations thereof. The reactive fluid 50 is preferably stored, monitored, and temperature controlled inside inner tank 2 . Located inside tank shroud 3 are heat exchanger tubes 4 connected to a heat exchanger 5 , which is preferably outside reactive fluid tank 1 . Heat exchange tubes 4 are also located inside inner tank 2 . The heat exchange permits safe temperature control of a reactive fluid, preferably cooling it to a temperature to retard its reactivity, but keeping it above a temperature such that it can be pumped into the well. This allows a reactive fluid to be introduced to a well in a activity-reduced state so that it can be directed to the outer parts of the reservoir 28 before reacting completely. In some embodiments, temperature control is required to heat the reactive fluid, such as when the ambient temperature would freeze the fluid to a point where it cannot be pumped.
[0037] In one embodiment, heat exchanger fan 6 blows air across heat exchanger tubes 4 in heat exchanger 5 , and is driven by prime mover 7 . Other means of heat exchange are also in the scope of this invention. In one embodiment, the tank shroud 3 is filled with a suitable fluid, and heat exchanger tubes 4 are submersed in the reactive fluid. The reactive fluid is enclosed by shrouds filled with dilution fluids like water that allows for dilution of the reactive fluid in the event of a leak. In one embodiment, the fluid filling tank shroud 3 is water, and for convenience this disclosure may refer to water. Of course, other fluids can be used that provide either heat exchange or safety via dilution, or preferably, both. Heat exchanger 5 , tank 1 , inner tank 2 , shroud 3 , and tubes 4 are not limited to the geometries, orientations, or structure disclosed in the FIG. 1 and FIG. 2 , but rather can be any form suitable for the objects of this invention.
[0038] The water in shroud 3 can be circulated from water tank 10 through pump 11 with the water returning from tank shroud 3 to water tank 10 . In one embodiment, tank 1 can be instrumented with temperature monitoring sensors 8 , and in one embodiment the sensors are optical fibers 8 , disposed inside tubes 4 and tubes 9 located inside tank 1 , both in tank shroud 3 and inside inner tank 2 . Optical fibers 8 can be used as temperature sensors themselves and are preferably monitored with an Optical Time Domain Reflectometer machine (“OTDR”) 12 that launches light down the fibers and interprets the backscatter light back to the machine to give continual distributed temperature profiles from the optical fibers 8 . This device is often referred to as an OTDR Distributive Temperature System (“OTDR DTS”). Additionally, the circulation of water from tank 10 through tank 1 in shroud 3 allows for an even heat to be maintained in the reactive fluid inside inner tank 2 . Thus, FIG. 1 shows the adding or removing of heat from the reactive fluid using a heat transfer fluid in tank 1 . Additionally, FIG. 1 shows the continuously monitoring of the temperature of shroud 3 and fluid inside inner tank 2 . For example, monitoring the temperature using optical fibers 8 interrogated with OTDR DTS machine 12 .
[0039] The embodiment of FIG. 1 has a hot oiler truck 13 that can heat the water in tank 10 , but other heating systems can be used. The hot oiler truck puts energy, Q in , into the system. The water can be transferred from the tank 10 through suction line 14 by pump 15 . The water is heated in hot oil truck 13 by burning propane on the truck and passing the water from tank 10 across the hot heat exchangers of truck 13 and then returning the heated water to tank 10 . The heated water from tank 10 can then be transferred to tank 1 through pump 11 and line 16 . The water from tank 1 is returned to tank 10 through line 17 to water tank 10 . Temperature sensors such as optical fibers 18 can monitor the temperature in tank 10 via methods such as an OTDR DTS machine 12 . Thus, the reactive fluid is indirectly heated by hot oil truck 13 using the fluid from tank, 10 which increases the safety of the temperature control process.
[0040] Thus FIG. 1 demonstrates how heat can be added to or removed from the reactive fluid 50 in tank 1 by using heat exchanger tubes 4 from the water in tank 10 . In some cases, the water in tank 10 is heated from the heat exchanger on truck 13 . The temperature of shroud 3 and the fluid inside inner tank 2 can be monitored continuously using temperature sensors, such as optical fibers interrogated with an OTDR DTS machine 12 .
[0041] The embodiment in FIG. 1 shows a reactive fluid being transferred from tank 1 where the reactive fluid 50 is stored and maintained at a temperature sufficiently above its solid temperature to allow transport downhole but sufficiently below a temperature such that its action is reduced. In one embodiment, the chilled reactive fluid travels through injection pump 19 through a shrouded suction conduit 16 A, which has water or other fluid circulated inside its shroud from water tank 10 . Water is delivered to shroud of conduit 16 A, via pump 11 and water line 16 , and the water returns from the shroud through line 17 .
[0042] In one embodiment, pump 19 is enclosed in shroud 20 , which may use fluid from tank 10 in a manner similar to other shrouds described above. Pump 19 is powered by any known means, but preferably by hydraulic power pack 21 and controlled remotely from a frac van 22 with hydraulic controls via hydraulic control line 23 . Hydraulic control pack 21 is powered by prime mover 24 that is preferably monitored and controlled remotely from the frac van 22 by hydraulic control line 25 . The use of hydraulic power increases safety when working with reactive fluids.
[0043] Injection pump 19 pressurizes the reactive fluid and the substances from tank 1 and injects them into (preferably shrouded) high pressure conduit 26 for injection into well 27 and out into subterranean reservoirs 28 . In a manner similar to other shrouds described, shrouded high pressure conduit 26 can have water supplied from tank 10 via pump 11 and line 29 , and water is returned to water tank 10 through line 34 . In one embodiment, wellhead 30 is shrouded with wellhead shroud 20 , which receives a fluid such as water from tank 10 through line 29 A, and the fluid returns to tank 10 through line 31 .
[0044] Thus FIG. 1 demonstrates how a temperature controlled reactive fluid is transferred from a temperature controlled tank and injected into well 27 and into subterranean reservoirs 28 . The water and other fluids in the shrouded conduits and pumps maintains the high pressure reactive fluid at a desirable temperature and maintains a means to capture and dilute any reactive fluid that may leak out from the inner high pressure conduit. In some embodiments, shrouds will serve to cool the reactive fluid, while in other embodiments they will serve to heat the reactive fluid. Thus, a reactive fluid is maintained at a proper temperature in a surface vessel located at a well site, tank 1 , and the reactive fluid is then injected at the desirable temperature into well 27 to allow the injected reactive fluid and substances to reach the subterranean reservoirs 28 in a low reactive state, thereby allowing the reactive fluid to be injected far afield beyond the wellbore, 40 , before the fluid and the substances react and release chemical energy. The position beyond the wellbore is shown in FIG. 1 as element 40 .
[0045] In one embodiment, the temperature of the reactive fluid is continually monitored in the well using at least one temperature sensor such as optical fiber 32 using the OTDR DTS machine 12 . Thus, FIG. 1 shows an exemplary embodiment that illustrates that the down hole temperature of an injected reactive fluid can be controlled from surface by adding or removing heat at surface from the fluid in tank 1 through the heat exchanger 5 . It is clear to those familiar with the art of well treatment that multiple injection pumps 19 can be used to inject reactive fluid from multiple reactive fluid tanks 1 and the temperature controlled by multiple heat exchangers 5 and injected through multiple surface shrouded conduit lines 26 into single well 27 allowing higher injection rates into subterranean reservoirs 28 .
[0046] In another embodiment shown in FIG. 2 , a reactive fluid can be mixed with other materials in mixer 36 . In one embodiment, temperature controlled tank 1 holds a cold fluid, like liquid nitrogen or liquid CO 2 , which is delivered to blender vessel 36 through pump 35 . Tank 1 can be temperature controlled by any known manner. A reactive material, like solid 90% hydrogen peroxide, is transferred into blender vessel 36 from tank 33 and the materials from tank 1 and tank 33 are then mixed into a pumpable form, such as a slurry, in blender vessel 36 and injected into well 27 through high pressure injection pump 19 and far into the subterranean reservoirs.
[0047] In another embodiment a reactive fluid like hydrogen peroxide can transferred from tank 1 at a controlled temperature, and solids like sand, ceramics, bauxite, proppants, and/or catalyst, can be added from tank 33 through a pump 240 into blender vessel 36 . Other reactive fluids and solids can be used as are known in the art. In embodiments where the temperature of the fluid in vessel 36 is desired to be cold, solids from tank 33 are preferably cool or cold. The solids and reactive fluid are mixed and injected into the well 27 and out into the reservoir 28 . Thus, reactive fluids are delivered into the reservoir 28 at a low temperature, increasing the distance the reactive fluid can be placed beyond the wellbore, releasing energy into the far field of subterranean reservoir 28 .
[0048] In another embodiment a reactive fluid is transferred from tank 1 at a controlled temperature, and very cold solids can be added from tank 33 into blender vessel 36 . The solids preferably have a temperature lower than the freezing point of the reactive fluid from tank 1 , thereby causing the reactive fluid to freeze around and in the solids. The solids thusly coated with reactive fluid are pumped out of blending vessel 36 into well 27 and into the subterranean reservoirs 28 . Thus, reactive fluids are delivered into the reservoir 28 at a low temperature, greatly increasing the distance the reactive fluid can be placed beyond the wellbore, releasing energy into the far field of subterranean reservoir 28 .
[0049] For example, the fluid in blender vessel 36 is kept cool by adding cold fluids, such as, cryogenic fluids, liquid nitrogen, methanol, or water, from tank 38 through pump 39 to the shroud of vessel 36 . Heat can be removed from mixing vessel 36 in heat exchanger 5 . Likewise, if the surface environmental temperatures are lower than the reactive fluids freezing point, blender 36 can be heated via a shroud or other heat exchanging system, which receives fluid such as hot water from tank 38 . Hot oiler truck 13 can heat the water in tank 38 using the propane burners and a heat exchanger on hot oiler truck 13 . If desired, the slurry leaving blender vessel 36 can be further temperature controlled before well injection by adding or removing heat via a heat exchange fluid in tank 37 , which can be controlled in any known manner, preferably with hot oiler truck 13 when heat, Q IN , is required.
[0050] Once the injected fluid and solid warms up in the subterranean reservoir 28 and releases energy, Q out , e.g., by igniting, the in-situ energized fluid in the reservoir can be flowed back to the well surface through a line to a surface tank. This high temperature reaction in the reservoir and the reaction products will combine and further enhance the in-situ hydrocarbons' ability to flow from the well.
[0051] FIG. 3 shows a schematic of an apparatus used to ignite monopropellants in a subterranean environment in a reaction chamber attached to a stainless steel coiled tubing while reciprocating the reaction chamber. In FIG., the reaction chamber, 310 has an igniter, 302 , located in reaction chamber 310 and is connected to an electrical power transmission cable, 309 . The electrical power transmission cable is interwoven in the continuous coiled tubing and the cable is connected to a battery and/or capacitor, 301 . The battery and/or capacitor is positioned near the reaction chamber 310 . The coiled tubing, 307 , is lowered from a reeling device 311 or drum, through an elastomeric seal, 308 . The elastomeric seal is located at the surface and separates the surface environment from the subterranean well environment containing the reaction chamber. The reactor chamber 310 is positioned in the well, 312 , inside a well casing 306 . In one aspect of the present invention, the igniter 302 inside the reaction chamber 310 is powered using electrical power from a surface source 313 and/or a subterranean source 301 . Monopropellant fluid 315 is then pumped from a vessel 314 on surface with at least one pump 316 and the monopropellant fluid is transmitted through a swivel joint 317 and through the coiled tubing 309 on reel 311 . The fluid is then ejected from atomizers 303 located inside the reaction chamber 310 . Within the reaction chamber, 310 , the atomized fluid is ignited using the igniter 302 . The igniter is initiated using transmitted electrical power from the surface source 313 , and/or the down hole source 301 to the igniter. Once the monopropellant 315 is ignited in the reaction chamber, the combustion products 316 are transmitted out of the reaction chamber 310 into the well casing 306 along with the heat produced by the combustion reaction within the chamber. The elastomeric seal 308 allows for the reciprocation of the coiled tubing 309 from surface. The coiled tubing is reciprocated from the surface to the reaction chamber 310 inside the well 312 while simultaneously pumping the monopropellant 315 into the coiled tubing 307 . The coiled tubing is directed through the coiled tubing injector head 321 , the elastomeric seal 308 and into the well casing 306 . Also, the coiled tubing transports the electrical power to the igniter in the reaction chamber 310 . Another function of the coiled tubing is to dispose the combustion products 316 and to direct the heat into the surrounding subterranean reservoir 304 . While simultaneously flowing well fluids 318 from a subterranean reservoir 304 through perforations 305 , directing combustion products 316 to surface and igniting monopropellant fluids 315 in the reaction chamber 310 , the surface injector head 321 reciprocates the coiled tubing 309 in the well.
[0052] In FIG. 3 , a Optical Time Domain Reflectometry machine, 319 , directs light down an optical fiber 320 which is disposed in the coiled tubing 309 . Directing light from the source 319 into the optical fiber 320 and monitoring the back scatter light reflected back to the optical machine, a computer 319 uses algorithms to analyze the reflected light and to determine the temperature profile of the well. Since an optical fiber is used, the entire length of the optical fiber 320 is capable of being used as a sensor.
[0053] Now directing your attention to the FIG. 4 which illustrates hydrogen sulfide gas sweetened in-situ. In FIG. 4 , a stainless steel continuous tube, 401 , is disposed inside a production tubing 402 . The production tubing is also disposed in a well casing 403 . The well casing has a packer 404 located on the production tubing. This packer seals the well casing 403 above the packer 404 from fluids in the casing below the packer 404 . Hydrogen peroxide fluid 405 is disposed in a temperature controlled vessel 406 , and pumped into the stainless steel coiled tubing 401 . As the hydrogen peroxide is pumped into the stainless steel coiled tubing, hydrogen peroxide is forced out an injection valve 407 . This injection valve is located at the distal end of the coiled tubing 401 which provides a means for mixing the hydrogen peroxide 405 with hydrogen sulfide fluids 408 being produced in the subterranean reservoir. The mixing of the hydrogen peroxide with the hydrogen sulfide allows the subterranean hydrogen sulfide fluid being produced from the reservoir to react with the hydrogen peroxide fluid 405 being injected into the well 312 . As stated above, the hydrogen peroxide is injected through the coiled tubing 401 . This subterranean fluid mixing serves to remove hydrogen sulfide gas from the flowing well fluid 408 . Because the fluid is flowing, the reaction products resulting from the reaction of hydrogen peroxide 405 and the well fluids with hydrogen sulfide gas 408 flows to the surface and these products are directed out of the well into a flow line 409 at surface.
[0054] In another embodiment, at least one hypergolic component is pumped down a wellbore. In yet another embodiment, at least two hypergolic components are separately pumped down a wellbore released such that they will mix in the wellbore. For example, a first reactive substance such as hydrogen peroxide is pumped from the surface into the wellbore and reservoir using one conduit, and a second substance that will spontaneously ignite with the first substance, such as ammonia, is pumped from the surface into the wellbore and reservoir using a separate conduit. The two substances will mix in the wellbore and subterranean formation forming a hypergolic fluid. The substances may, in some embodiments, be temperature, pressure controlled, and/or shrouded as described in any one of the above embodiments.
[0055] In any of the embodiments, the containers and conduits can be made from any material known in the art, such as stainless steel. The containers and/or conduits can, if desired, be passivated, coated with films, chemical films, or metal oxides, and/or otherwise treated to enhance the overall process. If a surface is passivated, it is desirable to test the surface for passivation at various times. In some embodiments, pressure monitoring and/or testing is desired for certain containers and/or conduits.
[0056] In another embodiment, a method provides energy to a subterranean environment by directing a reactive high energy density fluid from a surface source (such as a temperature controlled vessel), through surface lines, through a conduit (such as a coiled tubing) disposed in a wellbore, and into the wellbore where the fluid decomposes, ignites, or reacts to form products that comprise elemental oxygen. The energy of this reaction heats the surrounding formation. In addition, the elemental oxygen product reacts with in situ hydrocarbons to propagate additional reactions into the formation, which can generate heat, decompose heavy hydrocarbons and kerogen into lighter hydrocarbons, and increase the productivity of the well.
[0057] In an another aspect of the present invention, acoustical and/or seismic energy is transmitted from the surface to the reaction chamber. This energy is used to ignite an explosive in the reaction chamber. In an alternate and/or specific example, acoustical energy is used to heat at least one element in the reaction chamber.
[0058] In some embodiments, upon exiting the conduit, the fluid enters a down hole reaction chamber connected to the conduit. In the reaction chamber, the high energy density fluid is ignited, and atomized to aid the ignition. The reaction chamber can have a one-way valve that allows the fluid and/or reaction/decomposition products to exit the chamber and enter the formation, but prevents flow in the reverse direction. In some cases, the method includes reciprocating the reaction chamber (such as by moving the conduit) to release heat or reaction/decomposition products along a length of the wellbore. At or near the wellhead, the conduit is directed through an appropriate pack off elastomeric device to provide a seal.
[0059] In another embodiment, a method is provided for the in situ treatment of hydrogen sulfide. Hydrogen sulfide is a dangerous chemical with many undesirable qualities. Hydrogen peroxide reacts with hydrogen sulfide to produce elemental sulfur and other products. Moreover, hydrogen peroxide reacts with or interacts with many materials found in oxides of metals and subterranean minerals, with a very reactive catalyst being iron oxide. Hence the injection or transport of hydrogen peroxide into wells with iron or carbon steel tubulars, frac lines, or well heads is highly dangerous, and becomes exceedingly dangerous as the percentage of active hydrogen peroxide is increased.
[0060] In some embodiments, the current method uses a stainless steel (as opposed to carbon steel) conduit to carry substances, such as hydrogen peroxide, that react with hydrogen sulfide to produce desirable products, such as elemental sulfur. The reactant is delivered into a wellbore via a stainless steel conduit, where it reacts with the hydrogen sulfide to produce desirable products. Thus, as fluids are produced back, they contain less (or no) harmful hydrogen sulfide, which increases safety and saves time and money because the need to treat the hydrogen sulfide is reduced or eliminated. In any or all of the embodiments, the conduit is a continuous conduit, meaning that it is not made up from repeated threaded joints.
[0061] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | The invention relates to methods and apparatuses for the subterranean injection of reactive substances like propellants into wellbores and subterranean reservoirs. These methods and apparatuses controls the temperature of a reactive substance for safe handling at surface and controls the decomposition rate of the substances in the subterranean environment. In addition, these methods and apparatuses provide a means for safe dilution of reactive fluids in the event of a leak or spillage of the reactive substance. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to vehicle mounted accessory supports and in particular to a removable upright stanchion assembly.
Operators of pickup trucks, vans, recreational vehicles and automobiles oftentimes, while operating the vehicle, are faced with the difficulty of supporting a liquid drink container in stable relation to the vehicle. Accordingly, a variety of assemblies have been developed to this end. Some of those assemblies of which Applicant is aware provide for shaped arm members which mount to the window, the window frame, the dashboard or the engine cowling.
Depending upon the assembly, some either mount in a temporary or in a permanent fashion. Temporary mount assemblies conventionally support a single drink container, whereas permanent mount assemblies are typically constructed to support a plurality of containers and other items. Permanent mount assemblies, however, can disadvantageously mar the vehicle's interior trim, when removed.
Operators of pickup trucks, who desire the convenience and advantages of permanent mount assemblies, but who occasionally may desire to seat two or more passengers in the vehicle cab, are presented with a further difficulty or limitation of cramped space constraints. This is especially the situation if the vehicle provides a cab design which accommodates only two to three persons, as opposed to a so called extended cab or crew cab design. Accordingly, such individuals are not able to utilize most available permanent mount platform assemblies.
In appreciation of the foregoing difficulties, Applicant has developed a removable stanchion assembly for supporting a number of accessory or convenience items relative to a vehicle operator, yet which is selectively removable from the vehicle when additional space is required.
SUMMARY OF INVENTION
It is therefore a primarY object of the present invention to provide a selectively detachable upright stanchion for supporting an accessory platform relative to a vehicle operator.
It is a further object of the invention to provide a coupler, including latch means for restraining the upright stanchion thereto and wherein the stanchion includes an attachment means for securing a drink container support thereto.
It is a further object of the invention to provide a plurality of accessory supports along the upright stanchion.
It is a still further object of the invention to provide an extensible stanchion.
Various of the foregoing objects and advantages are particularly achieved in a presently preferred construction wherein the vehicle coupler provides for a right angled vehicle mounting portion having a slip-coupler collar portion for restrainedly receiving an upright support stanchion. The stanchion can be of either a fixed-length or of an extensible construction and can be bent to a desired form. An attachment plate secured to the upper end of the stanchion facilitates mounting of a drink support platform or C.B. radio thereto.
Still other constructions, objects, advantages and distinctions of the invention will become more apparent hereinafter upon reference to the detailed description thereof with respect to the appended drawings. It is to be appreciated however that the following description is illustrative only of presently considered forms of the invention and should not be strictly limited or construed to the construction disclosed. Rather, the invention is to be interpreted within the spirit and scope of the following presented claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric drawing of the present accessory stanchion in mounted relation to a vehicle seat.
FIG. 2 shows an isometric exploded assembly drawing of the accessory stanchion.
FIG. 3 shows an alternative latchable, floor mounted assembly which includes an offset extensible upright stanchion.
FIG. 4 shows an alternative seat mountable coupler.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an isometric drawing is shown of the accessory stand 2 of the present invention in mounted relation to a bench-type seat 4. For such a mounting, the stand 2 is secured to an angle iron, primary frame member (not shown) which typically runs the length of the lower front face of the seat 4. FIG. 2, otherwise, shows an exploded isometric drawing of the stand 2.
With attention to these drawings, the stand is generally comprised of a coupler portion 6, a removable stanchion or column 8, and an accessory attachment plate 10. Secured to the top of the attachment plate 10 is a drink container support platform 12, which can be of a variety of constructions. For the platform 12 shown, an apertured rail 13 is provided which is vertically offset via spacers 15 to support a drink container in each aperture 17. Accordingly, the stand 2 serves to conveniently position the platform 12 and/or any other accessories, for example, a citizens band radio, mounted to the stand 2 within reach of a vehicle operator.
The stand 2 is particularly secured to the seat 4 at a right angled mounting bracket 14. The bracket 14 is welded to a flat base member 16 and includes a plurality of mounting holes 18 which align with holes formed in the seat frame. Bolts 20, washers 22 and nut fasteners 24, in turn, secure the bracket 14 to the seat 4.
Vertically projecting from a forward portion of the flat base 16 is a tubular collar 26 which has an inside diameter closely approximating the outside diameter of the upright stanchion 8. The stanchion 8 is removably mountable in slip fit relation within the collar 26. A stable, normally secure mounting is thus obtained for the stanchion 8.
Appreciating, however, the possibility of travel over rough terrain, the alternative stanchion construction of FIG. 3, which will be discussed in greater detail below, shows a stanchion 28 wherein alignable through holes 29 are provided in a collar 30 and the stanchion 28 and wherethrough a pin fastener 31 is mountable to restrain one to the other. A fastened stanchion 28 is also particularly desired where the stanchion 28 exhibits a circular cross sectional shape, as opposed to the square or rectangular cross sectional shape of FIGS. 1 and 2; and, whereby rotation is prevented.
In lieu of a restraint pin 31, it is to be further appreciated that a variety of spring biased detente assemblies can alternativelY be used, as well as various set screw and latch arrangements which can be positioned to secure the aligned stanchion 8 or 28 to the collar 26 or 30 through holes. Similarly, in lieu of a tubular collar 26, a solid peg of mating cross sectional shape might project from the base 16 to mount inside the bore of the stanchion 8.
With still further attention directed to FIG. 3, an alternative floor mounted assembly 32 is disclosed. This assembly can advantageously be employed in vehicles having so called "bucket" or single person seats which do not readily permit the mounting of a stand assembly 2 thereto. For such vehicles, the base comprises a flat plate 34 having radiused edges 36 which can be directly secured to the vehicle floor, again with bolt and nut fasteners 20, 24 or the like. The base 34, due to its radiused edges can be mounted over the driveshaft hump in most vehicle floors. A draw plate 38 is also provided in lieu of separate washers 22.
Slip mounting within the collar is the upright stanchion 28. The stanchion 28 is formed to include back-to-back bends 40 which serve to properly position the stanchion 28 relative to the vehicle occupant.
Although a fixed length stanchion most commonly would be used, such as in FIGS. 1 and 2, the stanchion 28 of FIG. 3 discloses an alternative, extensible arrangement having slide mounted upper and lower sections 42, 44 which include a plurality of alignable through holes 46. A spring biased pin fastener 48 mounts within the upper section 42 such that a pin portion 50 projects from the selected through hole 46. The pin 50 can thus be selectively positioned within one of the holes 46 of the lower section 44 and whereby the overall length is established.
Welded lastly to the uppermost end of either stanchion 8 or 28 is a flat, drilled weldment 52 whereat the accessorY platform 12 having a plurality of drink support apertures is mounted with appropriate fasteners 54.
Without the flexibility of the present stanchion assemblies 8 and 28, such holders 12 are predominantly restricted to vehicles with relatively open flat, dashboard mounting surfaces. The present stanchions 8 and 28, however, further enable mountings in a pick-up truck. They also permit the vehicle operator to remove the holder 28 when it is not required.
Various other accessory features of the present stanchions 2 and 28 are the inclusion one or more hooks 56 which are securable to the stanchions for receiving trash collection containers, supporting a hat, sunglasses or other paraphernalia without cluttering the surface of the dash board. Spring biased clips, such as used on clip boards may similarly be secured to the columns 8, 28 to support still other items. Moreover, electronic appliances such as CB radios or AM/FM radios can be mounted permanently to the stanchion.
FIG. 4 lastly disclose another coupler assembly 60 which is usable with late model pick-up trucks. The assembly 60 provides a plate 62 having an offset bend 64 which permits mounting the plate 62 to the bottom of a vehicle seat at provided holes 66. A tubular collar 68 project from the fore-end of the plate 62 to receive an appropriate stanchion 8, 28.
While the present invention has been described with respect to its presently preferred and variously considered alternative constructions and modifications, it is to be appreciated that still other constructions may suggest themselves to those of skill in the art. Accordingly, it is contemplated that the subject invention should be interpreted to include all those equivalent embodiments within the spirit and scope of the following claims. | Apparatus comprising a vehicle mounted support coupler, an upright stanchion and an accessory support platform. In combination, the stanchion is mountable to a vehicle chassis or seat for advantageously supporting accessory items relative to the operator, yet permitting selective removal when not required. Liquid drinks and sundry other items are supportable from the stand. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/437,142 filed on Dec. 30, 2002 incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] Titanium dioxide pigments are used in many applications. One particular application demanding light fastness is the use in paper incorporated into paper laminates for decorative applications.
[0003] In this application the titanium dioxide pigmented paper is saturated with a laminating resin and subjected to heat and pressure to produce a hard surface laminate in which oxygen is absent. The titanium dioxide on exposure to UV light tends to gray as the concentration of Ti2+ ions are produced without the continual conversion by air oxidation of the ions back to the Ti4+ state.
[0004] Many techniques have been employed to make a light fast titanium dioxide pigment from the use of a calcination step in the pigment manufacture to the use of redox couples such as Ce2+/Ce4+ to keep the titanium ion in the colorless 4+ oxidation state. But the use of such oxidation couples may lead to a yellowing of the titanium dioxide. Calcination on the other hand adds time and cost to pigment manufacture.
[0005] In the present invention the objective was to find a noncolor producing method by which titanium dioxide pigment could be light stabilized. This was achieved by a process of precipitating a single layer coating of alumina phosphate on the surface of a titanium dioxide starting pigment. The product produced by the present process proved to be water dispersible and to exhibit a high retention in the paper making process.
[0006] Prior art methods of making a light fast titanium dioxide include U.S. Pat. Nos. 5,976,237; 5,785,748; 5,665,466; 4,400,365; and 3,853,575.
[0007] U.S. Pat. No. 5,976,237 to Halko et al. teaches a process for making durable pigments for plastics that may include a treatment step including a compound which is a source of P 2 O 5 . The Halko process requires that the pigment surface is first treated with alumina and silica and optionally another oxide such as a source of P 2 O 5 .
[0008] U.S. Pat. No. 5,785,748 to Banford et al. teaches the use of a prepared reagent that is a mixture of an aluminum compound and phosphoric acid prepared under heating. The source of the aluminum compound must be one that will dissolve in phosphoric acid. The aluminum compound is dissolved and the solution is clear, the mixture is diluted and added to a slurry of the titanium dioxide starting pigment. The pH is then adjusted to about 3.5 to 5 to precipitate the treatment on the pigment surface. For improved light fastness, a compound believed to be an oxidizing agent, such as potassium iodate, copper sulfate or potassium nitrate, is added in the process.
[0009] U.S. Pat. No. 5,665,466 to Guez et al. teaches a process for making a titanium dioxide of at least two layers. The first layer is an aluminum phosphate layer and the second is an aluminum oxide layer. The pigment is characterized by a positive zeta potential at high pH to ensure high physicochemical retention of the pigment in the paper.
[0010] U.S. Pat. No. 4,400,365 to Haacke et al. teaches a combination of aluminum and zinc phosphates as a means to increase titanium dioxide lightfastness, and U.S. Pat. No. 4,052,224 teaches a treatment of using compounds of phosphorus, aluminum, zirconium, titanium and silica to increase light fastness.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention is a process for making a water dispersible titanium dioxide pigment comprising:
(a) mixing dry titanium dioxide pigment with water to form a mixture having a pigment concentration of from about 14 to 40 weight percent based on the weight of the mixture then adjusting the pH of this mixture to about 7 with aqueous sodium hydroxide; (b) heating the mixture from step (a) to a temperature of about 40° C.; (c) adding to the mixture from step (a) simultaneously and at a rate such that the pH of the resulting mixture is maintained at about 7 throughout this step (c) from about 0.15 to 0.65 moles of phosphoric acid per kilogram of dry pigment and at least a portion of sodium aluminate aqueous solution required to react with the phosphoric acid to form aluminum phosphate; (d) adding any remaining aqueous sodium aluminate solution required to react with unreacted phosphoric acid added in step (c) to complete the formation of aluminum phosphate simultaneously with a solution of hydrochloric acid wherein the rate of addition of aluminate solution and that of the acid solution is adjusted so that that the pH of the resulting mixture from and in this step (d) is maintained in a range from 5 to 8; and (e) curing the mixture from step (d) for from about 10 to 30 minutes.
[0017] In step (c) of the present invention, the addition of aqueous sodium aluminate may be made so that the ratio of the moles of phosphorous added to the moles of aluminum added is from about 0.2 to 0.9; but it is more preferred to make the addition in step (c) of aqueous sodium aluminate is made so that the ratio of the moles of phosphorous added to the moles of aluminum added is from about 0.25 to 0.6, and most preferred that the addition of aqueous sodium aluminate is made so that the ratio of the moles of phosphorous added to the moles of aluminum added is about 0.5.
[0018] In the present invention, the amount of phosphoric acid added in step (c) may be from about 0.23 to 0.52 moles per kilogram of pigment; but is more preferred that the amount of phosphoric acid added in step (c) is about 0.40 moles per kilogram of pigment, and most preferred that the amount of phosphoric acid added in step (c) is about 0.44.
[0019] The present process may be varied and achieve the same result if in place of step (c), (i) first adding the phosphoric acid solution to the mixture from step (a) without the simultaneous addition of aqueous sodium aluminate, and then (ii) adding the solution of the sodium aluminate in an amount sufficient to raise the pH of the mixture from step (i) to a pH of about 7.
[0020] More particularly, the present process produces a light fast titanium dioxide pigment consisting of titanium dioxide and a single layer of inorganic surface treatment consisting of aluminum phosphate wherein the pigment is characterized by an isoelectric point which is greater than pH 6 and a negative zeta potential, for example, less than negative 20 mV, at a pH of 7.5 or more, from a rutile or anatase starting pigment particle. This pigment is characterized by an isoelectric point from about pH 5.4 to 6.7 and a zeta potential at pH=9.0 of less than negative 40 mV. Typically, the zeta potential at pH=9.0 is from negative 40 to negative 150. Preferably, the zeta potential at pH=9.0 is from negative 40 to negative 60. The starting pigment particles may be raw pigment, that is, a pigment particle has had no wet treatments applied to its surface before treatment according to the present invention, or the starting pigment particles may have undergone wet treatment. It is preferred that the starting pigment particle be raw pigment. If the starting pigment particles have undergone wet treatment, the wet treatment will typically involve treatments to provide metal oxide coatings on the particle surfaces. Examples of metal oxide coatings include alumina, silica, and zirconia. Recycled pigment may also be used as the starting pigment particles, where recycled pigment is pigment after wet treatment of insufficient quality to be sold as coated pigment. The present invention also relates to a titanium dioxide pigment consisting of titanium dioxide and single layer of inorganic surface treatment consisting of aluminum phosphate wherein the pigment is characterized by an isoelectric point which is greater than pH 6 and a negative zeta potential of less than negative 20 mV at a pH of 7.5 or more made by a process comprising:
(a) mixing dry titanium dioxide pigment with water to form a mixture having a pigment concentration of from about 14 to 40 weight percent based on the weight of the mixture then adjusting the pH of this mixture to about 7 with aqueous sodium hydroxide; (b) heating the mixture from step (a) to a temperature of about 40° C.; (c) adding to the mixture from step (a) simultaneously and at a rate such that the pH of the resulting mixture is maintained at about 7 throughout this step (c) from about 0.15 to 0.65 moles of phosphoric acid per kilogram of dry pigment and at least a portion of sodium aluminate aqueous solution required to react with the phosphoric acid to form aluminum phosphate; (d) adding any remaining aqueous sodium aluminate solution required to react with unreacted phosphoric acid added in step (c) to complete the formation of aluminum phosphate simultaneously with a solution of hydrochloric acid wherein the rate of addition of aluminate solution and that of the acid solution is adjusted so that that the pH of the resulting mixture from and in this step (d) is maintained in a range from 5 to 8; and (e) curing the mixture from step (d) for from about 10 to 30 minutes.
[0026] In the present invention it is preferred that following step (e) the mixture is filtered and the pigment recovered and washed and dried then fluid energy milled, i.e., micronized at a temperature of from 200° C. and above.
[0027] Pigment made according to the present invention is preferred for use in laminate papers and paper laminates.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention provides a titanium dioxide pigment for use in making paper laminates. Titanium dioxide pigment made according to the present invention forms a stable slurry of up to 80% by weight pigment through the use of pH adjustment alone without the addition of chemical dispersants, thus simplifying the slurry composition and reducing the cost of making the slurry. Typically, the slurries of the present invention will contain 30 to 80%, more preferably, 50 to 80%, and most preferably 70-80% by weight pigment. Stable slurries of the pigment of the present invention require a pH of just slightly more than 7.0 and typically about 7.8 for slurries having 80% by weight pigment. Pigment of the present invention is characterized by a large negative zeta potential at high pH. The pigment exhibits an isoelectric point less than about pH 6.2.
[0029] In the process of making paper laminates, laminate papers are made which usually contain titanium dioxide as an agent to enhance paper opacity and brightness. The titanium dioxide is first blended with water and dispersants such as citric acid, Rohm and Haas's Tamol brand dispersants or acidic dispersants to form a slurry. This slurry is then added to the furnace to be converted into paper. Pigment of the present invention may be loaded into the slurry at much higher concentrations than are currently available to paper makers. This is the case without incurring the cost or the need for adding a dispersant to the slurry.
[0030] The pigment surface treatment of the present invention ranges in composition from about 2.0-4% by weight P reported as P 2 O 5 and about 4 to 6% by weight Al reported as Al 2 O 3 . More preferred is a composition from about 2.5-3.2% by weight P reported as P 2 O 5 and about 4.6-5.4% by weight Al reported as Al 2 O 3 . The pigment of this invention has a negative zeta potential for example, less than negative 20 mV, at a pH of 7.5 or more. This pigment is characterized by an isoelectric point from about pH 5.4 to 6.7 and a zeta potential at pH=9.0 of less than negative 40 mV. Typically, the zeta potential at pH=9.0 is from negative 40 to negative 150. Preferably, the zeta potential at pH=9.0 is from negative 40 to negative 60.
[0031] Pigment according to the present invention may be made as follows:
[0032] 1. Prepare a slurry of titanium dioxide in water by mixing 4 parts titanium dioxide by weight on a dry basis and adjust the pH of this slurry to 7 using sodium hydroxide. The amount of water in the slurry is not critical so long as it is fluid enough to provide good mixing as the treatment agents are added. For example, in a chloride titanium dioxide manufacturing process, oxidation reactor discharge slurry may be used as the slurry for treatment.
[0033] 2. The additional materials required for the treatment are 2.05 parts of 85% by weight phosphoric acid, 6.66 parts of sodium aluminate solution at a concentration of 400 g per liter, and hydrochloric acid at a concentration of from 10-40% percent by weight HCl.
[0034] 3. Heat the slurry from step 1, to about 40° C.
[0035] 4. Simultaneously add the phosphoric acid and sodium aluminate solution at a rate to maintain the slurry pH at about 7 until all 2.05 parts of the phosphoric acid have been added to the slurry.
[0036] 5. Simultaneously add the remaining sodium aluminate solution (the remainder of 6.66 parts) and the hydrochloric acid at such rates that the pH of the slurry from step 4 is maintained at 7. Continue this addition until all 6.66 parts of the sodium aluminate has been added.
[0037] 6. Stir the mixture from step 5 for from 10 to 30 minutes.
[0038] Step 4 above may be accomplished alternatively by first adding all the required phosphoric acid (in this case 2.05 parts) and then adding sodium aluminate solution until the pH of the mixture is raised to 7. Steps 5 and 6 are carried out as described above.
[0039] The pigment from this process is water dispersible requiring no addition other than pH adjustment in order to form stable slurries of up to 80% solids and shows excellent light fastness as tested according to methods used in testing raw material used in laminate papers and in paper laminates. The method of making the laminate papers or paper laminates is not critical in the performance of the pigment of the present invention. | The present invention relates to a process for making a titanium dioxide pigment having consisting of titanium dioxide and single layer of inorganic surface treatment consisting of aluminum phosphate wherein the pigment is characterized by and isoelectric point which is greater than pH 6 and a negative zeta potential of at a pH of 7.5 or more. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns an endoscopy capsule of the type having at least one magnetic element interacting with an external magnetic field for magnetic navigation of the endoscopy capsule.
[0003] 2. Description of the Prior Art
[0004] For examination of the gastrointestinal tract a flexible catheter endoscope is typically used that is inserted orally or rectally and is advanced. A disadvantage of this technique is that the catheter is relatively stiff since the feed force must be passed along it. Such a forward shifting of the catheter tip means that regions further removed from the body orifice can be difficult to reach or, respectively, cannot be reached at all. Catheter endoscopy is relatively uncomfortable for the patient, it can lead to complications such as an organ perforation (when it is pressed too strongly against an organ wall), and the manual operation for the physician is also relatively elaborate and complicated.
[0005] As an alternative to this, the use of an endoscopy capsule is known that moves actively by means of an integrated magnetic element that interacts with a magnetic field (generated external to the patient) acting on the capsule, and with which the magnetic element is moved through the examination subject, meaning that the magnetic capsule navigation ensues by remote control, for example by actuation of a joystick or a mouse or the like. It is advantageous that an extensive automation of the medical procedure is possible. The automation capability has essentially two bases: the magnetic force effect ensues directly on the capsule; the perforation danger thereby drops drastically, and the control or the force no longer ensues directly manually, but rather indirectly via the control of the coil currents of the external magnetic system. The endoscopy capsule thus can be designed differently. It can be purely a video capsule that exhibits an image acquisition device with which images of the inside of the hollow organ can be acquired and transferred via radio to an external acquisition or control device. For example, a biopsy forceps or another mechanical instrument can be provided at the capsule, with the biopsy forceps or another mechanical instrument being externally controlled via radio in order to extract tissue samples or the like. In each case images and other measurement values or operations can be acquired or made at arbitrary locations in the gastrointestinal tract in this manner.
[0006] A disadvantage of catheter-free capsule endoscopy is that only limited resources for working or operating means or electrical energy can be carried by the capsule. A small battery that delivers only limited power is integrated therein for operating electrical loads such as an image acquisition device or the biopsy forceps or an electrical valve that connects a gas reservoir in the capsule with a balloon. If used, a gas quantity for inflation of the balloon (which, for example, serves for vessel widening or for setting a stent) as well as a possible fluid quantity (that, for example, is necessary for lavaging the intestinal wall or the like) as well as the quantity of a medicine that is to be applied on site, can be provided only in small quantities.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide an endoscopy capsule that is no longer subject to the limitations described above that result from the limited carrying capability of working or operating means or from the limited power supply capacity.
[0008] This object is achieved in accordance with the invention by an endoscopy capsule of the aforementioned type equipped with a tube composed of a flexible and material, via which tube one or more fluid or gaseous operating or working agents can be supplied to the capsule, and/or in which at least one conductor serving for the signal and/or power line is directed to the capsule. As used herein, “non-rigid” means a rigidity that is insufficient to permit feed of the capsule to be done using the aforementioned tube.
[0009] The capsule is connected with external supply or feed devices via the thin, highly flexible supply tube, such that a continuous feed of necessary operating or working agents or a power feed is possible. The excellent navigability of the capsule with all of its advantages is retained; the capsule merely pulls the thin non-feed rigid tube behind it, which does not affect the mobility via the external magnetic field navigation device since the thin, highly flexible tube slides along the organ walls without further measures and can be pulled along through corresponding intestinal coils or the like without further measures. The tube, which preferably is formed of an inelastic (i.e. bendable but not expandable) material such as polypropylene or polytetrafluorethylene so that it does not elastically expand (for example given feed of a gaseous operating or working means) can be executed with very thin walls and very small in terms of diameter; a feed or, respectively, supply or, respectively, communication is nevertheless possible without further measures. The wall thickness of the tube can be between 0.1-0.5 mm (preferably 0.2 mm) while the outer diameter of the tube can be between 2-6 mm (in particular 3-4 mm). The own weight of the tube is extremely low and lies in the range of a few grams, even when the tube is executed very long. Lengths of more than 2 m are realizable without further measures; a length of up to 8 m is also conceivable, such that the tube can be drawn through the length of the entire gastrointestinal tract.
[0010] Two or more separate channels sealed off from one another are advantageously fashioned in the tube (which should have a sufficient tensile strength so that it, together with the endoscopy capsule, can be pulled out from the gastrointestinal tract undamaged as needed), via which separate channels the various operating or working means can even be supplied simultaneously if needed. The corresponding channels are naturally directed at the capsule to the corresponding function devices of the capsule that should be supplied with the respective operating or working means, whereby the channels or continuation lines can be opened and closed as needed via corresponding electrical valves controllable via a capsule-side control device. For example, it is possible to feed a gas via a first channel, by means of which gas a balloon arranged at the capsule is inflated. By means of this balloon the capsule size (thus the capsule diameter) can be adapted to the size of the surrounding hollow organ for a sliding-contacting [sic] movement of the capsule along the organ wall, is fed, or via which a stent or a tamponade or the like can be placed, for example. Via the second channel a ravaging fluid that exits at a capsule-side exit opening (in order, for example, to clean the intestinal wall or the viewing window of an optical sensor in the capsule) can be fed, for example.
[0011] The at least one (but typically more) electrical conductor is appropriately set in the tube wall, but can also be directed on the tube wall. In the case of a power supply, only very slight currents are to be conducted via these conductors. The communication between the external operating or control device and the capsule-side control device can also ensue via these same conductors, i.e. the image and other measurement data that are acquired at the capsule can be transferred to the external operating or control device, or control commands can be provided from the outside to capsule-internal function devices.
[0012] As stated, at least one outlet opening for a supplied working or operating agent can be provided at the capsule, this outlet opening being advantageously positioned adjacent to an image acquisition device integrated into the capsule. For example, for an improved image acquisition a cleaning fluid can thus be supplied from outside and can be emitted via the outlet opening directly at the location of the Office Action. A number of such outlet openings can naturally also be provided. The tube-side channel opening at the capsule would then be coupled with the respective outlet openings via a corresponding connection channel system. Here as well a closing and opening of the respective channels or outlet openings via electrically controlled valves is naturally appropriate. The cleaning openings can also be combined with other sensors or probes on the capsule surface, for example a conductivity sensor or a bipolar probe for thermal coagulation.
[0013] In the event a working or operating agent cannot be supplied via the very thin tube with the sufficient pressure that would be required for a sufficient washing of the intestinal wall or for a sufficiently strong inflation of a balloon or the like, in an embodiment of the invention a reservoir is provided for the supplied working or operating agent in the capsule, from which reservoir the working or operating agent can be removed via a pump or the like for output to a function device of the capsule or into the capsule environment. The reservoir can thus be continuously filled from the outside, while via the pump sufficient pressure can be developed so that the working or operating agent can perform its function.
[0014] In addition to the extraction of tissue samples via a biopsy device, it is also sometimes appropriate to acquire liquid or gas samples from the examination location, for example. For this purpose, a suction device for suction of fluid or gas from the capsule environment via a capsule-side inlet opening and for feeding the fluid or gas into the tube (possibly the reservoir) is appropriately provided. The corresponding inlet opening (which, as described, can be opened and closed via an electrically controllable valve) thus enables the immediate acquisition of local fluid or local gas that can then be transported out with the capsule. The same acquisition can naturally ensue via an outlet opening provided anyway, which outlet opening is, for example, coupled with the pump already described, this pump can then be operated in reverse as a suction device.
[0015] As described above, the opening and closing of the outlet and inlet openings or of connection lines leading to function devices ensues via corresponding valves that are electrically controllable via a control device integrated into the capsule. Insofar as no electrical communication line to an external operating device is provided, this control device can also communicate wirelessly via radio with the external operating or control device (alternatively via the tube-side signal lines, naturally). The control device (a small microprocessor) controls all electrically controllable or operating functions or operating elements that are integrated into the capsule.
[0016] Because the capsule sometimes rotates around its own axis during the magnetic navigation, it is appropriate when a coupling element at which the tube is attached is arranged at or in the capsule, and said coupling element enables a rotation of the capsule relative to the tube. The capsule can thus rotate freely relative to the tube, which does not have to track the capsule rotation movement; it thus does not twist. The coupling element is designed such that naturally the corresponding conductor connections from the tube to the capsule are also not interrupted upon rotation. The coupling element itself does not necessarily have to be arranged at the point at which the tube discharges into the capsule; rather, the coupling can also be provided at an arbitrary point along the tube, preferably close to the capsule, naturally.
[0017] Furthermore, it is sometimes appropriate to be able to decouple the tube from the capsule as needed, which can possibly ensue via the coupling element. For example, this can ensue via an electrical signal given by the capsule-side control device, which electrical signal specifically opens a mounting at the coupling element or at the connection of the tube with the capsule, or, for example, by defined mechanical pull on the tube, such that a connection mechanism between tube and capsule is hereby opened in a defined manner. The tube can then be drawn out while the capsule (which, for example, requires no further supply with working or operating means or the like) can be further directed through the intestine or the like via external control. Alternatively, the tube can also remain in the body in order to be used as a feeding or drainage tube while the endoscopy capsule is no longer needed. In this case the capsule can then be magnetically navigated further and secured. Here the accessibility of the entire intestine via the navigable capsule proves to be particularly advantageous, such that in the case of ileus (for example) a discharge sample can be placed very far aboral (for example in the jejunum or ileum) or a feeding tube can be introduced through the colon into the small intestine given a failing continuity of the oral sections of the gastrointestinal tract.
[0018] Given use of tubes that are shorter than the entire length of the gastrointestinal tract, given oral examinations (gastroscopies) the decoupling capability offers the possibility to remove the tube without pain via mouth or nose after decoupling while the capsule is navigated further or moves via natural peristalsis and is secured anally. It is also sometimes possible to leave the capsule inside the gastrointestinal tract (possibly locally fixed) for further gastroenterological examination or treatment, however to already remove the tube because no further working or operating means or, respectively, energy supply is required.
[0019] In a further embodiment of the invention the magnetic element is arranged in a housing section that can be decoupled from the remaining capsule housing as needed. This enables the magnetic element to be retrieved via the tube after the positioning of the endoscopy capsule in a target region, meaning that the decoupling-capable housing section is connected with the tube and can be drawn out with this. This enables the patient to be examined in a magnetic resonance system after the positioning of the endoscopy capsule since, given corresponding design, after removal of the magnetic element the endoscopy capsule no longer contains components that would react to the magnetic fields predominating during the magnetic resonance examination. It is also conceivable to direct a further magnetic endoscopy capsule via magnetic control to the same location, whereby the already-positioned capsule no longer interacts with the navigation field, i.e. is no longer displaced into movement with the navigation field. The detaching of the housing section from the remaining housing can ensue in manner described above as with the tube decoupling.
[0020] Furthermore, an insertion element (for example a tube or the like) to be inserted into a body orifice of an examination subject (for example the rectum) can be associated with the endoscopy capsule, via which insertion element the capsule can be inserted into the examination subject, and the insertion element exhibits an arresting and/or advancement and retraction device for the tube. By means of the arrest the capsule can “dangle” on the tube in an intestinal section directed downwards; a magnetic levitation is not necessary. Particularly given the retrograde capsule movement, the pulling device in the insertion element can support the magnetic capsule navigation when both “movement types” (magnetic force on the capsule and drawing on the tube) are exerted with adjustment to one another.
[0021] An easier capsule navigation is thus possible via the insertion element. The arresting and/or advancement and retraction device can be manually or mechanically actuated, however can also be controlled automatically and electrically.
[0022] The insertion element itself can be executed gastight in order to enable a filling of the colon with gas to enlarge the same.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic block diagram of an endoscopy capsule in accordance with the present invention.
[0024] FIG. 2 is a section through the flexible, non-rigid feed tube of the endoscopy capsule shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] FIG. 1 shows an inventive endoscopy capsule 1 with a capsule housing 2 in which is integrated a magnetic element 3 , which can be a permanent magnet, a weakly magnetic element that can be magnetized in a magnetic field, or an electronic coil. This magnetic element 3 interacts with navigation magnetic fields that are generated via an external navigation device (not shown) so that the endoscopy capsule 1 accommodated in the patient body can be actively directed and moved via external control.
[0026] A control device 5 in the form of a microcontroller is integrated into the oblong, cylindrical capsule exhibiting a diameter of, for example, 10 mm, which control device 5 takes over all control tasks concerning the function devices of the capsule (which are subsequently described in detail). An image acquisition device 6 is also provided, comprising a camera (for example a CCD camera 7 with which two illumination devices are associated in the form of two LEDs 8 ). Via the image acquisition device 6 (that is arranged behind a transparent capsule window covering 9 ) it is possible to acquire images of the examination volume that is illuminated via the LEDs 8 . The image signals are passed to the control device 5 which transfers these outward via a conductor connection to an external control or operating device (as is described further in the following).
[0027] The detection of the position of the capsule inside the examination subject ensues in connection with a position sensor 10 provided at the capsule, which position sensor 10 interacts with a magnetic position detection system (not shown in detail). Also provided in the shown example is a function device in the form of a biopsy pincer 11 that can be controlled via the control device 5 in order to extract tissue samples. Finally a balloon or cuff 12 that can be reversibly inflated (which is discussed further in the following) is arranged at the capsule housing 2 . The outside of the capsule can be adapted or altered via this cuff 12 in order to adapt to changing diameters of the hollow organ examined or to be examined.
[0028] The endoscopy capsule 1 also has or is also connected with a highly flexible, non-feed rigid tube 13 via a coupling element 14 . This tube comprises polypropylene (PP) or polytetrafluorethylene (PTFE), thus an inelastic material that does not expand given internal pressurization, and is also extremely thin in diameter with regard to the wall thickness. The latter is preferably approximately 0.2 mm; the diameter is preferably 3-4 mm. This tube 13 , which can be two or more meters long, is inserted into the patient together with the endoscopy capsule. The endoscopy capsule, as it is actively moved forward, draws the tube after it. The tube itself is extremely smooth on the outside, thus in practice slides along the organ wall without resistance and follows any curve without further measures because as executed it is extremely thin-walled and highly flexible.
[0029] Inside the tube (see FIG. 2 ) three different lumens or channels 15 a , 15 b and 15 c are demarcated from one another via corresponding dividing walls 16 . Via these channels 15 a - 15 c it is possible to direct different working or operating means from the outside to the endoscopy capsule 1 which requires these in some form, thus requires these for internal operation or would like to emit them externally into the examination organ. For example, a CO 2 gas can hereby be fed as a washing gas that is emitted at the capsule into the intestine via an outlet opening. Water can also be supplied as a washing solution, or a medicinal substance that is emitted externally. Furthermore, the gas needed to inflate the balloon 12 can hereby be supplied. For this one the channel or channels are coupled with corresponding lines inside the capsule that lead to the function devices or outlets where the working or operating means are required (which is discussed further).
[0030] Furthermore, a number of electrical conductors 17 a , 17 b , 17 c are shown that, in the shown example, are directly attached to the inner wall 18 of the tube 13 as thin-film conductors and that, in the shown example, are sealed off from the channel 15 a with a thin membrane 19 . Via these electrical conductors it is possible on the one hand to ensure the power supply of the electrical loads inside the capsule. For example, the conductor 17 a serves for this, which conductor 17 a is correspondingly looped further inside the capsule and is connected with the corresponding loads such as the control device 5 , the image acquisition device 6 with its components or the biopsy pincer 11 , but also a pump integrated into the capsule (which is subsequently discussed further). For example, the conductor 17 b serves for bidirectional signal or data transfer. For example, the communication between an external control or operating device and the control device 5 can thus ensue via the conductor 17 b . The conductor 17 c is, for example, a common neutral conductor for the conductors 17 a and 17 b . Image signals acquired via the image acquisition device 6 can be transferred from the control device 5 (for example via the conductor 17 b ) to the external control or operating device that processes and prepares the image signals and outputs them onto an associated monitor.
[0031] The inventive endoscopy capsule 1 is thus clearly not autarkic, meaning it does not carry the necessary working or operating means with it; rather, in the shown example it is supplied from the outside with all required working or operating means including the necessary electrical current. This supply occurs via the highly flexible, extremely thin tube (serving exclusively as a connection element) that is drawn behind the capsule and that otherwise has no function whatsoever with regard to the mechanical capsule movement. Rather, the capsule movement ensues exclusively via the magnetic navigation.
[0032] As stated, a pump 20 is integrated inside the capsule, upstream from which pump 20 is a reservoir 21 that is coupled via a line connection section 22 with the tube 13 that leads to the coupling element 14 . In the shown example the reservoir 21 exhibits three separate chambers 21 a , 21 b and 21 c into which a channel 15 a , 15 b or 15 c respectively leads. The supplied working or operating means (thus for example a flushing gas or a cleaning fluid or the like) can be cached [buffered] in said reservoir 21 and be removed as needed via the pump 20 , upstream from which is a multi-path valve 23 that can be correspondingly switched via the control device 5 . The pump 20 can generate the higher (compared with the feed pressure possible due to the extremely low channel diameter) pressure sometimes required, which is required for example in order to enable a sufficient washing or to inflate the cuff 12 . At this point it is noted that the reservoir 21 can naturally also be omitted if, for example, the feed should be possible with sufficiently high pressure when, for example, only one channel is provided at the tube and different working or operating agents are supplied via this, for example sequentially.
[0033] In the shown example diverse lines exit from the pump 20 to different function devices. A first line 24 with integrated valve 25 that can be controlled via the control device 5 opens below the balloon 12 . If this should be inflated, the pump 20 pumps the corresponding gas supplied via the tube 13 (possibly after preceding extraction from the reservoir 21 ) into the balloon and inflates this.
[0034] Two further lines 26 with associated valves 27 switchable via the control device 5 open at the capsule housing 2 in the openings 28 just before the image acquisition device 6 . They serve for the deployment of washing gas or washing fluid that is conveyed via the pump 20 with relatively high pressure. Given reverse operation of the pump it is also possible when this thus acts as a suction pump to draw liquid or gas from the capsule environment (thus from the hollow organ) into the capsule and, for example, to store it in the reservoir 21 from where it can be extracted and examined when the capsule is secured.
[0035] At this point it is noted that the pump 20 , like the reservoir 21 , is naturally only optional. If, as stated, a feed of the working or operating means with sufficient pressure should be possible, these elements are not required; rather, the required CO 2 gas for inflation of the balloon can be supplied directed by a corresponding external feed controller and be conducted into the balloon, or, respectively, the flushing gas can then be directed directly to the openings 28 (that, as stated, can serve as outlet or inlet openings).
[0036] The coupling element 14 is fashioned such that a rotation of the capsule 1 around its longitudinal axis relative to the stationary tube is possible, meaning that it is a swivel coupling (as is shown by the arrow). This enables the tube 13 to not have to follow possible capsule rotations around the capsule longitudinal axis (not drawn). This embodiment is particularly suitable when the tube 13 has only one channel. Otherwise it must be ensured that, in spite of capsule rotation, the connection of the tube-side channels with the corresponding connections inside the capsule is maintained. The electrical connection can be realized by slip ring connections or the like in the coupling element 14 .
[0037] In order to enable the detachability of the tube 13 from the endoscopy capsule as needed, the coupling element 14 can be controlled via the control device 5 so that an opening mechanism (not shown in detail) integrated into the coupling element is activated and the tube 13 is decoupled. This can hereby be a simply fashioned, electrically controllable mechanism. This enables the tube to be detached from the capsule as needed, the tube to be withdrawn and the capsule to be directed further etc. Additionally or alternatively, it is also conceivable to separate the upper capsule housing 2 a which directly connects to the coupling element 14 and which is connected with the lower capsule housing 2 b via a sealed dividing wall 29 (shown here only dashed). Exclusively the magnetic element 3 is arranged in the upper capsule housing 2 a . Thus upper capsule part together with the magnetic element 3 can thus be removed as needed so that only the lower capsule part 2 b remains in the body. The remainder can be withdrawn with the tube 13 . This offers the possibility to leave the capsule in the body during a magnetic resonance examination.
[0038] In order to generally maintain the operation of the capsule even when the tube 13 is decoupled, it is moreover conceivable to integrate an auxiliary energy supply 30 into the capsule so that it is ensured that, for example, the image acquisition device can also still operate after the decoupling. The radio transmitter/receiver 31 , which wirelessly transmits the image signals outside to the operating or control device and/or receives control signals for opening or closing of the valves 23 , 25 , 27 , then serves, for example, to transfer the acquired images and receive external control signals. It is also possible to optionally provide one or more storages 32 for gas or liquid or the like from which a certain albeit small quantity can be removed and employed in case of need given a decoupled tube. This in particular lends itself when the optional reservoir 21 is not provided. The storage or storages 32 are naturally connected with the remaining line system via corresponding lines (not shown in detail).
[0039] As FIG. 1 also shows, the tube 13 is connected at its external end with a plurality of external supply or operating or control devices. In the shown example, for example, the supply devices A, B and C are connected with the channels 15 a , 15 b and 15 c via which a corresponding working or operating means can be supplied in a gaseous or liquid form. D exemplarily identifies the external control or operating device via which the entire capsule operation can be controlled (i.e. the electrical current feed and the data exchange can ensue) and that is connected with the capsule via the conductors 17 a, b, c.
[0040] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted heron all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | An endoscopy capsule has a capsule housing containing at least one magnetic element that interacts with an extracorporeally applied magnetic field to magnetically navigate the endoscopy capsule within a body lumen of a patient. The capsule housing has a tube connected thereto that is composed of a flexible, non-rigid material, i.e., of insufficient rigidity to feed the capsule housing in the body lumen. The tube is provided with a feed path for providing any of a liquid agent, a gaseous agent, electrical power and data between the capsule housing an extracorporeal source. | 0 |
This invention relates to improvements in the construction of moulds for making concrete blocks and other types of composite blocks using cementitious material.
Such blocks are moulded in moulds comprising a pair of parallel mould bars defining between them a longitudinally extending space for a plurality of individual moulds, arranged side-by-side. Divider walls separate the individual moulds. The end dividers walls are supported by tie bars, extending between the moulds while end core liners form the end walls of individual moulds.
A plate or pallet (`pallet` hereafter) extending longitudinally below and along the mould frame forms the bottom wall of the individual moulds. It will be noted that the mould bar maintains the divider and end core liner walls in their desired relationship to each other and to the bottom plate. However it is noted that none of the side, end or bottom mold members is fixedly attached to the other. The reason is that the individual moulds, arranged side by side along the mould bars, are of constant height and length (measured transversely of the mould frame) but may be of differing widths as determined by the width of the end core liners which act as spacers for the divider walls.
To the moulds as above described there are provided cores to provide the apertures in the blocks, means for feeding the mixture of cement and aggregate into the mould while vibrating it and means for pressing the cement and aggregate once in the mould.
However the invention is principally concerned with the dividers and end core liners and their relationship to the mould bar, the mould bar frame and the pallet.
The end core liner, forms the end wall of the mould, the spacer for the dividing walls and determines the contour of the ends of the block. It has heretofore been made as one piece. Thus when the end core liner wore out, the entire end core liner had to be replaced at material expense.
This invention provides an end liner performing the spacing and some of the shaping functions for the block with a separate end core which performs other of the shaping functions. The end liner is shaped for its purposes on both sides so that it is reversible. Thus the life of the end liner is doubled because of the two piece end core liner and the reversibility of the liner component.
In prior constructions the divider plates have been keyed by a lug to a single groove in the mould bars. Although the lug served to anchor the divider against removal it tended to allow vibratory pivotting about the lug under vibration of the mould, reducing the precision of the blocks produced.
This invention, in one aspect, provides a plurality of grooves in the mould bars and complementary lugs on the divider plates. The provision of two or more lugs sharply reduces the development of looseness under divider plate vertical vibration.
In another aspect of the invention the divider plate is provided with a lug at each end which goes below the adjacent mold bar and contacts its lower surface. Such lug also acts to reduce the development of looseness under vibration.
In a preferred version of the invention the divider plate has a lug at each end which goes below the adjacent mould bar and contacts its lower surface, such lug is provided with a, preferably detachable downward extension. The inward edges of these downward extensions are located and dimensioned to contact adjacent side edges of the pallet, so that the edges act as stops to prevent migration of the mould and mold bar relative to the pallet in directions perpendicular to the longitudinal axis of the mould bar frame.
(The mould bar frame encloses a number of side by side individual moulds. As a result the longitudinal dimension of the mould bar frame is perpendicular to the longitudinal dimension of individual moulds).
In a preferred aspect of the invention the two part end core liner has an end liner cut away along its bottom edge over an extent to be covered on the inside by the end core. The combined end core and liner, in accord with this aspect of the invention provide an outwardly facing lower niche in which loose particles or lumps of aggregate found on the pallet, may collect during the vibration of the members. The niche allowing such collection thus lowers the likelihood that such particles or lumps may collect below the end core liner which would create an unwanted spacing between the mould end and side walls, on the one hand, and the pallet on the other hand, which would tend to introduce irregularity into the shape of the resulting block.
In a preferred aspect of the invention the mould bars are provided with a lower surface which is contacted by the upper edge of a lug projecting outwardly from a divider plate. The lower surface may be provided by adding a detachable wear strip of harder material to the under surface of the integral part of the mould bar. In such arrangement the wear strip accepts the wear which would otherwise wear the more complex and expensive mould bar itself. Thus a worn wear strip may be replaced many times without replacement of the mould bar. The selection of the lower mould bar surface for the installation of such wear strip is of some importance. The upper surfaces of mould bar grooves, contacted by divider plate lugs would also benefit from the use of a wear strip. However in the latter locations, the provision of a wear strip would imply widening of the grooves and consequent weakening of the mould bar, hence it is unwise to do this.
In a preferred aspect of the invention, there is provided a keying member designed for mounting in a mould bar groove, to project inwardly therefrom and with the inward projection defining upper and lower substantially horizontal surfaces. The sided edges of the divider plate are contoured in a complementary manner to make edge to edge contact with the upper and lower edges. It may also be a hardened and relatively small member, designed to last the life of three or four divider plates. The use of the keying member reduces costs of the (then) smaller divider plates providing an overall saving in the day to day costs of the mould operation.
In a preferred aspect of the invention there is provided a hanger bar adapted to extend between said mould bars and over said mould bars for attachment thereto. The hanger bar is provided with means to attach to and suspend a divider plate. This provides a useful and advantageous alternative to the lug and groove method of mounting the divider plates.
Other features and advantages of the invention will be described in the description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate a preferred embodiment of the invention:
FIG. 1 is an exploded perspective view of part of a mould apparatus in accord with some features of the invention,
FIG. 2 is a partially schematic view of a mould apparatus in accord with some features of the invention,
FIG. 3 shows the prior art arrangement of mould bars, divider plates, and end core liners,
FIGS. 4 and 5 are perspective views of an end core liner in accord with the invention,
FIG. 6 shows a construction of end core liners, divider walls and mould bars in accord with the invention,
FIG. 7 demonstrates the provision of a wear strip in accord with the invention,
FIG. 8 demonstrates the cooperation between divider wall lugs and the lower surface of the mould bar in accord with the invention,
FIG. 9 demonstrates the provision of a hanger bar for suspending the divider plates,
FIG. 10 demonstrates the cooperation of divider wall lug extensions and a pallet in accord with the invention,
FIG. 11 demonstrates the cooperation between mould bar T inserts and a complementary shaped divider plate in accord with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The mold frame, individual mould members described herein, except where otherwise noted, are usually made of steel although other metals may be used.
In FIG. 1 is shown a stand 10 which will include rubber pads 12 to support the elements to be discussed, as they vibrate. A rectilinear plate or pallet (`pallet` hereafter) 14 has parallel side edges 16 and end edges 18. Blocks 20 are examples of products which would be moulded by the equipment shown. A mould bar frame comprises parallel spaced mould bars 22 which are fastened by bolts 25 to tie bars 24 to form, a rigid frame. The nearer bar 24 is broken away. It is noted that the tie bars include hooks 26' to prevent translation, under vibration, of the mould bar frame longitudinally relative to the pallet. Vibrating means for the frame are schematically shown as motor 26, by contacting the pallet edge belt 28, pulley 30 shaft 32 rotatably mounted in bearings on the mould bars and eccentric 34 rotatable with shaft 32. Shaft 32 is rotatably mounted in the mould bars. The drive for remote shaft 32 is omitted for clarity. It will be noted that the mould bar 22 spacing determines the length of individual moulds. It will be noted that the tie bar 24 spacing determines the accumulated widths of a number of individual moulds arranged side by side. Thus the width of individual molds is determined by the end core liners 36 which will act as spacers for the individual mould divider walls 38. Although not shown it will be noted that either the tie bars are made adjustable in spacing or special spacing members used so that the longitudinal sum of the divider wall thicknesses and end core liner widths and special spacers (if necessary) fills the space between the tie bars. The divider walls 38, end core liners 36 and cooperating aspects of the tie bars will be described in detail hereafter. Cores 40 are suspended on core hanger bars 42 which in turn are attached to the tie bars, as schematically shown at 43, so that the cores rest in the individual moulds and shape the individual apertures 44 in the blocks.
Parts having a similar (main) functions and differing features are denoted by the same number and a different letter. (Thus differing divider walls are 38, 38A, 38B etc.)
As demonstrated in FIG. 2, with reference back to FIG. 1, the mould frame formed by mould bars 22B and tie bars 24 with selected individual mould dimensions and cores in place is filled with any desired type of cementitious aggregate by means not shown, while vibration consolidates the aggregate in the mould. A presser 46 is shaped to pass downwardly, outward of the cores and inward of the end core liner and dividers to further compact the aggregate which then sets to its final form.
FIG. 3 shows the customary prior art arrangement of the divider walls 38A, end core liners 36 and mould bars 22A. It will be noted that the end core liner 36 is a single member so that when wear destroys its contour it must be entirely replaced. It will be noted that the divider walls 38A have single lugs 48 riding in single tie bar grooves 50 which will cause the dividing walls 38A to have after wear a relatively looseness under vibration, tending to degrade the contour of the block side walls 52. It will be noted that the divider walls 38A have no restraining contact with the lower surface 54 of the mould bar walls, increasing the relative vibratory motion of the divider walls. It will be noted that there is no provision for limiting relative translating motion of the mould frame dividers 38A and end core liners 36 relative to the pallet in the direction transverse to the mould bars.
FIGS. 4, 5 and 6 demonstrate the construction of an end core liner in accord with the invention. The end liner 36D or 36E is symmetrical about its median plane so that it can turn either face toward the inside.
Side edges 59 define the width of the block and act to bear on and space divider walls 38, 38A or 38C of an individual mould. The end liner 36D provides a rectilinear inner aperture or apertures 62A, (FIG. 4) or 62B and 62C (FIGS. 5 and 6) to allow passage of the shank 64A (FIG. 4) or shanks 64B, 64C (FIGS. 5 and 6) from end core 36B or 36C respectively. The separate end liner 36D, or 36E is held in place by the shank or shanks 62A (liner 36D) or 62B and 62C (liner 36E) which shank or shanks bolted to the mould bars 22 (FIG. 1), 22A (FIG. 3) or 22B (FIG. 9) by bolts not shown. FIG. 4 shows an end liner 36D with a single aperture 62A to combine with a single end core 36B. The FIG. 4 alternative would be used with mould bars having a single groove 50 as shown in FIGS. 3 and 8 and the tie bar shanks 64A would be bolted by bolts not shown in selected apertures 66A in the tie bars. FIGS. 5 and 6 show end liners with two apertures 62B, 62C to receive cores 36B with two shanks 64B, 64C for bolting to mould bar 22B with double grooves 50A, 50B as shown in FIGS. 1, 2 and 7 by bolts attached through apertures 66B. Above and below the large apertures 62A, 62B the liner may be provided with small apertures 68 in case it is desired to bolt the end liner to end core 36B or 36C at threaded apertures such as 70 (FIG. 4).
The end liner 36B or 36E is preferably provided with an upper transverse central groove 72 to receive the lower edge of core suspender bar 42 and ensure the registration of these members. The end liner 36D (or 36E) carries any keying grooves such as 74 with which it is desired to ornament the finished block. The contour of the end core 36C is likewise selected to produce the desired intaglio shaping ly the end of the moulded block. The lower edge of the end liner 36D or 36E preferably has a cut away arch 76 centrally located. The dimensions of the cut away portion are such that it is inwardly covered by the end core 36B or 36C so that the presence of the cut away portion does not affect the contour of the finished block. However the cut away portion 76 plus the surface of end core 36C (or 36B) form a downwardly and outwardly facing niche which provides a collection area for loose aggregate on the vibrating pallet and reduces the risk that such aggregate will get between the end core liner and the pallet reducing the integrity of the mould. The symmetry of the end liner 36 or 36E about its median plane, allows its reversal, once the inner face 80A (FIG. 4) 80B (FIG. 6) becomes worn to provide a fresh face for the mold. The innovation thus provided almost doubles the working life of the end liner.
As FIG. 3 demonstrates it is customary to provide mould bars with a single rectilinear groove 50 shaped to slidably receive lugs 48 on dividing plates 38A. The single groove 50 and lug 48 allows with wear the introduction of looseness of the divider plates. In accord with this invention the dividf-- plates are provided with two lugs 48A, 48B as shown in FIGS. 2, 6 and 7 which ride in two mould bar grooves 50A, 50B of complementary section. The provision of two grooves materially reduces looseness in a vertical direction of the divider plates relative to the end core liner, improving the integrity of the mould. As demonstrated in FIGS. 1, 2, 6, 7, 8, 10 the divider plate may also be provided with a lug 48C shaped to provide an upper edge 82 which contacts the lower surface 54 or 54A of each mould bar. This arrangement further reduces the rotary component of the divider plates 38B, 38C, 38D and the anchoring, during vibration of the divider wall relative to the mould bar.
FIG. 8 demonstrates the use of a divider plate 38C with a lug 48 for riding in a single grooved tie bar 22A (as shown in FIG. 8). A second lug 48C projects outwardly from the divider wall to provide the upwardly facing edge contacting on the lower surface 54 of the mould bar as discussed and with the advantages as described in the previous paragraph.
In general, and in each application the upper and lower edges of 84 and 86 of the divider wall determine the upper and lower limits of the mould cavity.
In the aspect of the invention shown in FIGS. 2, 6 and 10 the outwardly extending lug is bolted to a downwardly extending extension 88 which has an inwardly facing edge 90 designed to ride on the side edges 16 of pallet 14 and prevent migration transverse to the longitudinal direction of the mould bar frame during the vibrating process. The extensions 88, if desired, may of course be formed as an integral extension of the divider plate, if desired.
A further feature of the invention is demonstrated in FIGS. 2, 7 and 8 where the lower surface 54A of the mould bars is provided by a wear strip 92 detachably attached (by any conventional means not shown) to the mould bar . Strip 92 endures the functional wear of the upper surface of lug 48C . The wear strip 92 may be made of specially hardened steel and avoids wear to the mould bars proper thus extending the life of the latter many times.
FIG. 11 demonstrates a further feature of the invention. For each groove 50, 50A, or 50B in the opposed mould bars there is provided a T-shaped keying member with the rectilinearly contoured cross-bar 94 of the T-shaped to slide in the mould bar groove 50, 50A or 50B and attachable thereto by bolts 96 at locations corresponding to those of the divider walls. The upright 98 of the T extends inwardly of the innermost surfaces of the mould bars to rest in complementary shaped notches 100 of the divider wall. Thus upper and lower horizontal profile of the upright 98 (as viewed parallel to the mould bars) contacts corresponding defining edges of notch 100. It will be noted that the width of T uprights 98 is that of divider plates 38C. The reduction in material in the divider walls produced by the inwardly extending notches 100 in comparison to outwardly extending lugs provides a considerable saving in cost. The T inserts may be made of specially hardened material adapted to have approximately triple the life of a divider plate thus enhancing the cost saving due to the consequently reduced divider plate area.
FIG. 9 demonstrates a further feature of a preferred aspect of the invention. As shown the mould bars 22B are not grooved or, if grooved, are so only for attachment of the end core liners 36, 36A. The divider plate 38D is provided with straight side edges 114. A suspension bar 102 extends between the mould bars and rests on the upper surfaces 104 of the mould bars. Downward extensions 106 outwardly of the bars allow attachment to apertures 66C in the mould bars by pivot blocks 108 and bolts 110. The suspension bar 102 is provided with interlocking means complementary to the shape of the upper edge of the divider wall, to allow suspension of the divider wall. In the preferred embodiment, the interlocking means takes the form of diverging rectilinear notches in the suspension bars which receive complementary tabs 110 of the divider wall. Tabs 112 extending downwardly from the suspension bar are designed to contact the outer edges 114 of the divider walls. This results in a small inward spacing of the side edges 114 of the divider wall from the mould bars 22, 22A, 22B. However this does not affect the integrity of the mould cavity because of the thickness of the end core liner. Although the divider wall 38D is preferably slidably received in the suspension bar such alignment may be maintained because the location of the divider wall is determined by spacing means inside the mould frame as previously discussed. | A mould bar frame for making composite blocks has mould bars for supporting a plurality of individual moulds side by side. Each individual mould has end core liners at each end and divider plates both liners and plates cooperating with the mould bars. The end core liner may be made of two separable elements one of which is reversible to reduce wear. A plurality of lugs on each end of a divider wall ride in corresponding grooves in the mould bars to reduce wear. | 1 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.